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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2010

Kansas City Plant Celebrates Safety Milestone

A gang of motorcycle riders arrived at the NNSA's Kansas City Plant on July 1 to help celebrate a significant safety achievement - working nearly five million hours, covering a one-year period without a lost-time injury. The bikers -- some of whom are plant employees -- represent Bikers Against Child Abuse, the local nonprofit selected to receive a $5,000 donation as part of the plant's safety achievement celebration. The organization was selected because it aligns with the plant's community outreach focus on Family Safety & Security and partnership with the plant's union members.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2011

2010 Kansas City Plant Annual Illness and Injury Surveillance Report

The U.S. Department of Energy's (DOE) commitment to assuring the health and safety of its workers includes the conduct of illness and injury surveillance activities that provide an early warning system to detect health problems among workers. The Illness and Injury Surveillance Program monitors illnesses and health conditions that result in an absence, occupational injuries and illnesses, and disabilities and deaths among current workers.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2011

Final Long-Term Management and Storage of Elemental Mercury Environmental Impact Statement Summary and Guide for Stakeholders

Pursuant to the Mercury Export Ban Act of 2008 (P.L. 110-414), DOE was directed to designate a facility or facilities for the long-term management and storage of elemental mercury generated within the United States. Therefore, DOE has analyzed the storage of up to 10,000 metric tons (11,000 tons) of elemental mercury in a facility(ies) constructed and operated in accordance with the Solid Waste Disposal Act, as amended by the Resource Conservation and Recovery Act (74 FR 31723). DOE prepared this Final Mercury Storage EIS in accordance with the National Environmental Policy Act of 1969 (NEPA), as amended (42 U.S.C. 4321 et seq.), the Council on Environmental Quality (CEQ) implementing regulations (40 CFR 1500–1508), and DOE’s NEPA implementing procedures (10 CFR 1021) to evaluate reasonable alternatives for a facility(ies) for the long-term management and storage of elemental mercury. This Final Mercury Storage EIS analyzes the potential environmental, human health, and socioeconomic impacts of elemental mercury storage at seven candidate locations: Grand Junction Disposal Site near Grand Junction, Colorado; Hanford Site near Richland, Washington; Hawthorne Army Depot near Hawthorne, Nevada; Idaho National Laboratory near Idaho Falls, Idaho; Kansas City Plant in Kansas City, Missouri; Savannah River Site near Aiken, South Carolina; and Waste Control Specialists, LLC, site near Andrews, Texas. As required by CEQ NEPA regulations, the No Action Alternative was also analyzed as a basis for comparison. DOE intends to decide (1) where to locate the elemental mercury storage facility(ies) and (2) whether to use existing buildings, new buildings, or a combination of existing and new buildings. DOE’s Preferred Alternative for the long-term management and storage of mercury is the Waste Control Specialists, LLC, site near Andrews, Texas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2011

Final Long-Term Management and Storage of Elemental Mercury Environmental Impact Statement Volume1

Pursuant to the Mercury Export Ban Act of 2008 (P.L. 110-414), DOE was directed to designate a facility or facilities for the long-term management and storage of elemental mercury generated within the United States. Therefore, DOE has analyzed the storage of up to 10,000 metric tons (11,000 tons) of elemental mercury in a facility(ies) constructed and operated in accordance with the Solid Waste Disposal Act, as amended by the Resource Conservation and Recovery Act (74 FR 31723).DOE prepared this Final Mercury Storage EIS in accordance with the National Environmental Policy Act of 1969 (NEPA), as amended (42 U.S.C. 4321 et seq.), the Council on Environmental Quality (CEQ) implementing regulations (40 CFR 1500–1508), and DOE’s NEPA implementing procedures (10 CFR 1021) to evaluate reasonable alternatives for a facility(ies) for the long-term management and storage of elemental mercury. This Final Mercury Storage EIS analyzes the potential environmental, human health, and socioeconomic impacts of elemental mercury storage at seven candidate locations:Grand Junction Disposal Site near Grand Junction, Colorado; Hanford Site near Richland, Washington; Hawthorne Army Depot near Hawthorne, Nevada; Idaho National Laboratory near Idaho Falls, Idaho;Kansas City Plant in Kansas City, Missouri; Savannah River Site near Aiken, South Carolina; and Waste Control Specialists, LLC, site near Andrews, Texas. As required by CEQ NEPA regulations, the No Action Alternative was also analyzed as a basis for comparison. DOE intends to decide (1) where to locate the elemental mercury storage facility(ies) and (2) whether to use existing buildings, new buildings, or a combination of existing and new buildings. DOE’s Preferred Alternative for the long-term management and storage of mercury is the Waste Control Specialists, LLC, site near Andrews, Texas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2011

Final Long-Term Management and Storage of Elemental Mercury Environmental Impact Statement Volume 2

