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DOE OSTI2022

Tabulated Fluid Properties Research Report

The Multiphysics Object-Oriented Simulation Environment (MOOSE) enables a wide range of advanced nuclear reactor simulations.[6] Under the guidance of MOOSE’s Thermal Hydraulics Team,I worked to expand the capabilities of Tabulated Fluid Properties (TFP) in the fluid properties module. The fluid properties module allows the user to determine a variety of fluid properties by interpolating points between tabulated data. I implemented the ability to use bilinear interpolation instead of bicubic interpolation for interpolating tabulated data. I also changed the method of variable set inversions to use a 2-dimensional Newton’s Method utility that I created. Variable set inversions are often done from (v,e) to (p,T), where v is specific volume, e is specific internal energy, p is pressure and T is temperature. New routines have also been added into TFP such that it can be used with more applications, such as the Navier Stokes and Thermal Hydraulics modules in MOOSE for Pronghorn[5] and RELAP-7[1] respectively. This work was spurred by interest from NASA in testing a Nuclear Thermal Propulsion (NTP) engine system. NTP engines have drastically different fluid properties throughout the engine and Tabulated Fluid Properties provides the flexibility needed to properly simulate and test these engines.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2015

Affordable Development and Demonstration of a Small NTR Engine and Stage: How Small is Big Enough?

In FY11, NASA formulated a plan for Nuclear Thermal Propulsion (NTP) development that included Foundational Technology Development followed by system-level Technology Demonstrations The ongoing NTP project, funded by NASAs Advanced Exploration Systems (AES) program, is focused on Foundational Technology Development and includes 5 key task activities:(1) Fuel element fabrication and non-nuclear validation testing of heritage fuel options;(2) Engine conceptual design;(3) Mission analysis and engine requirements definition;(4) Identification of affordable options for ground testing; and(5) Formulation of an affordable and sustainable NTP development program Performance parameters for Point of Departure designs for a small criticality-limited and full size 25 klbf-class engine were developed during FYs 13-14 using heritage fuel element designs for both RoverNERVA Graphite Composite (GC) and Ceramic Metal (Cermet) fuel forms To focus the fuel development effort and maximize use of its resources, the AES program decided, in FY14, that a leader-follower down selection between GC and cermet fuel was required An Independent Review Panel (IRP) was convened by NASA and tasked with reviewing the available fuel data and making a recommendation to NASA. In February 2015, the IRP recommended and the AES program endorsed GC as the leader fuel In FY14, a preliminary development schedule DDTE plan was produced by GRC, DOE industry for the AES program. Assumptions, considerations and key task activities are presented here Two small (7.5 and 16.5 klbf) engine sizes were considered for ground and flight technology demonstration within a 10-year timeframe; their ability to support future human exploration missions was also examined and a recommendation on a preferred size is provided.

spacecraft design↗

NASA NTRS2015

Affordable Development and Demonstration of a Small NTR Engine and Stage: A Preliminary NASA, DOE, and Industry Assessment

In FY11, NASA formulated a plan for Nuclear Thermal Propulsion (NTP) development that included Foundational Technology Development followed by system-level Technology Demonstrations. The ongoing NTP project, funded by NASA's Advanced Exploration Systems (AES) program, is focused on Foundational Technology Development and includes 5 key task activities: (1) Fuel element fabrication and non-nuclear validation testing of heritage fuel options; (2) Engine conceptual design; (3) Mission analysis and engine requirements definition; (4) Identification of affordable options for ground testing; and (5) Formulation of an affordable and sustainable NTP development program. Performance parameters for Point of Departure designs for a small criticality-limited and full size 25 klb (sub f) (kip, or 1000 pound-force)-class engine were developed during FYs 13-14 using heritage fuel element designs for both Rover NERVA (Nuclear Engine for Rocket Vehicle Applications) Graphite Composite (GC) and Ceramic Metal (Cermet) fuel forms. To focus the fuel development effort and maximize use of its resources, the AES program decided, in FY14, that a leader-follower down-selection between GC and cermet fuel was required. An Independent Review Panel (IRP) was convened by NASA and tasked with reviewing the available fuel data and making a recommendation to NASA. In February 2015, the IRP recommended and the AES program endorsed GC as the leader fuel In FY14, a preliminary development schedule DDTE (Design Development Test and Evaluation) plan was produced by GRC (Glenn Research Center), DOE (Department of Energy) and industry for the AES program. Assumptions, considerations and key task activities are presented here. At the direction of NASA HQ (32515), NASA and DOE are to work together to formulate a detailed development plan and schedule allowing the affordable development of a small (7.5-16.5 klbf) GC engine for possible flight technology demonstration (FTD) mission within a 10-year timeframe.

