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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗
NASA NTRS1999

Shuttle and Transfer Orbit Thermal Analysis and Testing of the Chandra X-Ray Observatory Charge-Couple Device Imaging Spectrometer Radiator Shades

Thermal analyses of the Shuttle and Transfer Orbit of the Advanced X-Ray Astrophysics Facility Charge-Coupled Device (CCD) Imaging Spectrometer (ACIS), one of two science instruments on the Chandra X-Ray Observatory, revealed a low-earth orbit (LEO) overheating problem on the goldized Kapton faces of two radiator shades. The shades were coated with the goldized Kapton to provide a low hemispherical emittance to minimize direct and backloaded heating from the sun and the observatory and high specularity to optimize the coupling to space on two passive radiators which cool the focal plane to -120 C +/- 1 C during on-orbit operations. Since the observatory has a highly elliptical final orbit of 10,000 kilometers by 140,000 kilometers and the ACIS radiators and shades are oriented anti-sun, the high solar absorptance to emittance ratio of the goldized Kapton was not an issue. However, during Shuttle bay-to-earth operations, the short duration solar heating occurring near the eclipse entry and exit resulted in shade temperatures in excess of the cure temperature of the adhesive used to bond the goldized Kapton and honeycomb face-sheets. The detailed thermal analysis demonstrating the LEO overheating as well as the redesign options and thermal testing of a redesigned development unit shade are presented.

Sharp, John R.↗
DOE OSTI2022

Hydration of alumina (Al 2 O 3 ) toward advancing aluminum particles for energy generation applications

Transforming metal particle combustion may require alteration of the metal oxide passivation shell surrounding the metal core. One approach for aluminum (Al) relies on the hydrated form of the metal oxide to incite surface reactions. Here, this study explores the conditions required for hydrating alumina (Al 2 O 3 ) particles and then extends those conditions toward hydration of the Al 2 O 3 passivation layer surrounding an Al core particle. By raising the pH of the water slurry to 11 and controlling temperature and time in slurry (i.e., aging), aluminum hydroxide Al(OH) 3 formation from Al 2 O 3 particles was optimized. The procedure was then extended to Al nanoparticles (nAl). Even though heating and extended aging time in slurry proved advantageous for Al 2 O 3 particles, these conditions were discarded for nAl particles because they favored formation of AlOOH, a less desirable hydrate. Through microscopy, spectroscopy, X-ray diffraction, and thermal analyses, results indicate that for a pH range of 11.26–11.56, the original Al 2 O 3 shell on Al particles transformed into Al(OH) 3 . Results indicate a feasible path forward towards producing new shell chemistries that may result in more directed energy from metal particle combustion.

36 MATERIALS SCIENCE↗
DOE OSTI2026

ROADRUNNER uranium nitride MiniFuel: Experimental design, fabrication and pre-irradiation baseline characterization for accelerated burnup testing

Uranium nitride (UN) is a promising fuel candidate for advanced reactor systems owing to its high uranium density and thermal conductivity; however, its qualification remains constrained by the scarcity of well-controlled irradiation performance data. Here, to address this limitation, the ROADRUNNER (Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments) campaign employs the MiniFuel platform in the High Flux Isotope Reactor (HFIR) to enable accelerated burnup irradiation testing under tightly controlled and largely isothermal conditions. This paper presents the experimental design, fuel fabrication, and pre-irradiation baseline characterization of the ROADRUNNER UN MiniFuel campaign. Thirty-six UN minidisc specimens were fabricated with systematically varied as-fabricated density (86–96% of theoretical density), carbon impurity content (961–5240 ppm), oxygen content (≤ ∼2000 ppm), and grain size (2.5–24 μm). The irradiation matrix spans nominal fuel temperatures of 873 K, 1173 K, and 1473 K and target burnups of 3.75%, 6.0%, and 7.5% fissions per initial metal atom (FIMA). Neutronic and thermal analyses were performed to define specimen-specific burnup accumulation and temperature histories, establishing the boundary conditions for subsequent in-pile behavior. Comprehensive pre-irradiation characterization—including dimensional metrology, density verification, impurity analysis, X-ray diffraction, Raman spectroscopy, scanning electron microscopy, X-ray computed tomography, and confocal profilometry—provides a detailed baseline for post-irradiation examination. Pre-irradiation data were further used to generate predictive estimates of fission gas release and swelling using existing empirical correlations. This quantitative comparison reveals substantial inter-model divergence at intermediate and elevated temperatures that exceeds propagated input uncertainties, highlighting structural gaps in the historical irradiation database. The ROADRUNNER irradiation campaign is currently underway in HFIR, with initial firs cycle completed in late 2025 and remaining targets scheduled through 2027. The experimental design and baseline dataset presented here establish the framework needed to interpret forthcoming post-irradiation measurements and to provide discriminating data for the validation and refinement of physics-based UN fuel performance models.

