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DOE OSTI2020

FAST-1.0 Software Acceptance Testing Report

The purpose of this document is to detail the software testing of FAST-1.0 through unit, integration, and assessment tests. More than 400 tests were designed to provide coverage of the requirements for FAST-1.0. These requirements were developed in the NRC Statement of Work (SOW) for NRC Agreement Number NRC-HQ-25-14-D-001 and are transcribed to this document as part of the Software Quality Assurance Plan for the FAST Code System, PNNL-28767. FAST 1.0 represents the merger of the FRAPCON and FRAPTRAN codes and as such FAST-1.0 performs steady state and transient fuel performance calculations described below. FAST-1.0 calculates the steady state response of light-water reactor fuel rods during long-term burnup. The code calculates temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: 1) heat conduction through fuel and cladding to the coolant; 2) cladding elastic and plastic deformation; 3) fuel-cladding mechanical interaction; 4) fission gas release from the fuel and rod internal pressure; and 5) cladding oxidation. FAST is used to perform independent calculations for regulatory evaluations of fuel performance under normal operation and anticipated operational occurrences (AOOs). FAST calculates the temperature and deformation history of a fuel rod as a function of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by FAST include: 1) heat conduction; 2) heat transfer from cladding to coolant; 3) elastic-plastic fuel and cladding deformation; 4) cladding oxidation; 5) fission gas release; and 6) fuel rod gas pressure. FAST code assessment, development and maintenance drive a significant portion of the NRC fuel research activities and the tools are used in a substantial number of regulatory products. Given the centrality of the FAST code to the effectiveness of fuel research, it is critical to assess, develop and maintain this tool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2011

Pressure Testing of a Minimum Gauge PRSEUS Panel

Advanced aircraft configurations that have been developed to increase fuel efficiency require advanced, novel structural concepts capable of handling the unique load conditions that arise. One such concept is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) developed by the Boeing Company. The PRSEUS concept is being investigated by NASA s Environmentally Responsible Aviation (ERA) Program for use in a hybrid-wing body (HWB) aircraft. This paper summarizes the analysis and test of a PRSEUS panel subjected to internal pressure, the first such pressure test for this structural concept. The pressure panel used minimum gauge skin, with stringer and frame configurations consistent with previous PRSEUS tests. Analysis indicated that for the minimum gauge skin panel, the stringer locations exhibit fairly linear response, but the skin bays between the stringers exhibit nonlinear response. Excellent agreement was seen between nonlinear analysis and test results in the critical portion at the center of the panel. The pristine panel was capable of withstanding the required 18.4 psi pressure load condition without exhibiting any damage. The impacted panel was capable of withstanding a pressure load in excess of 28 psi before initial failure occurred at the center stringer, and the panel was capable of sustaining increased pressure load after the initial failure. This successful PRSEUS panel pressure panel test was a critical step in the building block approach for enabling the use of this advanced structural concept on future aircraft, such as the HWB.

Lovejoy, Andrew J.↗

NASA NTRS2015

Face Sheet/Core Disbond Growth in Honeycomb Sandwich Panels Subjected to Ground-Air-Ground Pressurization and In-Plane Loading