Pursuant to the Mercury Export Ban Act of 2008 (P.L. 110-414), DOE was directed to designate a facility or facilities for the long-term management and storage of elemental mercury generated within the United States. Therefore, DOE has analyzed the storage of up to 10,000 metric tons (11,000 tons) of elemental mercury in a facility(ies) constructed and operated in accordance with the Solid Waste Disposal Act, as amended by the Resource Conservation and Recovery Act (74 FR 31723). DOE prepared this Final Mercury Storage EIS in accordance with the National Environmental Policy Act of 1969 (NEPA), as amended (42 U.S.C. 4321 et seq.), the Council on Environmental Quality (CEQ) implementing regulations (40 CFR 1500–1508), and DOE’s NEPA implementing procedures (10 CFR 1021) to evaluate reasonable alternatives for a facility(ies) for the long-term management and storage of elemental mercury. This Final Mercury Storage EIS analyzes the potential environmental, human health, and socioeconomic impacts of elemental mercury storage at seven candidate locations: Grand Junction Disposal Site near Grand Junction, Colorado; Hanford Site near Richland, Washington; Hawthorne Army Depot near Hawthorne, Nevada; Idaho National Laboratory near Idaho Falls, Idaho; Kansas City Plant in Kansas City, Missouri; Savannah River Site near Aiken, South Carolina; and Waste Control Specialists, LLC, site near Andrews, Texas. As required by CEQ NEPA regulations, the No Action Alternative was also analyzed as a basis for comparison. DOE intends to decide (1) where to locate the elemental mercury storage facility(ies) and (2) whether to use existing buildings, new buildings, or a combination of existing and new buildings. DOE’s Preferred Alternative for the long-term management and storage of mercury is the Waste Control Specialists, LLC, site near Andrews, Texas.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Surviving nanoscale interfacial stability in extreme thermal expansion contrast Zn(CN) 2 -epoxy resin matrix composites

Here, we report the remarkable stability at the nanoscale matrix-filler interface in a series of overall low coefficient of thermal expansion (CTE) zinc cyanide (ZC)/epoxy resin composites. These interfaces demonstrate the stability of highly contrasting materials. These composites are designed to optimize the properties of both materials: epoxy resins are valued for their high strength, superb chemical resistance, low dielectric properties, and adhesive abilities. ZC, a model flexible framework, exhibits negative thermal expansion (NTE) behavior and compensates for the epoxy resin’s detrimentally large thermal expansion values. Filled resins minimize the native 65 ppm/°C CTE values to 19 ppm/° C over a wide temperature range while maintaining linearity, yielding composites compatible with typical metal and ceramic substrates’—commonly bonded to the resin— 0–20 ppm/° C CTE values. Additionally, with significant intrinsic differences in the materials, we use wide-angle X-ray diffraction and atomic force microscopy to elucidate thermal movement. The ZC/epoxy interface is surprisingly resilient over 1,000 cycles between -55° C and 75° C, extremes typical to aerospace applications. Further, we show that the resin viscosity remains less than 21 Pa*s at up to 30 vol% ZC, an important consideration for workability. We also discuss settling distribution, glass transition temperature, flexural strength, and longevity. All results point favorably towards practical implementation in low thermal expansion application needs: filling the gap in component design.

42 ENGINEERING↗
DOE OSTI2025

Crystallographic stability of the BCC phase during quenching of metastable beta titanium alloy Ti-5553 and comparison of structural criteria for the predictive capability of α” martensite

This work evaluates the compositional standard currently developed for Ti-5553 powder and explores the metastable β region for sensitivity to martensitic formation during rapid quenching from the melt. Ti-5553 is a beta-stabilized titanium alloy that is increasingly being used in additive manufacturing applications. A series of alloys within the Ti-5553 compositional space was processed using two-piston spat quenching to perform rapid solidification and quenching for each of these alloy compositions. Typical empirical models such as molybdenum equivalency are not able to fully separate the retained BCC and martensitic compositions. Further, the use of thermodynamic data to estimate the transformation energy needed to form martensite can differentiate the alloys and provide a metric to further develop compositional limits for metastable beta titanium alloy development.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Classified Component Disposal at the Nevada National Security Site (NNSS) - 13454

The Nevada National Security Site (NNSS) has added the capability needed for the safe, secure disposal of non-nuclear classified components that have been declared excess to national security requirements. The NNSS has worked with U.S. Department of Energy, National Nuclear Security Administration senior leadership to gain formal approval for permanent burial of classified matter at the NNSS in the Area 5 Radioactive Waste Management Complex owned by the U.S. Department of Energy. Additionally, by working with state regulators, the NNSS added the capability to dispose non-radioactive hazardous and non-hazardous classified components. The NNSS successfully piloted the new disposal pathway with the receipt of classified materials from the Kansas City Plant in March 2012. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Developing an Abaqus *HYPERFOAM Model for M9747 (4003047) Cellular Silicone Foam

