ART GCR Metals and High Temperature Design Methodology Overview
Overview presentation on high temperature metals and design methodology work for the ART Gas Cooled Reactor Program Review.
36 - MATERIALS SCIENCE↗
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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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Class B Materials Code Case
Class B Materials Code Case to include: FY25 - High temperature design methodology, overview of ASME Section III (Division 5), Design for elevated temperature service, Goal to address current gaps, evaluation of proposed rules, allowable stress development, Class A materials (existing ASME approach), variable confidence index, data extrapolation, bounding value for SEE, and next steps.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
GCR: Class B Code Case
This PowerPoint presentation is for Joint ART Materials/AMMT Program Review, Germantown, MD, on June-5-8, 2023. It will discuss development to revamp the ASME Section III Division 5 Class B design rules. There will be a plan in the FY24 to assess extrapolation methods for other Class A materials, alternative strain range evaluations for fatigue damage, evaluation of Class B intersection point in D-diagram relative to material-specific Class A intersection points, and evaluation of new Class B rules against Class A rules based on Elastic-Perfectly Plastic (EPP) methodology and full inelastic analysis method, using sample problems.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Fast Reactor Materials R&D Update
Focus on materials and design methods to support advanced reactors deployment Design, construction, licensing and operations
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Design for ASIC reliability for low-temperature applications
In this paper, we present a methodology to design for reliability for low temperature applications without requiring process improvement. The developed hot carrier aging lifetime projection model takes into account both the transistor substrate current profile and temperature profile to determine the minimum transistor size needed in order to meet reliability requirements. The methodology is applicable for automotive, military, and space applications, where there can be varying temperature ranges. A case study utilizing this methodology is given to design for reliability into a custom application-specific integrated circuit (ASIC) for a Mars exploration mission.
reliability↗
Solid lubrication design methodology, phase 2
The high temperature performance of solid lubricated rolling elements was conducted with a specially designed traction (friction) test apparatus. Graphite lubricants containing three additives (silver, phosphate glass, and zinc orthophosphate) were evaluated from room temperature to 540 C. Two hard coats were also evaluated. The evaluation of these lubricants, using a burnishing method of application, shows a reasonable transfer of lubricant and wear protection for short duration testing except in the 200 C temperature range. The graphite lubricants containing silver and zinc orthophosphate additives were more effective than the phosphate glass material over the test conditions examined. Traction coefficients ranged from a low of 0.07 to a high of 0.6. By curve fitting the traction data, empirical equations for slope and maximum traction coefficient as a function of contact pressure (P), rolling speed (U), and temperature (T) can be developed for each lubricant. A solid lubricant traction model was incorporated into an advanced bearing analysis code (SHABERTH). For comparison purposes, preliminary heat generation calculations were made for both oil and solid lubricated bearing operation. A preliminary analysis indicated a significantly higher heat generation for a solid lubricated ball bearing in a deep groove configuration. An analysis of a cylindrical roller bearing configuration showed a potential for a low friction solid lubricated bearing.
Pallini, R. A.↗
Tungsten fiber reinforced superalloy composite high temperature component design considerations
Tungsten fiber reinforced superalloy composites (TFRS) are intended for use in high temperature turbine components. Current turbine component design methodology is based on applying the experience, sometimes semiempirical, gained from over 30 years of superalloy component design. Current composite component design capability is generally limited to the methodology for low temperature resin matrix composites. Often the tendency is to treat TFRS as just another superalloy or low temperature composite. However, TFRS behavior is significantly different than that of superalloys, and the high environment adds consideration not common in low temperature composite component design. The methodology used for preliminary design of TFRS components are described. Considerations unique to TFRS are emphasized.