Typical damage modes in light honeycomb sandwich structures include face sheet/core disbonding and core fracture, both of which can pose a threat to the structural integrity of a component. These damage modes are of particular interest to aviation certification authorities since several in-service occurrences, such as rudder structural failure and other control surface malfunctions, have been attributed to face sheet/core disbonding. Extensive studies have shown that face sheet/core disbonding and core fracture can lead to damage propagation caused by internal pressure changes in the core. The increasing use of composite sandwich construction in aircraft applications makes it vitally important to understand the effect of ground-air-ground (GAG) cycles and conditions such as maneuver and gust loads on face sheet/core disbonding. The objective of the present study was to use a fracture mechanics based approach developed earlier to evaluate the loading at the disbond front caused by ground-air-ground pressurization and in-plane loading. A honeycomb sandwich panel containing a circular disbond at one face sheet/core interface was modeled with three-dimensional (3D) solid finite elements. The disbond was modeled as a discrete discontinuity and the strain energy release rate along the disbond front was computed using the Virtual Crack Closure Technique (VCCT). Special attention was paid to the pressure-deformation coupling which can decrease the pressure load within the disbonded sandwich section significantly when the structure is highly deformed. The commercial finite element analysis software, Abaqus/Standard, was used for the analyses. The recursive pressure-deformation coupling problem was solved by representing the entrapped air in the honeycomb cells as filled cavities in Abaqus/Standard. The results show that disbond size, face sheet thickness and core thickness are important parameters that determine crack tip loading at the disbond front. Further, the pressure-deformation coupling was found to have an important load decreasing effect [6]. In this paper, a detailed problem description is provided first. Second, the analysis methodology is presented. The fracture mechanics approach used is described and the specifics of the finite element model, including the fluid-filled cavities, are introduced. Third, the initial model verification and validation are discussed. Fourth, the findings from a closely related earlier study [6] are summarized. These findings provided the basis for the current investigation. Fifth, an aircraft ascent scenario from 0 to 12192 m (0 to 40000 ft) is considered and the resulting crack tip loading at the disbond front is determined. In-plane loading to simulate maneuvers and gust conditions are also considered. Sixth, the results are shown for a curved panel, which was used to simulate potential fuselage applications. Finally, a brief summary of observations is presented and recommendations for improvement are provided.

Chen, Zhi M.↗

NASA NTRS2019

Transfer-Function Determination for Infinite-Tube-Probe Pressure Transducers with Application to Turbofan Core/Combustor Noise

Turbofan hot-section unsteady pressure measurements are complicated by environmental limitations of current-generation sensors. Accurate direct measurements are normally not possible and engine-external measurement techniques, using sufficiently long sense lines, are utilized instead. Remote measurement comes at a cost, however, as it introduces a magnitude reduction within the line as well as a phase lag relative to the desired engine-internal measurement location. Determination, or validation, of a transfer function relating the engine internal pressure to the observed remote value is necessary. Transfer functions are examined for various configurations of the so-called infinite-tube-probe arrangement in order to optimize measurement performance. The experimental setup uses a normal-incidence tube that ordinarily is utilized for impedance eduction. Here, its downstream end instead is made up of a hard-wall termination instrumented with a flush-mounted microphone and a Kulite pressure transducer as well as a sense line connection. This allows the remote and direct measurements to be related under controlled conditions. Transfer-function measurements are presented and compared to predictions for several parametric variations.

Combustor Noise↗

NASA NTRS2019

Transfer-Function Determination for Infinite-Tube-Probe Pressure Transducers with Application to Turbofan Core/Combuster Noise

Turbomachinery Noise↗

DOE OSTI2020

FAST-1.0: A Computer Code for Thermal-Mechanical Nuclear Fuel Analysis under Steady-state and Transients: Developed under NQA-1-2017

Fuel Analysis under Steady-state and Transients (FAST) is the US Nuclear Regulatory Commission (NRC)’s computer code that calculates the steady-state and transient response of nuclear reactor fuel rods during long-term in-reactor burnup, anticipated operational occurrences (AOOs), design basis accidents (DBAs), and dry storage conditions. The code calculates the temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: heat conduction through the fuel and other materials, heat transfer from the cladding-to-coolant, cladding elastic and plastic deformation, including creep, fuel-cladding mechanical interaction, fission gas release from the fuel, rod internal pressure and void volume, and cladding oxidation. The code contains necessary material and coolant properties, as well as clad-to-coolant heattransfer correlations, for normal operation through postulated accidents for today’s US-based light water reactor (LWR) fuel designs. FAST-1.0 also contains preliminary materials and models for new LWR fuel concepts, such as accident tolerant fuel (ATF), and non-LWR fuel concepts such as metallic fuels for sodium fast reactors (SFRs). FAST has been developed for use on Windows and Linux operating systems. This document describes FAST-1.0, which is the first official version of this code. This document is one of a series of documents on FAST; the other documents detail the material properties used by FAST as well as its integral assessment to experiments and commercial data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

FAST-1.1: A Computer Code for Thermal-Mechanical Nuclear Fuel Analysis under Steady-state and Transients (Developed under NQA-1-2017)

