Extreme Environment Testing via Ballistically Fired Water Impact with Dialable Effects.
Abstract not provided.
Wilson, Natasha↗
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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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Ultrasonic measurement of temperature distributions in extreme environments: Electrical power plants testing in utility-scale steam generators
Thermal heterogeneities within energy conversion and storage, material processing, nuclear processes, aerospace, and military applications are often inaccessible to characterization by insertion sensors. When sensor deployment is possible, conventional pointwise temperature probes quickly degrade when inserted into harsh environments typical of such processes. We developed spatially-resolved ultrasonic thermometry to noninvasively measure the spatial distributions of thermal properties in such applications, even when sizable thermal gradients are present. Our method divides the path of ultrasonic propagation into segments bound by echogenic features, which create echoes in pulse-echo mode, encoding the information about interior temperature distributions. We use the acquired ultrasonic responses to estimate the internal temperature distributions by solving an inverse problem or concatenating segmental estimates. This work describes the implementation and industrial testing of the developed method at a coal-fired electrical power generation plant. We inserted an echogenically segmented Inconel 625 waveguide into the combustion zone of the utility-scale boiler and continuously acquired ultrasonic data while keeping sensitive components away from the damaging combustion environment. The accuracy of the time-dependent temperature distributions reconstructed from the ultrasonic measurements was comparable to that of thermocouples. The resiliency of ultrasonic thermometry to harsh combustion conditions was far superior to conventional insertion sensors. The measurements obtained during plant operation captured daily steam generation cycles in response to changing customer demand and intermittent contributions of renewable power sources to the power grid. These measurements have revealed new insights into the relationship between the dynamic power generation load and the conditions inside the steam generator. As a result, the successful industrial testing of spatially-resolved ultrasonic thermometry in solids indicates that the developed technology has matured to become an attractive alternative to conventional sensing in solving challenging problems of long-term thermal characterizations in extreme environments.
42 ENGINEERING↗
In-situ Nanomechanical Testing in Extreme and Coupled Environments.
Abstract not provided.
Hattar, Khalid↗
Ultrasonic Measurements of Temperature Distribution in Extreme Environments: Results of Power Plant Testing
The most hardened insertion sensors do not perform reliably in extreme environmental conditions. We address this problem by developing an ultrasonic thermometry system for the measurements of segmental temperature distributions (MSTD) in solid materials and, specifically, across containments of energy conversion processes. The MSTD approach uses an echogenically segmented ultrasound propagation path, structured to contain engineered or naturally occurring echogenic features. In pulse-echo mode, these features produce a train of echoes in response to an external pulse of ultrasonic excitation created and acquired by a transducer located outside the extreme environment. The delays between the echoes encode the information on the temperature distribution in the corresponding segments of the ultrasonic propagation path, which we use to reconstruct an unknown temperature profile. This note describes the preliminary results and initial experience in applying the developed MSTD ultrasonic thermometry system to the measurements of temperatures in a utility-scale 500MW coal-fired boiler.
John, Mason↗
Materials properties characterization in the most extreme environments
Abstract There is an ever-increasing need for material systems to operate in the most extreme environments encountered in space exploration, energy production, and propulsion systems. To effectively design materials to reliably operate in extreme environments, we need an array of tools to both sustain lab-scale extreme conditions and then probe the materials properties across a variety of length and time scales. Within this article, we examine the state-of-the-art experimental systems for testing materials under extreme environments and highlight the limitations of these approaches. We focus on three areas: (1) extreme temperatures, (2) extreme mechanical testing, and (3) chemically hostile environments. Within these areas, we identify six opportunities for instrument and technique development that are poised to dramatically impact the further understanding and development of next-generation materials for extreme environments. Graphical abstract
Schreiber, Daniel K.↗
Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers
Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.
