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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Phase stability and mechanical properties of wire + arc additively manufactured H13 tool steel at elevated temperatures

Wire + arc additive manufacturing (WAAM) is considered an innovative technology that can change the manufacturing landscape in the near future. WAAM offers the benefits of inexpensive initial system setup and a high deposition rate for fabricating medium- and large-sized parts such as die-casting tools. Here, AISI H13 tool steel, a popular die-casting tool metal, is manufactured by cold metal transfer (CMT)-based WAAM and is then comprehensively analyzed for its microstructural and mechanical properties. Location-dependent phase combinations are observed, which could be explained by nonequilibrium thermal cycles that resulted from the layer-by-layer stacking mechanism used in WAAM. In addition, remelting and reheating of the layers reduces welding anomalies (e.g., pores and voids). The metallurgical characteristics of the H13 strongly correlate with the mechanical properties. The combinations of phases at different locations of the additively manufactured part exhibit a periodic microhardness profile. Martensite, Retained Austenite, Ferrite, and Carbide phases are found in combination at different locations of the part based on the part’s temperature distribution during additive deposition. Moreover, the tensile properties at elevated temperatures (23 °C, 300 °C, and 600 °C) are comparable to those from other WAAM and additive manufacturing (AM) processes. The X-ray diffraction results verify that the microstructural stability of the fabricated parts at high temperatures would allow them to be used in high temperatures.

36 MATERIALS SCIENCE↗

NASA NTRS2009

Carbon Nanotube Based Chemical Sensors for Space and Terrestrial Applications

A nanosensor technology has been developed using nanostructures, such as single walled carbon nanotubes (SWNTs), on a pair of interdigitated electrodes (IDE) processed with a silicon-based microfabrication and micromachining technique. The IDE fingers were fabricated using photolithography and thin film metallization techniques. Both in-situ growth of nanostructure materials and casting of the nanostructure dispersions were used to make chemical sensing devices. These sensors have been exposed to nitrogen dioxide, acetone, benzene, nitrotoluene, chlorine, and ammonia in the concentration range of ppm to ppb at room temperature. The electronic molecular sensing of carbon nanotubes in our sensor platform can be understood by intra- and inter-tube electron modulation in terms of charge transfer mechanisms. As a result of the charge transfer, the conductance of p-type or hole-richer SWNTs in air will change. Due to the large surface area, low surface energy barrier and high thermal and mechanical stability, nanostructured chemical sensors potentially can offer higher sensitivity, lower power consumption and better robustness than the state-of-the-art systems, which make them more attractive for defense and space applications. Combined with MEMS technology, light weight and compact size sensors can be made in wafer scale with low cost. Additionally, a wireless capability of such a sensor chip can be used for networked mobile and fixed-site detection and warning systems for military bases, facilities and battlefield areas.

Li, Jing↗

NASA NTRS2005

Nanostructure Engineered Chemical Sensors for Hazardous Gas and Vapor Detection

A nanosensor technology has been developed using nanostructures, such as single walled carbon nanotubes (SWNTs) and metal oxides nanowires or nanobelts, on a pair of interdigitated electrodes (IDE) processed with a silicon based microfabrication and micromachining technique. The IDE fingers were fabricated using thin film metallization techniques. Both in-situ growth of nanostructure materials and casting of the nanostructure dispersions were used to make chemical sensing devices. These sensors have been exposed to hazardous gases and vapors, such as acetone, benzene, chlorine, and ammonia in the concentration range of ppm to ppb at room temperature. The electronic molecular sensing in our sensor platform can be understood by electron modulation between the nanostructure engineered device and gas molecules. As a result of the electron modulation, the conductance of nanodevice will change. Due to the large surface area, low surface energy barrier and high thermal and mechanical stability, nanostructured chemical sensors potentially can offer higher sensitivity, lower power consumption and better robustness than the state-of-the-art systems, which make them more attractive for defense and space applications. Combined with MEMS technology, light weight and compact size sensors can be made in wafer scale with low cost.

