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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Quantifying Dynamic Processes in Reactive Materials: An Extended Burn Tube Test

Abstract A common method for measuring the reactivity of rapidly deflagrating materials has been to loosely pack a desired mixture into an approx. 10 cm long×3 mm diameter acrylic tube, ignite the material on one end, and report the observed self‐propagating flame velocity through the material. While this method can yield qualitative information, linking this to quantitative intrinsic properties, such as particle burn time, has remained challenging. In this work, we significantly redesign the traditional burn tube experiment. Between 25 and 250 mg of nanocomposite aluminum/copper oxide (Al/CuO) thermite is loosely packed into the capped end of a 1.8 m long tube, and the remainder of the tube is left unfilled. The material is ignited using a hot wire, resulting in a steadily‐propagating luminous front, which extends part, or all, of the way down the length of the tube. We suggest the behavior is a result of “reactive entrainment”, which occurs when the reaction time scale becomes longer than the characteristic momentum relaxation time scale. When this criterion is met, and when there are significant pressure gradients present or produced during the reaction, material will be entrained by the gases before and/or during the reaction; a behavior very different from conventional thermites, which use larger particle sizes. The effect of sample mass and tube diameter on propagation velocity is investigated, and we find a linear scaling with mass and a power law scaling with tube radius ( r −1.3 ) between 1.56 and 4.76 mm radii. For several conditions, we observe the reaction complete; defined by the distance where the propagation velocity decreases to a fixed fraction of its steady value. The ratio of quench distance to propagation velocity was found to approach a constant value of 3.29±0.70 ms, which we suggest is the burn time of the Material. For the range of masses studied in this work, the burn time was found to be independent of mass, implying that it is an intrinsic particle burn time. We expect other quantitative information can be deduced from this experiment, so long as the chosen sample mass and tube dimensions allow one to observe the full extent of reaction.

Sullivan, Kyle T.↗
DOE OSTI2019

Evolution of Microstructure and Creep Behavior in an Fe-Ni-Cr-Nb-C Alloy during Service in Hydrocarbon Cracker Tubes

Heat resistant, cast austenitic Fe-Ni-Cr-Nb-C alloy tubes are used by the petrochemical industry to transport hydrocarbons at temperatures between 850 and 1050 °C. Exposure to carbon from the process stream and nitrogen from the air causes severe carburization and nitridation in the tube walls, which influences creep resistance and degrades their ductility. A better understanding of these processes would enable their service life to be extended. To this end, we report the results of an experimental and computational study of the changes in microstructure and creep behavior in a representative alloy during service. The microstructure of the fresh material is compared to that of 8- and 10-year-old tubes. The results confirm the presence of M{sub 23}C{sub 6}, M{sub 7}C{sub 3}, and M{sub 2}(CN) phases reported in prior studies, and also reveal the nucleation and growth of the carbo-nitride phase M{sub 6}(CN). We show that the spatial variations of carbide and nitride particle volume fractions in aged tubes can be predicted by a simple reaction–diffusion equation. In addition, the uniaxial compressive creep response of the fresh and aged tubes was obtained as functions of temperature and strain rate. The materials deform by power-law creep, with strain rate versus stress relation as ε-dot =Aσ{sup n}. Aging reduces the stress exponent from n = 8 in fresh tubes to n = 5 in aged tubes, and also reduces the pre-exponential coefficient A. Tests on model alloys with composition identical to that of the matrix combined with finite element simulations of creep in model microstructures reveal that Cr depletion is responsible for the change in stress exponent, while the change in A is caused by the increase in particle volume fraction. By combining the microstructure-scale simulations of creep with the predictions of the reaction–diffusion model of microstructure evolution, the creep behavior of tubes left in service beyond 10 years is estimated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The deformation and burst behavior of Zircaloy-4 cladding tubes with hydride rim features subject to internal pressure loads