Lunar Flyby Mission↗

NASA NTRS1991

An overview of tested and analyzed NTP concepts

If we buy into the goals of the Space Exploration Initiative (SEI) and accept that they are worthy of the hefty investment of our tax dollars, then we must begin to evaluate the technologies which enable their attainment. The main driving technology is the propulsion systems; for interplanetary missions, the safest and most affordable is a Nuclear Thermal Propulsion (NTP) system. An overview is presented of the NTP systems which received detailed conceptual design and, for several, testing.

Walton, James T.↗

DOE OSTI2020

PARAMETRIC EVALUATION OF ALTNERNATIVE NUCLEAR PROPULSION CORES USING CURVED FUEL PLATES

Nuclear Thermal Propulsion (NTP) holds the potential of reducing travel times for deep space missions (e.g. to Mars). Previous reactor core designs considered by the Rover/NERVA program relied on highly enriched uranium (HEU) fuel contained within a hexagonal graphite matrix. An alternative layout is investigated in this paper. It consists of a circular assembly containing concentric curved plates of UN fuel. These fuel assemblies are placed within a beryllium block and reflector. Preliminary results indicate that many variations of this design are viable, with high power to mass ratio and outlet temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1991

SEI needs for space nuclear power

The use of nuclear electric propulsion (NEP) and nuclear thermal propulsion (NTP) for transportation to the moon and Mars is examined, and the use on Mars and moon bases of thermal conversion subsystems based on either a Brayton or a Stirling cycle is examined. It is shown that both cycles are attractive alternatives for those applications where continuous field operation is desired. Nuclear power systems have a clear advantage with regard to the moon and a lesser one with regard to Mars.

Brandhorst, H. W.↗

NASA NTRSDate not supplied

Considerations for Nuclear Thermal Propulsion Reactor Technology Readiness Level Advancement

Nuclear thermal propulsion (NTP) is a candidate in-space propulsion technology for crewed missions to Mars. An NTP engine relies on the use of a reactor as a heat exchanger to directly heat a hydrogen propellant which is expanded through a nozzle for high specific impulse (> 850s), high thrust (>15 klbf) propulsion. NTP reactor and engine technologies are currently being developed to enable a future NTP engine prototype demonstration. Technology readiness level (TRL) definitions are a useful tool to plan necessary technology advancement tasks as they provide guidance on expected development activities and necessary level of fidelity of test article or testing conditions for demonstration tasks. However, technology readiness definitions for an NTP reactor and related demonstration tasks have not yet been defined. This paper identifies relevant TRL definitions by the National Aeronautics and Space Administration (NASA) and Department of Energy (DOE). Based on these definitions, preliminary recommendations on testing conditions and important parameters to consider for NTP reactor technology development planning are provided for TRL 1 - 6. As a part of this effort, functional characteristics and important performance parameters for the reactor are identified, as well as a summary of relevant literature which was considered when assessing development tasks capable of meeting TRL definition criteria.

nuclear thermal propulsion↗

NASA NTRSDate not supplied

Considerations for Nuclear Thermal Propulsion Reactor Technology Readiness Level Advancement

nuclear thermal propulsion↗

DOE OSTI2021

Modeling Nuclear Thermal Propulsion Startup Transients

A poster for the 2021 intern poster session. This poster details the RELAP-7/Griffin model developed for transient simulations to compare the effects of startup sequencing on the propellant efficiency, startup time, and maximum core temperature of a nuclear thermal propulsion (NTP) system. The sequencing parameters under consideration in this study are the ramping rates of both reactivity insertion and hydrogen propellant mass flow rate. Recommendations are made regarding startup sequencing based on the results produced by this model.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRSDate not supplied

