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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanisms of Mitigating Chloride-Induced Stress Corrosion Cracking of Austenitic Steels by Laser Shock Peening

This study investigates the effect of laser shock peening (LSP) on the chloride-induced stress corrosion cracking (SCC) of 304 austenitic steels. LSP can induce a high compressive residual stress to a depth of 700 µm and plastic deformation structures of dislocations, deformation twins, and stacking faults. Constant-load SCC tests in MgCl2 solution suggested that LSP can retard the crack initiation and slow the crack growth. LSP-treated subsurface layers experience ductile fracture while the central regions exhibit intergranular SCC. The LSP-induced deformation structures may impede dislocation slips, while the LSP-induced compressive residual stress can lessen the stress intensity factor of crack tips and decrease the local stress for film rupture.

Materials Science↗
DOE OSTI2016

Liquid salt environment stress-rupture testing

Disclosed herein are systems, devices and methods for stress-rupture testing selected materials within a high-temperature liquid salt environment. Exemplary testing systems include a load train for holding a test specimen within a heated inert gas vessel. A thermal break included in the load train can thermally insulate a load cell positioned along the load train within the inert gas vessel. The test specimen can include a cylindrical gage portion having an internal void filled with a molten salt during stress-rupture testing. The gage portion can have an inner surface area to volume ratio of greater than 20 to maximize the corrosive effect of the molten salt on the specimen material during testing. Also disclosed are methods of making a salt ingot for placement within the test specimen.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Room-Temperature Microstructural Evolution of Extruded AM80 Magnesium Alloys under Dynamic Loading

Dynamic compression tests were conducted using a split Hopkinson pressure bar along the transverse direction at strain rates (SRs) of 3200 and 6000 s{sup −1}. The initial microstructure significantly affected the flow stress behavior and microstructural evolution of the two studied AM80 magnesium alloys. Under the same SR loading, the as-extruded alloy exhibited an apparently higher flow stress. At a SR of 6000 s{sup −1}, the flow stress of the as-extruded alloy exhibited a visible decrease (~ 34 MPa) as the strain increased to ~ 0.2, whereas a constant flow stress was exhibited by the solution-treated alloy. High-density dislocations and mechanical twins were detected in the two alloys at a SR of 3200 s{sup −1}. Interestingly, dynamic recrystallization (DRX) with an average grain size of ~ 2 µm was only identified in the as-extruded alloy as the applied SR increased to 6000 s{sup −1}. The increased localized deformation in the as-extruded alloy due to the retained strain energy and high critical twinning stress improved the DRX driving force, thereby resulting in visibly different micrographs of the two alloys when impacted at the SR of 6000 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Development of a 2 MW CW Waterload for Electron Cyclotron Heating Systems

Calabazas Creek Research, Inc. developed a load capable of continuously dissipating 2 MW of RF power from gyrotrons. The input uses HE11 corrugated waveguide and a rotating launcher to uniformly disperse the power over the lossy surfaces in the load. This builds on experience with a previous load designed to dissipate 1 MW of continuous RF power. The 2 MW load uses more advanced RF dispersion to double the capability in the same size device as the 1 MW load. The new load reduces reflected power from the load to significantly less than 1 %. This eliminates requirements for a preload to capture reflected power. The program updated control electronics that provides all required interlocks for operation and measurement of peak and average power. The program developed two version of the load. The initial version used primarily anodized aluminum to reduce weight and cost. The second version used copper and stainless steel to meet specifications for the ITER reactor currently under construction in France. Tests of the new load at the Japanese Atomic Energy Agency confirmed operation of the load to a power level of 1 MW, which is the highest power currently available for testing the load. Additional tests will be performed at General Atomics in spring 2013. The U.S. ITER organization will test the copper/stainless steel version of the load in December 2012 or early in 2013. Both loads are currently being marketed worldwide.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2012

Electric Power Delivery Testing Feasibility Study (Task 6 Final Report)

