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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Quality Control Metrics to Assess MoS 2 Sputtered Films for Tribological Applications [Slides]

Easily measured metrics that could assign quantifiable values to coating batches for quality control have started to be developed. High-density is an attribute of quality films. Increased density results in harder, more wear resistant coatings in inert and humid environments. Denser films are more resistant to oxidation from aging, limiting the severity and depth of oxide into the coating. Future work includes using metrics for quality. The next step is to develop in house deposition capabilities to develop process-structure relationships.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Emulation Modeling for Development of Cyber-Defense Capabilities for Satellite Systems

The objective of this project was to develop a novel capability to generate synthetic data sets for the purpose of training Machine Learning (ML) algorithms for the detection of malicious activities on satellite systems. The approach experimented with was to a) generate sparse data sets using emulation modeling and b) enlarge the sparse data using Generative Adversarial Networks (GANs). We based our emulation modeling on the Open Source NASA Operational Simulator for Small Satellites (NOS3) developed by the Katherine Johnson Independent Verification and Validation (IV&V) program in West Virginia. Significant new capabilities on NOS3 had to be developed for our data set generation needs. To expand these data sets for the purpose of training ML, we experimented with a) Extreme Learning Machines (ELMs) and b) Wasserstein-GANs (WGAN-GP).

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2026

Development of SAM Code Capabilities for Safety Analysis of GCR Air-ingress Events

Air-ingress following a depressurized loss-of-forced-cooling (DLOFC) event is a challenging, multiphysics safety scenario for High-Temperature Gas-Cooled Reactors (HTGRs), involving coupled gas composition transport, buoyancy-driven flow redistribution, graphite oxidation, and structural heat-up. Despite its importance — air ingress is a key scenario identified in the PIRT process for the HTGRs — existing system-level safety codes have lacked the integrated capability to simulate the complete event sequence with high confidence. This report documents the development, validation, and demonstration of three new capabilities in the SAM code to address this gap: (1) a multi-component gas mixture flow model with binary diffusion to track the helium-air composition and its effect on system density and flow; (2) a 0-D graphite oxidation model based on the Roes correlation, including oxygen consumption and exothermic heat release; and (3) an isentropic critical flow model for accurate representation of primary system depressurization through a break. These capabilities are validated against two benchmark experiments. The NSTF heavy-gas ingress experiment validates the multi-component flow model: SAM correctly reproduces the rapid buoyancydriven flow stagnation and subsequent natural circulation recovery driven by composition-dependent density changes. The NACOK graphite oxidation experiment validates the oxidation model: SAM predicts a bottom-level graphite weight loss of 25%, in close agreement with the measured 24%, and reproduces the strong axial nonuniformity and block-geometry dependence of oxidation, at a level comparable to the SPECTRA and TINTE codes. The validated capabilities are then exercised together in an integrated, reactor-scale simulation of a DLOFC air-ingress transient in a simplified HTR-PM pebble-bed reactor. In a single calculation spanning approximately 8 days, SAM reproduces the complete accident sequence: rapid depressurization, densityand diffusion-driven air ingress over ˜15 hours, onset of buoyancy-driven natural circulation, exothermic graphite oxidation with a peak fuel temperature at ˜62 hours, and eventual passive cooldown. These results demonstrate that SAM now provides the nuclear community with a preliminarily validated, modern systemlevel tool for HTGR air-ingress safety analysis, filling a recognized capability gap. Future extensions to broaden species tracking, improve oxidation chemistry, and refine the reactor model are discussed.

