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Class B Materials Code Case to include: FY25 - High temperature design methodology, overview of ASME Section III (Division 5), Design for elevated temperature service, Goal to address current gaps, evaluation of proposed rules, allowable stress development, Class A materials (existing ASME approach), variable confidence index, data extrapolation, bounding value for SEE, and next steps.
Here, this study investigates the fatigue crack growth rate (FCGR) behavior of pipeline and low-alloy pressure vessel steels in high-pressure gaseous hydrogen. Despite a broad range of yield strengths and microstructures ranging from ferrite/pearlite, acicular ferrite, bainite, and martensite, the FCGR in gaseous hydrogen remained consistent (falling within a factor of 2–3). Steels with higher fractions of pearlite, typical of older vintage pipeline steels, exhibited modestly lower crack growth rates in gaseous hydrogen compared to steels with lower fractions of pearlite. Crack growth rates in these materials exhibit a systematic dependence on stress ratio and partial pressure of hydrogen, as captured in the recently published fatigue design curves in ASME B31 code case 220 for pipeline steels and ASME BPVC code case 2938 for pressure-vessel steels.
This report summarizes a research effort undertaken by Argonne National Laboratory to accelerate the development of creep data package for ASME code qualification. Progress on the fabrication of a 3-sample load train and the application of a direct current potential drop (DCPD) technique to measure large creep strains are reported. Specifically: (1) The 3-sample load train, with three sets of Linear Variable Differential Transformers (LVDT), has been fabricated and assembled. (2) A DCPD method for creep-strain measurement up to 50% has been demonstrated. The DCPD data matches very well to LVDT results, suggesting its potential application in future creep testing. The technical developments contribute towards shortening the time needed to generate a creep data package for an ASME code case of the laser powder bed fusion 316H stainless steel, an effort under the US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program.
The ASME code qualification effort for Alloy 709 (A709) is currently underway to qualify it for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5. The United States (U.S.) Department of Energy (DOE) national laboratories are collaborating in the advanced materials development initiative to investigate the mechanical performance of A709 in support of its code qualification. As part of the A709 code qualification effort, this report summarizes ORNL’s initial experimental findings that support the integration of A709 into the elastic-perfectly plastic (EPP) strain limits code case. It also covers thermomechanical fatigue testing conducted to develop viscoelastic material models, along with the preliminary results of creep-fatigue experiments at 816°C using the Simplified Model Test (SMT) method.
To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.
This report describes a framework for storing, processing, and displaying qualification data for high temperature mechanical properties. The framework automates the process of generating design data from mechanical test results, for example for a data qualification report for the ASME Boiler \& Pressure Vessel Code. The framework has three parts: a data storage model with common formats for several types of typical mechanical property tests, a backend based on the \pycreep Python library for correlating and extrapolating the data to generate design material properties and allowable stresses, and a demonstration user interface for displaying, sorting, and filtering the data and exploring different options for modeling the design mechanical properties. The report discusses the options available for data processing, with illustrations from real test data on Alloy 617, Alloy 709, Alloy 740H, and Laser-Powder Bed Fusion 316H. The framework is complete for ASME type data analysis and will be used to store test data generated by the Department of Energy, Office of Nuclear Energy, Advanced Materials and Manufacturing Technologies sponsored qualification programs. Future work could extend the tool to other types of material properties and/or expand the demo user interface to make it accessible across the AMMT program.
The Blending Pipeline Analysis Tool for Hydrogen (BlendPATH) is a flexible, open-source Python tool designed to provide users with case-by-case analysis capabilities to identify the necessary modifications to repurpose existing natural gas transmission pipeline networks to transport hydrogen as a blend of a user-specified volume fraction of hydrogen or as a pure stream and to estimate the associated capital and operating expenditures resulting from those modifications. This tool is intended to be applied during the initial screening stage of a prospective project when pipeline developers compile transmission pipeline technical documentation and history but prior to performing detailed pipeline inspections. Performing analysis with BlendPATH during this initial screening stage can provide the user with an understanding of promising opportunities and probable economic outcomes of repurposing their pipeline network for hydrogen before proceeding with detailed pipeline materials testing and pipeline inspections. BlendPATH consists of multiple modules to simulate, assess, and modify existing natural gas transmission pipeline network designs to be compatible with hydrogen as a blend or pure stream. The tool employs an open-source gas network hydraulic model to simulate existing, user-specified transmission pipeline networks, and it applies ASME B31.12 to assess the pipe segments within these networks for compatibility with hydrogen and to modify the networks to achieve compatibility where the existing infrastructure is inadequate. Users can specify ASME B31.12 design options for pipeline assessment and can select from multiple methods for pipeline modification. This report details the functionalities of BlendPATH Version 2.0.2 and demonstrates an example of applying BlendPATH to a case study. Potential and intended users of this framework include natural gas pipeline developers and operators and researchers at both public and private institutions. BlendPATH is publicly available at https://github.com/NREL/BlendPATH.