This Final Report is covers the completion of the Electric Power Delivery Testing Feasibility Study. The objective of this project was to research, engineer, and demonstrate high-power laboratory testing protocols to accurately reproduce the conditions on the electric power grid representing both normal load switching and abnormalities such as short-circuit fault protection. Test circuits, equipment, and techniques were developed and proven at reduced power levels to determine the feasibility of building a large-scale high-power testing laboratory capable of testing equipment and systems at simulated high-power conditions of the U.S. power grid at distribution levels up through 38 kiloVolts (kV) and transmission levels up through 230 kV. The project delivered demonstrated testing techniques, high-voltage test equipment for load testing and synthetic short-circuit testing, and recommended designs for future implementation of a high-power testing laboratory to test equipment and systems, enabling increased reliability of the electric transmission and distribution grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2012

Enhanced Sulfate Management in HLW Glass Formulations

The present report describes a series of small-scale crucible tests to determine sulfate solubility in HLW glasses, tests to assess the effect of compositional changes on sulfate solubility, and small-scale meIter tests to determine maximum acceptable sulfate loadings in HLW feeds to the meIter. The work was performed in accordance with the Test Plan for this work and the ORP contract. Glasses produced in previous melter tests using WTP and ORP waste and glass compositions were tested in the present work to determine sulfur solubility. In parallel, a glass formulation was developed for a previously untested HLW composition with one of the highest projected sulfate concentrations; that formulation was subsequently processed on the DM10 melter system at successively higher waste loadings to determine the maximum waste loading. Tests were also conducted on the DM10 on several HLW formulations which had been previously subjected to crucible-scale sulfur solubility testing; these formulations were selected based on sulfur solubility information for HLW glasses that was compiled in a previous report to WTP; similar information for LAW glasses was compiled in a report to ORP.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Gearbox Reliability Collaborative Gearbox 3 Planet Bearing Calibration

The Gearbox Reliability Collaborative gearbox was redesigned to improve its load-sharing characteristics and predicted fatigue life. The most important aspect of the redesign was to replace the cylindrical roller bearings with preloaded tapered roller bearings in the planetary section. Similar to previous work, the strain gages installed on the planet tapered roller bearings were calibrated in a load frame. This report describes the calibration tests and provides the factors necessary to convert the measured units from dynamometer testing to bearing loads, suitable for comparison to engineering models.

17 WIND ENERGY↗
DOE OSTI2018

Material Model Testing in the DYNA3D Code: Material Models 1 through 5

This report is the first volume in an effort to study the material model implementations in DYNA3D, using the latest developmental version of the code. Input files were derived from a template supplied by Jerry Lin to perform an equation-of-state study. Most of the simulations use 10 cubes, each 1 cm on a side with a density of 8.03 (steel). Each of the cubes tests a different aspect of the material model. The first three cubes are testing normal stresses and normal strains (uniaxial stresses and strains) placed on the cube parallel to the x-axis, y-axis and z-axis, respectively. The x (or y or z) = 1 face of the cube is moved along the x-axis (or y-axis or z-axis) to test the model, while the opposite side remains in the x (or y or z) = 0 plane. For some of the tests, the nodes are free to move perpendicular to the applied strain to allow the cross-sectional area of the cube to change in response to being placed under pressure or tension (to test Poisson’s Ratio), while in others the nodes are frozen to eliminate dynamic effects resulting from the code. The cube is placed in tension along the axis being tested and then released, followed by a cycle of compression and release. This tension/compression cycle is repeated 3 more times. The additional cycles allow for the model to be tested under different loads. For these calculations, the amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. Cubes number 4 and 5 are intended to test xy shear stresses/strains. This is done by sliding one face of the cube in its plane parallel to the axis of interest. For example, for cube 4, the upper face of the cube is slid in the y=1 plane in a direction parallel to the x-axis (so there are no changes in the y and z coordinates of the points in the plane) and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. For cube 5, the plane of the cube satisfying x=1 is slid in this plane in a direction parallel to the y-axis and then returned to its starting position. This preserves the volume of the cube, so there is no change in density or pressure. The cycle is repeated 8 times. Cubes number 6 through 9 repeat these tests for yz shear stresses/strains (Cubes 6 and 7) and zx shear stresses and strains (Cubes 8 and 9). For reasons discussed in the next paragraph, it is unclear if these tests represent a state of pure shear stress and shear strain in the code. Application of shear stresses and strains should not, in general, result in the appearance of normal stresses and strains in Cubes 4 - 9. In the infinitesimal limit, this result might be obtained. However, DYNA3D is a finite deformation code and in the real deformations used in the code, this result is not achieved and the individual components of the normal stresses and strains are non-zero during the cycling. However, the sums of the normal strains are zero in these tests and, except in the case of thermally dependent models, so are the sums of the normal stresses. Cube 10 tests the response of the material model to a hydrostatic loading of the cube. The load curve used for the first three tests is used again and applied to each of the 8 nodes in a manner causing the cube to be either compressed or expanded. This compression/tension cycle is repeated 4 times. The additional cycles allow for the model to be tested under different loads. The amount by which the cube is stretched and compressed is varied from cycle to cycle to allow testing of model features. This document will discuss the testing of Material Models 1 through 5. Relevant results from the test cubes will be discussed. A discussion of the results from all 10 test cubes will be presented only if necessary.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Investigation of high-speed shaft bearing loads in wind turbine gearboxes through dynamometer testing

