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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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DOE OSTI2026

Report on the Update and Codification of Expert Knowledge into ASTM Standard Practice E521

The overall purpose of the Grand Challenge Integrated Research Project (IRP), Accelerating the Qualification of Materials to Enable Rapid Deployment of Advanced Reactors, is to fulfill several objectives. The first objective is to complete and demonstrate/establish the process for predicting the microstructure and properties of structural materials in reactor and at high doses using ion irradiation as an accurate predictive tool for assessing behavior under reactor irradiation. The second objective is for this process to be adopted as part of an ASTM standard, and to work with the US Nuclear Regulatory Commission to utilize this standard in licensing decisions on advanced reactor designs for which such data are nonexistent or impractical to achieve. The need for standardized procedures is apparent based on the outcomes of a recent round-robin experiment from laboratories using ion beams for radiation damage studies and the roadmap for ion beam technologies to address challenges for the advancement of nuclear energy technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Status memorandum on ORNL support of vendor irradiation capsule design and ASME irradiation code development and new ASTM test standard development activities

This report is in submission of completion of the Level 4 milestone number M4TG-24OR0501111 within the larger Advanced Reactor Technologies Gas Cooled Reactor program at Oak Ridge National Laboratory (ORNL). The focus of this year’s efforts is to continue support of industry needs related to the development of future industry-funded irradiation programs. At ORNL these efforts included the development of a generalized three-dimensional CAD model of an irradiation creep capsules for graphite, cost estimates of the expansion of the Materials Irradiation Facility (MIF), involvement with ASTM D02.F0 “Manufactured Carbon and Graphite Products” and the ASME Boiler and Pressure Vessel Code, and publication of papers supporting these efforts. This report will document the status of these activities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Report on the Update and Codification of Expert Knowledge into ASTM Standard Practice E521

The overall purpose of the Grand Challenge Integrated Research Project (IRP), Accelerating the Qualification of Materials to Enable Rapid Deployment of Advanced Reactors, is to fulfill several objectives. The first objective is to complete and demonstrate/establish the process for predicting the microstructure and properties of structural materials in reactor and at high doses using ion irradiation as an accurate predictive tool for assessing behavior under reactor irradiation. The second objective is for this process to be adopted as part of an ASTM standard, and to work with the US Nuclear Regulatory Commission to utilize this standard in licensing decisions on advanced reactor designs for which such data are nonexistent or impractical to achieve. The need for standardized procedures is apparent based on the outcomes of a recent round-robin experiment from laboratories using ion beams for radiation damage studies and the roadmap for ion beam technologies to address challenges for the advancement of nuclear energy technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Investigation of nonlinear mechanical behavior of two superfine-grained graphites with DIC assisted disc splitting test

Using standardized uniaxial tensile test specimens is not practical due to the limited volumes in irradiation capsules, molten salt degradation facilities, or oxidation apparatus. The ASTM International Standard Test Method for Tensile Strength Estimate by Disc Compression of Manufactured Graphite (ASTM D8289) was developed to provide a convenient way for estimating tensile strength. Unlike the traditional uniaxial tensile test in ASTM C749 (International Standard Test Method for Tensile Stress–Strain of Carbon and Graphite), which uses dog-bone shaped specimens larger than 12.95 mm × 120.65 mm, the ASTM D8289 standard uses smaller discs with diameters of 6–12.7 mm. A digital image correlation (DIC) system, which uses a full-field noncontact surface displacement measurement technique, was applied along with the ASTM D8289 disc splitting test on IG-110 samples and compared with previous measurements from Mersen 2114 samples. Results confirmed that the DIC technique can measure the surface displacement/strain on these small (Ø6 mm × 3 mm) graphite specimens with good repeatability. However, Mersen 2114 and IG-110 samples exhibited strain discrepancies when DIC measurements were compared with analytical and finite element simulation values. The loading history and strain results also indicated different mechanical behaviors between Mersen 2114 and IG-110, particularly the nonlinear behavior of the IG-110 samples. Good agreement was observed by comparing the splitting tensile strengths of two superfine-grained grades with results from other work. The specimen size effect is discussed when comparing the splitting tensile strength with corresponding uniaxial tensile strength of these two graphite grades.