Fuel Analysis under Steady-state and Transients (FAST) is the U.S. Nuclear Regulatory Commission (NRC)’s computer code that calculates the steady-state and transient response of nuclear reactor fuel rods during long-term in-reactor burnup, anticipated operational occurrences (AOOs), design basis accidents (DBAs), and dry storage conditions. The code calculates the temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: * heat conduction through the fuel and other materials * heat transfer from the cladding-to-coolant * cladding elastic and plastic deformation, including creep * fuel-cladding mechanical interaction * fission gas release from the fuel * rod internal pressure and void volume * cladding oxidation The code contains necessary material and coolant properties, as well as clad-to-coolant heat transfer correlations, for normal operation through postulated accidents and AOOs for today’s U.S.-based light water reactor (LWR) fuel designs. FAST-1.1 also contains preliminary materials and models for new LWR fuel concepts, such as accident tolerant fuel (ATF), and non-LWR fuel concepts such as metallic fuels for sodium fast reactors (SFRs). FAST has been developed for use on Windows and Linux operating systems. This document describes FAST-1.1 and is one of a series of documents on the code; the other documents detail the material properties used by FAST as well as its integral assessment to experiments and commercial data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

FAST-1.2: A Computer Code for Thermal-Mechanical Nuclear Fuel Analysis under Steady-state and Transients

Fuel Analysis under Steady-state and Transients (FAST) is the U.S. Nuclear Regulatory Commission (NRC)’s computer code that calculates the steady-state and transient response of nuclear reactor fuel rods during long-term in-reactor burnup, anticipated operational occurrences (AOOs), design basis accidents (DBAs), and dry storage conditions. The code calculates the temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include: • heat conduction through the fuel and other materials • heat transfer from the cladding-to-coolant • cladding elastic and plastic deformation, including creep • fuel-cladding mechanical interaction • fission gas release from the fuel • rod internal pressure and void volume • cladding oxidation The code contains necessary material and coolant properties, as well as clad-to-coolant heat-transfer correlations, for normal operation through postulated accidents and AOOs for today’s U.S.-based light water reactor (LWR) fuel designs. FAST-1.2 also contains preliminary materials and models for new LWR fuel concepts, such as accident tolerant fuel (ATF), and non-LWR fuel concepts such as metallic fuels for sodium fast reactors (SFRs). FAST has been developed for use on Windows and Linux operating systems. This document describes FAST-1.2 and is one of a series of documents on the code; the other documents detail the material properties used by FAST as well as its integral assessment to experiments and commercial data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

FAST-1.2.2: A Computer Code for Thermal-Mechanical Nuclear Fuel Analysis under Steady-state and Transients

Fuel Analysis under Steady-state and Transients (FAST) is the U.S. Nuclear Regulatory Commission (NRC)’s computer code that calculates the steady-state and transient response of nuclear reactor fuel rods during long-term in-reactor burnup, anticipated operational occurrences (AOOs), design basis accidents (DBAs), and dry storage conditions. The code calculates the temperature, pressure, and deformation of a fuel rod as functions of time-dependent fuel rod power and coolant boundary conditions. The phenomena modeled by the code include heat conduction through the fuel and other materials, heat transfer from the cladding-to-coolant, cladding elastic and plastic deformation (including creep), fuel-cladding mechanical interaction, fission gas release from the fuel, rod internal pressure, void volume, and cladding oxidation. The code contains necessary material and coolant properties, as well as clad-to-coolant heat transfer correlations, for normal operation through postulated accidents and AOOs for today’s U.S.-based light water reactor (LWR) fuel designs. FAST-1.2.2 also contains preliminary materials and models for new LWR fuel concepts, such as accident tolerant fuel (ATF), and non-LWR fuel concepts such as metallic fuels for sodium fast reactors (SFRs). FAST has been developed for use on Windows and Linux operating systems. This document describes FAST-1.2.2 and is one of a series of documents on the code; the other documents detail the material properties used by FAST as well as its integral assessment to experiments and commercial data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1977

Identification and measurement of combustion noise from a turbofan engine using correlation and coherence techniques