Many wind turbine gearboxes require repair or replacement well before reaching the end of their design life. The most common failure is bearing axial cracks, commonly called white etching cracks (WECs), which typically occur in the inner raceways of the high-speed parallel-stage rolling element bearings. Although the root causes of WECs are debated, one theory is that they are related to routine dynamic operating conditions and occasional transient events prevalent in wind turbines that can result in high bearing stress and sliding of the rolling elements. Here, this paper examined wind turbine gearbox high-speed shaft bearing loads and stresses through modeling and full-scale dynamometer testing. Bearing outer race loads were directly measured and predicted using a variety of modeling tools in normal operations, misaligned conditions, and transient events particularly prone to bearing sliding. Test data and models of bearing loads were well correlated. Neither operational misalignment due to rotor moments nor static generator misalignment affected the bearing loads when compared with pure-torque conditions. Thus, it is not likely that generator misalignment is a causal factor of WECs. In contrast, during transient events, the bearings experienced alternating periods of high stress, torque reversals, and loads under the minimum requisite at high rotating speeds while showing indications of sliding, all of which could be related to the formation of WECs.

17 WIND ENERGY↗
DOE OSTI2018

Effect of Hot Deformation on Texture and Microstructure in Fe-Mn Austenitic Steel During Compression Loading

Hot compression tests of a new high-Mn austenitic steel were carried out at deformation temperatures of 700, 800, 900, and 1000 °C under strain rate of 0.01 s{sup −1}. The hot deformation behavior was investigated by the analyses of flow curves, texture, and deformed microstructures. Microstructures of the deformed specimens and macrotexture were examined using electron backscatter diffraction and x-ray diffraction methods, respectively. The results showed that the flow stress depended strongly on the deformation temperature and decreased by increasing deformation temperature. The microstructural evidence indicated that the dynamic recrystallization (DRX) process of experimental steel was initiated at 800 °C with necklace structure. The volume fraction of DRX grains was considerably increased by increasing deformation temperature to 1000 °C. Texture of the DRX grains tended to become a weak texture and was associated with the formation of Goss and R-Cube components. Meanwhile, martensitic transformation was detected in the hot-deformed austenite. The martensitic transformation was the most difficult in the DRX grains because of the effect of small grain size. The tendency of transformation was decreased after compression at 1000 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Utilization and Application of Kurion Mobile Processing System in Remediation of Radioactively Contaminated Water - 16370