Lin, Lianshan [ORNL] (ORCID:0000000203399219)↗
DOE OSTI2024

CONSTRAINT-INDEPENDENT CONSTANT CTOA DETERMINATION FOR DUCTILE STABLE CRACK GROWTH

Crack tip opening angle (CTOA) has been used as a reliable fracture toughness parameter for decades to characterize stable ductile crack growth for thin-walled aerospace structures in the low-constraint conditions. Recently, the CTOA parameter was also applied to the pipeline industry, and a CTOA test standard ASTM E3039 was thus developed for testing a critical constant CTOA. Research showed that the constant CTOA can reasonably describe fracture toughness required to arrest a dynamic crack propagation for a modern gas pipeline. However, the CTOA fracture criterion requires constraint-independent CTOA toughness against stable ductile crack growth. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen for CTOA testing. Since a shallow crack is used, DWTT measured CTOA may depend on constraint level at the crack tip. To understand if it is the case, this paper evaluates the critical CTOA for a set of fracture toughness tests on single edge notched bend (SENB) specimens with shallow and deep cracks based on four CTOA estimation models. In which, the Ln(P)-LLD linear fit model is similar to that used by ASTM E3039 in the CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel are considered in the CTOA evaluation. The results show that the four CTOA models can determine a crack size-independent constant CTOA over stable ductile crack growth for the SENB specimens. As a result, CTOA determined by ASTM E3039 is constraintindependent and transferable to use for an actual crack propagating in a gas pipeline.

Zhu, Xian-Kui↗
DOE OSTI2024

Metal Scrap Upcycling with Shear Assisted Processing and Extrusion (ShAPE)

The overarching objective of this project is to convert metal scraps, such as aluminum, titanium, and other alloys provided by the industry, into extruded tubing, wires, and rods. Upcycling of scrap will be accomplished using Shear Assisted Processing and Extrusion (ShAPE). This approach is a new solution for recycling. The specific aims of this project are as follows: 1. Receive metal scrap under a Material Transfer Agreement (MTA), in the form of billets, from select industry partners that meet the following requirements: outer diameter of 1.245 inches (+/-0.003 inches), inner diameter drilled with a 0.404-inch drill bit, and a length of 4.0 inches (+/-0.01 inches). The billet must be cast or compacted to greater than 98% density. If the industry partner does not have the capabilities to prepare the billets, PNNL can make introductions to third-party entities as needed. Industry partners will also provide a composition analysis as weight percent. 2. Extrude metal scrap via the ShAPE process at PNNL. 3. Evaluate and benchmark the extrudate material properties per the ASTM B557-15 – Testing Tubulars Standard or similar wire and rod standards. 4. Characterize the extrudate microstructure for any of the following: grain size, second phase composition, and texture. Additional testing may include corrosion per the ASTM B117 standard and electro-potential. 5. Deliver specimens to industry partners under an MTA for additional third-party evaluations. Industry partners will, in return, provide a non-proprietary report on any testing, including testing per the ASTM B557-15, ASTM B117, and other industry standards. 6. PNNL will develop data and insights to support intellectual property capture, a published non-proprietary technical report, research collaborations, and commercialization opportunities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Determination of Constraint-Independent Crack Tip Opening Angle for Stable Crack Growth in High-Strength Ductile Steels