This report documents work done to develop an Abaqus *HYPERFOAM hyperelastic model for M9747 (4003047) cellular silicone foam for use in quasi-static analyses at ambient temperature. Experimental data, from acceptance tests for 'Pad A' conducted at the Kansas City Plant (KCP), was used to calibrate the model. The data includes gap (relative displacement) and load measurements from three locations on the pad. Thirteen sets of data, from pads with different serial numbers, were provided. The thirty-nine gap-load curves were extracted from the thirteen supplied Excel spreadsheets and analyzed, and from those thirty-nine one set of data, representing a qualitative mean, was chosen to calibrate the model. The data was converted from gap and load to nominal (engineering) strain and nominal stress in order to implement it in Abaqus. Strain computations required initial pad thickness estimates. An Abaqus model of a right-circular cylinder was used to evaluate and calibrate the *HYPERFOAM model.

42 ENGINEERING↗
DOE OSTI2025

The Ductility of 49Fe-49Co-2V Soft Magnetic Alloy Bar: Surface Effects and Test Methods

The tensile ductility of 49Fe-49Co-2V (Hiperco® 50A) bar was investigated in both as-received and heat-treated conditions. The as-received/machined specimens exhibit very low ductility compared to samples where heat treatment was the final step prior to testing. Microstructural characterization showed that internal residual strain from bar processing and, most importantly, surface machining damage, cause lower elongation in the as-received material. Because fracture of this intermetallic alloy initiates at the surface, it is particularly susceptible to surface machining damage, i.e., the near-surface region has already exhausted most of its ability to accumulate tensile strain. During heat treatment, the internal residual strain and near-surface machining damage are eliminated and ductility is improved, despite a higher degree of crystallographic ordering in the heat-treated condition (which typically lowers ductility). Furthermore, if machining is again performed after heat treatment, the material again exhibits brittle behavior, even with only light touch-up machining passes. Here, in this work, methods of tensile strain measurement were investigated, namely conventional knife-edge extensometry and noncontact digital image correlation (DIC) on heat-treated material. For clip-on knife-edge extensometry, the range of failure strain was 2.5-5.5% for heat-treated Hiperco. For noncontact methods, ductility up to 7% was observed. The results highlight the tendency for the alloy to fail at surface imperfections, even those produced by application of the extensometer itself. Noncontact laser extensometry is recommended for determining the intrinsic ductility of the alloy. A method of laser surface modification was developed which increased ductility by ~ 100% compared to unmodified samples. The high cooling rates achieved during laser surface processing can bypass the ordering reaction and produce a ductile disordered structure at the surface that exhibits ductile fracture characteristics.

EBSD↗
DOE OSTI2025

Strongly nonlinear wave propagation in elasto-plastic metamaterials: Low-order dynamic modeling

Nonlinear elastic metamaterials are known to support a variety of dynamic phenomena that enhance our capacity to manipulate elastic waves. Since these properties stem from complex, subwavelength geometry, full-scale dynamic simulations are often prohibitively expensive at scales of interest. Prior studies have therefore utilized low-order effective medium models, such as discrete mass-spring lattices, to capture essential properties in the long-wavelength limit. While models of this type have been successfully implemented for a wide variety of nonlinear elastic systems, they have predominantly considered dynamics depending only on the instantaneous kinematics of the lattice, neglecting history-dependent effects, such as wear and plasticity. Here, to address this limitation, the present study develops a lattice-based modeling framework for nonlinear elastic metamaterials undergoing plastic deformation. Due to the history- and rate-dependent nature of plasticity, the framework generally yields a system of differential-algebraic equations whose computational cost is significantly greater than an elastic system of comparable size. We demonstrate the method using several models inspired by classical lattice dynamics and continuum plasticity theory and explore means to obtain empirical plasticity models for general geometries, thereby gaining insight into the influence of microstructural plasticity on effective material performance, which can be used to improve the design of nonlinear mechanical metamaterials.