This study is motivated by the desire to conduct a separate effects test replicating specific aspects of an in-pile pulse reactor test on high exposure light water reactor (LWR) fuel rods. The principal purpose of the tests was to determine whether temperature and or hydrogen concentration thresholds exist in assessing the vulnerability of a stress relieved zirconium alloy cladding tubes to low strain ruptures. A secondary objective was to determine whether observations of the cladding stress during deformation could aid in the understanding of the crack formation and propagation in cladding tubes with hydride rim features. Here, the study utilized artificially hydrided Zircaloy-4 cladding tubes and an isothermal, internal pressure test that was controlled with an in-situ strain measurement. The test results show a clear transition in failure vulnerability between room temperature and 150 °C. Below 150 °C, cladding tubes rupture at very low uniform plastic strain—even at relatively modest cladding hydrogen levels. At and above 150 °C, cladding tubes only rupture at low uniform plastic strain if the cladding hydrogen content is greater than 500 ppm and usually experience at least some modest amount of plastic deformation prior to rupture. Post-test metallographs from non-ruptured cladding tubes show numerous primary cracks forming in the hydride rim and arresting at the metal/hydride interface. This observation combined with the decrease in bulk yielding of hydrided cladding tubes when compared to fresh non-hydrided tubes leads to the conclusion that the fracture stress of the hydride rims is related to and bounded by the yield stress of the zirconium metal. Some evidence is presented for a change in crack propagation mechanism from one of void formation on hydride plates and linkage at temperatures below 150 °C to more classical ductile shearing beneath the primary crack tip at temperatures above 150 °C. This apparent change in crack propagation mechanism may help explain the observed temperature and hydrogen concentration thresholds.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

A new flow pattern map for flow boiling of R410A in horizontal micro-fin tubes considering the effect of the helix angle

This paper presents an improved flow pattern map for flow boiling in horizontal micro-fin tubes considering the effect of helix angle. The proposed map is modified from the one developed for horizontal smooth tubes by Wojtan et al. (2005) and takes the early transition to annular flow due to micro-fin geometry into account. Visualization of R410A flow boiling is carried out through the transparent smooth and micro-fin tubes with 0°, 10° and 18° helix angle and plotted on the proposed map for comparison. The result shows that the flow pattern map for micro-fin tube with 0° helix angle is generally similar to that for the smooth tube. For the tube with 10° and 18° helix angle, the annular flow occurs at lower vapor quality and lower mass flux. The proposed map shows good agreements when compared with the visualization and reflects the downward shift (to lower mass flux and vapor quality conditions) of the SW-WA transition with the increase of the helix angle. In order to further validate the proposed model, the flow pattern transitions calculated from the equations are also compared with the experimental data of the micro-fin tube in literature. The results show that the modified map increase the prediction accuracy of the flow patterns in the micro-fin tube.

42 ENGINEERING↗
DOE OSTI2020

Cross-code comparison of the impact of the fill tube on high yield implosions on the National Ignition Facility

Fill tubes are used to inject deuterium and tritium fuel into inertial confinement fusion capsules fielded on the National Ignition Facility. These fill tubes have been shown to have a detrimental effect on capsule performance, primarily by introducing a low-density pathway into the central fuel region that enables the jetting of ablation material into the hot spot. Due to the complexity of the highly nonlinear flow associated with the fill tube and the challenge of diagnosing the evolution of the fill tube jet late in the implosion experiments, the uncertainty in how this perturbation source evolves is great. In this work, we report on the results of a detailed code comparison performed to understand uncertainties in computational modeling of the impact of fill tubes on implosion performance. The study employed two radiation-hydrodynamics codes, HYDRA and xRAGE, which employ very different meshing strategies and hydrodynamics solvers, as well as two radiation transport methodologies, discrete ordinates and multi-group diffusion. Our results demonstrate generally good agreement between codes through most of the implosion although they indicate sensitivity to opacity averaging methods. Late in the implosion, differences arise in the distribution and amount of contaminant although these differences have a remarkably small impact on the amount of yield reduction due to the fill tube. While these results demonstrate sensitivity in fill tube modeling to algorithmic choices, the observed differences between codes are small relative to known sensitivities due to expected variations in the fill tube geometry. Finally, we have developed a methodology for performing multi-group diffusion simulations that show good agreement with the more accurate discrete ordinates method

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Thermal shock resistance of multilayer silicon carbide receiver tubes for 800°C molten salt concentrating solar power application