Li, Jing↗

DOE OSTI2024

Comparative Life Cycle Analysis of Carbon Dioxide Utilization in Concrete Products

In this study, a comparative LCA of CO2U concrete processes is conducted, revealing promise in several research areas. The environmental impacts of replacing conventional binder and aggregates with carbonated steel slag and direct carbonation of concrete are investigated in ten different product systems, which include both ready-mix and pre-cast concretes. The results indicate that cement substitution, CO2 uptake, electricity consumption, and the electricity grid mix constitute critical levers for deep decarbonization of concrete building materials. This presentation applies LCA to inform the use of CO2U concrete technology pathways in the design of sustainable concrete while promoting transparency and rational assumptions in the presence of uncertainty. Broader themes in the work include LCA of emerging technologies and the sensitivity of LCA results to co-product management methods.

Clarke, James↗

NASA NTRS2014

Some Challenges in the Design of Human-Automation Interaction for Safety-Critical Systems

Increasing amounts of automation are being introduced to safety-critical domains. While the introduction of automation has led to an overall increase in reliability and improved safety, it has also introduced a class of failure modes, and new challenges in risk assessment for the new systems, particularly in the assessment of rare events resulting from complex inter-related factors. Designing successful human-automation systems is challenging, and the challenges go beyond good interface development (e.g., Roth, Malin, & Schreckenghost 1997; Christoffersen & Woods, 2002). Human-automation design is particularly challenging when the underlying automation technology generates behavior that is difficult for the user to anticipate or understand. These challenges have been recognized in several safety-critical domains, and have resulted in increased efforts to develop training, procedures, regulations and guidance material (CAST, 2008, IAEA, 2001, FAA, 2013, ICAO, 2012). This paper points to the continuing need for new methods to describe and characterize the operational environment within which new automation concepts are being presented. We will describe challenges to the successful development and evaluation of human-automation systems in safety-critical domains, and describe some approaches that could be used to address these challenges. We will draw from experience with the aviation, spaceflight and nuclear power domains.

systems engineering↗

DOE OSTI2016

Nanostructure/Swelling Relationships of Bulk and Thin-Film PFSA Ionomers

Perfluorinated sulfonic acid (PFSA) ionomers are the most widely used solid electrolyte in electrochemical technologies due to their remarkable ionic conductivity with simultanous mechanical stability, imparted by their phase-separated morphology. In this work, the morphology and swelling of PFSA ionomers (Nafion and 3M) as bulk membranes (>10 μm) and dispersion-cast thin films (<100 nm) are investigated to identify the roles of equivalent weight (EW) and side-chain length across lengthscales. Humidity-dependent structural changes as well as different PFSA chemistries are explored in the thin-film regime, allowing for the development of thickness-EW phase diagrams. The ratio of macroscopic (thickness) to nanoscopic (domain spacing) swelling during hydration is found to be affine (1:1) in thin films, but increases as the thickness approaches bulk values, revealing the existence of a mesoscale organization governing the multiscale swelling in PFSAs. Ionomer chemistry, in particular EW, is found to play a key role in altering the confinement-driven structural changes, including thin-film anisotropy, with phase separation becoming weaker as the film thickness is reduced below 25 nm or as EW is increased. Lastly, for the lower-EW 3M PFSA ionomers, confinement appears to induce even stronger phase separation accompanied by domain alignment parallel to the substrate.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Understanding turbulence in compressing plasma as a quasi-EOS

