Development of improved thermoelectric materials for spacecraft applications final summary report, apr. 29 - jul. 29, 1964
Thermoelectric and thermomagnetic cooling and material development for spacecraft application
THERMOELECTRIC MATERIAL↗
SEARCH · Engineering Papers
Results for “materials development”
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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Application of Chemistry in Materials Research at NASA GRC
Overview of NASA GRC Materials Development. New materials enabled by new chemistries offering unique properties and chemical processing techniques. Durability of materials in harsh environments requires understanding and modeling of chemical interaction of materials with the environment.
Chemistry↗
Deactivation Mechanisms of Base Metal/Zeolite Urea Selective Catalytic Reduction Materials, and Development of Zeolite-Based Hydrocarbon Adsorber Materials
Reducing NOx emissions and particulate matter (PM) are primary concerns for diesel vehicles required to meet current LEV II and future LEV III emission standards which require 90+% NOx conversion. Currently, urea SCR as the NOx reductant and a Catalyzed Diesel Particulate Filter (CDPF) are being used for emission control system components by Ford Motor Company for 2010 and beyond diesel vehicles. Because the use of this technology for vehicle applications is new, the relative lack of experience makes it especially challenging to satisfy durability requirements. Of particular concern is being able to realistically simulate actual field aging of the catalyst systems under laboratory conditions.
Environmental Molecular Sciences Laboratory↗
A lattice model for composite materials
Development of lattice model for composite materials
Chang, T. Y.↗
Preparation and characterization of the Pyrrones as thermal structural materials
Development of technique for preparing foam materials to be used as thermal structural components in spacecraft construction
Kimmel, B. G.↗
Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles
This project, Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles, develops Integrated Computational Materials Engineering (ICME) techniques for Carbon Fiber Reinforced Polymer (CFRP) composites and uses these ICME tools within a multi-disciplinary optimization scheme to design a carbon-fiber intensive front subframe for a passenger sedan. The subframe is a structural automotive component with stringent requirements for vibration, strength, durability and safety performance. CFRP composites, with a density of 1.55 g/cm3 and a tensile strength of up to 2,000 MPa in the fiber direction, have a high strength-to-weight ratio, making them one of the most promising candidates to replace the metals currently used for automotive structural components. By increasing the accessibility of CFRP component designs, reducing development-to-deployment lead time of CFRP components, and improving the robustness of initial designs, this project supports weight reduction in light-duty vehicles. These efforts can help mitigate greenhouse gas emissions from passenger vehicles and have the potential to improve national energy independence.
36 MATERIALS SCIENCE↗
Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles
This project, Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles, develops Integrated Computational Materials Engineering (ICME) techniques for Carbon Fiber Reinforced Polymer (CFRP) composites and uses these ICME tools within a multi-disciplinary optimization scheme to design a carbon-fiber intensive front subframe for a passenger sedan. The subframe is a structural automotive component with stringent requirements for vibration, strength, durability and safety performance. CFRP composites, with a density of 1.55 g/cm 3 and a tensile strength of up to 2,000 MPa in the fiber direction, have a high strength-to-weight ratio, making them one of the most promising candidates to replace the metals currently used for automotive structural components. By increasing the accessibility of CFRP component designs, reducing development-to-deployment lead time of CFRP components, and improving the robustness of initial designs, this project supports weight reduction in light-duty vehicles. These efforts can help mitigate greenhouse gas emissions from passenger vehicles and have the potential to improve national energy independence.
36 MATERIALS SCIENCE↗
NASA's Advanced TPS Materials and Technology Development: Multi-Functional Materials and Systems for Space Exploration
NASA's future missions will be more demanding. They require materials to be mass efficient, robust, multi-functional, scalable and able to be integrated with other subsystems to enable innovative missions to accomplish future science missions. Thermal protection systems and materials (TPSM) are critical for the robotic and human exploration of the solar system when it involves entry. TPSM is a single string system with no back-up. Mass efficiency and robustness are required. Integration of TPSM with the aeroshell is both a challenge and an opportunity. Since 2010, NASA's Space Technology Mission Directorate has invested in innovative new materials and systems across a spectrum of game changing technologies. In this keynote address, we plan to highlight and present our successful approaches utilized in developing four different materials and system technologies that use innovative new manufacturing techniques to meet mission needs. 3-D weaving and felt manufacturing allowed us to successfully propose new ways of addressing TPSM challenges. In the 3-D MAT project, we developed and delivered a multi-functional TPS materials solution, in under three years that is an enabler for Lunar Capable Orion Spacecraft. Under the HEEET project, we are developing a robust heat-shield that can withstand extreme entry conditions, both thermally and mechanically, for entry at Venus, Saturn or higher speed sample return missions. The improved efficiency of HEEET allows science missions entry at much reduced G'loads enabling delicate science instruments to be used. The ADEPT concept is a foldable and deployable entry system and the critical component is a multi-functional fabric that is foldable and deployable and also functions as a mechanical aeroshell and a TPS. The fourth technology we will highlight involves felt to address integration challenges of rigid ablative system such as PICA that was used on MSL. The felt technology allows us to develop a compliant TPS for easy integration. The above four technology developments have focused on mission infusion as the success criteria. These technologies are in different stages of mission infusion. These innovations have led to new mission concepts to be proposed in the future. In our keynote address we will present approaches we have employed throughout the project to create the bridge to transition from low TRL to mission infusion and to overcome the traditional TRL valley of death.