Winsa, E. A.↗
Tungsten-fiber-reinforced superalloy composite, high-temperature component design considerations
Tungsten fiber reinforced superalloy composites (TFRS) are intended for use in high temperature turbine components. Current turbine component design methodology is based on applying the experience, sometimes semiempirical, gained from over 30 years of superalloy component design. Current composite component design capability is generally limited to the methodology for low temperature resin matrix composites. Often the tendency is to treat TFRS as just another superalloy or low temperature composite. However, TFRS behavior is significantly different than that of superalloys, and the high environment adds consideration not common in low temperature composite component design. The methodology used for preliminary design of TFRS components are described. Considerations unique to TFRS are emphasized. Previously announced in STAR as N82-21259
Winsa, E. A.↗
Development of methodology for optimum design of structures at elevated temperatures
This paper surveys a number of activities aimed at applying optimum design techniques to structures where high temperatures are important design considerations. An improved variant of fully-stressed design (FSD), denoted thermal fully-stressed design (TFSD), is described which converges significantly faster than FSD for problems where thermal stresses are comparable in magnitude to mechanical stresses. Second, an optimality criterion is described for sizing structures subjected to temperature constraints. Simultaneous requirements on strength and temperatures are handled by two different techniques: (1) a state-of-the-art mathematical programming method and (2) the optimality criterion technique for temperature constraints combined with FSD for strength constraints. A method is described to optimize the insulation and ply thicknesses of an insulated composite panel with a time-varying temperature applied to the outer surface of the insulation and a general set of in-plane loads applied to the panel.
Adelman, H. M.↗
Thermal design of composite materials high temperature attachments
The thermal aspects of using filamentary composite materials as primary airframe structures on advanced atmospheric entry spacecraft such as the space shuttle vehicle were investigated to identify and evaluate potential design approaches for maintaining composite structures within allowable temperature limits at thermal protection system (TPS) attachments and/or penetrations. The investigation included: (1) definition of thermophysical data for composite material structures; (2) parametric characterization and identification of the influence of the aerodynamic heating and attachment design parameters on composite material temperatures; (3) conceptual design, evaluation, and detailed thermal analyses of temperature limiting design concepts; and (4) the development of experimental data for assessment of the thermal design methodologies and data used for evaluation of the temperature-limiting design concepts. Temperature suppression attachment concepts were examined for relative merit. The simple isolator was identified as the most weight-effective concept and was selected for detail design, thermal analysis, and testing. Tests were performed on TPS standoff attachments to boron/aluminum, boron/polyimide and graphite/epoxy composite structures.
Source record↗
Methodology to evaluate design modifications intended to eliminate frosting and high discharge temperatures in air-source heat pumps (ASHPs) in cold climates
Air-source heat pumps (ASHPs) operating in cold climates experience problems with frosting and high refrigerant temperatures. These problems increase energy consumption, and their severity depends on the climatic conditions. In the present paper, a methodology for identifying the prevailing problem between frosting and high discharge temperatures is presented. Three performance indices, the frosting index (FI), the discharge index (DI), and the total loss index (TLI), are proposed to quantify the impacts of frosting and high discharge temperatures on the annual performance of ASHPs in different climatic conditions. The FI and DI show which problem (frosting or high discharge temperature) dominates, and the TLI indicates the combined effect of frosting and high discharge temperatures on the performance of an ASHP. A thermodynamic model of an ASHP coupled with the TRNSYS building simulation tool is used to estimate the performance of an ASHP and the proposed loss indices to estimate the impact of both frosting and high discharge temperatures for 45 cities in Canada. The results can be extended to other parts of the world that experience similar climatic conditions The results reveal that in cities in ASHRAE climatic zones 5 and 6 (classified as cold regions) where the ambient air temperatures are predominantly between -15 °C to 6 °C, ASHPs are heavily impacted by frosting. The problem of high discharge temperatures in ASHPs is predominant in cities in climate zones 7 and 8 (classified as very cold and subarctic regions) where the temperatures are frequently below -20 °C in winter. Among the cities considered, St. John, NL has the highest fraction of heating hours experiencing frosting (90 %), where the annual increase in energy consumption due to frosting is 13.5 % of the annual heating energy consumption. The highest annual increase in energy consumption due to high discharge temperatures is in Isachsen, NU (zone 8), where the increase is 30 % of the annual heating energy consumption. Based on the proposed indices, another index called the performance gain index (PGI) is created, which can be used as a first step to assess the energy-saving potential of design modifications applied to ASHPs to solve the problems of frosting and high discharge temperatures. The PGI will aid in developing climate specific ASHPs. One possible design modification is the use of a two-stage ASHP with an economizer. It is observed that the two-stage ASHP with economizer can mitigate high discharge temperatures and improve performance in very cold and subarctic regions (zones 7 and 8). However, it is not as beneficial in zones 5 and 6, where the impact of high discharge temperatures on performance is minimal and frosting dominates. Finally, a case study, using the PGI to evaluate the economic and environmental effectiveness of a two-stage ASHP with economizer is presented for the city of Saskatoon.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Turbine Seal Research at NASA GRC
Low-leakage, long-life turbomachinery seals are important to both Space and Aeronautics Missions. (1) Increased payload capability (2) Decreased specific fuel consumption and emissions (3) Decreased direct operating costs. NASA GRC has a history of significant accomplishments and collaboration with industry and academia in seals research. NASA's unique, state-of-the-art High Temperature, High Speed Turbine Seal Test Facility is an asset to the U.S. Engine / Seal Community. Current focus is on developing experimentally validated compliant, non-contacting, high temperature seal designs, analysis, and design methodologies to enable commercialization.