Kurion{sup R} Mobile Processing Systems (KMPS) were deployed in Fukushima as first-of-a- kind at-tank isotope removal systems to remediate Sr from reverse osmosis concentrated salt water. The systems were successful in their efforts and achieved their decontamination and availability goals. The use of KMPS has been considered for other applications where a modular system is of benefit. The use of different Kurion Ion Specific Media (ISM) allows for precision removal of hazardous ions from a variety of waste streams. This paper describes a range of projects in which KMPS modularity will benefit the nuclear industry. The KMPS is a flexible system that can be deployed quickly and efficiently. One treatment system option being considered is the utilization of a KMPS for the removal of contamination from groundwater. Similar to its use in Japan, the KMPS can be sent to remote locations for the direct treatment of ground water. In particular, there are several sites across the world where uranium contamination is a problem. Uranium treatability testing was performed on collected groundwater samples from a radiologically contaminated site. The tests were used to help provide designs for KMPS modifications. These designs included the addition of chemical treatment module for the control of pH and other chemistry, the addition of an ultraviolet module for the destruction of biological material, among others. The tests determined the loading capacities of uranium capture resins (UCR) and media (UCM) for this specific waste stream. Based on uranium loading capacities of 37.3 mg/L (end of test C/C{sub 0} = 0.5) and 54.6 mg/L (extrapolated to C/C{sub 0} = 0.98), and the longevity of the resin (45,911 BV for C/C{sub 0} = 0.5, and 80,556 BV for C/C{sub 0} = 0.98) UCR-1 was selected as the media/resin to be proposed for a uranium treatment system. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Planetary Load Sharing in Three-Point Mounted Wind Turbine Gearboxes: A Design and Test Comparison

This work compares the planetary load-sharing characteristics of wind turbine gearboxes supported by cylindrical roller bearings (CRBs) and preloaded tapered roller bearings (TRBs) when subjected to rotor moments. Planetary bearing loads were measured in field-representative dynamometer tests and compared to loads predicted by finite-element models. Preloaded TRBs significantly improved load sharing. In pure torque conditions, the upwind planet bearing load in the gearbox with preloaded TRBs was only 14% more than the assumed load compared to 47% more for the gearbox with CRBs. Consequently, the predicted fatigue life of the complete set of planetary bearings for the gearbox with preloaded TRBs is 3.5 times greater than that of the gearbox with CRBs.

17 WIND ENERGY↗
DOE OSTI2023

Development of an accelerated creep testing technique via multi-specimen loading

This report summarizes a research effort undertaken by Argonne National Laboratory to accelerate the development of creep data package for code qualification. The goal is to explore new creep testing techniques to shorten the overall time needed to generate high-quality data to support an ASME code case on laser powder bed fusion 316H stainless steel. Progresses on the design and implementation of a 3-specimen load train and an innovative strain measurement method with direct potential current drop (DCPD) technique are reported.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Creep and microstructural processes in a low-alloy 2.25%Cr1.6%W steel (ASTM Grade 23)

A low-alloy 2.25%Cr1%Mo steel (ASTM Grade 22) has been greatly improved by the substitution of almost all of the 1%Mo by 1.6%W. The improved material has been standardized as P/T23 steel (Fe–2.25Cr–1.6W–0.25V–0.05Nb–0.07C). The present investigation was conducted on T23 steel in an effort to obtain a more complete description and understanding of the role of the microstructural evolution and deformation processes in high-temperature creep. Constant load tensile creep tests were carried out in an argon atmosphere in the temperature range 500–650 °C at stresses ranging from 50 to 400 MPa. It was found that the diffusion in the matrix lattice is the creep-rate controlling process. The results of an extensive transmission electron microscopy (TEM) analysis programme to investigate microstructure evolution as a function of temperature are described and compared with the thermodynamic calculations using the software package Thermo-Calc. The significant creep-strength drop of T23 steel after long-term creep exposures can be explained by the decrease in dislocation hardening, precipitation hardening and solid solution hardening due to the instability of the microstructure at high temperature. - Highlights: • The constant load creep tests of T23 steel were carried out at 500–650 °C. • The stress exponents of the creep rate correspond to power law (dislocation) creep. • Diffusion in the matrix lattice is the creep-rate controlling process. • The microstructure instability is the main creep degradation process in T23 steel.

36 MATERIALS SCIENCE↗