The crack tip opening angle (CTOA) is one of fracture toughness parameters that has been used for decades in describing large stable crack growth in thin-walled aerospace structures under the low-constraint conditions. Recently, the pipeline industry has developed a growing interest in using the CTOA parameter to serve as the minimum required fracture toughness to arrest dynamic crack propagation in modern gas transmission pipelines made of high-strength ductile steel. To meet this industrial need, the CTOA test standard ASTM E3039 was therefore developed for measuring the constant critical CTOA. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen with a shallow crack for standard CTOA testing, but its CTOA may depend on the low constraint condition of the DWTT specimen at the crack tip. Verifying the constraint independence of the DWTT-measured CTOA thus becomes indispensable for applying CTOA toughness to the running fracture control in the pipeline design. For this purpose, the present paper evaluates critical CTOA values in a set of fracture toughness tests on single-edge notched bend (SENB) specimens with shallow and deep cracks, based on four CTOA estimation models. Among these, the Ln(P)-LLD linear fit model is similar to that recommended by ASTM E3039 for CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel were considered in the CTOA evaluation. The results showed that the four CTOA models were able to determine a constraint independent CTOA value for stable crack growth in the SENB specimens. As a result, a single, reliable, constant CTOA value could be determined regardless of the specimen geometry or the crack-tip constraint conditions. Therefore, the CTOA measured using ASTM E3039 is constraint-independent and transferable to use in cases of actual cracks propagating in gas transmission pipelines.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Graphite Oxidation Rate Study on ET-10 and ETU-10 Grades - Task 4: QA Support and Testing for Structural Graphite Oxidation

INL performed targeted oxidation tests to measure oxidation rates for samples of ET-10 and ETU-10 graphite under CRADA No. 21CRA22 Mod. 3, Annex A, “Tritium Testing to Support Kairos Power Advanced Reactor Demonstration” (04/02/2024). All testing was conducted within INL’s Carbon Characterization Laboratory (CCL) using test standard ASTM D7542-21 "Standard Test Method for Air Oxidation of Carbon and Graphite in the Kinetic Regime" [ASTM International, 2021]. Kairos Power provided all test specimens through its graphite vendor Ibiden, Inc. to INL and ASTM specimen specified dimensions. Information within this report only provides the Arrhenius oxidation rate plots as a function of temperature for each graphite grade tested. The raw mass loss per time data will be provided on the Nuclear Data Management and Analysis System (NDMAS) portal located on the INL information system.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Understanding Geometry and Microstructure Interactions In LPBF By Linking Lab Scale Studies To Real Part Case Examples

The mechanical properties derived from simple tensile tests are uniquely important in the design and qualification of load bearing metallic components. The tensile properties in standards for wrought metallic materials are generally accessible for design and simulation engineers, but this is not the case for additively manufactured metals. This work investigates the influence of tensile specimen geometry on the mechanical properties of laser powder bed fusion (LPBF) additively manufactured Ti-6Al-4V, particularly in relation to properties measured from specimens excised from an exemplar part. A comprehensive analysis was conducted across various specimen geometries, considering factors such as thermal history, cross-sectional area, shape, and surface roughness. Key findings reveal that sample size, particularly cross-sectional area, significantly affects reported tensile properties, with ASTM E8 flat and round specimens exhibiting differences in elastic modulus (13%), yield strength (17%), ultimate tensile strength (UTS) (14%), and elongation to failure (11%). Additionally, surface roughness was found to have a limited impact on ASTM round geometries, but it becomes critical in thin-walled and small high-throughput samples. The ASTM flat samples closely matched the properties of samples excised from the exemplar part, underscoring the necessity of testing witness samples that accurately represent end-use conditions. Furthermore, mechanical properties of samples built within the stitch zone of the exemplar part demonstrated reduced ductility, highlighting the importance of laser alignment and qualification in multi-laser additive manufacturing processes. Overall, this study emphasizes the need for careful consideration of specimen geometry and testing conditions to ensure accurate reporting of mechanical properties in LPBF Ti-6Al-4V.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Rapid Assessment of Sulfate Resistance in Mortar and Concrete