Lopes, Denise Adorno [Oak Ridge National Laborator↗
DOE OSTI2026

A structural and electrochemical study of perfluoropolyether-poly(ethylene oxide) solid polymer electrolytes

Solid polymer electrolytes offer attractive safety, processability, and interfacial adhesion for enabling high–energy solid-state lithium batteries, but they are often limited by narrow oxidative stability windows and low lithium-ion transference numbers. In an attempt to broaden the electrochemical stability window and increase lithium-ion transference number of poly(ethylene oxide) (PEO)-based solid polymer electrolytes, we produce an optically clear, crosslinked membrane of PEO and perfluoropolyether (PFPE) using a mixed solvent method and subsequently infuse the membrane with a lithium salt. Structural and thermal analyses reveal nanoscale phase separation between fluorocarbon and hydrocarbon domains with characteristic spacings of 7–8 nm and an elevated glass transition for the hydrocarbon phase. Consistent with this, PFPE-containing membranes exhibit substantially lower ionic conductivity than PEO analogs (dry and plasticized). The transference number and electrochemical stability are similar to pure PEO. These results demonstrate that fluorination implemented as segregated nanoscale domains does not deliver the anticipated transport or stability benefits; instead, phase separation increases tortuosity and suppresses hydrocarbon-phase dynamics. The work underscores the importance of fluorine placement and morphology control, guiding the design of partially fluorinated solid polymer electrolytes toward architectures that avoid detrimental nanoscale phase separation.

Carden, Peyton [ORNL] (ORCID:0000000162296538)↗
DOE OSTI2020

Reactions during conversion of simplified low-activity waste glass feeds

The mechanisms that affect the incorporation of 99Tc, a volatile radioactive component of concern, into glass melt during vitrification of low-activity waste (LAW) are being investigated to develop the method to increase the retention of 99Tc in glass waste form. Previous studies with simulated LAW glass feeds (slurry mixture of liquid waste and chemical/mineral additives) demonstrated that the early stage feed-to-glass conversion reactions below 800°C are critical for the Re (used as a nonradioactive surrogate of 99Tc) retention in glass. To examine the effect of feed composition on the feed-to-glass conversion reactions, simplified systems containing major LAW components (NaNO3 and NaOH) and representative additive components (SiO2 and H3BO3) were designed and tested. The ratio of H3BO3 to NaNO3 was varied in three-component system without NaOH and that of NaOH to NaNO3 was varied in the four-component system at a fixed H3BO3 to NaNO3 ratio. As a first step of testing with simplified feeds, this study applied thermal analyses and phase characterization of the reacting feeds, which were performed without the addition of Re, to investigate the evolution of salt phases during slurry drying process and upon heating of dried feeds.

Jin, Tongan↗
DOE OSTI2020

A Comprehensive Review of Permanent Magnet Transverse Flux Machines: Use in Direct-Drive Applications

The use of direct-drive machines in renewable and industrial applications is increasing at a rapid rate. Transverse flux machines (TFMs) are ideally suited for direct-drive applications due to their high torque density. This article presents a comprehensive review of permanent magnet (PM) TFMs for direct-drive applications. It introduces TFMs and their operating principle and reviews the different types of TFMs proposed in the literature. TFMs are categorized by the number of stator sides, types of stator cores, and magnet arrangement in the rotor. The review covers different design topologies, materials used for manufacturing, structural and thermal analyses, modeling, design optimization, and cogging torque minimization in TFMs. The article also examines various applications and comparisons for TFMs presented in the literature.

air gaps↗
DOE OSTI2025

Effect of calcite filler on carbonation behavior in a synthesized C‐S‐H binder

Widespread implementation of portland limestone cements (PLC) in industry has raised new questions about their carbonation resistance due to higher initial limestone content than ordinary portland cement. While carbonation of portland cement and each of its hydrate phases has been studied at a fundamental level, the integral role of how limestone fillers interact chemically or physically during carbonation necessitates further study. In this study, a C-S-H binder comprised of a highly reactive zeolite pozzolan and lime was used to evaluate the effect of varying calcite additions on carbonation behavior at a microstructural level. Fundamental insight into hydration kinetics and carbonation mechanisms of hydraulic binders was obtained via analysis of the C-S-H and calcite microstructure. X-ray microcomputed tomography (X-ray CT) was used to quantify microstructural changes, and the results showed a decrease in shrinkage for increased calcite dosages, with a ∼50% reduction observed for a 45% wt. calcite replacement level. Crystallographic and thermal analyses measured compositional changes in the binder and confirmed that shrinkage was related to the decalcification of C-S-H. Furthermore, the addition of calcite to the C-S-H binder effectively reduced the liquid-to-solid ratio, porosity, and amount of C-S-H present in these binders. Ultimately, these results help elucidate how the carbonation risks of PLC can be mitigated by proportioning the mixture water only to the reactive component of the binder.