TPS↗
Report on FY 2023 Experimental Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms
The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2023). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART A709 materials. The objective of this A709 development work in FY 2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023. This report summarizes the results of the high-speed dilatometry project to develop the CCP diagram using the commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Surveillance Test Articles Development
Material degradation in Advance Test Reactors (ATR) is governed by irradiation, corrosion, elevated temperature exposure and cyclic mechanical creep-fatigue loads. This degradation information during reactor operation condition is limited. Hence, material damage monitoring is a key aspect of the design, analysis and licensing of ATR components. The idea is to monitor material component operation conditions of component by using a surveillance test article. This test article is fabricated with bi-metal configuration with two different thermal expansion coefficients, and design is motivated by Simplified Model Test (SMT) specimen which can capture structure-like mechanical response. Upon raising temperature of the bi-metal test article configuration, expansion mismatch results tensile load on specimen. Thus, temperature dependent passively actuated loading is achieved. The idea is to place this surveillance test article in reactor at location ‘x’ to surveil the mechanical response at critical location ‘y’. By calibrating the test article design, material degradation at critical location can be surveilled through assessing the degradation in surveillance test article. This study presents test article development with different material combinations and follow-up experimental testing work through passively loading test article with temperature history. The test article geometry and observed test results are presented in presentation slides.
36 MATERIALS SCIENCE↗
Research Plan and Preliminary Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms―Grain Coarsening Temperature Evaluation
The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A component design in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, piping and forging using the available ART A709 materials. The objective of this A709 development work at ORNL in FY2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution annealing process. This report summarizes the work performed to identify the grain coarsening temperature for commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Flat Rolled Products.
36 MATERIALS SCIENCE↗
Nonlinear acoustic theory for rigid porous materials
Development of nonlinear acoustic theory for rigid porous materials and concept of temporal impedance operator
Parrott, T. L.↗
Towards Thermomechanical Processing of Alloy 709: Progress in Defining High-Temperature Deformation-Recrystallization "Space"
The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel, generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2025). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the Alloy 709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of Alloy 709 plate fabricated from three heats. The goal of the overall Alloy 709 development program is to establish the necessary microstructural and mechanical properties relationship for Alloy 709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART Alloy 709 materials. This study will enable its deployment in the industry as an advanced construction material for high-temperature components. The objective of this Alloy 709 development work in FY 2025 is to experimentally determine the high-temperature deformation-recrystallization response of the Alloy 709 heats and to experimentally generate true stress-true strain data for Alloy 709 using the available commercial heat plate materials. Integral to this work is the previous characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023, and the evaluation of the effect of controlled cooling on the resultant precipitation in these commercial heats. This report summarizes and builds on the results of the previous reports to assess the high-temperature deformation behavior as a function of deformation temperature, strain and strain rate using commercial Alloy 709 heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
The Role of Machine Learning in the Understanding and Design of Materials
Developing algorithmic approaches for the rational design and discovery of materials can enable us to systematically find novel materials, which can have huge technological and social impact. However, such rational design requires a holistic perspective over the full multistage design process, which involves exploring immense materials spaces, their properties, and process design and engineering as well as a techno-economic assessment. The complexity of exploring all of these options using conventional scientific approaches seems intractable. Instead, novel tools from the field of machine learning can potentially solve some of our challenges on the way to rational materials design. Here we review some of the chief advancements of these methods and their applications in rational materials design, followed by a discussion on some of the main challenges and opportunities we currently face together with our perspective on the future of rational materials design and discovery.
