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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report

This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.

03 NATURAL GAS↗
DOE OSTI1993

Nuclear Safety [Vol. 34, No. 1, January-March 1993]

Nuclear Safety is a review journal that covers significant developments in the field of nuclear safety. Its scope includes the analysis and control of hazards associated with nuclear energy, operations involving fissionable materials, and the products of nuclear fission and their effects on the environment. Primary emphasis is on safety in reactor design, construction, and operation; however, the safety aspects of the entire fuel cycle, including fuel fabrication, spent-fuel processing, nuclear waste disposal, handling of radioisotopes, and environmental effects of these operations, are also treated. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 1 An Integrated Regional Approach To Risk Management of Industrial Systems, S. Chakraborty and R. Stratton; 9 Annual Technical Meeting of the NRC Cooperative Severe Accident Research Program, E. G. Silver; ACCIDENT ANALYSIS: 13 Deterministic Severe Accident Criteria as Severe Accident Design Criteria and Policy for the New Production Reactor-Heavy Water Reactor, P. T. Rhoads; 20 Proposed Deterministic Severe Accident Criteria for the Heavy Water Reactor-New Production Reactor Containment, K. D. Bergeron, S. E. Slezak, and C. E. Leach; 33 Quasi-Static Core Liquid Level Depression and Long-Term Core Uncovery During a PWR LOCA, Y. Kukita, R. R. Schultz, H. Nakamura, and J. Katayama; 49 LIRA: An Advanced Containment System to Minimize the Accidental Radioactivity Releases, A. Turricchia; 63 Errata to “A Review of Hydrogen Production During Melt/Water Interaction in LWRs,” Vol. 33, No. 4; CONTROL AND INSTRUMENTATION: 64 The Nuplex 80+™ Advanced Control Complex from ABB Combustion Engineering, F. Ridolfo, D. Harmon, and K. Scarola; DESIGN FEATURES: 76 A Scheme for Passive Isolation of the Containment of a Reactor, A. K. Ghosh, V. V. Raj, and K. Kakodkar; 84 Utility Requirements for Safety in the Passive Advanced Light-Water Reactor, T. U. Marston, W. H. Layman, and G. Bockhold, Jr.; WASTE AND SPENT FUEL MANAGEMENT: 91 Activities Related to Waste and Spent Fuel Management, Compiled by M. D. Muhlheim and E. G. Silver; OPERATING EXPERIENCES: 103 Testing Deficiencies in Auxiliary Systems Feedwater Systems, J. D. Kueck; 110 Reactor Shutdown Experience, Compiled by J. W. Cletcher; 113 Selected Safety-Related Events, Compiled by G. A. Murphy; 115 Operating U.S. Power Reactors, Compiled by M. D. Muhlheim and E. G. Silver; RECENT DEVELOPMENTS: 133 General Administrative Activities, Compiled by M. D. Muhlheim and E. G. Silver; 145 Reports, Standards, and Safety Guides, D. S. Queener; 150 Proposed Rule Changes as of Sept. 30, 1992; ANNOUNCEMENTS: 75 Harvard Short Course on Risk: Science, Assessment, and Management; 102 International Conference on Reactor Physics and Reactor Computations; 102 The Fourth International Conference on Nuclear Waste Reprocessing and Waste Management [RECOD ’94]; 132 International Symposium on the Radiological Exposure of the Population of the European Community from Radioactivity in the Mediterranean Sea [MARINA-MED]; 162 International High-Level Radioactive Waste Conference ‘Technology Integration—Above and Below”; 154 The Authors; 158 Indexes to Nuclear Safety, Volume 33.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2003

Pulsed Magnetic Field Driven Gas Core Reactors for Space Power & Propulsion Applications

The present results indicated that: 1. A pulsed magnetic driven fission power concept, PMD-GCR is developed for closed (NER) and semi-open (NTR) operations. 2. In power mode, power is generated at alpha less than 1 for power levels of hundreds of KW or higher 3. IN semi open NTR mode, PMD-GCR generates thrust at I(sub sp) approx. 5,000 s and jet power approx. 5KW/Kg. 4. PMD-GCR is highly subcritical and is actively driven to critically. 5. Parallel path with fusion R&D needs in many areas including magnet and plasma.