Inspired by experimental Z-pinch results, we investigate plasma turbulence undergoing compression. In addition to Z-pinches, plasma turbulence can be compressed in a range of natural and laboratory settings, including inertial fusion experiments and astrophysical molecular clouds. The plasma viscosity, when modeled as described by Braginskii, depends strongly on both temperature and ionization state, giving it the possibility to have a large range of behavior. Here, we highlight the importance of viscous variation in these settings, as well as various insights that can be gained by considering this variation. Included are a “sudden viscous dissipation” effect that leads to a new concept for inertial fusion or X-ray bursts and a bound on turbulent energy behavior under compression. This bound, which was previously applied in inviscid molecular cloud turbulence, is here shown in an application to turbulence that transitions from inviscid to viscous regimes. In conclusion, the task of understanding turbulence under compression can be cast as the process of seeking a “quasi equation of state” for turbulent energy under compression.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Report on the completion of the development of processing map from as-cast Alloy 709 materials

This report provides details on the completion of the development of the processing map from the as-cast Alloy 709 materials. The report is a Level 4 deliverable in FY18 (M4NT18AN050502012), under the Work Package NT-18AN05050201, “A709 Development” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Technologies (ART). The report describes the development of a processing map to guide the development of hot work regimens for A709. The maps combine high-temperature flow stress measurements, described in a companion report by Oak Ridge National Laboratory, and metallographic observations, described here, into a single diagram that can be used to select hot working parameters to avoid regions of plastic instability and to avoid the development of unfavorable microstructures. This report describes the process of creating the map, provides the final map for A709, and uses the processing map to describe two potential hot work regimens that could be used in processing a DOE round ingot into bar stock.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Prototyping and Manufacturing of Magnetic Gearbox Components using Innovations in Castings

In a previous collaboration with Emrgy (CRADA agreement NFE-17-06532), a housing component of Emrgy’s 10 kW gearbox was casted out of aluminum alloys using impression molds prepared using 3D printed techniques. (Henderson, 2018). After comparison with Emrgy’s existing hardware and material testing, the 3D printed impression molds were verified to represent a valid approach to advance technology readiness and commercialize Emrgy’s technology.

13 HYDRO ENERGY↗

NASA NTRS1985

Terrestrial applications from space technology

NASA's Technology Utilization Program, which is concerned with transferring aerospace technologies to the public and private sectors, is described. The strategy for transferring the NASA technologies to engineering projects includes: (1) identification of the problem, (2) selection of an appropriate aerospace technology, (3) development of a partnership with the company, (4) implementation of the project, and (5) commercialization of the product. Three examples revealing the application of aerospace technologies to projects in biomedical engineering, materials, and automation and robotics are presented; the development of a programmable, implantable medication system and a programmable, mask-based optical correlator, and the improvement of heat and erosion resistance in continuous casting are examined.

Clarks, H.↗

DOE OSTI2025

Distributed Sapphire Fiber Bragg Gratings Based Thermal Profiling of Submerged Entry Nozzles

This research focuses on the application of sapphire fiber Bragg gratings (FBGs) for instrumentation in submerged entry nozzles (SEN) within the steelmaking industry. The SEN is pivotal for transferring molten steel from a tundish to a mold, while preventing the infiltration of oxygen and nitrogen from the surrounding environment. Maintaining optimal flow conditions in the mold is crucial for ensuring casting process stability and maintaining high quality steel. Sapphire FBG sensors have been instrumented in SENs to enable distributed thermal mapping for monitoring the health of the SEN. The optical sensor comprises three cascaded sapphire FBGs inscribed using femtosecond laser technology into a one-meter-long sapphire crystalline fiber. The sensor underwent characterization in a laboratory setting up to 1600°C and was tested for long-term stability over 40 hours under extreme environmental conditions. The coupling between silica and sapphire fibers was investigated and implemented during sensor packaging. Here, the sensor successfully captured the pre-heat sequence of the SEN in real-world steelmaking operations. Compared to conventional thermocouples, sapphire FBG sensors demonstrated exceptional efficiency and precision. They offer potential benefits such as increased productivity, reduced energy consumption, and minimized carbon footprint in the steel industry.