C-S-H↗
DOE OSTI2022

INGENIOUS - Great Basin Regional Dataset Compilation

This is the regional dataset compilation for the INnovative Geothermal Exploration through Novel Investigations Of Undiscovered Systems (INGENIOUS) project. The primary goal of this project is to accelerate discoveries of new, commercially viable hidden geothermal systems while reducing the exploration and development risks for all geothermal resources. These datasets will be used in INGENIOUS as input features for predicting geothermal favorability throughout the Great Basin study area. Datasets consist of shapefiles, geotiffs, tabular spreadsheets, and metadata that describe: 2-meter temperature probe surveys, quaternary faults and volcanic features, geodetic shear and dilation models, heat flow, magnetotellurics (conductance), magnetics, gravity, paleogeothermal features (such as sinter and tufa deposits), seismicity, spring and well temperatures, spring and well aqueous geochemistry analyses, thermal conductivity, and fault slip and dilation tendency. For additional project information, see the INGENIOUS project site linked in the submission. Terms of use: These datasets are provided "as is", and the contributors assume no responsibility for any errors or omissions. The user assumes the entire risk associated with their use of these data and bears all responsibility in determining whether these data are fit for their intended use. These datasets may be redistributed with attribution (see citation information below). Please refer to the license information on this page for full licensing terms and conditions.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Analysis and Design for Irradiation of High Power TRISO Fuel Compact Specimens in HFIR

Tristructural isotropic (TRISO) fuel is being proposed for use in several high-temperature advanced reactor concepts because of its structural integrity under high operating temperatures and burnup. One of these advanced reactor concepts is the Kairos Power fluoride salt-cooled high-temperature reactor (KP- FHR) under development by Kairos Power, LLC. Previous TRISO irradiation experiments were focused on qualification for high-temperature gas reactors (HTGRs), which have higher operating temperatures but lower particle powers than the KP-FHR design. To study the performance of TRISO fuel designed for HTGRs under prototypical FHR conditions, a set of experiments was designed using the MiniFuel irradiation vehicle at the Oak Ridge National Laboratory’s (ORNL) High Flux Isotope Reactor (HFIR). The experiments will irradiate 30 TRISO-containing carbon matrix compacts at inner small vertical experiment facilities in HFIR. Each compact will contain 20 TRISO particles (600 particles total) developed for HTGRs, consisting of either 14% enriched uranium dioxide uranium carbide, naturally enriched uranium dioxide, uranium carbide, or 9.6% enriched uranium dioxide fuel kernels with time- and volume-averaged silicon carbide layer temperatures between 500 and 900°C. This report summarizes the vehicle designs that have been developed, as well as the neutronic and thermal analyses completed for these irradiation experiments. These analyses show that MiniFuel compact irradiation is a versatile experiment that can be used to study a range of TRISO particle powers and fuel types while providing reasonable separation of burnup and temperature effects.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Beam Induced Heating Analysis Update for the EIC Vacuum Chamber Components

One of the challenges of designing the Electron-Ion Col lider (EIC) is to mitigate beam-induced heating due to the intense electron and hadron beams. Heating of the ESR vac uum chamber components is mainly due to beam-induced resistive wall (RW) losses and synchrotron radiation. For the HSR heating is mainly due to large radial offsets and heat conduction from room temperature to cryogenic tem perature for cryo-components. In this paper, we provide an update on the beam-induced heating and thermal analysis of some critical ESR vacuum chamber components, such as the ESR Large Angle Bremhustraulung Monitor (LABM). We also provide a similar update for critical HSR vacuum com ponents, including the cryo-cooled BPM button assembly, beam screen, abort kicker, and polarimeter. To perform the thermal analyses, the resistive wall loss on individual compo nents is calculated with CST and the synchrotron radiation (if exists) is evaluated using SynRad. These losses, along with realistic boundary conditions are then fed to ANSYS to determine the temperature distribution.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

ROADRUNNER MiniFuel Experiment: Irradiation Target Design and Sample Characterization