Yang, Gang↗
DOE OSTI2024

Triple oxygen and hydrogen stable isotope composition of water in Murchison carbonaceous chondrite accessed by thermogravimetry-enabled laser spectroscopy

For this work, we have developed the capability to measure 17 O/ 16 O in H 2 O and OH - of hydrous minerals by a technique using thermogravimetric analysis coupled with isotope ratio infrared spectroscopy (TGA-IRIS) on a suite of liquid water standards, terrestrial mineral standards, multi-mineral synthetic mixtures of terrestrial samples, and Murchison carbonaceous chondrite. This 17 O/ 16 O analytical capability is combined with the previously developed TGA-IRIS capability of 18 O/ 16 O, which enables us to calculate Δ `17 O values. Additionally, we have made 2 H/ 1 H measurements by TGA-IRIS on the suite of materials. Analyses of 328 standard water samples sealed into silver tubes (0.25 μL, 174 VSMOW and 154 GISP) analyzed over the course of three years yielded δ 18 O values by TGA-IRIS with precision of ±0.30 ‰, δ 17 O of ±0.24 ‰, Δ `17 O of ±0.126 ‰, and δ 2 H ± 7.5 ‰ (± 1 Std. Dev.). TGA-IRIS analyses of a suite of hydrous minerals (oxy-hydroxide, mica, serpentines, sulfide, phyllosillicates) yields similar precision. TGA-IRIS analyses of the CM2 carbonaceous chondrite Murchison resulted in δ 18 O, δ 17 O, Δ `17 O, and δ 2 H values of the H 2 O and/or OH - from its hydrous minerals. Δ `17 O values of Murchison H 2 O range from 1.034 ‰ at 350 °C, to -0.368 ‰ at 650 °C, to -1.75 ‰ at 850 °C. TGA-IRIS can generate Δ `17 O values of H 2 O and/or OH - in hydrous materials that are well within the precision needed for the analysis of meteoritic samples, as well as samples returned from asteroids, such as Ryugu and Bennu.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Establishing capabilities for quantum computing and simulations for energy applications

Quantum information science (QIS) is creating potential transformative opportunities to exploit intricate quantum mechanical phenomena in new ways for obtaining and processing information to advance many areas of science and engineering. Since the National Quantum Initiative Act was signed into law in 2018, developing QIS capability and competency is one of the most urgent tasks of DOE to make sure the US win the quantum race. The QIS contains four pillars: quantum computing, quantum simulations, quantum sensing, and quantum networking. To apply QIS in energy related applications, the key is to develop the capability of quantum computing & simulation tools. In this project, we propose to develop the capability of quantum computing and simulations at NETL to target fossil energy related problems. We will install a simulator (e. g. IBM qiskit) on the NETL supercomputer to simulate the environments of quantum computer. Based on the current available quantum algorithms for quantum chemistry, we will develop quantum computing codes to perform simulation which will focus on fossil energy sector challenges, including CO2 capture & conversion, sensing, and fuel conversion. We then will seek opportunities to run our codes on real quantum computers (such as IBM-Q, google Sycamore, etc.). Through this project, the new capability of quantum computing and simulations will be established at NETL. In addition, the NETL workforce in this area will be trained ready to conduct more complicated tasks in line with NETL missions to enhance the nation’s energy foundation.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

4140 low-alloy steel↗
DOE OSTI2025

Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels

Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.

Pierce, Dean T. [Oak Ridge National Laboratory (OR↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of PNNL’s Plutonium Metallography Capability

The goal of this project was to develop plutonium metallography capabilities and establish workflows for characterization at PNNL’s Radiological Processing Facility (RPL). Developing and expanding on this capability opens more opportunities for PNNL to better support science through collaborations with other labs, plants, and sites withing the Department of Energy Complex and through programs within the National Nuclear Security Administration. This project established metallography equipment in an air glovebox, polishing protocols, as well as radiological and facility controls and procedures so that gram quantities of plutonium metal could be analyzed on multiple characterization tools. Data was collected and analyzed on two different delta phase plutonium - Gallium samples and a calciothermically reduced alpha plutonium metal using a combination of optical and electron microscopy, powder X-ray diffraction, and atom probe tomography. This report highlights the metallography capabilities, some preliminary data collections, and plans at PNNL to support plutonium material science.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Navier: Dataflow Architecture for Computation Chemistry