36 MATERIALS SCIENCE↗
ATF material model development and validation for priority fuel concepts
Development, implementation, and validation of material and behavior models for accident tolerant fuel (ATF) concepts in the Bison fuel performance code began in 2014 in response to the events that occurred at the Fukushima Daichii nuclear power plant in March 2011. Early on the focus was on U 3 Si 2 fuel and FeCrAl cladding as part of a high impact problem through the Nuclear Energy and Advanced Modeling Simulation (NEAMS) program. Then, developments for Cr 2 O 3 -doped UO 2 fuel, and SiC-SiC and Cr-coated zirconium-based claddings began based upon industry interests. In late fiscal year 2018 the Consortium for Advanced Simulation of Light Water Reactors (CASL) took over further ATF work in Bison in support of the Nuclear Regulatory Commission (NRC) engagement. Discussions with the NRC identified their list of priority fuel and cladding concepts, which included Cr 2 O 3 -doped UO 2 and U 3 Si 2 fuels, and Cr-coated zirconium-based and FeCrAl claddings. In particular, the NRC suggested that reports similar in form to NUREG/CR-7024 [1] that was developed for traditional LWR materials UO 2 and zirconium-based claddings (i.e., Zircaloy-4, M5®, ZIRLO) be created for the priority ATF concepts. The approach to ATF capability development in Bison since the beginning has been two-fold: (1) empirical correlations and (2) multiscale model development. Both approaches have uncertainty inherent to them. Uncertainty in empirical correlations is bounded by the experimental data upon which with the correlation was developed. Models developed through a multiscale approach have uncertainty associated with the lower length scale calculations and input parameters that must be propagated to the engineering scale model in Bison. In this report, the recommended models, their range of applicability (e.g., temperature, burnup), and associated uncertainty for the NRC priority fuel concepts Cr 2 O 3 -doped UO 2 and U 3 Si 2 are presented in a manner similar to the aforementioned NUREG. In addition, the Cr 2 O 3 -doped UO 2 models are validated to the Halden Reactor tess IFA-677.1 rods 1 and 5 and IFA-716.1 rod 1. For U 3 Si 2 the models are validated to the recent post-irradiation examination (PIE) data ATF-13 and ATF-15 rods that were irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory. Finally, an uncertainty quantification (UQ) and sensitivity analysis (SA) is completed on a single rod for each fuel concept that takes into account the defined uncertainty in select models. The results of the UQ and SA analyses indicate that given the large uncertainty in some of the input ATF models that the uncertainty on the Bison predictions of fuel performance metrics of interest bound the available experimental data. Correlation coefficients are also reported that identified the uncertain inputs with the strongest correlation (positive or negative) with the outputs of interest. Fuel performance metrics investigated include fuel elongation, rod internal pressure, fuel centerline temperature, and fission gas release.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
ATF material model development and validation for priority cladding concepts
Development, implementation, and validation of material and behavior models for accident tolerant fuel (ATF) concepts in the Bison fuel performance code began in 2014 in response to the events that occurred at the Fukushima Daichii nuclear power plant in March 2011. Early on the focus was on U 3 Si 2 fuel and FeCrAl cladding as part of a high impact problem through the Nuclear Energy and Advanced Modeling Simulation (NEAMS) program. Then, developments for Cr 2 O 3 -doped UO 2 fuel, and SiC-SiC and Cr-coated zirconium-based claddings began based upon industry interests. In late fiscal year 2018 the Consortium for Advanced Simulation of Light Water Reactors (CASL) took over further ATF work in Bison in support of the Nuclear Regulatory Commission (NRC) engagement. Discussions with the NRC identified their list of priority fuel and cladding concepts, which included Cr 2 O 3 -doped UO 2 and U 3 Si 2 fuels, and Cr-coated zirconium-based and FeCrAl claddings. In particular, the NRC suggested that reports similar in form to NUREG/CR-7024 that was developed for traditional LWR materials UO 2 and zirconium-based claddings (i.e., Zircaloy-4, M5 ® , ZIRLO TM ) be created for the priority ATF concepts. The approach to ATF capability development in Bison since the beginning has been two-fold: (1) empirical correlations and (2) multiscale model development. Both approaches have uncertainty inherent to them. Uncertainty in empirical correlations is bounded by the experimental data upon which with the correlation was developed. Models developed through a multiscale approach have uncertainty associated with the lower length scale calculations and input parameters that must be propagated to the engineering scale model in Bison. In this report, the recommended models, their range of applicability (e.g., temperature, fluence), and associated uncertainty for the NRC priority clad concepts Cr-coated zirconium based clad and FeCrAl are presented in a manner similar to the aforementioned NUREG. In addition, in the absence of experimental data for validation, demonstration cases are presented that investigate the ballooning and burst behavior of Cr-coated and FeCrAl clads as well as tritium permeation in FeCrAl. A portion of the study by Gamble et al. on FeCrAl failure is also revisited with the latest updated models. First, the nominal results are shown using the as implemented models. Then a sensitivity analysis and uncertainty quantification is performed to assess the impact of the uncertainties in the models on the parameters of interest. For the Cr-clad ballooning case the parameter of interest is the time to burst. For the revisited FeCrAl study, the parameter of interest is the pressure at burst.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Materials technology development for long life large space systems
Large Space Systems materials requirements are discussed in terms of types of materials, critical properties, and environmental stability. An outline is given of the materials technology development that will be needed to meet these requirements.
Gause, R. L.↗