Results of research on a single-component system for a liquid-metal MHD converter
Single component closed loop, liquid potassium magnetohydrodynamic generator
Bogomolv, B. G.↗
SEARCH · Engineering Papers
Results for “metallic components”
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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Aluminum metallic nanoparticle-polymer nanocomposites for energy storage
A nanoparticle composition comprising a substrate comprising a metal oxide component and an aluminum oxide component; and a metallocene olefin polymerization catalyst component coupled to the substrate is disclosed. The metal oxide component is homogenously dispersed throughout the nanocomposite composition.
36 MATERIALS SCIENCE↗
Net Shaped Component Fabrication of Refractory Metal Alloys using Vacuum Plasma Spraying
The vacuum plasma spraying (VPS) technique was employed to produce dense and net shaped components of a new tungsten-rhenium (W-Re) refractory metal alloy. The fine grain size obtained using this technique enhanced the mechanical properties of the alloy at elevated temperatures. The alloy development also included incorporation of thermodynamically stable dispersion phases to pin down grain boundaries at elevated temperatures and thereby circumventing the inherent problem of recrystallization of refractory alloys at elevated temperatures. Requirements for such alloys as related to high temperature space propulsion components will be discussed. Grain size distribution as a function of cooling rate and dispersion phase loading will be presented. Mechanical testing and grain growth results as a function of temperature will also be discussed.
Sen, S.↗
Coated refractory metals for high-temperature structural components.
Tensile properties of protectively coated refractory metals for structural components in high temperature oxidizing environments
TENSILE STRENGTH↗
Magnetohydrodynamics in free surface liquid metal flow relevant to plasma-facing components
Abstract While flowing Liquid Metal (LM) Plasma-Facing Components (PFCs) represent a potentially transformative technology to enable long-pulse operation with high-power exhaust for fusion reactors, Magnetohydrodynamic (MHD) drag in the conducting LM will reduce the flow speed. Experiments have been completed in the linear open-channel LMX-U device [Hvasta et al 2018 Nucl. Fusion 58 01602] for validation of MHD drag calculations with either insulating or conducting walls, with codes similar to those used to design flowing LM PFCs for a Fusion Nuclear Science Facility [Kessel et al 2019 Fusion Sci. Technol . 75 886]. We observe that the average channel flow speed decreased with the use of conducting walls and the strength of the applied transverse magnetic field. The MHD drag from the retarding Lorentz force resulted in an increase of the LM depth in the channel that ‘piled up’ near the inlet, but not the outlet. As reproduced by OpenFOAM and ANSYS CFX calculations, the magnitude and characteristics of the pileup in the flow direction increased with the applied traverse magnetic field by up to 120%, as compared to the case without an applied magnetic field, corresponding to an average velocity reduction of ∼45%. Particle tracking measurements confirmed a predicted shear in the flow speed, with the surface velocity increasing by 300%, despite the 45% drop in the average bulk speed. The MHD effect makes the bulk flow laminarized but keeps surface waves aligned along the magnetic field lines due to the anisotropy of MHD drag. The 3D fringe field and high surface velocity generate ripples around the outlet region. It was also confirmed that the MHD drag strongly depends on the conductivity of the channel walls, magnetic field, and volumetric flow rate, in agreement with the simulations and a developed analytical model. These validated models are now available to begin to determine the conditions under which the ideal LM channel design of a constant flow speed and fluid depth could be attained.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Quench process modeling & simulation in the heat-treatment of critical aerospace components
To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1
99 GENERAL AND MISCELLANEOUS↗
Quench process modeling & simulation in the heat-treatment of critical aerospace components
To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.
36 MATERIALS SCIENCE↗
Ceramic automotive Stirling engine program
The Ceramic Automotive Stirling Engine Program evaluated the application of advanced ceramic materials to an automotive Stirling engine. The objective of the program was to evaluate the technical feasibility of utilizing advanced ceramics to increase peak engine operating temperature, and to evaluate the performance benefits of such an increase. Manufacturing cost estimates were also developed for various ceramic engine components and compared with conventional metallic engine component costs.
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Composite fastener for use in high temperature environments
A fastener includes a composite body and a metal coupling attached to the body. The metal coupling includes an attachment structure to connect the fastener to an external structure. An assembly of components includes a first metallic component having a first coefficient of thermal expansion, a second non-metallic component having a second coefficient of thermal expansion different from the first thermal expansion and having a groove that receives a fastener that extends between the groove and the second component, the fastener slidably engaging the groove to accommodate relative expansion between the components.