Extensive research has been conducted on the sulfate attack of concrete structures; however, the need to adopt the use of more sustainable materials is driving a need for a quicker test method to assess sulfate resistance. This work presents accelerated methods that can reduce the time required for assessing the sulfate resistance of mixtures by 70%. Class F fly ash has historically been used in concrete mixtures to improve sulfate resistance. However, environmental considerations and the evolving energy industry have decreased its availability, requiring the identification of economically viable and environmentally friendly alternatives to fly ash. Another challenge in addressing sulfate attack durability issues in concrete is that the standard sulfate attack test (ASTM C1012) is time-consuming and designed for only standard mortars (not concrete mixtures). To expedite the testing process, accelerated testing methods for both mortar and concrete mixtures were adopted from previous work to further the development of the accelerated tests and to assess the feasibility of testing the sulfate resistance of mortar and concrete mixtures rapidly. This study also established criteria for interpreting sulfate resistance for each of the test methods used in this work. A total of 14 mortar mixtures and four concrete mixtures using two types of Portland cement (Type I and Type I/II) and various supplementary cementitious materials (SCMs) were evaluated in this study. The accelerated testing methods significantly reduced the evaluation time from 12 months to 21 days for mortar mixtures and from 6 months to 56 days for concrete mixtures. The proposed interpretation method for mortar accelerated test results showed acceptable consistency with the ACI 318-19 interpretations for ASTM C1012 results. The interpretation methods proposed for the two concrete sulfate attack tests demonstrated excellent consistency with the ASTM C1012 results from mortar mixtures with the same cementitious materials combinations. Metakaolin was shown to improve sulfate resistance for both mortar and concrete mixtures, while silica fume and natural pozzolan had a limited impact. Using 15% metakaolin in mortar or concrete mixtures with Type I/II cement provided the best sulfate resistance.

Chemistry↗
DOE OSTI2026

Effect of Specimen Thickness on Fracture Toughness and Plane Stress to Plane Strain Transition in Medium-Density Polyethylene

This study investigates the effect of specimen thickness on fracture toughness and the transition from plane stress to plane strain conditions in Medium-Density Polyethylene (MDPE) using Single Edge Notched Bend (SENB) specimens. Three thickness groups (7.5 mm, 9.0 mm, and 12.1 mm) were tested following ASTM D5045 protocol. Conditional stress intensity factors (KQ) increased from 2.2 MPavm to 2.8 MPavm with increasing thickness, demonstrating significant size dependency. Confocal microscopy revealed a 34% reduction in maximum crack tip opening displacement (CTOD) from 0.478 mm to 0.314 mm as thickness increased, with plastic zone lateral extent decreasing by 32%. This quantitative evidence validates Irwin's theoretical prediction of plastic zone size transition from plane stress r_y˜ (1/2p) (K_I/s_y )^2 to plane strain conditions r_y˜ (1/6p) (K_I/s_y )^2.Scanning electron microscopy confirmed progressive suppression of shear lips and evolution from ductile tearing with extensive polymer chain drawing in thin specimens to localized crazing in thick specimens. Despite all specimens satisfying the ASTM D5045 criterion (B = 2.5(KQ/s_y )^2 ) ,residual shear lips persisted even in the thickest specimens, demonstrating that nominal size requirements alone are insufficient for achieving complete plane strain conditions in highly ductile polymers. The findings emphasize the necessity of integrated analytical and morphological assessment for valid fracture toughness characterization, with critical implications for life assessment and integrity prediction in thick-section polymer components such as natural gas distribution pipelines.

Medium-Density Polyethylene↗
DOE OSTI2027

Hydrotreating pine-derived catalytic fast pyrolysis oil to jet fuel: Process durability and impact of operating conditions

Hydrotreating woody biomass-derived catalytic fast pyrolysis (CFP) oil to jet fuel has the potential to enhance energy security due to the large abundance of forest and woody resources. CFP oil produced from pine over ZSM-5 was hydrotreated over sulfided NiMo/Al 2 O 3 for 410 h to study the impact of hydrotreating conditions (pressure, temperature, and weight hourly space velocity (WHSV)). The degree of deoxygenation remained high across the tested hydrotreating conditions, and the products contained < 0.01 wt% oxygen. Increasing hydrotreating pressure from 84 to 125 bar enhanced hydrogenation of aromatic rings and the formation of cycloalkanes and increasing the temperature from 385 to 400 degrees C enhanced cracking and the formation of jet-range molecules. Decreasing the weight hourly space velocity from 0.2 to 0.1 g/(g cat h) further enhanced cracking and led to higher gasoline- and lower jet fuel-range fractions. The highest jet fuel fraction (49 wt%) was obtained at 400 degrees C, 125 bar, 0.2 g/(g cat h) WHSV. CFP oils produced from pine over phosphorous-modified ZSM-5 were hydrotreated at this condition for 588 h to investigate the process durability. The hydrogenation performance of the catalyst gradually stabilized in approximately 300 h after which the product composition remained constant. Of the final hydrotreated CFP oil, 53 wt% fell in the jet fuel range with most of the tested fuel properties meeting ASTM D4054 and/or ASTM D7566 specifications. The freeze points were < -50 degrees C vs. guideline of < -40 degrees C and the viscosities at -20 degrees C were 3.8-4.1 mm 2 /s vs guideline of 8 mm 2 /s. Increasing the fraction of cycloalkanes could increase the cetane number and heating value, which did not meet the guidelines.