CSP power tower receiver systems during rapid transient weather periods can be vulnerable to thermal shock conditions from rain that which can facilitate the onset of leaks and failures that can have catastrophic consequences. Silicon carbide (SiC) materials have attractive receiver application characteristics for being light weight, having high-strength and excellent thermal shock resistance performance which make them a particularly good fit for receiver absorber materials in CSP. In this investigation, the performance characteristics of Ceramic Tubular Products (CTP) SiC ceramic matrix composite (CMC), multilayered tubes were explored with respect to thermal shock performance for solar receiver applications in next generation CSP plants. Here, thermal shock testing was performed at the Sandia National Laboratories (SNL) Solar Furnace facility using a dynamic stage and thermal shock tube test setup. The tubes tested under incident solar heat flux of 100 W/cm2 were heated with inner tube temperatures reaching approximately 800 °C, with outer temperatures exceeding or just reaching 1000 El for the multilayer and monolithic SiC tubes respectively. The tubes were then quenched with simulated rain. The tubes were then cooled and subjected to hoop stress analysis using an Instron device to assess their subsequent mechanical strength. Furthermore, the on-sun study experimental results indicate an average of 24.2% and 97% higher hoop strength for the CMC tubes than those composed of monolithic SiC and aluminum oxide (A1203) respectively.

14 SOLAR ENERGY↗
DOE OSTI2011

ON THE DISPERSION AND SCATTERING OF MAGNETOHYDRODYNAMIC WAVES BY LONGITUDINALLY STRATIFIED FLUX TUBES

We provide a fairly general analytic theory for the dispersion and scattering of magnetohydrodynamic waves by longitudinally stratified flux tubes. The theory provides a common framework for, and synthesis of, many previous studies of flux tube oscillations that were carried out under various simplifying assumptions. The present theory focuses on making only a minimal number of assumptions. As a result it thus provides an analytical treatment of several generalizations of existing tube oscillation models. The most important practical cases are inclusion of plasma pressure and possibly buoyancy effects in models of straight non-diverging tubes as applied in coronal seismology, and relaxation of the 'thin tube' approximation in oscillation models of diverging tubes as applied both in the context of p-mode scattering and coronal seismology. In particular, it illustrates the unifying theoretical framework underlying both the description of waves scattered by flux tubes and the dispersion of waves carried along flux tubes.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

Magnetohydrostatic equilibrium. II. Three-dimensional multiple open magnetic flux tubes in the stratified solar atmosphere

A system of multiple open magnetic flux tubes spanning the solar photosphere and lower corona is modeled analytically, within a realistic stratified atmosphere subject to solar gravity. This extends results for a single magnetic flux tube in magnetohydrostatic equilibrium, described in Gent et al. Self-similar magnetic flux tubes are combined to form magnetic structures, which are consistent with high-resolution observations. The observational evidence supports the existence of strands of open flux tubes and loops persisting in a relatively steady state. Self-similar magnetic flux tubes, for which an analytic solution to the plasma density and pressure distribution is possible, are combined. We calculate the appropriate balancing forces, applying to the equations of momentum and energy conservation to preserve equilibrium. Multiplex flux tube configurations are observed to remain relatively stable for up to a day or more, and it is our aim to apply our model as the background condition for numerical studies of energy transport mechanisms from the solar surface to the corona. We apply magnetic field strength, plasma density, pressure, and temperature distributions consistent with observational and theoretical estimates for the lower solar atmosphere. Although each flux tube is identical in construction apart from the location of the radial axis, combinations can be applied to generate a non-axisymmetric magnetic field with multiple non-uniform flux tubes. This is a considerable step forward in modeling the realistic magnetized three-dimensional equilibria of the solar atmosphere.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2015

