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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 OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗
DOE OSTI2023

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2023

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gears sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne. To date, the Inconel 718 gears used in all six GTA experimental campaigns have completed over 23.2 million revolutions under various loads equivalent to approximately 37,156 simulated fuel assembly maneuvers (removal from and reinsertion to core) using a conventional height of a core assembly. While the heat treated and untreated tapered roller bearings and cylindrical pin thrust bearings used in the first five experimental campaigns have experienced mechanical or material failure after completing a range of fuel assembly maneuvers ranging from as early as 575 operations in Campaign #5 to 9800 operations in Campaign #1, Campaign #6 was the most successful campaign, achieving 22,563 maneuvers and was concluded before any catastrophic failure occurred. In this report we will present the results from the most recent campaigns, #5 and #6. The longevity of Campaign #6 was likely aided by a variety of adjustments made to the materials and components used and to the experimental testing procedures employed. In terms of materials and components, new gearboxes were fabricated, as opposed to using the old gear boxes which had been impacted by the previous bearing failures, and ball bearings were replaced with tapered roller bearings. The adjustments to the experimental procedure focused on a lowering of the maximum torque applied to the gears and bearings and the increase of the duration of each simulated fuel assembly maneuver conducted. This report will present and discuss the changes made to the materials, components, and procedures and the subsequent results for Campaign #5 and Campaign #6.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Gear Test Assembly – Experimental Testing and Analysis of Gears and Bearings – FY2024

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gear sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Gear Test Assembly - Experimental Testing and Gear Analysis - FY2022

The Gear Test Assembly (GTA) is an experimental test article built for use in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GTA was the first test article to operate in METL, with the initial experimental campaign beginning in early 2019. A total of four experimental campaigns have been completed to-date, and the fifth is currently underway. This report will discuss the results of the four completed campaigns with gear analysis in the form of over-pin dimensions. Finally, information regarding Experimental Campaign #5 will be discussed. All over-pin measurements of the gears tested in sodium will be available in the Appendix.

42 ENGINEERING↗
NASA NTRS1988

Assembly Test Article (ATA)

The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.

Ricks, Glen A.↗
NASA NTRS1973

Compression test assembly

A compression test assembly is described which prevents buckling of small diameter rigid specimens undergoing compression testing and permits attachment of extensometers for strain measurements. The test specimen is automatically aligned and laterally supported when compressive force is applied to the end caps and transmitted to the test specimen during testing.

Kariotis, A. H.↗
NASA NTRS2019

A Simple Transient Thermal Test Assembly for Insulation Materials

A simple transient thermal test was developed for evaluating the thermal performance of high-temperature flexible insulation materials in atmospheric pressure air. The test setup was inspired by the test assembly used for evaluating the performance of fire shelters and fire protective clothing. The heating source used was a burner supplied with propane gas that can generate relatively uniform heating over a wide area. The ratio of the in-plane width to thickness of the insulation test sample in the test assembly was selected to be greater than ten so that the heat transfer in the center of the test assembly was nearly one-dimensional. A rigid, thin Inconel plate was used as the septum plate directly exposed to the flame to provide a relatively uniform, known-temperature boundary condition for the test assembly, and to prevent convective heat transfer through the test insulation from the burner. The test sample, flexible alumina paper insulation, was placed between the Inconel plate and a thin titanium witness plate. The overall assembly was further insulated using a combination of rigid and flexible ceramic insulations to minimize heat losses from the periphery of the test assembly. Thermocouples installed on the septum and witness plates and inside the insulation test sample provided temperature measurements at various locations. For the evaluation tests, the Inconel septum plate reached temperatures between 780°C and 850°C for tests with flame exposure durations of 120 sec to 300 sec. The measured temperatures for various tests with similar flame exposure times were repeatable. A one-dimensional numerical heat transfer model of the test assembly was developed. The close agreement between measured and predicted temperatures on the titanium witness plate and inside the insulation test sample indicated that this test may provide a one-dimensional thermal testing capability for evaluation of thermal performance of similar insulations.

Daryabeigi, Kamran↗
NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗
NASA NTRS1974

Anti-buckling fatigue test assembly

An antibuckling fatigue test assembly is described for holding a metal specimen which is subjected to compression and to rapid cyclical heating and cooling while permitting visual observation. In an illustrative embodiment of this invention, the anti-buckling fatigue test apparatus includes first and second guide members between which the metal specimen is disposed and held, a heating assembly comprising a suitable heating source such as a quartz lamp and a reflecting assembly directing the heat onto the specimen, and a cooling assembly for directing a suitable cooling fluid such as air onto the specimen. The guide members each have a passage to permit the heat to be directed onto the specimen. An opening is provided in the reflecting assembly to permit visual inspection of that region of the specimen adjacent to the opening onto which the heat is directed.

Eichenbrenner, F. F.↗
DOE OSTI2025

Cataloging Legacy Data from the Tritium Systems Test Assembly Program

The Tritium Systems Test Assembly (TSTA) at Los Alamos National Laboratory, operational from 1984 to 2001, was critical in advancing fusion fuel cycle technologies, including tritium storage, gas separation, and pumping. TSTA’s contributions, particularly in safe tritium operations, have influenced subsequent fusion projects. This paper discusses the ongoing effort to digitize and catalog TSTA’s historical data to create a searchable resource for the fusion research community. While the long-term objective is to develop a relational database for structured data management, the project remains in the early phase, with current efforts focused on scanning and indexing physical documents. Initial plans for database implementations are also presented, outlining key considerations for structure, query indexing, and standardization. As digitization progresses, future discussions will refine these implantation details to ensure an efficient and comprehensive system. This initiative aims to preserve critical legacy data, enhance the design of tritium system facilities, and support the next generation of fusion energy research.