Miller, Robert J.↗
Blanco DECam Bulge Survey (BDBS) II: project performance, data analysis, and early science results
ABSTRACT The Blanco DECam Bulge Survey (BDBS) imaged more than 200 sq deg of the Southern Galactic bulge using the ugrizY filters of the Dark Energy Camera, and produced point spread function photometry of approximately 250 million unique sources. In this paper, we present details regarding the construction and collation of survey catalogues, and also discuss the adopted calibration and dereddening procedures. Early science results are presented with a particular emphasis on the bulge metallicity distribution function and globular clusters. A key result is the strong correlation (σ ∼ 0.2 dex) between (u − i)o and [Fe/H] for bulge red clump giants. We utilized this relation to find that interior bulge fields may be well described by simple closed box enrichment models, but fields exterior to b ∼ −6° seem to require a secondary metal-poor component. Applying scaled versions of the closed box model to the outer bulge fields is shown to significantly reduce the strengths of any additional metal-poor components when compared to Gaussian mixture models. Additional results include: a confirmation that the u band splits the subgiant branch in M22 as a function of metallicity, the detection of possible extratidal stars along the orbits of M 22 and FSR 1758, and additional evidence that NGC 6569 may have a small but discrete He spread, as evidenced by red clump luminosity variations in the reddest bands. We do not confirm previous claims that FSR 1758 is part of a larger extended structure.
Johnson, Christian I.↗
Description of a computerized method for predicting thermal fatigue life of metals
A computer program called TFLIFE is described which can be used to predict the thermal fatigue life of metals and structural components from conventional metal properties. This program is used as a subroutine with a main program supplied by the user. The main program calculates input cycles of temperature and total strain for TFLIFE which then calculates a stress cycle, creep and plastic strain damage, and cyclic life. A unique feature of TFLIFE is that it calculates lives according to several different failure criteria for the same input data. These criteria are surface crack initiation, interior crack initiation, and complete fracture of both unnotched and notched fatigue specimens. Results are presented for two typical problems: thermal-mechanical fatigue of bar specimens of the tantalum alloy T-111 and thermal-stress fatigue of wedge specimens of the nickel alloy B-1900. The computer program is now ready for more extensive evaluation on structural components and additional laboratory specimens.
Spera, D. A.↗
Description of a computerized method for predicting thermal fatigue life of metals
A computer program is described which can be used to predict the thermal fatigue life of metals and structural components from conventional metal properties. A unique feature of TFLIFE is that it calculates lives according to several different failure criteria for the same input data. These criteria are surface crack initiation, interior crack initiation, and complete fracture of both unnotched and notched fatigue specimens. Sample output tables are shown, together with results for two typical problems: (1) Thermal-mechanical fatigue of bar specimens of the tantalum alloy T-111, and (2) thermal-stress fatigue of wedge specimens of the nickel alloy B-1900.
Spera, D. A.↗
Marangoni effect and its potential utilization in supporting lunar habitats and other extraterrestrial endeavors
Tears of wine is a phenomenon frequently observed as a ring of wine formed near the top of the glass generates droplets that fall back into the wine. This phenomenon can be explained by the Marangoni effect driven by the surface tension created via gradient on concentration and temperature along with the interface between two phases. Besides being observed while drinking wine, the Marangoni effect is crucial for welding metals, manufacturing integrated circuits, and growing crystals; the Marangoni effect might be also crucial in supporting lunar habitats and other extraterrestrial endeavors as vacuum and reduced gravity are expected to augment the Marangoni effect on extraterrestrial molten soil leading to sustainable extraterrestrial in-situ resources utilization (ISRU). Preliminary Marangoni effect assessment on molten lunar regolith was conducted via JSC-1A lunar regolith simulant under vacuum yielding a spontaneous upwards migration of a uniform molten thin-film front that climbed the crucible wall covering the entire wall’s surface and reaching the crucible’s top end. A temperature gradient within the melt’s bulk and along the crucible’s wall generates a surface tension large enough not only to form a meniscus within the three-phase junction (crucible’s wall, bulk melt, and vacuum) but also to supersede the gravitational force to create the upwards migration of a thin film front originated on the meniscus. The observed extensive wettability of the melt with the crucible surface, an additional key factor besides surface tension necessary to sustain upwards migration, is atypical to what it has been witnessed on molten JSC-1A lunar regolith simulant under non-vacuum conditions and smaller sample sizes. The unique formation and self-migration of a thin-film front could enable key ISRU processes such as thin-film coating, crystal growth, and feedstock generation for additive 3D printing. Further assessment on the higher-temperature vacuum-driven decomposition of the uniform thin-film front as it climbed the crucible’s wall revealed a significant decomposition of various simulant’s metal-oxide components into their respective oxygen and metal elements strengthening the feasibility of extraterrestrial generation and fractional separation of oxygen and metals/alloys with none or minimal need for terrestrial precursors. The Marangoni effect assessment on molten JSC-1A lunar regolith simulant clearly opens novel pathways in future extraterrestrial ISRU endeavors including manufacturing and mining. Extraterrestrial mining will require an operational approach completely different from the terrestrial one that heavily relies on not only mechanical excavation and transportation but also post-processing; an in-situ all-in-one process might be feasible via these two coupled phenomena, self-migration and decomposition.