Navier’s objectives were two evaluate the use of emerging technologies, especially dataflow accelerators, for high-performance computing (HPC) applications, specifically in the domain of chemistry, and to develop a prototype software stack to support such applications. Navier builds on capabilities previously developed by synergistic projects, such as PNNL Data Model Convergence (DMC) LDRD Hardware Advanced Workflows (HAW) and DuOMO, as well as DOE ARIAA. Throughout its 18 months, the Navier team developed new capabilities and artifacts at all levels of the HW/SW stack, provided a seamless way to integrate novel computing architectures (Sambanova SN10 and Xilinx Versal AI) into an existing software stack, developed chemistry workflows, data analytics tools, and HPC molecular dynamics workflows that leverage the developed stack and PNNL institutional investments in emerging architectures. Navier also explored the use of active learning to accelerate a computational chemistry workflow for organic molecules on PNNL Junction cluster (in collaboration with AMD/Xilinx). Navier developed tools, methodologies, and studies for hardware software co-design and (sparse) dataflow accelerators that are composable and can be used together or separately. These methodologies are now used in other projects, such as DOE AMAIS and HPDA. This report describes Navier’s achievement, the developed tools and methodologies, and the research findings and conclusions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Extension of Plant Dynamics Code Capabilities for Simulation of TerraPower Pascal Reactor

Argonne National Laboratory has been developing the Plant Dynamics Code (PDC) for design and transient analysis of supercritical carbon dioxide (sCO 2 ) Brayton cycles. In previous analyses with PDC, only indirect sCO 2 cycles, where the heat is being added through a heat exchanger, such as sodium-to-CO 2 HX, were analyzed. Under the U.S. Department of Energy Technology Commercialization Fund (TCF), Argonne cooperated with TerraPower to bring the Plant Dynamics Code to commercial market. The main focus of the TCF project is to extend the application base and the code usability by developing the capabilities to be able to simulate reactor systems with direct sCO 2 cycles. These new PDC capabilities have been developed in application to the TerraPower’s Pascal reactor concept. This report documents the Pascal reactor modeling with the PDC, including simulation of the Pascal split-expansion cycle, the development of the reactor module in the PDC, modeling of the Pascal’s shutdown heat removal system in PDC, and other updates to the code. The report also describes the results of the steady state and transient demonstration of the newly developed code features.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Light Water Reactor Sustainability Program: Complete the weld campaign on Ni-base irradiated materials using stress improved laser welding including the preliminary weld quality inspections

This report summarizes the most recent welding campaign on irradiated Ni-base alloy 182 and the preliminary weld quality inspections at the Radiochemical Engineering Development Center (REDC). Equipment and capabilities were developed jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program (and the Welding and Repair Technology Center), and Oak Ridge National Laboratory. Irradiated nickel alloy 182, with target helium contents of 5 atom parts-per million (appm), 10 appm, and 20 appm, were laser welded in the hot cell successfully. The significant, on-going effort to weld irradiated alloys with high helium concentrations and comprehensively analyze the results will eventually yield validated repair techniques and guidelines for use by the nuclear industry in extending the operational lifetimes of nuclear power plants. This report fulfills the FY 2023 milestone M3LW-22OR0406013, “Complete the weld campaign on Ni base irradiated materials using stress improved laser welding including the preliminary weld quality inspections”.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Influence of microstructure and temperature on impact toughness of H13 steel produced by binder jet additive manufacturing