Creep-fatigue (CF) interaction damage is the primary damage mode for high-temperature structural components subjected to cyclic loading. Over the past several decades, researchers within the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5, have focused on developing elevated temperature code rules to ensure conservative structural designs that mitigate CF failure in high-temperature reactors. The existing CF evaluation methodologies in the Code are based on the creep and fatigue damage diagram approach, which is complex and often excessively conservative. The alternative CF evaluation approach proposed here is intended to significantly simplify the evaluation procedure while reducing conservatism in high-temperature component design analysis. This alternative CF evaluation method integrates the elastic–perfectly plastic (EPP) analysis approach with the simplified model test (SMT) CF design concept, leveraging the advantages of both methods. This report presents the preliminary analysis and the approach for developing CF design curves for Alloy 709, utilizing fatigue and CF data generated for the 100,000-hr Code Case to support its qualification to ASME Section III, Division 5 for Class A construction of high temperature reactors. This study is to support the incorporation of Alloy 709 in this alternative CF evaluation method. Recommendations for the remaining work needed to complete the effort are also provided.
ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic and electromagnetic simulation capabilities. ANSYS LS-DYNA is the most used explicit simulation program capable of simulating the response of materials to short periods of severe loading. Its many elements, contact formulations, material models, and other controls can be used to simulate complex models with control over all the details of the problem. ANSYS LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Engineers can tackle simulations involving material failure and look at how the failure progresses through a part or through a system. Models with large amounts of parts or surfaces interacting with each other are also easily handled, and the interactions and load passing between complex behaviors are modeled accurately. Using computers with higher numbers of CPU cores can drastically reduce solution times. In addition, many consulting firms and hundreds of universities use ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. ANSYS has successfully passed over 100 customer quality system audits against American Society of Mechanical Engineers (ASME) NQA-1 and 10 CFR Part 50, Appendix B, since the company was founded, over 60 of which have been since 1997. ANSYS has successfully passed over 100 International Organization for Standardization (ISO) 9001 assessments. ANSYS design analysis software is the first created within a quality system with ISO 9001 certification, which is the internationally accepted quality standard. Product development, testing, maintenance, and support processes also meet the US Nuclear Regulatory Commission’s (NRC’s) quality requirements, as they have for nearly four decades. ANSYS staff perform more than 60,000 software verification tests before releasing each new product. ASME NQA-1-2012 (Subpart 2.7 is specific to software) is the industry- and NRC-accepted approach (consensus standard) for meeting 10 CFR Part 50, Appendix B, requirements.
The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel, generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2025). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the Alloy 709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of Alloy 709 plate fabricated from three heats. The goal of the overall Alloy 709 development program is to establish the necessary microstructural and mechanical properties relationship for Alloy 709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART Alloy 709 materials. This study will enable its deployment in the industry as an advanced construction material for high-temperature components. The objective of this Alloy 709 development work in FY 2025 is to experimentally determine the high-temperature deformation-recrystallization response of the Alloy 709 heats and to experimentally generate true stress-true strain data for Alloy 709 using the available commercial heat plate materials. Integral to this work is the previous characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023, and the evaluation of the effect of controlled cooling on the resultant precipitation in these commercial heats. This report summarizes and builds on the results of the previous reports to assess the high-temperature deformation behavior as a function of deformation temperature, strain and strain rate using commercial Alloy 709 heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.
A significant research and development effort is underway to support the qualification of Alloy 709 as a Class A construction material in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. This initiative includes a comprehensive Alloy 709 code qualification plan aimed at generating extensive material testing data crucial for compiling the code case data package. The data package is essential in establishing material-specific design parameters for Alloy 709 to be used as Section III, Division 5 Class A construction material for fast reactors, molten salt reactors and gas-cooled reactors. An ASME Section III, Division 5 material code case requires the evaluation of mechanical properties from a minimum of three commercial heats, covering anticipated compositional ranges. A key part of the data package involves fatigue and creep-fatigue testing at elevated temperatures, needed for developing the fatigue design curves and the damage envelope of the creep-fatigue interaction diagram (D-diagram). This paper summarizes the strain-controlled fatigue testing on three commercial heats of Alloy 709 at 760 and 816°C with strain ranges between 0.25% and 3%. The fatigue failure data are used to generate a preliminary fatigue design curve. Additionally, the creep-fatigue testing results at 816°C with tensile hold times of 10, 30, and 60 minutes are presented in support of developing the D-diagram for Alloy 709.