MULTI-PARAMETRIC STUDY OF RISING 3D BUOYANT FLUX TUBES IN AN ADIABATIC STRATIFICATION USING AMR

We study the buoyant rise of magnetic flux tubes embedded in an adiabatic stratification using two-and three-dimensional, magnetohydrodynamic simulations. We analyze the dependence of the tube evolution on the field line twist and on the curvature of the tube axis in different diffusion regimes. To be able to achieve a comparatively high spatial resolution we use the FLASH code, which has a built-in Adaptive Mesh Refinement (AMR) capability. Our 3D experiments reach Reynolds numbers that permit a reasonable comparison of the results with those of previous 2D simulations. When the experiments are run without AMR, hence with a comparatively large diffusivity, the amount of longitudinal magnetic flux retained inside the tube increases with the curvature of the tube axis. However, when a low-diffusion regime is reached by using the AMR algorithms, the magnetic twist is able to prevent the splitting of the magnetic loop into vortex tubes and the loop curvature does not play any significant role. We detect the generation of vorticity in the main body of the tube of opposite sign on the opposite sides of the apex. This is a consequence of the inhomogeneity of the azimuthal component of the field on the flux surfaces. The lift force associated with this global vorticity makes the flanks of the tube move away from their initial vertical plane in an antisymmetric fashion. The trajectories have an oscillatory motion superimposed, due to the shedding of vortex rolls to the wake, which creates a Von Karman street.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2017

Large Eddy Simulation of Heat Transfer Over In-Line Flat-Tube Array in Laminar and Turbulent Flows

This study presents a transient three-dimensional numerical study on fluid flow and heat transfer of flat-tube array using large eddy simulation (LES) covering both laminar and turbulent flow regimes. The simulations were performed in a rectangular region containing only one tube with periodic conditions specified on all boundaries. A staggered flat-plate array was first studied, and an existing solution was used for validation purpose. The numerical models were then applied to an in-line array composed of flat tubes with an aspect ratio of 0.25 and fixed tube spacings. By varying the in-flow velocity, the tube array was studied over a wide range of Reynolds number (600–12000). Temperature, velocity, and turbulent kinetic energy distributions as well as the interactions between them are presented and analyzed. Furthermore, the local heat transfer rate was analyzed along the various parts of the tube (leading edge, flat-top and wake or trailing-edge regions). Heat transfer correlation for each region of the tube and the entire tube array is proposed..

Taghizadeh, Salar↗
DOE OSTI2016

SU-F-T-24: Impact of Source Position and Dose Distribution Due to Curvature of HDR Transfer Tubes

Purpose: Brachytherapy is a highly targeted from of radiotherapy. While this may lead to ideal dose distributions on the treatment planning system, a small error in source location can lead to change in the dose distribution. The purpose of this study is to quantify the impact on source position error due to curvature of the transfer tubes and the impact this may have on the dose distribution. Methods: Since the source travels along the midline of the tube, an estimate of the positioning error for various angles of curvature was determined using geometric properties of the tube. Based on the range of values a specific shift was chosen to alter the treatment plans for a number of cervical cancer patients who had undergone HDR brachytherapy boost using tandem and ovoids. Impact of dose to target and organs at risk were determined and checked against guidelines outlined by radiation oncologist. Results: The estimate of the positioning error was 2mm short of the expected position (the curved tube can only cause the source to not reach as far as with a flat tube). Quantitative impact on the dose distribution is still in the process of being analyzed. Conclusion: The accepted positioning tolerance for the source position of a HDR brachytherapy unit is plus or minus 1mm. If there is an additional 2mm discrepancy due to tube curvature, this can result in a source being 1mm to 3mm short of the expected location. While we do always attempt to keep the tubes straight, in some cases such as with tandem and ovoids, the tandem connector does not extend as far out from the patient so the ovoid tubes always contain some degree of curvature. The dose impact of this may be significant.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2013

Measurement of Passive Uptake Rates for Volatile Organic Compounds on Commercial Thermal Desorption Tubes and the Effect of Ozone on Sampling