An Extremely High Isp Spacecraft Propulsion System

Specific Impulse, Isp, is a measure of a rocket engine’s efficiency. It is calculated relative to the Earth’s gravitational field, where Isp = ve/ go, with go= 9.8 m/s2 and the escape velocity of the propellant, ve, in m/s. Chemical rockets have ve < 4.4x103 m/s and Isp < 450 seconds. As an alternative, the NASA Glenn Research Center developed multiple generations of Solar Electric Propulsion (SEP), high Isp, ion engines using Xe gas as a propellant. Consequently, over 100 SEP Ion Thrusters provide geo-synchronous station keeping along with deep space probes like Deep Space One and Dawn. These have ve » 2.9 x 104 m/s with Isp = 3x103 seconds. These thrusters have continuous operating lifetimes of thousands of hours allowing continuous acceleration making up for the very low thrust. Chang-Diaz’ Variable Specific Impulse Magnetoplasma Rocket (VASIMR) has the potential for four times the propellant escape velocity and four times the specific impulse1. Unfortunately, this comes at a tremendous electrical power cost, estimated at 200 kWe for maintaining the International Space Station in Low Earth Orbit (LEO). Although nuclear fission and fusion reactors2 have been suggested for powering nuclear thermal propulsion (NTP) it only doubles the Isp over chemical rockets but with comparable thrust. Instead, we propose using Lattice Confinement Fusion (LCF) reactions.

High Isp Propulsion↗

NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗

DOE OSTI2020

Design and out-of-pile testing of a novel irradiation experiment vehicle to support qualification of nuclear thermal propulsion components

Fission power systems have demonstrated higher thermal energy density per unit mass than chemical systems. High mass specific energy density offers advantages in space thermal propulsion applications. In the 1960s, nuclear thermal propulsion (NTP) development included the ROVER/NERVA program, in which full-scale prototype reactors were tested on the ground using hydrogen as the reactor coolant and propellant. NTP systems are being revisited, with expectations of improved performance resulting from improved fuel materials, allowing propellant temperatures near 2,800 K and over 20 thermal propulsion cycles. An apparatus has been developed to test NTP fuel materials in a research reactor at temperature and in a radiation environment typical of the NTP application. Here, this paper presents the design constraints, preliminary scoping thermal analysis, and basic thermal qualification testing for the out-of-pile experiment set apparatus, or OUTSET.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2013

Advances in the Development of a WCl6 CVD System for Coating UO2 Powders with Tungsten

W-UO2 CERMET fuels are under development to enable Nuclear Thermal Propulsion (NTP) for deep space exploration. Research efforts with an emphasis on fuel fabrication, testing, and identification of potential risks is underway. One primary risk is fuel loss due to CTE mismatch between W and UO2 and the grain boundary structure of W particles resulting in higher thermal stresses. Mechanical failure can result in significant reduction of the UO2 by hot hydrogen. Fuel loss can be mitigated if the UO2 particles are coated with a layer of high density tungsten before the consolidation process. This paper discusses the work to date, results, and advances of a fluidized bed chemical vapor deposition (CVD) system that utilizes the H2-WCl6 reduction process. Keywords: Space, Nuclear, Thermal, Propulsion, Fuel, CERMET, CVD, Tungsten, Uranium

Mireles, Omar R.↗

NASA NTRSDate not supplied

Hot Hydrogen Testing of Uranium Nitride Cermet for Nuclear Thermal Propulsion

This study investigated the thermochemical stability and performance characteristics of uranium mononitride tungsten molybdenum cermet (UN-Mo30W) as a potential fuel material for Nuclear Thermal Propulsion (NTP) engines. Twelve monolithic cylinders were subjected to conditions simulating an active NTP engine. The tests demonstrated thermal variability within the test article and highlighted the dissociation of UN into U and N2 at elevated temperatures, affecting the microstructure and causing bonding between cermet wafers and cooling tubes. Findings indicate that while UN-Mo30W cermet exhibits some desirable properties for NTP applications, its suitability is limited by high-temperature thermochemical instability.