42 ENGINEERING↗
DOE OSTI2023

Gripper Test Assembly Status of Fabrication and Assembly Report – FY2023

The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Concept Descriptions for the VTR Rabbit System and Driver Fuel Test Assemblies

Two of the experiment vehicles being developed for the Versatile Test Reactor (VTR) are presented here. The first is a rabbit system that will enable rapid insertion of small test capsules into the high fast flux of the VTR core for relatively short durations. The rabbit concept development includes the construction/demonstration of a near-full-scale system in a deep-water pool to demonstrate functionality, development of a concept of operations and initial procedures, and validation of thermal-hydraulic modeling. In addition, modeling efforts are underway to simulate the thermal and neutronic environment of a rabbit capsule. The second type of experiment vehicle presented here is a driver fuel test assembly for inserting fuel and materials tests into the core by replacing a driver fuel assembly. Here, a novel design for dismountable test assemblies is proposed for the VTR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

DOESC Closure Leak Test Assembly

This conceptual design report is for the DOESC Closure Leak Test Assembly, which satisfies a portion of the milestone "Preliminary Design Report for Remote Helium Leak Test System". This CDR is part of the Preliminary Design Report/Package.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Shock test assembly

An assembly for shock testing a specimen, the assembly including first and second opposing brackets and opposing lower and upper caps. The opposing brackets include lower and upper angled surfaces. The lower cap includes lower angled surfaces configured to engage the lower angled surfaces of the left and right brackets. The upper cap includes upper angled surfaces configured to engage the upper angled surfaces of the left and right brackets. The first and second brackets are configured to be drawn toward each other via fasteners, thereby wedging the lower and upper caps toward each other against the specimen.

Busenitz, Clark↗
DOE OSTI2023

Shock test assembly

An assembly for shock testing a specimen, the assembly including first and second opposing brackets and opposing lower and upper caps. The opposing brackets include lower and upper angled surfaces. The lower cap includes lower angled surfaces configured to engage the lower angled surfaces of the left and right brackets. The upper cap includes upper angled surfaces configured to engage the upper angled surfaces of the left and right brackets. The first and second brackets are configured to be drawn toward each other via fasteners, thereby wedging the lower and upper caps toward each other against the specimen.

Busenitz, Clark↗
DOE OSTI2025

IER 516: Zirconium Test Assembly CED Phase-1: Preliminary Experiment Design

IER-516, Zirconium Test Assembly (ZTA), is a campaign to design, execute, and document a series of high-fidelity critical benchmark experiments to validate current and future zirconium (Zr) and zirconium hydride (ZrH x ) nuclear data evaluations. ZTA is a collaborative project between Los Alamos National Laboratory and the French Autoritè de Sûretè Nuclèaire et de Radioprotection. The experiments will be fueled with highly enriched uranium (HEU), and utilize the Comet critical assembly machine at the National Criticality Experiments Research Center. A total of ten preliminary critical experiments were designed and optimized for Zr and ZrHx nuclear data sensitivities using the MCNP-Particle Swarm Optimization methodology in the thermal, epithermal, intermediate, and fast neutron energy regions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2020

Prokaryotic and Fungal Characterization of the Facilities Used to Assemble, Test, and Launch the OSIRIS-REx Spacecraft

To characterize the ATLO (Assembly, Test, and Launch Operations) environment of the OSIRIS-REx spacecraft, we analyzed 17 aluminum witness foils and two blanks for bacterial, archaeal, fungal, and arthropod DNA. Under NASA’s Planetary Protection guidelines, OSIRIS-REx is a Category II outbound, Category V unrestricted sample return mission. As a result, it has no bioburden restrictions. However, the mission does have strict organic contamination requirements to achieve its primary objective of returning pristine carbonaceous asteroid regolith to Earth. Its target, near-Earth asteroid (101955) Bennu, is likely to contain organic compounds that are biologically available. Therefore, it is useful to understand what organisms were present during ATLO as part of the larger contamination knowledge effort—even though it is unlikely that any of the organisms will survive the multi-year deep space journey. Even though these samples of opportunity were not collected or preserved for DNA analysis, we successfully amplified bacterial and archaeal DNA (16S rRNA gene) from 16 of the 17 witness foils containing as few as 7 ± 3 cells per sample. Fungal DNA (ITS1) was detected in 12 of the 17 witness foils. Despite observing arthropods in some of the ATLO facilities, arthropod DNA (COI gene) was not detected. We observed 1,009 bacterial and archaeal sOTUs (sub-operational taxonomic units, 100% unique) and 167 fungal sOTUs across all of our samples (25–84 sOTUs per sample). The most abundant bacterial sOTU belonged to the genus Bacillus. This sOTU was present in blanks and may represent contamination during sample handling or storage. The sample collected from inside the fairing just prior to launch contained several unique bacterial and fungal sOTUs that describe previously uncharacterized potential for contamination during the final phase of ATLO. Additionally, fungal richness (number of sOTUs) negatively correlates with the number of carbon-bearing particles detected on samples. The total number of fungal sequences positively correlates with total amino acid concentration. These results demonstrate that it is possible to use samples of opportunity to characterize the microbiology of low-biomass environments while also revealing the limitations imposed by sample collection and preservation methods not specifically designed with biology in mind.

Aaron B. Regberg↗