42 ENGINEERING↗
Multi-technique characterization of iron reduction by an Antarctic Shewanella : an analog system for putative Martian biosignature identification
ABSTRACT Microbes from terrestrial extreme environments enable testing of biosignature production in conditions relevant to astrobiological targets. Mars, which was likely more conducive to life during early warmer and wetter epochs, has inspired missions that search for signs of early life in the surficial rock record, including mineral or organic biosignatures. Microbial iron reduction is a common and ancient metabolism that may have also operated on other rocky celestial bodies. To investigate biosignature production during iron reduction, aShewanellasp. (strain BF02_Schw) isolated from a subglacial discharge known as Blood Falls, Antarctica, was incubated with the electron acceptor ferrihydrite (Fh). Biosignatures associated with Fh reduction were identified using a suite of techniques currently utilized or proposed for Mars missions, including X-ray diffraction and infrared, Mössbauer, and Raman spectroscopy. The biotic origin of features was validated by transcriptional changes observed between treatments with and without Fh and comparison to killed controls. In live treatments, Fh was reduced to magnetite and goethite, both detected in Martian lacustrine basins. Several soluble and volatile metabolites were also detected, including riboflavin and dimethyl sulfide (DMS), which could be astrobiological indicators of active microbial processes. While none of the identified biosignatures individually would serve as definitive proof of life (past or present), detecting concomitant features associated with known terrestrial biotic processes would provide compelling rationale for more targeted life detection missions. Terrestrial extremophiles can support the exploration of astrobiologically relevant microbial processes, validation of life detection instrumentation, and potentially the discovery of new biomarkers. IMPORTANCE Culture-based experiments with terrestrial extremophiles can elucidate biosignatures that may be analogous to those produced under extraterrestrial conditions, and thus inform sampling and technology strategies for future missions. Here, we demonstrate the production of several biosignatures under iron-reducing conditions byShewanellasp. BF02_Schw, originally isolated from an Antarctic analog feature. These biosignatures could be detectable using flight-ready instrumentation. Growth experiments with terrestrial extremophiles can identify biosignatures measurable by current methodologies and inform the development and optimization of techniques for detecting extant or extinct life on other worlds.
Biotechnology & Applied Microbiology↗
Advanced Manufactured Strain Sensors for Extreme Environments
Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.
36 - MATERIALS SCIENCE↗
Advanced Manufactured Strain Sensors for Extreme Environments
Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.
36 - MATERIALS SCIENCE↗
The Geothermal Entrepreneurship Organization (GEO) Accelerating Technology Transfer, Testing and Adoption of Cutting-edge Extreme Environment Drilling
The Geothermal Entrepreneurship Organization launched in 2019 with the goal of building a geothermal innovation ecosystem at the University of Texas at Austin (UT Austin), and in the State of Texas at large. The theses underlying the work of GEO were 1) that with targeted advocacy, recruitment, organization, and coalition building, research institutions with legacy excellence in petroleum and geosystems engineering could become engines of geothermal innovation, research and development; 2) that startups were the appropriate vehicle to speed these innovations from the lab into the field, and building a geothermal startup ecosystem in Texas would not only advance next generation geothermal concepts into the field, but also help spur oil and gas engagement in the space, and 3) that with targeted engagement, education, and recruitment across stakeholders in the oil and gas industry and the State of Texas generally, the oil and gas industry, and other legacy oil and gas entities in the State could become sources of large scale deployment of geothermal energy. The overall goal was to create a ‘snowball’ effect, where targeted impactful actions would catalyze self-sustaining, organic growth of a new geothermal ecosystem in the State of Texas. That goal was achieved through GEO’s work. To test its theses, GEO began work by interviewing and recruiting UT Austin faculty and alumni into geothermal. At the beginning of the GEO project, there was no geothermal activity ongoing within the UT Austin Petroleum and Geosystems Engineering Department, the Bureau of Economic Geology, or the Jackson School of Geoscience, and many faculty approached had not before considered how their skillsets might apply in the space. By the end of the project period, three major research consortia focused on geothermal were launched as a result of GEO’s work, one at the Bureau of Economic Geology, one within the Petroleum and Geosystems Engineering Department, and another organized by GEO across six research institutions across the State of Texas, called the Texas Geothermal Institute. Geothermal curricula was launched at UT Austin, and UT Austin began attracting new geothermal enthusiasts into its faculty, including Dr. Silviu Livescu, former Chief Scientist of Baker Hughes. Startups recruited and mentored by GEO launched, raised funding, and deployed (or are currently deploying) their concepts in the field. By the end of the project period, the GEO concept expanded to faculty beyond UT Austin to other institutions, like Texas A&M, the University of Houston, and Rice University, and geothermal engagement began at those institutions as well. Multiple faculty members and alumni across these institutions launched geothermal startup companies, launched geothermal research consortia, and/or began teaching geothermal courses. In 2020, GEO launched what was to become the largest geothermal conference in the world by its second year, ‘PIVOT – From Hydrocarbons to Heat’, and the resulting momentum catalyzed the Society of Petroleum Engineers to launch a geothermal technical section, drove more startups to launch out of the ecosystem, and drove actors in the State of Texas, NGOs, and stakeholders globally to become engaged. Riding this momentum, the Texas Geothermal Energy Alliance was launched, the first ever industry association dedicated to advancing geothermal energy in the State of Texas. The Texas geothermal ecosystem after only two years of building and support is now robust, quickly growing, and self-sustaining. By 2021, the Texas geothermal ecosystem had attracted the attention of philanthropists, funding entities, media, and influencers outside of Texas, and GEO’s executive director was invited to give a TED talk about oil and gas engagement in building the future of geothermal energy, which elevated the success of the ecosystem to a global audience.