Diffusive or passive sampling methods using commercially filled axial-sampling thermal desorption tubes are widely used for measuring volatile organic compounds (VOCs) in air. The passive sampling method provides a robust, cost effective way to measure air quality with time-averaged concentrations spanning up to a week or more. Sampling rates for VOCs can be calculated using tube geometry and Fick’s Law for ideal diffusion behavior or measured experimentally. There is evidence that uptake rates deviate from ideal and may not be constant over time. Therefore, experimentally measured sampling rates are preferred. In this project, a calibration chamber with a continuous stirred tank reactor design and constant VOC source was combined with active sampling to generate a controlled dynamic calibration environment for passive samplers. The chamber air was augmented with a continuous source of 45 VOCs ranging from pentane to diethyl phthalate representing a variety of chemical classes and physiochemical properties. Both passive and active samples were collected on commercially filled Tenax TA thermal desorption tubes over an 11-day period and used to calculate passive sampling rates. A second experiment was designed to determine the impact of ozone on passive sampling by using the calibration chamber to passively load five terpenes on a set of Tenax tubes and then exposing the tubes to different ozone environments with and without ozone scrubbers attached to the tube inlet. During the sampling rate experiment, the measured diffusive uptake was constant for up to seven days for most of the VOCs tested but deviated from linearity for some of the more volatile compounds between seven and eleven days. In the ozone experiment, both exposed and unexposed tubes showed a similar decline in terpene mass over time indicating back diffusion when uncapped tubes were transferred to a clean environment but there was no indication of significant loss by ozone reaction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Confined Tube Crimp Using Portable Hand Tools

The Lawrence Radiation Laboratory developed handheld tools that crimp a 1/16 inch OD tube, forming a leak tight seal1 (see Figure 1). The leak tight seal forms by confining the 1/16 inch OD tubing inside a die while applying crimp pressure. Under confined pressure, the tube walls weld at the crimp. The purpose of this study was to determine conditions for fabricating a leak tight tube weld. The equipment was used on a trial-and-error basis, changing the conditions after each attempt until successful welds were fabricated. To better confine the tube, the die faces were polished. Polishing removed a few thousandths of an inch from the die face, resulting in a tighter grip on the tubing wall. Using detergent in an ultrasonic bath, the tubing was cleaned. Also, the time under crimp pressure was increased to 30 seconds. With these modifications, acceptable cold welds were fabricated. After setting the conditions for an acceptable cold weld, the tube was TIG welded across the crimped face.

42 ENGINEERING↗
DOE OSTI2017

Determination of He and D permeability of neutron-irradiated SiC tubes to examine the potential for release due to micro-cracking

Driven by the need to enlarge the safety margins of light water reactors in both design-basis and beyond-design-basis accident scenarios, the research and development of accident-tolerant fuel (ATF) has become an importance topic in the nuclear engineering and materials community. Continuous SiC fiber-reinforced SiC matrix ceramic composites are under consideration as a replacement for traditional zirconium alloy cladding owing to their high-temperature stability, chemical inertness, and exceptional irradiation resistance. Among the key technical feasibility issues, potential failure of the fission product containment due to probabilistic penetrating cracking has been identified as one of the two most critical feasibility issues, together with the radiolysisassisted hydrothermal corrosion of SiC. The experimental capability to evaluate the hermeticity of SiC-based claddings is an urgent need. In this report, we present the development of a comprehensive permeation testing station established in the Low Activation Materials Development and Analysis laboratory at Oak Ridge National Laboratory. Preliminary results for the hermeticity evaluation of un-irradiated monolithic SiC tubes, uncoated and coated SiC/SiC composite tubes, and neutron-irradiated monolithic SiC tubes at room temperature are exhibited. The results indicate that this new permeation testing station is capable of evaluating the hermeticity of SiC-based tubes by determining the helium and deuterium permeation flux as a function of gas pressure at a high resolution of 8.07 x 10 -12 atm-cc/s for helium and 2.83 x 10 -12 atm-cc/s for deuterium, respectively. The detection limit of this system is sufficient to evaluate the maximum allowable helium leakage rate of lab-scale tubular samples, which is linearly extrapolated from the evaluation standard used for a commercial as-manufactured light water reactor fuel rod at room temperature. The un-irradiated monolithic SiC tube is hermetic, as is manifested by the un-detectable deuterium permeation flux at various feeding gas pressures. A large helium leakage rate was detected for the uncoated SiC/SiC composite tube exposed to atmosphere, indicating it is inherently not hermetic. The hermeticity of coated SiC/SiC composite tubes is strongly dependent on the coating materials and the preparation of the substrate SiC/SiC composite samples. To simulate the practical application environment, monolithic CVD SiC tubes were exposed to neutron irradiation at the High Flux Isotope Reactor under high heat flux from the internal surface to the external surface. Although finite element analysis and resonant ultrasound spectroscopy measurement indicated that the combined neutron irradiation and high heat flux gave rise to a high probability of cracking within the sample, the hermeticity evaluation of the tested sample still exhibited gas tightness, emphasizing that SiC cracking is inherently a statistical phenomenon. The developed permeation testing station is capable of measuring the gas permeation flux in the range of interest with full confidence based on the presented results. It is considered a critical pre- /post-irradiation examination technique to characterize SiC-based cladding materials in asreceived and irradiated states to aid the research and development of ATF.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Coiled Tube Gas Heaters For Nuclear Gas-Brayton Power Conversion