Fluctuating pressure measurements within the combustor and tailpipe of a turbofan engine are made simultaneously with far field acoustic measurements. The pressure measurements within the engine are accomplished with cooled semi-infinite waveguide probes utilizing conventional condenser microphones as the transducers. The measurements are taken over a broad range of engine operating conditions and for 16 far field microphone positions between 10 deg and 160 deg relative to the engine inlet axis. Correlation and coherence techniques are used to determine the relative phase and amplitude relationships between the internal pressures and far field acoustic pressures. The results indicate that the combustor is a low frequency source region for acoustic propagation through the tailpipe and out to the far field. Specifically, it is found that the relation between source pressure and the resulting sound pressure involves a 180 deg phase shift. The latter result is obtained by Fourier transforming the cross correlation function between the source pressure and acoustic pressure after removing the propagation delay time. Further, it is found that the transfer function between the source pressure and acoustic pressure has a magnitude approximately proportional to frequency squared. These results are shown to be consistent with a model using a modified source term in Lighthill's turbulence stress tensor, wherein the fluctuating Reynolds stresses are replaced with the pressure fluctuations due to fluctuating entropy.

Karchmer, A. M.↗

NASA NTRS2014

Nonlinear Finite Element Analysis of a Composite Non-Cylindrical Pressurized Aircraft Fuselage Structure

The Environmentally Responsible Aviation Project aims to develop aircraft technologies enabling significant fuel burn and community noise reductions. Small incremental changes to the conventional metallic alloy-based 'tube and wing' configuration are not sufficient to achieve the desired metrics. One of the airframe concepts that might dramatically improve aircraft performance is a composite-based hybrid wing body configuration. Such a concept, however, presents inherent challenges stemming from, among other factors, the necessity to transfer wing loads through the entire center fuselage section which accommodates a pressurized cabin confined by flat or nearly flat panels. This paper discusses a nonlinear finite element analysis of a large-scale test article being developed to demonstrate that the Pultruded Rod Stitched Efficient Unitized Structure concept can meet these challenging demands of the next generation airframes. There are specific reasons why geometrically nonlinear analysis may be warranted for the hybrid wing body flat panel structure. In general, for sufficiently high internal pressure and/or mechanical loading, energy related to the in-plane strain may become significant relative to the bending strain energy, particularly in thin-walled areas such as the minimum gage skin extensively used in the structure under analysis. To account for this effect, a geometrically nonlinear strain-displacement relationship is needed to properly couple large out-of-plane and in-plane deformations. Depending on the loading, this nonlinear coupling mechanism manifests itself in a distinct manner in compression- and tension-dominated sections of the structure. Under significant compression, nonlinear analysis is needed to accurately predict loss of stability and postbuckled deformation. Under significant tension, the nonlinear effects account for suppression of the out-of-plane deformation due to in-plane stretching. By comparing the present results with the previously published preliminary linear analysis, it is demonstrated in the present paper that neglecting nonlinear effects for the structure and loads of interest can lead to appreciable loss in analysis fidelity.

Przekop, Adam↗

NASA NTRS1976

Combustion contribution to noise in jet engines

The relative importance of combustion as a source of noise in a flow regime representative of a subsonic jet engine exhaust was investigated. The combustion noise source characteristics were obtained from pressure and temperature fluctuation measurements in the combustor and exhaust nozzle. The similarity between the fluctuations in this source region and the far field noise were compared. In the jet exhaust velocity range between 450 and 660 ft/sec investigated in detail, the frequencies of dominant pressure and temperature fluctuations in the combustor were also the frequencies of the dominant far field noise. The overall noise levels were 14 to 20 dB higher than from a corresponding clean jet in the same velocity range. Thus it seemed clear that the unsteadiness associated with the combustion process was responsible for the dominant noise in the far field. A simple analysis to predict the far field noise due to the internal pressure fluctuations causing exit plane velocity fluctuations produced trends closely resembling the measured results, but under predicted the far field noise over the spectral range examined. The possible reason for the higher far field noise is direct transmission of acoustic waves through the nozzle, which was not accounted for in the prediction scheme.