Samim Anghaie↗
NASA NTRSDate not supplied

The Future of Oaks in the Santa Monica Mountains: A Case Study in Using Remote Sensing Data for Species Distributions Models

The Woolsey Fire began on November 8, 2018, and lasted for almost two weeks, during which it burned almost 100,000 acres of valuable landscape and habitat, including a vast area of woodland. The persistence of key woodland species provides aesthetic, monetary, and ecological value to the landscape through carbon sequestration, air temperature moderation, and erosion mitigation, among other ecosystem services. This study investigated the impact of the Woolsey Fire on native woodland species distributions and identified areas suitable for restoration within the Santa Monica Mountains National Recreation Area. The team partnered with the Resource Conservation District of the Santa Monica Mountains; National Park Service, Santa Monica Mountains National Recreation Area; California Department of Parks and Recreation, Los Angeles County Division; County of Los Angeles Fire Department, Prevention Services Bureau, Forestry Division; County of Los Angeles Department of Regional Planning; and the University of Montana. The Earth observations used include data from Landsat 8 Operational Land Imager, NASA ER-2 Jet Airborne Visible InfraRed Imaging Spectrometer, Shuttle Radar Topography Mission, and RapidEye. The team produced maps of burn severity from the Woolsey Fire, its impact on plant species distributions, and habitat suitability projections for 2050 and 2099 to assist partners in prioritizing areas for restoration. A plant community classification was successfully created using Multiple Endmember Spectral Mixture Analysis (MESMA). Overall accuracy was assessed at 90.54% by comparing the classification to validation pixels derived from ground truth information provided by our partners.

Roger Ly↗
DOE OSTI2024

Fast, Nondestructive and Precise Biomass Measurements Are Possible Using Lidar-Based Convex Hull and Voxelization Algorithms

Light detection and ranging (lidar) scanning tools are available that can make rapid digital estimations of biomass. Voxelization and convex hull are two algorithms used to calculate the volume of the scanned plant canopy, which is correlated with biomass, often the primary trait of interest. Voxelization splits the scans into regular-sized cubes, or voxels, whereas the convex hull algorithm creates a polygon mesh around the outermost points of the point cloud and calculates the volume within that mesh. In this study, digital estimates of biomass were correlated against hand-harvested biomass for field-grown corn, broom corn, and energy sorghum. Voxelization (r = 0.92) and convex hull (r = 0.95) both correlated well with plant dry biomass. Lidar data were also collected in a large breeding trial with nearly 900 genotypes of energy sorghum. In contrast to the manual harvest studies, digital biomass estimations correlated poorly with yield collected from a forage harvester for both voxel count (r = 0.32) and convex hull volume (r = 0.39). However, further analysis showed that the coefficient of variation (CV, a measure of variability) for harvester-based estimates of biomass was greater than the CV of the voxel and convex-hull-based biomass estimates, indicating that poor correlation was due to harvester imprecision, not digital estimations. Overall, results indicate that the lidar-based digital biomass estimates presented here are comparable or more precise than current approaches.

Environmental Sciences & Ecology↗
DOE OSTI2026

ClassNMSW- a real-time classification approach for non-recycled municipal solid waste using hyperspectral imaging

Real-time classification of non-recycled municipal solid waste (NMSW) is essential for efficient valorization. This study introduces ClassNMSW, a comprehensive framework for classifying 22 NMSW subclasses under industrial constraints by using hyperspectral imaging (HSI). A primary innovation of this work is the development of a variance-controlled spectral extraction algorithm. Unlike traditional methods that rely on simple averaging, this approach systematically investigates the extent of pixel extraction to minimize the loss of critical chemical information while maximizing data reduction thus ensuring high spectral fidelity with low computational cost. The approach developed in this work integrates automated, computer-vision-based background removal, eliminating the need for the manual thresholding common in current literature. To resolve ambiguities among chemically similar subclasses, a tiered classification and multi-camera fusion strategy (NIR17 and NIR22) is implemented. Results demonstrate that ClassNMSW achieves an object-wise weighted accuracy of 98.70% for single-sensor configurations and 100% under sensor fusion. A novel rolling-window strategy satisfies desired end-to-end latency of <2 s, satisfying the strict deterministic requirements of high-speed industrial sorting environments. The ClassNMSW framework provides a scalable foundation for advancing circularity and resource recovery in large-scale waste valorization operations.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

An Analysis of Energy Needs and Seawater Extraction Approaches for the Integration of Primary Magnesium Production with Nuclear Power