15 GEOTHERMAL ENERGY↗
Boosting SNR of cascaded FBGs in a sapphire fiber through a rapid heat treatment
This Letter reports the performance of femtosecond (fs) laser-written distributed fiber Bragg gratings (FBGs) under high-temperature conditions up to 1600°C and explores the impact of rapid heat treatment on signal-to-noise ratio (SNR) enhancement. FBGs are essential for reliable optical sensing in extreme temperature environments. Comprehensive tests demonstrate the remarkable performance and resilience of FBGs at temperatures up to 1600°C, confirming their suitability for deployment in such conditions. Here, the study also reveals significant fringe visibility improvements of up to ∼10 dB on a 1-m-long sapphire optical fiber through rapid heat treatment, representing a first-time achievement to the best of our knowledge. These enhancements are vital for improving the SNR and overall performance of optical fiber systems in extreme temperatures. Furthermore, the research attains long-term stability for the cascaded FBGs over a 24-hr period at 1600°C. This research expands our understanding of the FBG behavior in high-temperature environments and opens avenues for developing robust optical fiber systems for energy, aerospace, oil and gas, and high-temperature distributed sensing applications.
47 OTHER INSTRUMENTATION↗
Retractable Sensor Poster for ANIMMA 2023 Conference
Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-pile environment. The test environment within these reactors are extremely harsh and long-term exposure causes sensor decalibration or failure. Most tests only require data points at daily intervals meaning that the sensor does not necessarily need to be in place continuously for the full experiment. One proposed solution to the issue described above is to have a sensor which can be periodically inserted through a guide tube into the test region and retracted; this would act as a reference check on the sensors installed permanently. If a compact and robust enough design can be made, it has the potential to extend the life of the sensor and keep it within calibration. This LRS entry is for a poster summarizing a presentation that will be given at the ANIMMA 2023 conference. The poster will be on display in the Measurement Sciences Laboratory booth at ANIMMA. Most of the material on this poster came from LRS entry INL/CON-23-72797.
42 ENGINEERING↗
Advanced Characterization Capabilities for Nuclear Materials via Nuclear Science User Facilities (NSUF)
Advanced post-irradiation examination (PIE) techniques are required to design new or improved nuclear materials, characterize, and understand in-core behavior of fuel and materials, and support the qualification of new reactor materials. The Nuclear Science User Facilities (NSUF) is the U.S. Department of Energy Office of Nuclear Energy's only designated nuclear science user facility. NSUF provides researchers access to PIE capabilities at Idaho National Laboratory and at a diverse mix of university, national laboratory and industrial partner institutions. The PIE capabilities include novel destructive and non-destructive techniques for radiation damage characterization, such as advanced diffraction techniques (X-ray, electron, or neutron) coupled to extreme environments; in-situ observation of microstructural evolution under irradiation; in-situ irradiation to monitor corrosive attack in coolant environments; in-situ irradiation and mechanical testing; and test methods for synergistic effects of superimposed extreme environments (temperature, irradiation, stress, corrosion) on materials behaviors. This talk will provide an overview of NSUF PIE capabilities.
36 MATERIALS SCIENCE↗
Path-Integrated Stereo X-Ray Digital Image Correlation: Resolving the Violation of Conservation of Intensity
In this study, x-ray imaging addresses many challenges with visible light imaging in extreme environments, where optical diagnostics such as digital image correlation (DIC) and particle image velocimetry (PIV) suffer biases from index of refraction changes and/or cannot penetrate visibly occluded objects. However, conservation of intensity—the fundamental principle of optical image correlation algorithms—may be violated if ancillary components in the X-ray path besides the surface or fluid of interest move during the test. The test series treated in this work sought to characterize the safe use of fiber-epoxy composites in aerospace and aviation industries during fire accident scenarios. Stereo X-ray DIC was employed to measure test unit deformation in an extreme thermal environment involving a visibly occluded test unit, incident surface heating to temperatures above 600°C, and flames and soot from combusting epoxy decomposition gasses. The objective of the current work is to evaluate two solutions to resolve the violation of conservation of intensity that resulted from both the test unit and the thermal chamber deforming during the test. The first solution recovered conservation of intensity by pre-processing the path-integrated X-ray images to isolate the DIC pattern of the test unit from the thermal chamber components. These images were then correlated with standard, optical DIC software. The second solution, called Path-Integrated Digital Image Correlation (PI-DIC), modified the fundamental matching criterion of DIC to account for multiple, independently-moving components contributing to the final image intensity. The PI-DIC algorithm was extended from a 2D framework to a stereo framework and implemented in a custom DIC software. Both solutions accurately measured the cylindrical shape of the undeformed test unit, recovering radii values of R = 76.20±0.12 mm compared to the theoretical radius of R theor = 76.20 mm. During the test, the test unit bulged asymmetrically as decomposition gasses pressurized the interior and eventually burned in a localized jet. Both solutions measured the heterogeneous radius of this bulge, which reached a maximum of approximately R = 91 mm, with a discrepancy of 2–3% between the two solutions. Two solutions that resolve the violation of conservation of intensity for path-integrated X-ray images were developed. Both were successfully employed in a stereo X-ray DIC configuration to measure deformation of an aluminum-skinned, fiber-epoxy composite test unit in a fire accident scenario.