Dynamic simulation↗
DOE OSTI2012

Los Alamos National Laboratory and Lawrence Livermore National Laboratory Plutonium Sustainment Monthly Program Report September 2012

In September of 2012 the Plutonium Sustainment program at LANL completed or addressed the following high-level activities: 1) Completed assembly, inspection, packing, and approvals for Pollux. Completed shipment to DAF in early October in accordance with the Gemini Core Team’s schedule. 2) Delivered the draft Program Implementation Plan and revised repeatedly. 3) Met with Kansas City Plant staff to “kick-off” the non-nuclear pit-component production mission. All MRT L2 Milestones 4195-4198 or the relevant PBIs associated with Plutonium Sustainment have been met and evidence packages submitted. The year-end budget/performance indices were 0.96 (S.P.I.) and 1.00 (C.P.I.). Table 1 identifies all Baseline Change Requests (BCRs) that were initiated, in process, or completed during the month. The earned value metrics overall for LANL are within acceptable thresholds, so no high-level recovery plan is required. Note that the planned (budget) and earned value for September includes planned carryover holdbacks (no allocation) with no associated FY12 costs. This has a minor (positive) impact on S.P.I. and a significant (positive) impact on the C.P.I. For Pu Sustainment overall, the C.P.I. in September neglecting the $10.75M holdback is 0.90. Likewise, the C.P.I. for FY12 is 1.004. With the facility infrastructure element removed, the C.P.I. in September becomes 0.92. Likewise, the C.P.I. for FY12 is 0.992. Again neglecting the holdback, the S.P.I. numbers for Pu Sustainment overall are 0.94 (Sept) and 0.96 (FY12) and with the facility infrastructure element removed 0.95 (Sept) and 0.95 (FY12).

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2013

Identification of volatile butyl rubber thermal-oxidative degradation products by cryofocusing gas chromatography/mass spectrometry (cryo-GC/MS).

Chemical structure and physical properties of materials, such as polymers, can be altered as aging progresses, which may result in a material that is ineffective for its envisioned intent. Butyl rubber formulations, starting material, and additives were aged under thermal-oxidative conditions for up to 413 total days at up to 124 ÀC. Samples included: two formulations developed at Kansas City Plant (KCP) (#6 and #10), one commercially available formulation (#21), Laxness bromobutyl 2030 starting material, and two additives (polyethylene AC-617 and Vanax MBM). The low-molecular weight volatile thermal-oxidative degradation products that collected in the headspace over the samples were preconcentrated, separated, and detected using cryofocusing gas chromatography mass spectrometry (cryo-GC/MS). The majority of identified degradation species were alkanes, alkenes, alcohols, ketones, and aldehydes. Observations for Butyl #10 aged in an oxygen-18 enriched atmosphere (18O2) were used to verify when the source of oxygen in the applicable degradation products was from the gaseous environment rather than the polymeric mixture. For comparison purposes, Butyl #10 was also aged under non-oxidative thermal conditions using an argon atmosphere.

Smith, Jonell Nicole↗
DOE OSTI2011

Evaluation of Subjective Measurement Systems with Focus on Workmanship Scratches and Characterization

The presence of workmanship defects at the Kansas City Plant (KCP) is not a new problem nor is it an easy one to remedy. The lack of well defined parameters, subjective evaluations, and operator dependency makes this problem difficult to analyze. At the time of project assignment, workmanship defects comprised approximately 50% of all non-conformance reports for internally produced products. Not all of these non-conformances result in product rejections, thus inferring that inconsistency in evaluations were present. The purpose of this study was to identify a method for evaluating an operator’s ability to properly characterize subjective defects. Since the scope of the project was limited to no funding, scratch depth was selected as the only criteria to evaluate. It was determined that the introduction of a reference standard coupled with a predefined gate-sorting technique approved by the customer can statistically improve an operators ability to perform subjective evaluations.

42 ENGINEERING↗
DOE OSTI2013

Evaluation of Transportation Vibration Associated with Relocation of Work in Process As Part of KCRIMS

During relocation of the Kansas City Plant (KCP) from the site at Bannister Road to the site at Botts Road, work in process (WIP) within a production department must be transported. This report recommends packaging to mitigate vibration levels experienced by products during between-facility transportation. Measurements and analysis demonstrate that this mitigation results in vibration levels less than those experienced by the product during routine production processes within potentially damaging frequency ranges.

42 ENGINEERING↗
DOE OSTI2012

Process Guide for Deburring Technologies

This report is an updated and consolidated view of the current deburring processes at the Kansas City Plant (KCP). It includes specific examples of current burr problems and the methods used for their detection. Also included is a pictorial review of the large variety of available deburr tools, along with a complete numerical listing of existing tools and their descriptions. The process for deburring all the major part feature categories is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Classified Component Disposal at the Nevada National Security Site

The Nevada National Security Site (NNSS) has added the capability needed for the safe, secure disposal of non-nuclear classified components that have been declared excess to national security requirements. The NNSS has worked with U.S. Department of Energy, National Nuclear Security Administration senior leadership to gain formal approval for permanent burial of classified matter at the NNSS in the Area 5 Radioactive Waste Management Complex owned by the U.S. Department of Energy. Additionally, by working with state regulators, the NNSS added the capability to dispose non-radioactive hazardous and non-hazardous classified components. The NNSS successfully piloted the new disposal pathway with the receipt of classified materials from the Kansas City Plant in March 2012.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