The cost of primary magnesium production is highly dominated by the energy required to produce the metal. This, along with the current geographical concentration of its production, makes the magnesium price vulnerable as energy-production paradigms begin to rapidly change. In this work, four nuclear-integration pathways for the efficient supply of heat and electricity to magnesium production from a nuclear power plant are considered. A production route using electrified metallothermic reduction is compared to a nuclear-heat-integrated electrolytic pathway. It is shown that the latter can achieve significantly lower primary energy consumption, 261 MJ/kg Mg compared with 416 MJ/kg Mg. The electrolytic pathway can also reduce emissions down to around 2.1 kgCO2/kg Mg, compared to around 34 kgCO2/kg Mg in the Pidgeon process. Beyond energy and emissions, the four pathways considered are also compared to their ability to reduce locational dependence of the production plant and reduce process complexity. This work also highlights future advances in magnesium production with a potential scheme for the efficient extraction of magnesium from seawater with coproduction of desalinated water and the potential of demand-side response from magnesium electrolysis. This is the first work to consider the full integration of primary magnesium production using nuclear cogeneration, and it is hoped the study paves the way for the analysis of economic nuclear integration within metal extraction and manufacturing.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Coordinated Natural Gas and Electric Planning: Case Studies of Current Approaches and Practices

This paper examines how natural gas and electric utilities across eight U.S. states and two Canadian provinces are beginning to coordinate historically separate planning processes in response to growing system interdependencies, policy mandates, aging infrastructure, and changing customer energy choices. Electricity planning has long relied on robust integrated resource planning frameworks that weigh numerous objectives, risks, and costs. Natural gas planning, on the other hand, is typically less transparent and more narrowly focused on safety and system integrity. As economic, reliability, and policy drivers place new and shared demands on both systems, jurisdictions and utilities are experimenting with approaches such as coordinated forecasting, non pipeline alternatives, and combined planning pilots. A few have issued regulatory or statutory directives for greater data sharing and methodological alignment. Case studies from British Columbia, California, Colorado, Illinois, Massachusetts, Minnesota, New York, Québec, Rhode Island, and Washington illustrate a wide range of approaches to rethinking siloed planning. The paper identifies several common themes across the jurisdictions examined. It provides observations on the methods, processes, and organizational steps that may be needed in the future to address the challenges being faced by states and utilities. Lastly, it identifies some initial steps that states and utilities can consider if they would like to pursue more integrated, cost-effective, policy-aligned energy system planning.

03 NATURAL GAS↗
NASA NTRS1977

Observations of the microclimate of a lake under cold air advective conditions

The moderating effects of Lake Apopka, Florida, on downwind surface temperatures were evaluated under cold air advective conditions. Point temperature measurements north and south of the lake and data obtained from the NOAA satellite and a thermal scanner flown at 1.6 km, indicate that, under conditions of moderate winds (approximately 4m/sec), surface temperatures directly downwind may be higher than surrounding surface temperatures by as much as 5 C. With surface wind speed less than 1m/sec, no substantial temperature effects were observed. Results of this study are being used in land use planning, lake level control and in agriculture for selecting planting sites.

R. G., Jr. Bill↗
NASA NTRS2003

Concept to Reality: Contributions of the Langley Research Center to US Civil Aircraft of the 1990s

This document is intended to be a companion to NASA/SP-2000-4519, Partners in Freedom: Contributions of the Langley Research Center to U.S. Military Aircraft of the 1990s . Material included in the combined set of volumes provides informative and significant examples of the impact of Langley's research on U.S. civil and military aircraft of the 1990s. This volume, 'Concept to Reality: Contributions of the NASA Langley Research Center to U.S. Civil Aircraft of the 1990s', highlights significant Langley contributions to safety, cruise performance, takeoff and landing capabilities, structural integrity, crashworthiness, flight deck technologies, pilot-vehicle interfaces, flight characteristics, stall and spin behavior, computational design methods, and other challenging technical areas for civil aviation. The contents of this volume include descriptions of some of the more important applications of Langley research to current civil fixed-wing aircraft (rotary-wing aircraft are not included), including commercial airliners, business aircraft, and small personal-owner aircraft. In addition to discussions of specific aircraft applications, the document also covers contributions of Langley research to the operation of civil aircraft, which includes operating problems. This document is organized according to disciplinary technologies, for example, aerodynamics, structures, materials, and flight systems. Within each discussion, examples are cited where industry applied Langley technologies to specific aircraft that were in operational service during the 1990s and the early years of the new millennium. This document is intended to serve as a key reference for national policy makers, internal NASA policy makers, Congressional committees, the media, and the general public. Therefore, it has been written for a broad general audience and does not presume any significant technical expertise. An extensive bibliography is provided for technical specialists and others who desire a more in-depth discussion of the contributions.