J A Dominguez↗
Systems and Methods for Structurally Interrelating Components Using Inserts Made from Metallic Glass-Based Materials
Systems and methods in accordance with embodiments of the invention operate to structurally interrelate two components using inserts made from metallic glass-based materials. In one embodiment, a method of structurally interrelating two components includes: forming an insert from a metallic glass-based composition; where the formed insert includes a metallic glass-based material; affixing the insert to a first component; and structurally interrelating the second component to the first component using the insert.
Hofmann, Douglas C.↗
MRP: Design Rules for Refractory Metals
Presentation on Design rules for refractory metals to be given at the Joint ART Materials/AMMT Program Review at DOE Headquarters, Germantown, MD, June 5-8, 2023. Includes microreactor program work for structural materials, failure points of interest, technology, technology maturation and de-risk designs, refractory metals, plan for developing code case as prototype by advanced reactor developers which meets design requirements, and also provides ASME Section III rules.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Integration Science and Technology of Silicon-Based Ceramics and Composites:Technical Challenges and Opportunities
Ceramic integration technologies enable hierarchical design and manufacturing of intricate ceramic and composite parts starting with geometrically simpler units that are subsequently joined to themselves and/or to metals to create components with progressively higher levels of complexity and functionality. However, for the development of robust and reliable integrated systems with optimum performance for high temperature applications, detailed understanding of various thermochemical and thermomechanical factors is critical. Different technical approaches are required for the integration of ceramic to ceramic and ceramic to metal systems. Active metal brazing, in particular, is a simple and cost-effective method to integrate ceramic to metallic components. Active braze alloys usually contain a reactive filler metal (e.g., Ti, Cr, V, Hf etc) that promotes wettability and spreading by inducing chemical reactions with the ceramics and composites. In this presentation, various examples of brazing of silicon nitride to themselves and to metallic systems are presented. Other examples of joining of ceramic composites (C/SiC and SiC/SiC) using ceramic interlayers and the resulting microstructures are also presented. Thermomechanical characterization of joints is presented for both types of systems. In addition, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be presented.
Singh, M.↗
Excited-State Dynamics and Nonlinear Optical Properties of Hyperpolarizable Chromophores Based on Conjugated Bis(terpyridyl)Ru(II) and Palladium and Platinum Porphyrinic Components: Impact of Heavy Metals upon Supermolecular Electro-Optic Properties
A new series of strongly coupled oscillators based upon (porphinato)Pd, (porphinato)Pt, and bis(terpyridyl)-ruthenium(II) building blocks is described. These RuPPd, RuPPt, RuPPdRu, and RuPPtRu chromophores feature bis- (terpyridyl)Ru(II) moieties connected to the (porphinato)metal unit via an ethyne linker that bridges the 4!-terpyridyl and porphyrin macrocycle meso-carbon positions. Pump–probe transient optical data demonstrate sub-picosecond excited singlet-to-triplet-state relaxation. The relaxed lowest-energy triplet (T 1 ) excited states of these chromophores feature absorption manifolds that span the 800–1200 nm spectral region, microsecond triplet-state lifetimes, and large absorptive extinction coefficients [ε(T 1 → T n ) > 4 × 10 4 M –1 cm –1 ]. Dynamic hyperpolarizability (β λ ) values were determined from hyper-Rayleigh light scattering (HRS) measurements carried out at several incident irradiation wavelengths over the 800–1500 nm spectral region. Relative to benchmark RuPZn and RuPZnRu chromophores which showed large βHRS values over the 1200–1600 nm range, RuPPd, RuPPt, RuPPdRu, and RuPPtRu displayed large βHRS values over the 850–1200 nm region. Generalized Thomas–Kuhn sum (TKS) rules and experimental hyperpolarizability values were utilized to determine excited state-to-excited state transition dipole terms from experimental electronic absorption data and thus assessed frequency-dependent β λ values, including two- and three-level contributions for both β zzz and β xzx tensor components to the RuPPd, RuPPt, RuPPdRu, and RuPPtRu hyperpolarizability spectra. Furthermore, these analyses qualitatively rationalize how the βzzz and βxzx tensor elements influence the observed irradiation wavelength-dependent hyperpolarizability magnitudes. The TKS analysis suggests that supermolecules related to RuPPd, RuPPt, RuPPdRu, and RuPPtRu will likely feature intricate dependences of experimentally determined βHRS values as a function of irradiation wavelength that derive from substantial singlet–triplet mixing, and complex interactions among multiple different β tensor components that modulate the long wavelength regime of the nonlinear optical response.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Design criteria monograph for metal tanks and tank components
Significant elements in detail tank design are wall and end structures, weld joints at bulkhead and attachment junctures, and ports and access openings. Additional design considerations are influence and effect of fabrication processes on tank component design, and finally, testing and inspection that are required to establish confidence in tank design.
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