47 OTHER INSTRUMENTATION↗
Searching For Transiting Planets Around Halo Stars. I. Sample Selection and Validation
By measuring the elemental abundances of a star, we can gain insight into the composition of its initial gas cloud—the formation site of the star and its planets. Planet formation requires metals, the availability of which is determined by the elemental abundance. In the case where metals are extremely deficient, planet formation can be stifled. To investigate such a scenario requires a large sample of metal-poor stars and a search for planets therein. This paper focuses on the selection and validation of a halo star sample. We select ~17,000 metal-poor halo stars based on their Galactic kinematics, and confirm their low metallicities ([Fe/H] < -0.5), using spectroscopy from the literature. Furthermore, we perform high-resolution spectroscopic observations using LBT/PEPSI and conduct detailed metallicity ([Fe/H]) analyses on a sample of 13 previously-known halo stars that also have hot kinematics. We can use the halo star sample presented here to measure the frequency of planets and to test planet formation in extremely metal-poor environments. The result of the planet search and its implications will be presented and discussed in a companion paper by Boley et al.
47 OTHER INSTRUMENTATION↗
Oscillation-independent probes of nonstandard neutrino interactions from supernovae
Extreme astrophysical environments provide unique laboratories for testing fundamental neutrino interactions. We present the first oscillation-independent astrophysical probe of nonstandard neutrino interactions (NSI), using coincident neutral-current signals across diverse detectors to break degeneracies that have long limited sensitivity reach. Using self-consistent NSI supernova simulations and flavor-independent neutral-current scattering we show that anticorrelated signatures between JUNO liquid scintillator and dark matter detectors such as DARWIN/XLZD, ARGO, or RES-NOVA enable clear discrimination between NSI and flavor-conversion effects. For a Galactic supernova at Betelgeuse distance our approach enables an independent probe of neutrino-quark NSI couplings in parameter space that can reach and extend beyond current terrestrial limits. This multidetector approach enables breaking degeneracies in terrestrial searches and is broadly applicable to a wide range of upcoming experiments, establishing a new principle for testing fundamental interactions with astrophysical data.
Beatty, Angela R. [San Francisco State U.; LBL, Be↗
Accelerated Materials Design for Molten Salt Technologies Using Innovative High-Throughput Methods
The focus of the project is on building an innovative accelerated materials design platform for molten salt technologies using novel high-throughput methods coupled to data analytics. The main objectives is to predict a FeCrMnNi alloy compositional space with better corrosion resistance than stainless steel 316 and identify new molten salt corrosion mechanisms. The project demonstrates the feasibility to use high-throughput methods coupled to data analytics to accelerate alloy design for extreme environments applications. Using a trained and tested machine learning (ML) model, 2000 FeCrMnNi alloy corrosion rate in molten chloride salts were predicted and a compositional field with corrosion rate lower than 316 stainless steel was identified. The ML model interpretability unveiled multiple features of importance in the model prediction. Some features were expected to be of relative significance, such as work function, surface energy and alloy electronegativity, and the ML model interpretability analysis confirmed those. On the other hand, the most important feature is the diffusion coefficient of Ni in the bulk alloy which indicates that a surface diffusion mechanism plays an important role in the overall corrosion mechanism in molten salts.
36 MATERIALS SCIENCE↗
Bayesian optimization scheme for the design of a nanofibrous high power target
High Power Targetry (HPT) R&D is critical in the context of increasing beam intensity and energy for next generation accelerators. Many target concepts and novel materials are being developed and tested for their ability to withstand extreme beam environments; the HPT R&D Group at Fermilab is developing an electrospun nanofiber material for this purpose. The performance of these nanofiber targets is sensitive to their construction parameters, such as the packing density of the fibers. Lowering the density improves the survival of the target, but reduces the secondary particle yield. Optimizing the lifetime and production efficiency of the target poses an interesting design problem, and in this paper we study the applicability of Bayesian optimization to its solution. We first describe how to encode the nanofiber target design problem as the optimization of an objective function, and how to evaluate that function with computer simulations. We then explain the optimization loop setup. Thereafter, we present the optimal design parameters suggested by the algorithm, and close with discussions of limitations and future refinements.
43 PARTICLE ACCELERATORS↗