Sapphire Fiber Bragg Grating↗

NASA NTRS2007

Detailed Analysis of Indian Summer Monsoon Rainfall Processes with Modern/High-Quality Satellite Observations

We examine, in detail, Indian Summer Monsoon rainfall processes using modernhigh quality satellite precipitation measurements. The focus here is on measurements derived from three NASA cloud and precipitation satellite missionslinstruments (TRMM/PR&TMI, AQUNAMSRE, and CLOUDSATICPR), and a fourth TRMM Project-generated multi-satellite precipitation measurement dataset (viz., TRMM standard algorithm 3b42) -- all from a period beginning in 1998 up to the present. It is emphasized that the 3b42 algorithm blends passive microwave (PMW) radiometer-based precipitation estimates from LEO satellites with infi-ared (IR) precipitation estimates from a world network of CEO satellites (representing -15% of the complete space-time coverage) All of these observations are first cross-calibrated to precipitation estimates taken from standard TRMM combined PR-TMI algorithm 2b31, and second adjusted at the large scale based on monthly-averaged rain-gage measurements. The blended approach takes advantage of direct estimates of precipitation from the PMW radiometerequipped LEO satellites -- but which suffer fi-om sampling limitations -- in combination with less accurate IR estimates from the optical-infrared imaging cameras on GEO satellites -- but which provide continuous diurnal sampling. The advantages of the current technologies are evident in the continuity and coverage properties inherent to the resultant precipitation datasets that have been an outgrowth of these stable measuring and retrieval technologies. There is a wealth of information contained in the current satellite measurements of precipitation regarding the salient precipitation properties of the Indian Summer Monsoon. Using different datasets obtained from the measuring systems noted above, we have analyzed the observations cast in the form of: (1) spatially distributed means and variances over the hierarchy of relevant time scales (hourly I diurnally, daily, monthly, seasonally I intra-seasonally, and inter-annually), (2) time series at these different time scales taken as area-averages over the hierarchy of relevant space scales (Indian sub-Division, Indian sub-continent, and Circumambient Indian Ocean), (3) principal autocorrelation and cross-correlation structures over various monsoon space-time domains, (4) diurnally modulated amplitude-phase properties of rain rates over different monsoon space-time domains, (5) foremost rain rate probability distributions intrinsic to monsoon precipitation, and (6) behavior of extreme events including occurrences of flood and drought episodes throughout the course of inter-annual monsoon processes.

Smith, Eric A.↗

DOE OSTI2016

Melt-cast organic glasses as high-efficiency fast neutron scintillators

In this work we report a new class of organic-based scintillators that combines several of the desirable attributes of existing crystalline, liquid, and plastic organic scintillators. The prepared materials may be isolated in single crystalline form or melt-cast to produce highly transparent glasses that have been shown to provide high light yields of up to 16,000 photons/MeVee, as evaluated against EJ-200 plastic scintillators and solution-grown trans -stilbene crystals. The prepared organic glasses exhibit neutron/gamma pulse-shape discrimination (PSD) and are compatible with wavelength shifters to reduce optical self-absorption effects that are intrinsic to pure materials such as crystalline organics. In conclusion, the combination of high scintillation efficiency, PSD capabilities, and facile scale-up via melt-casting distinguishes this new class of amorphous materials from existing alternatives.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Casting of Reinforced Concrete Beam: Project Progress

Aging concrete structures in nuclear power plants undergo mechanical, physical, chemical, and radioactive degradation. One of the chemical degradation mechanisms that is investigated in the research project under the Plant Modernization Pathway of the Light Water Reactor Sustainability Program is the alkali-silica reaction (ASR). The ASR is a chemical process that over time, causes expansion of calcium silicate hydrate gel. To date, the research project has studied the ASR gel formation and expansion in non-reinforced concrete specimens using vibro-acoustic modulation (VAM) technique. However, nuclear plant concrete structures are reinforced, and it might influence the application of VAM technique on reinforced concrete specimens compared to non-reinforced specimens. A research activity is initiated between Idaho National Laboratory, Vanderbilt University, and University of Nebraska - Lincoln to study the impact of reinforcement in concrete structures on the application of the VAM technique. To support this activity, University of Nebraska - Lincoln is casting and curing four reinforced concrete samples that at the end of the curing period will be transferred to Vanderbilt University to perform experimental VAM study. Vanderbilt University and Idaho National Laboratory will perform the data analysis and enhance the developed structural health monitoring framework. In this report, a progress on casting and curing of reinforced concrete samples at University of Nebraska – Lincoln is provided.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1978