Proctor, Margaret P.↗
Technology Demonstration Mission (TDM) evolvable Cryogenics (eCryo) Project Structural Heat Intercept, Insulation and Vibration Evaluation Rig (SHIIVER) Diode Rake Assembly and Installation
NASA designed, assembled and installed a temperature diode rake into the SHIIVER test article for use of measuring liquid and gaseous hydrogen temperatures. Several special steps were taken to ensure that fluid temperatures were measured as opposed to structural temperatures. This document outlines design practices and methodologies that have become standard practice at Glenn Research Center to ensure the measurement of fluid temperatures for cryogenic systems research.
Cryogenic Fluid Management↗
Experimental and Analytical Verification of ASME Section IiII Division 5 Creep-Fatigue Design Rules
The continuous advancement of structural materials and the growing demands for more reliable and economical structural components in high-temperature reactor applications have necessitated the development of comprehensive design methodologies and design rules. Mechanical degradation of structural components at elevated temperatures subjected to cyclic deformation is controlled by the creep-fatigue damage. Over the past few decades, diligent research efforts have been dedicated to refining the development of elevated temperature design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5 and to develop conservative design rules that can effectively guard against the risk of creep-fatigue failure. In ASME Section III, Division 5, for a design to pass the creep-fatigue acceptance criteria, creep damage and fatigue damage are evaluated separately, and these damages must not violate the bi-linear creep-fatigue interaction diagram, i.e., the so-called D-diagram. The creep-fatigue damage evaluation procedure assumes that the effects of the actual cyclic loading sequence can be bounded by assuming that the individual loading cycles are uniformly distributed throughout the component design life. In this study, creep-fatigue experiments with variable amplitudes and loading sequencies were designed and performed on Alloy 617 at high temperatures. The results were analyzed to evaluate the loading history effect on creep-fatigue damage accumulation and to verify the assumptions for the creep-fatigue evaluation design rules.
36 - MATERIALS SCIENCE↗
Multiphysics Pebble-Bed Reactor Control Rod Withdrawal Study
This work studied the responses of both a generic gas- and a fluoride-cooled PBR concept---the gPBR-200 and gFHR, respectively---during reactivity insertion accidents. Both models rely on 2-D axisymmetric simulations to solve the neutron flux distribution, nuclide concentrations, and temperature across the core---in addition to numerous representative pebble and TRISO particle simulations for determining fuel and moderator temperatures. This not only allows for computing maximum temperatures in the core---thus enabling estimation of how near the fuel is to peak operational and safety limits---as prescribed by specified acceptable fuel design limits, which are determined in such a way that fuel is not damaged during operational or anticipated abnormal occurrences---but also predicting how much of the core exceeds a given temperature limit, as well as determining the local energy deposition rate. These models consider both control rod withdrawal and ejection events. The former introduces a great deal more reactivity, as all the control rods are withdrawn (as opposed to a single one in the latter case), though at a much slower pace. In addition, for the gPBR-200, two limiting cases were considered: one with the core starting under hot full-power conditions and one with it starting under cold zero-power conditions. While the amount of reactivity added in the latter case is much higher (due to the far lower temperatures and the lack of neutron poisons such as Xe-135), the margin to temperature limits is also much more significant. Overall, for the design considered, none of the accidents resulted in the maximum fuel temperature reaching values close to the TRISO limit. However, the methodology presented herein could be very relevant if some designs consider reduced margins (e.g., higher temperatures) to achieve enhanced economics. Further model improvement is needed to better capture control rod worth, both in terms of cusping effects (as the rods are slowly withdrawn) and differential worth, especially as the tips of the rods near the upper cavity.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Development of a Framework and Methodology for an Advanced Reactor Materials Environmental Effects Design Guide