This project developed an alternative design for heat exchangers for application to heating supercritical carbon dioxide (S-CO 2 ) or air for power conversion. We have identified an annular coiled tube bundle configuration–where hot sodium enters tubes from multiple vertical inlet manifold pipes, flows in a spiral pattern radially inward and downward, and then exits into an equal number of vertical outlet manifold pipes–as a potentially attractive option. The S-CO 2 gas or air flows radially outward through the tube bundle. Coiled tube gas heaters (CTGHs) are expected to have excellent thermal shock, long-term thermal creep, in-service inspection, and reparability characteristics, compared to alternative options. CTGHs have significant commonality with modern nuclear steam generators. Extensive experience exists with the design, manufacture, operation, in-service inspection and maintenance of nuclear steam generators. The U.S. Nuclear Regulatory Commission also has extensive experience with regulatory guidance documented in NUREG 0800. CTGHs leverage this experience and manufacturing capability. The most important difference between steam generators and gas-Brayton cycles such as the S-CO 2 cycle is that the heat exchangers must operate with counter flow with high effectiveness to minimize the pinch-point temperature difference between the hot liquid coolant and the heated gas. S-CO 2 -cycle gas heaters also operate at sufficiently elevated temperatures that time dependent creep is important and allowable stresses are relatively low. Designing heat exchangers to operate in this regime requires configurations that minimize stresses and stress concentrations. The cylindrical tubes and cylindrical manifold pipes used in CTGHs are particularly effective geometries. The first major goal of this research project was to develop and experimentally validate a detailed, 3-D multi-phase (gas-solid-liquid) heat transport model for CTGHs, using methods similar to earlier UCB multi-scale models for PCHEs, which will enable optimization of CTGH designs with respect to the number of manifold pipes, S-CO 2 and sodium circulating power, and other design parameters. CTGHs are relatively novel because the tubes loaded in compression as well as the manifold pipes which form the tube sheets. The second major goal of the experimental and modeling effort was to optimize the assembly and heat treatment of the tube-to-tubesheet joints, using a novel tapered joint configuration, and to develop diffusion-bonded joints with high shear strength and creep resistance, as has been done in other applications for tapered plugs. The project would also conduct creep testing of these tubesheet joints in pressurized furnaces under prototypical conditions of stress and temperature, however this was not feasible due to numerous hinderances. Detailed microstructural investigations was conducted on the diffusion bond interface, while the bond strength was evaluated by tensile testing. The mechanical testing quantified the overall strength of the bond and measured the pull out force as well as long term behavior, which complemented the microstructural analysis and gave a complete understanding of the diffusion bond.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Tensile Strength and Steam Oxidation Resistance of ODS FeCrAl Sheet and Tubes

ORNL is developing advanced low-Cr oxide dispersion strengthened (ODS) FeCrAlY alloys for accident tolerant fuel cladding, and this report describes the fabrication and characterization of a new ODS FeCrAlYZr (CrAZY) tube. This CrAZY tube was produced by successive steps of pilgering and annealing, in collaboration with a Japanese tube manufacturer. Very fine, elongated sub-grain structure in the as-received tube was consistent with the fine sub-grain structure observed for CrAZY foils fabricated by cold rolling at ORNL and led to very high tensile strength at room temperature. The elongated grain structure along the pilgering direction resulted in lower ductility in the hoop direction compared to the ductility along the tube. Similar anisotropic tensile behavior was also observed for the CrAZY foil with very limited ductility perpendicular to the rolling direction. The foil and tube were heat treated in the 850- 1100ºC range to reduce the residual stress. Recrystallization was observed at temperature as low as 900ºC, with an increasing number of recrystallized grains with increasing temperature. Exposure for 1h at 900ºC resulted in a significant improvement of the foil and tube, with a moderate decrease of strength. Atom probe tomographic analysis revealed the presence of many nano oxide precipitates but also areas with fewer precipitates due to the relatively high extrusion temperature (1100ºC). Finally, the CrAZY tube showed good oxidation resistance in steam at temperature up to 1400ºC.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Lizard-inspired Tube Inspector (LTI) Robot