NASA History Series↗
NASA NTRSDate not supplied

Evaluations of Additively Manufactured Superalloy Lattice Blocks

Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.

superalloy↗
NASA NTRS1977

Calculations of the Moon's Thermal History at Different Concentrations of Radioactive Elements, Taking Into Account Differentiation on Melting

Calculations of the thermal history of the moon were carried out by solving the thermal conductivity equation for the case in which the heat sources are the long-lived radioactive elements Th, U, and K 40 . The concentrations of these elements were adjusted to give four variations of the heat flow: 1.35 x 10 -8 and 0.91 x 10 -6 cal cm -2 s -1 (I and I**), 0.61 x 10 -6 (variant II, the terrestrial mixture of Lyubimova and Starkova), and 0.236 x 10 -6 (variant III, the chondrite model of Urey and MacDonald). In the same calculations, we considered layering of the differentiated material with transport to the surface of the radioactive elements after the temperature of the layer rose to 200 K above the melting temperature, which is considered in five variants that differ in the amount of transported radioactive elements: 100 percent ( n = 1), 80 percent n = 0.8), 40 percent, 20 percent ( n = 0.6, 0.4, 0.2). During fusion the heat capacity and heat conductivity were changed. We considered two variants of an initially cold (273 K) and hot (900 K) Moon. Calculations show that the interior of the Moon was heated to melting during the first 0.7 to 2.3 x 10 9 years. The maximum fusion involved practically the entire Moon to a distance from 15 to 45 km beneath the surface, and started 3.5 to 4.0 x 10 9 years ago (I, I**), or 2.5 to 3.0 x 10 9 years ago (II, III) and continued for 1 to 2 x 10 9 years. Today the Moon is cooling. The current thickness of the solid crust is from 150 to 200 km and the heat flow exceeds the stationary value 1.5 fold. Apparently the most realistic variant is II (terrestrial mixture) for an initially hot Moon, and gives, regardless of the moderate concentration of radioactive elements, a heat flow of 0.9 to 0.95 x 10 -6 cal cm -2 s -1 , which agrees with the radioastronomical measurements of Troitsky and Krotikov and with the Apollo 15 data.

O I Ornatskaya↗
DOE OSTI2026

Utilization of Unmanned Aircraft Systems for Environmental Purposes at the Savannah River Site – 26578

Born in the 1950s, the Savannah River Plant was constructed as a plutonium and tritium production plant. As the Cold War era came and went, a change of direction was signaled when the name of the facility changed from Savannah River Plant to Savannah River Site (1989) – the main mission at Savannah River shifted from “production” to “cleanup.” The Department of Energy is responsible for managing the 310 square miles of land that is the Savannah River Site and the cleanup/remediation activities that occur. The Savannah River National Laboratory utilizes unmanned aircraft systems to assist with some of those environmental monitoring and remediation activities. One function of unmanned aircraft systems at the Savannah River National Laboratory is conducting aerial photography and videography. Various infrastructure evaluations have been performed with unmanned aircraft – facility rooftop inspections, water tower lock verifications, earthen dam surveys, etc. An unmanned aircraft system has been used for progress footage of remediation projects – Dunbarton Bay remediation, Saltstone Disposal Unit construction, etc. Thermal cameras on an unmanned aircraft system are used to help identify cracks/leaks in structures from vantage points not readily accessible by personnel. Virtual tours of different waste units are conducted with unmanned aircraft systems for Site groups and federal/state regulators to save costs and travel time. Additionally, advanced remote sensing technologies are used on unmanned aircraft systems at the Savannah River Site. Light Detection and Ranging uses laser pulses to measure distances to the Earth's surface or other targets to create highly detailed topographic maps that accurately portray terrain (e.g., elevation changes, slopes, and contours). Data collection with a Light Detection and Ranging unit mounted on an unmanned aircraft system is quick and efficient – large-area surveys are conducted in shorter time frames. Because Light Detection and Ranging can penetrate through foliage and vegetation to ground level, it is being used in conjunction with a watershed model to study the General Separations Area of the Site to determine stormwater flow volume and direction, monitor stream stability, and forecast river flow behavior. A hyperspectral camera captures a wide spectrum of electromagnetic wavelengths across numerous narrow bands, beyond what the human eye can see. It provides detailed spectral information about the objects or surfaces in an image, which can be used to identify and analyze materials based on their spectral signatures. A hyperspectral camera mounted on an unmanned aircraft system has been used at the Savannah River Site for non-destructive evaluation of concrete and concrete structures. Unmanned aircraft systems at the Savannah River Site are also used for the application of herbicide on identified rooftops. P-Reactor and R-Reactor are entombed nuclear reactors at the Savannah River Site. Unwanted vegetation is often present on these rooftops – over time roots can penetrate seams, cracks, and joints of the general roof and concrete caps, leading to water ingress and deterioration of the structural components. For time and cost efficiencies as well as in the interest of personnel safety, an unmanned aircraft is used to dispense herbicide on rooftop areas where vegetation is noticed to help alleviate the issues/hazards.