Advanced non-light-water reactor components may operate at elevated temperature while experiencing cyclic loading, significant neutron irradiation, and exposure to reactor coolant. ASME Boiler and Pressure Vessel Code, Section III, Division 5, provides design rules for elevated-temperature service but does not include specific procedures to account for environmental effects on material properties. This report develops an initial framework and methodology for an Environmental Effects Design Guide (EEDG) focused on neutron irradiation; coolant-environment effects are reserved for future work. The proposed approach treats irradiation as a property-based overlay on the existing Division 5 design process, with two routes: a sparse-data route applying two reduction factors — FCR on creep-rupture strength and FF on fatigue life — for the creep-fatigue evaluations that typically control the design of advanced high-temperature reactor components, and a fuller framework developing the property-to-rule chain across the four Division 5 checks (primary load, strain limits and ratcheting, creep-fatigue, and buckling), together with swelling and weldments as scope items. Both routes are scoped by an in-pile qualification that restricts the use of post-irradiation-examination-derived properties in regimes where an in-pile mechanism could control the design outcome. Illustrative outputs derived on a compiled annealed Type 316 database — FCR ≈ 0.78–0.86 and FF ≈ 0.4 — demonstrate the calculation method within that specific dataset. The framework is an initial, testable design-rule concept; it identifies a practical path for preliminary design evaluations under sparse data and the material data and testing needed to develop the framework further.
Barua, Bipul (ORCID:0000000247184113)↗
Machine learning for optimizing the manufacture and operation of intermediate temperature fuel cells
The project developed machine learning and artificial intelligence (ML/AI) methodologies for guiding and accelerating the materials design and processing of new high temperature proton conducing electrode ionomer binders and reinforced membranes for high-temperature proton exchange membrane fuel cell (HT-PEMFC; aka intermediate-temperature polymer electrolyte membrane fuel cells).
08 HYDROGEN↗
AGT (Advanced Gas Turbine) technology project
An overall summary documentation is provided for the Advanced Gas Turbine Technology Project conducted by the Allison Gas Turbine Division of General Motors. This advanced, high risk work was initiated in October 1979 under charter from the U.S. Congress to promote an engine for transportation that would provide an alternate to reciprocating spark ignition (SI) engines for the U.S. automotive industry and simultaneously establish the feasibility of advanced ceramic materials for hot section components to be used in an automotive gas turbine. As this program evolved, dictates of available funding, Government charter, and technical developments caused program emphases to focus on the development and demonstration of the ceramic turbine hot section and away from the development of engine and powertrain technologies and subsequent vehicular demonstrations. Program technical performance concluded in June 1987. The AGT 100 program successfully achieved project objectives with significant technology advances. Specific AGT 100 program achievements are: (1) Ceramic component feasibility for use in gas turbine engines has been demonstrated; (2) A new, 100 hp engine was designed, fabricated, and tested for 572 hour at operating temperatures to 2200 F, uncooled; (3) Statistical design methodology has been applied and correlated to experimental data acquired from over 5500 hour of rig and engine testing; (4) Ceramic component processing capability has progressed from a rudimentary level able to fabricate simple parts to a sophisticated level able to provide complex geometries such as rotors and scrolls; (5) Required improvements for monolithic and composite ceramic gas turbine components to meet automotive reliability, performance, and cost goals have been identified; (6) The combustor design demonstrated lower emissions than 1986 Federal Standards on methanol, JP-5, and diesel fuel. Thus, the potential for meeting emission standards and multifuel capability has been initiated; (7) Small turbine engine aerodynamic and mechanical design capability has been initiated; and (8) An infrastructure of manpower, facilities, materials, and fabrication capabilities has been established which is available for continued development of ceramic component technology in gas turbine and other heat engines.
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