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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Phase transition mechanism and bandgap engineering of Sb2S3 at gigapascal pressures

Abstract Earth-abundant antimony trisulfide (Sb 2 S 3 ), or simply antimonite, is a promising material for capturing natural energies like solar power and heat flux. The layered structure, held up by weak van-der Waals forces, induces anisotropic behaviors in carrier transportation and thermal expansion. Here, we used stress as mechanical stimuli to destabilize the layered structure and observed the structural phase transition to a three-dimensional (3D) structure. We combined in situ x-ray diffraction (XRD), Raman spectroscopy, ultraviolet-visible spectroscopy, and first-principles calculations to study the evolution of structure and bandgap width up to 20.1 GPa. The optical band gap energy of Sb 2 S 3 followed a two-step hierarchical sequence at approximately 4 and 11 GPa. We also revealed that the first step of change is mainly caused by the redistribution of band states near the conduction band maximum. The second transition is controlled by an isostructural phase transition, with collapsed layers and the formation of a higher coordinated bulky structure. The band gap reduced from 1.73 eV at ambient to 0.68 eV at 15 GPa, making it a promising thermoelectric material under high pressure.

Cui, Zhongxun (ORCID:0000000275044177)↗
DOE OSTI2024

Latent Pitfalls in Microstructure-Based Modeling for Thermally Aged 9Cr-1Mo-V Steel (Grade 91)

A case study was conducted on a mechanistic model development that predicted tensile strength deterioration with thermal aging of 9Cr-1Mo-V steel in supporting the 60-year design life expected for advanced nuclear reactors. For property prediction beyond practical testing times, mechanistic modeling is highly desired, as it taps into the physics of structure–property relationships and therefore can generate reliable results for extrapolation. Meanwhile, as mechanistic models are often complicated, reflecting the intricacy of microstructure and strengthening mechanisms, pitfalls that are difficult to detect often exist. Here, this paper discusses latent pitfalls that are common in mechanistic modeling or specific in this 9Cr-1Mo-V case development through using the American Society of Mechanical Engineers verification and validation in computational solid mechanics (ASME V&V 10) standard for evaluating credibility of modeling in materials engineering. Suggestions are also made for enhancing reliability of microstructure-based modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Bio-inspired non self-similar hierarchical elastic metamaterials

Hierarchy provides unique opportunities for the design of advanced materials with superior properties that arise from architecture, rather than from constitutive material response. Contrary to the quasi-static regime, where the potential of hierarchy has been largely explored, its role in vibration mitigation and wave manipulation remains elusive. So far, the majority of the studies concerning hierarchical elastic metamaterials have proposed a self-similar repetition of a specific unit cell at multiple scale levels, leading to the activation of the same bandgap mechanism at different frequencies. On the contrary, here, we show that by designing non self-similar hierarchical geometries allows us to create periodic structures supporting multiple, highly attenuative and broadband bandgaps involving (independently or simultaneously) different scattering mechanisms, namely, Bragg scattering, local resonance and/or inertial amplification, at different frequencies. The type of band gap mechanism is identified and discussed by examining the vibrational mode shapes and the imaginary component of the wavenumber in the dispersion diagram of the unit cell. Finally, we also experimentally confirm this by performing measurements in the lowest frequency regime on a 3D printed structure. Hierarchical design strategies may find application in vibration mitigation for civil, aerospace and mechanical engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2025

FY25 status report on the addition of candidate materials in Class B Code Case

This report provides the time-dependent allowable stress calculation strategy leveraging the limited creep rupture tests data generated to support the allowable stress for 100,000 hours in American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section II, Part D. A variable confidence index procedure to extrapolate material properties to support 500,000 hours design life is discussed. Time-dependent allowable stresses for Class B component design and analysis are presented for Grade 1 and Grade 2 of Alloy 625. The presented data extrapolation and allowable stress calculation method will support new material addition using limited creep rupture data in the new ASME Boiler and BPVC, Section III, Division 5, Class B rules.

Part D↗
DOE OSTI2022

Polyimide aerogels for ballistic impact protection

The ballistic performance of edge-clamped monolithic polyimide aerogel blocks (12 mm thickness) has been studied through a series of impact tests using a helium-filled gas gun connected to a vacuum chamber and a spherical steel projectile (approximately 3 mm diameter) with an impact velocity range of 150–1300 m s -1 . The aerogels had an average bulk density of 0.17 g cm -3 with high porosity of approximately 88%. The ballistic limit velocity of the aerogels was estimated to be in the range of 175–179 m s -1 . Moreover, the aerogels showed a robust ballistic energy absorption performance (e.g., at the impact velocity of 1283 m s -1 at least 18% of the impact energy was absorbed). At low impact velocities, the aerogels failed by ductile hole enlargement followed by a tensile failure. By contrast, at high impact velocities, the aerogels failed through an adiabatic shearing process. Given the substantially robust ballistic performance, the polyimide aerogels have a potential to combat multiple constraints such as cost, weight, and volume restrictions in aeronautical and aerospace applications with high blast resistance and ballistic performance requirements such as in stuffed Whipple shields for orbital debris containment application.