nuclear fuels↗

DOE OSTI2020

Assessment of Near-Term Fuel Screening and Qualification Needs for Nuclear Thermal Propulsion Systems

Nuclear thermal propulsion (NTP) is an in-space propulsion technology capable of both high specific impulse (850–1000 s) and thrust (44–1112 kN), which can help reduce trip times for crewed missions beyond low Earth orbit. NTP technology has been demonstrated during historic programs. Over 20 ground test reactor experiments were performed, which demonstrated the prototypic reactor operations, during the Nuclear Engine for Rocket Vehicle Application (NERVA)/Rover program (1955–1972). Although historical programs have shown that NTP is a viable in-space propulsion technology, developing NTP in modern programs is contingent on the development and qualification of ultrahigh-temperature nuclear fuel technologies that can withstand engine operating conditions. In historical NTP development programs such as NERVA/Rover, prototypic reactor/engine schemes were ground tested to assess the overall system feasibility and to qualify the reactor fuel forms for eventual flight systems. Although this approach is effective to verify fuel performance under prototypic conditions, relying solely on full-scale NTP reactor tests as the pathway for verifying or qualifying fuel is inefficient and cost prohibitive today. Additionally, modern nuclear licensing requirements state that before test reactor approval, reactor components and fuel elements should be qualified via non-nuclear (out-of-pile) and nuclear (in-pile) testing under representative operating conditions. Using this methodology, fuel matures as production scale fabrication methods are established, and as produced fuel performance is demonstrated. Here, this paper provides an overview of historical approaches to NTP fuel performance maturation, including fuel screening and qualification needs, and provides insight for establishing an efficient testing paradigm that can be implemented to rapidly and affordably develop NTP fuel forms for eventual qualification.

42 ENGINEERING↗

NASA NTRSDate not supplied

Effects of Varying the Heat Transfer Coefficient on Engine Performance

A physics-based Nuclear Thermal Propulsion (NTP) Testing Reference Design (TRD) power balance model was coded in Simulink to investigate engine performance for various design and parameter modifications. Since the primary mode of heat transfer in NTP engines is convective, the convective heat transfer coefficient (HTC) is a key parameter that requires accurate representation. The industry standard Westinghouse correlation has an uncertainty of ±20% which was investigated in this study. The results showed that a 20% decrease in the HTC led to a 4.14% increase in maximum fuel temperature while a 20% decrease in the HTC led to a 1.81% decrease in maximum fuel temperature suggesting that narrowing the uncertainty of this correlation through experimental work would be a critical step in the development of NTP engines. Furthermore, a maximum fuel temperature relationship with specific impulse was developed for the TRD engine which showed potential engine operation between specific impulse values of 715 and 900 seconds with minimal changes to the engine design. This graph could be useful for high level vehicle performance estimations for fuel types with different maximum operating temperatures.

Heat Transfer Coefficient↗

NASA NTRSDate not supplied

Effects of Heat Transfer Coefficient Variation on Nuclear Thermal Propulsion Engine Performance

Heat Transfer Coefficient↗

NASA NTRS2012

Fabrication and Testing of CERMET Fuel Materials for Nuclear Thermal Propulsion

A first generation Nuclear Cryogenic Propulsion Stage (NCPS) based on Nuclear Thermal Propulsion (NTP) is currently being developed for Advanced Space Exploration Systems. The overall goal of the project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of NTP systems. The current technology roadmap for NTP identifies the development of a robust fuel form as a critical near term need. The lack of a qualified nuclear fuel is a significant technical risk that will require a considerable fraction of program resources to mitigate. Due to these risks and the cost for qualification, the development and selection of a primary fuel must begin prior to Authority to Proceed (ATP) for a specific mission. The fuel development is a progressive approach to incrementally reduce risk, converge the fuel materials, and mature the design and fabrication process of the fuel element. A key objective of the current project is to advance the maturity of CERMET fuels. The work includes fuel processing development and characterization, fuel specimen hot hydrogen screening, and prototypic fuel element testing. Early fuel materials development is critical to help validate requirements and fuel performance. The purpose of this paper is to provide an overview and status of the work at Marshall Space Flight Center (MSFC).

Hickman, Robert↗