The General Electric Company, Missiles and Space Division, submitted/a proposal to NASA for the development of an IBM 7094 computer program which would select the exterior surface coatings for passively controlling spacecraft temperatures. G. E. claims that the "trial and error" procedures currently used can be accomplished more rationally and can therefore be programmed for a digital computer. In the ASME paper, 63-HT-41, which was presented at the ASME-AIChE Heat Transfer Conference at Boston in August, 1963, Costello, Harper, and Cline, described the procedures that have been used at G. E. to develop a coating selection program subject to the following restrictions: 1. Steady-state conditions prevail, 2. Heat transfer occurs by radiation only, 3. Temperatures are optimized at only one interior point in the spacecraft, an d 4. Only the solar absorptance of the external coatings is varied to optimize temperature. The emittance must remain constant at initially specified values. General Electric proposes to develop a generalized program in three steps: 1. The program would vary both solar absorptance and hemispherical emittance to obtain the optimum coating patterns; 2. Temperatures would be optimized at more than one interior point; and 3. The equations would be modified to account for both conduction and radiation heat transfer. In the development of the general program, the scope would be restricted to steady-state heat transfer. Since the thermal designs of most spacecraft are based primarily on nearly equilibrium conditions, the proposed program could have wide application. An obvious extension of the proposed program would be to account for transient temperatures.
Considerations for an all-sky monitor for the Ariel-5 mission are evaluated. The monitors with the best signal-to-noise utilize the pinhole-camera principle, and are also least expensive in hardware and data analysis costs. The sensitivity sufficient to sensibly monitor compact extragalactic sources requires a system with approximately 100 times the sensitivity of the Ariel-5 ASM. A system identical in size to the Ariel-5 ASM can be made with approximately 5 times better sensitivity, and can satisfy the minimum requirements for this mission if it spins. An all-sky monitor appears to be essential to assure that rare occurrences in compact objects can be observed with the pointed experiment, and to ascertain that large amounts of pointing time will not be wasted by observing at the wrong times.
Experimental data have been obtained in an incompressible turbulent flow over a rearward-facing step with superimposed adverse pressure gradient. Mean velocities, Reynolds stresses and triple-products measured by a laser Doppler velocimeter are presented for two cases of adverse pressure gradient. Mixing lengths, eddy viscosities, production, convection, turbulent diffusion, and dissipation terms are extracted from the data. These data are compared with various mixing length and eddy-viscosity turbulence models. Numerical calculations incorporating the k-epsilon and the algebraic-stress turbulence models are compared with the data. When determining quantities of engineering interest, the modified algebraic-stress model (ASM) is a significant improvement over the unmodified ASM and the unmodified k-epsilon model
The NASA/JSC ground scatterometer system was used in a row structure and row direction effects experiment to understand these effects on radar remote sensing of soil moisture. Also, a modification of the scatterometer system was begun and is continuing, to allow cross-polarization experiments to be conducted in fiscal years 1982 and 1983. Preprocessing of the 1978 agricultural soil moisture experiment (ASME) data was completed. Preparations for analysis of the ASME data is fiscal year 1982 were completed. A radar image simulation procedure developed by the University of Kansas is being improved. Profile soil moisture model outputs were compared quantitatively for the same soil and climate conditions. A new model was developed and tested to predict the soil moisture characteristic (water tension versus volumetric soil moisture content) from particle-size distribution and bulk density data. Relationships between surface-zone soil moisture, surface flux, and subsurface moisture conditions are being studied as well as the ways in which measured soil moisture (as obtained from remote sensing) can be used for agricultural applications.
The advanced servomanipulator (ASM) slave was designed with an anthropomorphic stance gear/torque tube power drives, and modular construction. These features resulted in increased inertia, friction, and backlash relative to tape driven manipulators. Studies were performed which addressed to human factor design and performance tradeoffs associated with the corresponding master controller best suited for the ASM. The results of these studies, as well as the conceptual design of the dual arm master controller, are presented.
Experimental data have been obtained in an incompressible turbulent flow over a rearward-facing step in a diverging channel flow. Mean velocities, Reynolds stresses, and triple products that were measured by a laser Doppler velocimeter are presented for two cases of tunnel wall divergence. Eddy viscosities, production, convection, turbulent diffusion, and dissipation (balance of kinetic energy equation) terms are extracted from the data. These data are compared with various eddy-viscosity turbulence models. Numerical calculations incorporating the k-epsilon and algebraic-stress turbulence models are compared with the data. When determining quantities of engineering interest, the modified algebraic-stress model (ASM) is a significant improvement over the unmodified ASM and the unmodified k-epsilon model; however, like the others, it dramatically overpredicts the experimentally determined dissipation rate.
Developments in telerobotics applicable to nuclear and space environments are discussed. The advanced servomanipulator (ASM) slave arm force-reflected servomanipulators designed for modular remote maintainability of the Advanced Integrated Maintenance System is examined. Consideration is given to the master controller, transporter, interface package, operator control station, and the control system for the ASM arm. A prototype of a telerobot capable of performing the activity of an astronaut during EVA is developed. The mechanical and control system features of the telerobot are described.