This final report summarizes the research findings of the current project. This project is a collaboration between New Mexico State University (NMSU) as a lead (Recipient) and Arizona State University (ASU) as a Co-Recipient. Tubular structures are common components of boilers and heat exchangers in power plants. Over time, these components may suffer corrosion, cracks, and stress-corrosion cracks in either the body or the welded connections. A single tube leakage can cause an outage of several weeks. Regular inspection is a key safety factor when ensuring that power plants are maintained in reliable, operational condition. This inspection, however, is challenging, time-consuming, and in many cases impossible due to accessibility issues and safety concerns. Recent developments in robotic-based inspection can offer a great solution. Hard-to-reach places can be inspected without overhauling the unit, saving time and cost. Although several robots have been designed and implemented successfully for inspecting power plant components, in particular tubular structures, their mobility and flexibility are limited. Most of these robots use wheels for mobility which reduces their maneuverability of these robots. Moreover, they usually use magnets to attach to tubes which will not work on tubes with non-ferromagnetic materials. These robots usually carry measurement tools for a particular non-destructive testing (NDT) method such as ultrasound testing (UT) that requires a couplant to perform a point-by-point (scanning) inspection of the tubular structure. In this project, we developed a versatile lizard-inspired tube inspector (LTI) robot with embedded inspection sensing components for tube inspection which removes the need for point-by-point scanning of tube surface for crack and corrosion detection. Inspired by a “lizard”, the novelty of the current project is the integration of couplant-free ultrasound sensing and transmission, advanced data-driven defect detection and imaging, and friction-based mechanical mobility components in a single robot to eliminate a need for smooth surfaces and simple geometry for mobility and scanning. The LTI robot could replace the wheel-based approach with friction-based mobility to significantly increase the flexibility and maneuverability of the robot. The LTI robot can get into a power plant unit, such as a boiler, from a small area allowing it to access a component of interest for inspection (e.g., move on OD, curved and flat surfaces, non-ferromagnetic or ferromagnetic materials, and tubes with rough surfaces and complex geometries). Additionally, an advanced data-driven method using ultrasound data was pioneered to allow the robot to detect defects in the entire area between the robot’s multi-functional mobility system (grippers). Integrating a couplant-free ultrasound sensing in the robot’s grippers as well as using advanced data-driven methods allowed the LTI to detect defects in the entire cross-section of a tube using its grippers when stationary and when mobile.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Quality Optimization of Commercial FeCrAl Tube Production

The objectives of this report are to summarize the various process parameters and conditions that trigger premature failures during the production steps for Generation II ATF FeCrAl seamless tubes in commercially available manufacturing processes, and to suggest optimized processing routes and parameters to improve the quality and the material yield of commercial tube production. The production process steps include (1) the heat production process, (2) the master bar production process, and (3) the tube reduction process. For heat production, not only chemical composition control but also elimination of solidification defects in the vacuum induction–melted ingot are key. A hot-isostatic press helped in reducing and eliminating the internal, preexisting cracks in the ingot, which could be a source of premature failure (e.g., crack initiation from oxide particles) in the latter part of the tube production process. The master bars were produced by a hot-extrusion process. The area reduction ratio and the extrusion temperature are key to controlling the quality of the master bars and the grain structure. Because of the limited deformation ability of FeCrAl alloys, especially at ambient temperatures, a controlled, uniform grain structure with relatively small grains (<100 µm) is required at the beginning of the tube reduction process. Furthermore, a relatively small amount of area reduction per pass, combined with controlled inter-pass annealing, is important to achieve a reduction in failure events, a highly uniform wall thickness, concentricity, and a high-quality surface finish. Based on the knowledge obtained regarding process conditions, FeCrAl tube production with optimized process parameters is currently in progress. A portion of the final tube inventory was delivered in late June 2017. Cross-sectional microstructural characterization was completed for screening the quality of as-received tubes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