High-density uranium nitride (UN) is a fuel candidate for several advanced nuclear reactor designs currently under development. Because there are limited UN performance data relative to fuel fabrication impurity and density variation, an irradiation campaign has been developed as part of a collaborative effort among the University of Texas at San Antonio (UTSA), Westinghouse Electric Company, Oak Ridge National Laboratory (ORNL), and Los Alamos National Laboratory (LANL) under the Nuclear Science User Facilities program. This project, entitled ROADRUNNER, or Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments, aimsto support UN fuel qualification for advanced reactors by investigating the impact of density and impurity variations on UN performance as a function of irradiation temperature and burnup. The MiniFuel experiment vehicle developed by ORNL, which leverages the High Flux Isotope Reactor, was selected to perform this accelerated separate-effects irradiation testing. The experiment test matrix consists of six MiniFuel targets containing miniature UN fuel disks, and targets three distinct burnup levels (37.5, 60, and 75 MWd/kg U) and three distinct temperatures (600, 900, and 1200°C). Neutronics and thermal analyses were performed to determine the experimental parameters needed to meet the desired irradiation conditions and to predict the experiment components temperatures. UN pellets were fabricated at LANL with tightly controlled parameters to produce specimens with three distinct densities and three levels of carbon content. The pellets were then thinned down by UTSA to the experiment-required thickness. The pre-characterization of the specimens includes density measurements, carbon and oxygen contents, microstructure analysis, and x-ray computed tomography. The selected specimens will be assembled into the MiniFuel experiment, and the first ROADRUNNER MiniFuel targets are intended for HFIR insertion during the Fall of 2024. After irradiation, the targets will be shipped to ORNL’s hot cell facility for disassembly. The post-irradiation examination on the fuel specimens includes fission gas release measurements, visual inspection, fuel swelling measurements, gamma spectroscopy, and microstructure analysis. The data collected post-irradiation will be used to develop fuel performance models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

AMMT Round Robin 316H HFIR Irradiation Test Matrix and Readiness for Insertion

The Round Robin 316H HFIR-2 irradiation campaign, conducted under the Advanced Materials and Manufacturing Technologies (AMMT) Program, is designed to evaluate the variability in irradiation response of laser powder bed fusion (LPBF) stainless steel (SS)-316H across multiple national laboratories, powder heats, and processing conditions, with comparison to wrought counterparts. A total of 11 materials are intended for irradiation in the High Flux Isotope Reactor (HFIR), targeting two irradiation temperatures (400°C and 600°C) and one level of irradiation damage (2 dpa). This irradiation campaign utilizes the standardized general tensile (GENTEN) capsule design to accommodate subsized tensile specimens of these materials. Thermal analyses were performed to ensure appropriate temperature control by design and uniformity within the capsules. All the capsules for this irradiation except one have been successfully assembled, welded, and tested and are ready for HFIR insertion. The last capsule requires re-build following a failed weld. All eight capsules are intended to be inserted in HFIR cycle 517, which is scheduled to start September 8, 2026. This report summarizes the design, material selection, and readiness for insertion of the capsules.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Irradiation of Advanced Cladding Specimens in the High Flux Isotope Reactor: Capsule Designs and Test Matrix

The Advanced Fuels Campaign (AFC) has initiated the Advanced Reactor Cladding (ARC) irradiation campaign to generate irradiation performance data for candidate fuel cladding concepts. The campaign includes a diverse set of ferritic/martensitic steels, oxide dispersion strengthened (ODS) alloys, FeCrAlbased alloys, coated materials, and welded cladding specimens produced through multiple US Department of Energy (DOE) programs and international collaborations. Three complementary experimental thrusts comprise the campaign: tensile testing (ARC Tensile) to rapidly screen candidate alloys, fracture toughness testing (ARC Fracture) to evaluate irradiation effects on crack resistance, and tubular weld testing (ARC Weld) to quantify irradiation-induced changes in the mechanical performance of end cap welds. This report documents the irradiation campaign design, including the selected materials, specimen types, irradiation matrix, and capsule designs for irradiation within the High Flux Isotope Reactor (HFIR). A total of 14 irradiation capsules were developed to achieve target irradiation temperatures between 300°C and 600°C and doses up to 30 dpa. Thermal analyses were performed using finite element methods to establish capsule geometries capable of achieving the desired specimen temperatures while accommodating differences in specimen geometry and material properties. The resulting capsule designs provide the basis for irradiation of the AFC-ARC experimental matrix and subsequent post-irradiation examination to assess the effects of neutron irradiation on advanced cladding materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1972

Radiation heating in selected NERVA engine components

The role of heating from nuclear radiation in design of the NERVA engine is treated. Some components are subjected to very high gamma heating rates in excess of 0.5 Btu/cubic inch/sec in steel in the primary nozzle or 0.25 Btu/cubic inch/sec in aluminum in the pressure vessel. These components must be cooled by a fraction of the liquid hydrogen propellant before it is passed through the core, heated, and expanded out the nozzle as a gas. Other components that are subjected to lower heating rates such as the thrust structure and the disk shield are designed so that they would not require liquid hydrogen cooling. Typical gamma and neutron heating rates, resulting temperatures, and their design consequences are discussed. Calculational techniques used in the nuclear and thermal analyses of the NERVA engine are briefly treated.

Courtney, J. C.↗