Binder Jet Additive Manufacturing (BJAM) is a promising manufacturing pathway to produce H13 steel dies and tooling with complex geometries for applications in high pressure aluminum die casting, hot stamping, and injection molding. While fully dense H13 coupons produced using BJAM have been subjected to detailed microstructure characterization, properties which are critical and relevant to the aforementioned applications, such as impact toughness, have not been reported. Here, this work evaluated the influence of microstructural characteristics and test temperature on the impact toughness of H13 produced by BJAM. Coupons were produced from three different powder size distributions (PSDs), with nominal powder size ranges of −22 μm, 10-32 μm, and 15-53 μm. Coupons were printed, sintered, hot isostatically pressed (HIPed), and heat treated by quenching and tempering. After HIPing, the measured porosities of the different PSDs were all less than 0.015 vol%. The −22 μm PSD BJAM material exhibited the best impact toughness of all three PSDs across the entire test temperature range from 25 to 400 °C, and also exhibited an ambient temperature impact toughness of 10.9 J at a hardness of 46 HRC, equivalent to minimum threshold requirements for premium grade H13. However, all three BJAM PSDs exhibited moderately lower impact toughness than premium grade wrought H13 from RT to 400 °C. We attribute this in part due to the very large prior-austenite grain (PAG) sizes near 400 μm and segregation from former liquid channels leading to greater amounts of carbide precipitation on PAG boundaries. Technical pathways for optimizing processing and chemistry of BJAM H13 to further improve impact toughness are discussed.

Binder jet additive manufacturing↗
DOE OSTI2022

Development of Plant Reload Optimization Framework Capabilities for Core Design and Fuel Performance Analysis

The United States (U.S.) nuclear industry faces a challenge in maintaining required levels of safety while ensuring economic competitiveness to stay in business. Safety remains a key parameter for all aspects of light water reactor (LWR) nuclear power plant (NPP) operations. Safety can become more economical by using a risk-informed ecosystem, such as the one being developed by the Risk-Informed Systems Analysis (RISA) Pathway under the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program. The LWRS Program promotes a wide range of research and development activities with the goal of maximizing both the safety and economic efficiency of NPPs through improved scientific understanding, especially given many plants are now considering second license renewals. The RISA Pathway has two main goals: (1) deploy methodologies and technologies that better represent safety margins and cost and safety factors and (2) develop advanced applications that enable cost-effective plant operation. The Plant Reload Optimization Platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses, and also uses artificial intelligence to support optimization of core design solutions. This report summarizes Fiscal Year 2022 (FY-22) activity in platform capability developments in RAVEN. This platform performs simulations using industry codes for core design (i.e., PARCS) and fuel performance (i.e., TRANSURANUS) which will allow expansion of the capabilities to include advanced fuel designs such as accident-tolerant fuel (ATF)s with high burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Developing in-situ capabilities for synchrotron light source relevant to PNNL mission research areas

The main objective of the proposed research is to engage synchrotron light source capabilities to address the critical mission areas at PNNL. We have carried out Multi-model chemical analysis and imaging to unravel the role of surface chemistry during realistic heterogeneous interfacial processes - through a close collaboration that will help BES and BER research projects. In particular, we performed the following activities to understand role of surface chemistry on metal and oxide reactivity and metal ion transfer across oxide surface and aqueous solutions: 1) Perform light source experiments utilizing samples generated at PNNL; 2) Develop early career PNNL scientists utilizing light sources; 3) Build collaborations with ALS scientists in developing new in-situ capabilities; 4) Complete AMBER capabilities in collaboration with ALS scientists and make those available to the scientific community including PNNL scientists.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Compare Mechanistic Predictions for Doped UO 2 Mechanical Response and Other Properties with Empirical Models and Experimental Measurements

The U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation program develops predictive capabilities using computational methods for the analysis and design of advanced reactor and fuel cycle systems. This program has been supporting the development of BISON, a high-fidelity, high resolution fuel performance tool at the engineering scale. As part of its development, additional modeling capabilities and improvements have been developed for relevant fuel forms. In this work, a fuel creep deformation model for Cr-doped fuel has been implemented into BISON, along with improvements to the empirical UO 2 fuel creep model based on experimental data and improvements to the radial power factor calculation for doped fuels. This work allows for more accurate simulation analyses for both UO 2 and doped-UO 2 fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