Plett, E. G.↗

NASA NTRS1998

Residual Strength Pressure Tests and Nonlinear Analyses of Stringer-and Frame-Stiffened Aluminum Fuselage Panels with Longitudinal Cracks

The results of residual strength pressure tests and nonlinear analyses of stringer- and frame-stiffened aluminum fuselage panels with longitudinal cracks are presented. Two types of damage are considered: a longitudinal crack located midway between stringers, and a longitudinal crack adjacent to a stringer and along a row of fasteners in a lap joint that has multiple-site damage (MSD). In both cases, the longitudinal crack is centered on a severed frame. The panels are subjected to internal pressure plus axial tension loads. The axial tension loads are equivalent to a bulkhead pressure load. Nonlinear elastic-plastic residual strength analyses of the fuselage panels are conducted using a finite element program and the crack-tip-opening-angle (CTOA) fracture criterion. Predicted crack growth and residual strength results from nonlinear analyses of the stiffened fuselage panels are compared with experimental measurements and observations. Both the test and analysis results indicate that the presence of MSD affects crack growth stability and reduces the residual strength of stiffened fuselage shells with long cracks.

Young, Richard D.↗

NASA NTRS1999

Residual Strength Pressure Tests and Nonlinear Analyses of Stringer- and Frame-Stiffened Aluminum Fuselage Panels with Longitudinal Cracks

Young, Richard D.↗

NASA NTRS1983

High-temperature, high-pressure optical cells

For measuring the thermal diffusivity of HgCdTe melts by the laser-pulse method, an infrared transparent cell with flat windows of sufficient strength to withstand the high-vapor pressure of mercury had to be developed. Since mercury telluride expands on freezing, certain difficulties arose in returning the cell to room temperature without cracking it. T08 commercial fused silica is used in the construction of the cell, and the cells are transparent for wavelengths from about 3.5 microns in the infrared to 260 nm in the ultraviolet. The construction procedure for the required cells has been laborious. However, the obtained cell has routinely withstood internal pressures in excess of 60 atm at 900 C. Attention is given to the design of the windows, aspects of cell construction, and questions of loading.

Holland, L. R.↗

DOE OSTI2024

Multiport high-pressure synchrotron x-ray microscopy cell (CRADA Final Report)

The LBNL team developed a multiport cell allowing for fluid flow, with electrical contacts for sample bias, and with reference electrodes. The cell is currently installed and operating in beam-line 11.0.2 of the ALS, the Berkeley Synchrotron. The cell is closed by a membrane consisting of several stacked layers of graphene (1 to 3). The graphene membrane is supported on a 100 nm thick Si3N4 membrane covered with a 20 nm thin gold film for improved adhesion of the graphene and to ensure electrical conductivity. The Si3N4 film is perforated with a periodic array of holes 1 to 2 micrometers diameter. The cell can withhold an internal pressure (gas or liquid) of up to 10 atmospheres for in situ/operando studies using X-ray Photoelectron emission (XPS), and X-ray Absorption Spectroscopy (XAS). It is also ideal for tip-enhanced nano-Infrared Spectroscopy studies of molecules at the interface between the graphene and the liquid or gas filling the cell. Materials studied in the LBNL laboratory are in the form of nanoparticles, or thin films (few nm) deposited on the side of the graphene membrane facing the solution or gas inside the cell.

36 MATERIALS SCIENCE↗

NASA NTRS2000

Nonlinear Local Bending Response and Bulging Factors for Longitudinal and Circumferential Cracks in Pressurized Cylindrical Shells

Results of a geometrically nonlinear finite element parametric study to determine curvature correction factors or bulging factors that account for increased stresses due to curvature for longitudinal and circumferential cracks in unstiffened pressurized cylindrical shells are presented. Geometric parameters varied in the study include the shell radius, the shell wall thickness, and the crack length. The major results are presented in the form of contour plots of the bulging factor as a function of two nondimensional parameters: the shell curvature parameter, lambda, which is a function of the shell geometry, Poisson's ratio, and the crack length; and a loading parameter, eta, which is a function of the shell geometry, material properties, and the applied internal pressure. These plots identify the ranges of the shell curvature and loading parameters for which the effects of geometric nonlinearity are significant. Simple empirical expressions for the bulging factor are then derived from the numerical results and shown to predict accurately the nonlinear response of shells with longitudinal and circumferential cracks. The numerical results are also compared with analytical solutions based on linear shallow shell theory for thin shells, and with some other semi-empirical solutions from the literature, and limitations on the use of these other expressions are suggested.

Young, Richard D.↗

NASA NTRSDate not supplied

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