09 BIOMASS FUELS↗
DOE OSTI2024

The corrosion behavior of borosilicate glass in the presence of cementitious waste forms

Borosilicate glasses are widely used for radioactive waste disposal due to their ability to incorporate a variety of contaminants and radionuclides while exhibiting high durability in various disposal scenarios. This research evaluated the dissolution of borosilicate glass using both single-pass-flow-through (ASTM C1662-18) and product consistency test (ASTM C1285-21) methods with different solutions, including a cementitious-contacted water (called grout-contacted, GC, from this point) and solutions with varying levels of dissolved cementitious species such as Si, Ca, Al. Here, the results indicated that the presence of Ca plays a crucial role in suppressing glass corrosion, as evidenced by the slower normalized dissolution rates, which were one order of magnitude lower for boron and two orders of magnitude lower for rhenium, observed in both Ca-amended and GC solutions compared to the pH 12 buffer solution. This effect is attributed to the formation of a dense, low-porosity, and strongly bonded calcium silicate hydrate (CSH) layer on the glass surface, which implies that a glass corrosion process is influenced by ion exchange involving alkali ions Na + , K + , Ca 2+ , and hydrogen-containing species. A small number of glass particles treated in the GC solution showed minor corrosion pits in the form of shallow craters with an average diameter of approximately 500 μm. This observation is correlated with a significant reduction, 2000 to 3000 times lower, in the cumulative volume of glass pores, indicating that smaller pore voids were “sealed” in the presence of Ca 2+ ions, likely attributed to the formation of CSH precipitation or other corrosion products such as calcium carbonate saturated from the grout solution. These findings suggest that the presence of dissolved Ca in the GC solution can slow down the dissolution of borosilicate glass, contrary to the expected trend of higher dissolution rates resulting from exposure to high alkaline and thus higher pH solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The shard test and nanoporomechanics reverse classical paradigm of cement hydration being contractive

Le Chatelier in 1887 and Powers in 1947 demonstrated that the volume of nanoscale C-S-H (calcium silicate hydrate) particles formed during hydration is smaller than the combined volume of the reactants—the anhydrous Portland cement and water. Hydration has thus been considered as contractive. An experiment shows that the opposite is true above the nanoscale. The porous skeleton of cement paste expands as the growing C-S-H particles push each other apart, similar to crystal growth pressure. This is significant for high-performance concretes (HPC) with low water-cement ratios (w/c ≤ 0.4), where chemical self-desiccation lowers pore relative humidity by 40%, compared to just 1% in traditional concretes (w/c ≈ 0.5). Standard American Society for Testing and Materials (ASTM) C1608 tests, using 10 mm thick water-immersed specimens, show large shrinkage because the half-time of water ingress is many decades, unable to offset shrinkage-causing self-desiccation. The present experiment, using a laser microscopy-topography technique, proves the opposite—expansion, evidenced by measuring the length changes of water-immersed HPC shards 0.5 mm thick in which the diffusion halftime, only about one hour, allows continuous resaturation of pores, canceling self-desiccation. The faster diffusion (halftime of one hour) enables continuous pore resaturation, preventing shrinkage. When sealed with paraffin oil, the shards self-desiccate and shrink. These findings align with studies since 2015, showing that models excluding hydration expansion cannot fit test data across various specimen sizes and sealing conditions. The results suggest that standardized ASTM tests for the so-called chemical shrinkage in modern concretes with very low water-cement ratios are misleading and need revision.

Science & Technology - Other Topics↗