Lorier, Troy [Savannah River National Laboratory (↗
DOE OSTI2026

Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS)

Opportunities exist for realizing transformative advances in productivity and reductions in energy footprint through ubiquitous sensing in manufacturing environments. Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS) is a 21-month (4 academic semesters, plus one summer) experience for graduate students that focuses on scaling the knowledge, understanding and leadership skills in the cyber manufacturing area. Masters students (8/year, 32 total) complete 2-year projects on industrially-driven project topics, rotating to internships in summer semester to work on scoping and implementation at project partners. Students complete academic training in embedded systems, process modeling, data science, and cloud-based systems design. Their projects are targeted toward sensor retrofit, process monitoring, root cause analysis, and sensor fusion.

Advanced Manufacturing↗
DOE OSTI2024

The first high-redshift cavity power measurements of cool-core galaxy clusters with the International LOFAR Telescope

Radio-mode feedback associated with the active galactic nuclei (AGNs) at the cores of galaxy clusters injects a large amount of energy into the intracluster medium (ICM), offsetting radiative losses through X-ray emission. This mechanism prevents the ICM from rapidly cooling down and fueling extreme starburst activity as it accretes onto the central galaxies, and it is therefore a key ingredient in the evolution of galaxy clusters. However, the influence and mode of feedback at high redshifts (z ∼ 1) remains largely unknown. Low-frequency sub-arcsecond-resolution radio observations taken with the International LOFAR Telescope have demonstrated their ability to assist X-ray observations with constraining the energy output from the AGNs (or “cavity power”) in galaxy clusters, thereby enabling research at higher redshifts than before. In this pilot project, we tested this hybrid method on a high-redshift (0.6 < z < 1.3) sample of 13 galaxy clusters for the first time with the aim of verifying the performance of this method at these redshifts and providing the first estimates of the cavity power associated with the central AGN for a sample of distant clusters. We were able to detect clear radio lobes in three out of 13 galaxy clusters at redshifts of 0.7 < z < 0.9, and we used these detections in combination with ICM pressures surrounding the radio lobes obtained from standard profiles to calculate the corresponding cavity powers of the AGNs. Combining our results with the literature, the current data appear to suggest that the average cavity power peaked at a redshift ofz ∼ 0.4 and slowly decreases toward higher redshifts. However, we require more and tighter constraints on the cavity volume and a better understanding of our observational systematics to confirm any deviation of the cavity power trend from a constant level.

Astronomy & Astrophysics↗
DOE OSTI2026

Technoeconomic Studies for the Rorex Creek Pumped Storage Hydro Project: An Evaluation of New Pumped Storage Hydro in the Tennessee Valley Authority System

This report evaluates the economic viability of the proposed 1,200 MW, 23,365 MWh Rorex Creek Pumped Storage Hydro (PSH) plant that would be located near Pisgah, Alabama. In addressing this question, this study has developed processes, models and data that better value PSH from a utility perspective, more specifically a vertically integrated utility, enabling optimal PSH design and deployment. This study is designed to enhance TVA’s toolset in making PSH investment decisions and contribute to the design of a more cost-effective, stable future grid. These techniques can then be applied to a broader range of assets and utilities.

Cohen, Stuart↗
DOE OSTI2026

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗
NASA NTRSDate not supplied

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing↗