The production of ultrathin polyimide films for the solar sail program and Large Space Structures Technology (LSST): A feasibility study

Polyimide membranes of a thickness range from under 0.01 micron m to greater than 1 micron m can be produced at an estimated cost of 50 cents per sq m (plus the cost of the polymer). The polymer of interest is dissolved in a solvent which is solube in water. The polymer or casting solution is allowed to flow down an inclined ramp onto a water surface where a pool of floating polymer develops. The solvent dissolves into the water lowering the surface tension of the water on equently, the contact angle of the polymer pool is very low and the edge of the pool is very thin. The solvent dissolves from this thin region too rapidly to be replenished from the bulk of the pool and a solid polymer film forms. Firm formation is rapid and spontaneous and the film spreads out unaided, many feet from the leading edge of the pool. The driving force for this process is the exothermic solution of the organic solvent from the polymer solution into the water.

Forester, R. H.↗

DOE OSTI2020

Magnesium Technology 2020

Magnesium and its alloys are being investigated widely for applications that require extraordinarily high strength-to-weight ratio, vibration damping, electromagnetic shielding, reduction in carbon footprint, sustainability improvements, and low toxicity. In the past decade or so, this drive has led to increased adoption of magnesium and its alloys in everyday products and it is no longer regarded as an esoteric material. The overarching goal of its widespread adoption and replacement of conventional materials such as steel and aluminum alloys has been restricted because of the cost of the material, limited sources of primary material, alloying constraints, high chemical reactivity, and challenges associated with its plasticity. Researchers, scientists, engineers, and economists from industry, government agencies and laboratories, and academic institutions alike are actively developing roadmaps for next-generation products and addressing these challenges as quickly as possible through unique and innovative methods. The TMS Magnesium Committee has been actively involved in providing a platform to these entities for disseminating the latest information, developments, and cutting-edge research and development, and showcasing the latest research and development trends related to magnesium and its alloys through the Magnesium Technology Symposium, which takes place every year at the TMS Annual Meeting. This proceedings volume retains the essence of this longstanding tradition. The twenty-first volume in the series, Magnesium Technology 2020, is the proceedings of the Magnesium Technology Symposium held during the 149th TMS Annual Meeting & Exhibition in San Diego, CA, February 23–27, 2020. The volume captures commentaries and papers from 15 different countries. The papers have been categorized systematically based on topics pertaining to magnesium production, casting and solidification, thermomechanical processing, deformation mechanisms, modeling, corrosion, and applications. The symposium began with keynote sessions that featured several distinguished invited speakers from government organizations and academia, who provided their perspectives on the state of the art, goals, and opportunities in magnesium alloy research and development. Dr. Carlos Tomé from Los Alamos National Laboratory, U.S. Department of Energy, discussed 3D characterization of mechanical twins across grain boundaries. This was followed by a talk on hierarchically structured ultrafine-grained magnesium alloys by Dr. Rajiv Mishra from the University of North Texas, USA, who presented an example of using friction stir additive manufacturing for implementing such microstructures at a component level. Dr. Mark Horstemeyer from Liberty University, USA, presented an overview of fatigue modeling to capture the corrosion-fatigue behavior of magnesium alloys. The final talk in this session was presented by Dr. Bin Jiang from Chongqing University, China, who presented a novel extrusion approach for achieving high-strength magnesium alloy plates.

Jordon, J. Brian↗

DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Magnesium Technology 2019

Joshi, Vineet V.↗