42 ENGINEERING↗
DOE OSTI2022

NNSA Minority Serving Institute Partnership Program (MSIPP)— Advanced Synergistic Program for Indigenous Research in Engineering (ASPIRE) (FY22 Q1 Progress Report)

In 2016, the National Nuclear Security Agency (NNSA) initiated the Minority Serving Institution Partnership Plan (MSIPP) targeting Tribal Colleges and Universities (TCUs) to offer programs that will prepare students for technical careers in NNSA’s laboratories and production plants. The MSIPP consortium’s approach is as follows: 1) align investments at the college and university level to develop a curriculum and workforce needed to support NNSA’s nuclear weapon enterprise mission, and 2) to enhance research and education at under-represented colleges and universities. The first TCU consortium that MSIPP launched was known as the Advanced Manufacturing Network Initiative (AMNI) whose purpose was to develop additive manufacturing (AM) learning opportunities. The AMNI consortium consisted of Bay Mills Community College, Cankdeska Cikana Community College, Navajo Tech University, Salish Kootenai Community College, Turtle Mountain Community College, and United Tribes Technical College. In 2016, the American Indian Higher Education Consortium (AIHEC), the AMNI consortium and the Southwestern Indian Polytechnic Institute (SIPI), in collaboration with Sandia National Labs, using a grant by NNSA hosted the first TCU Advanced Manufacturing Technology Summer Institute (TCU AMTSI). The AMNI consortium will officially end Sept. 2022. However, building on the successes of AMNI, in FY22 NNSA’s MSIPP launched three additional consortiums: (1) the Indigenous Mutual Partnership to Advanced Cybersecurity Technology (IMPACT), which focuses on STEM and cybersecurity, (2) the Advanced Synergistic Program for Indigenous Research in Engineering (ASPIRE), which focuses on STEM and the electrical and mechanical engineering skills set needed for renewable and distributed energy systems, and (3) the Partnership for Advanced Manufacturing Education and Research (PAMER), which focuses on developing and maintaining a sustainable pathway for a highly trained, next-generation additive manufacturing workforce and a corresponding community of subject matter experts for NNSA enterprises. The following report summarizes the status update during this quarter for the ASPIRE program.

42 ENGINEERING↗
DOE OSTI2023

Gripper Test Assembly Status of Fabrication and Assembly Report – FY2023

The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Characterizing mechanical and microstructural properties of novel montmorillonite-rich polyethylene composites

Montmorillonite (MMT) clays are important industrial materials used as catalysts, chemical sorbents and fillers in polymer–clay nanocomposites. The layered structure of these clays has motivated research into further applications of these low-cost materials, including use as ion exchange media and solid-state ionic conductors. In these applications, the mechanical properties of MMT are key when considering long-term, reliable performance. Previous studies have focused on the mechanical properties of nanocomposites with MMT as the minority component or pure MMT thin films. In this work, the microstructure and mechanical properties of pure MMT and majority MMT/polyethylene composites pressed into dense pellets are examined. Characterization methods such as X-ray diffraction, atomic force microscopy and scanning electron microscopy together with nanoindentation reveal important structure–property relationships in the clay-based materials. Here, utilizing these techniques, we have discovered that MMT processing impacts the layered microstructure, chemical stability and, critically, the elastic modulus and hardness of bulk MMT samples. Particularly, the density of the pellets and the ordering of the clay platelets within them strongly influence the elastic modulus and hardness of the pellets. By increasing pressing force or by incorporating secondary components, the density, and therefore mechanical properties, can be increased. If the layered structure of the clay is destroyed by exfoliation, the mechanical properties will be compromised. Understanding these relationships will help guide new studies to engineer mechanically stable MMT-based materials for industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Status Update for the Bearing Test Article Design Development – FY2025

Argonne National Laboratory’s (ANL) Mechanism Engineering Test Loop (METL) team has completed the design of a new Bearing Test Article (BTA) to test mechanical bearings for sodium fast reactor (SFR) mechanism applications. Recognition of the need for further bearing testing arose due to failure of rolling element bearings during testing of components for in-vessel fuel handling machines (FHMs) conducted at ANL in the METL facility. While the initial concept of the BTA arose from a need for bearing testing for FHM applications, the BTA design is configurable to test bearings of various sizes, types, and materials submerged in liquid sodium. Requirements for loading, shaft speed, temperature, and bearing size range were chosen based on requirements for SFR fuel handling. Modular components in the test bearing housings and shaft sleeves allow the design to accommodate a wide range of bearing sizes without modification to the larger assembly. Loading will be applied with screw jacks on the air side of the test article that will be adjusted to apply radial, thrust, or combined loading conditions. Applied force will be measured by load cells in-line with the loading mechanisms. In FY25 we have completed the design of the test article that will be fabricated and undergo testing at the METL facility. Drawing packages for the fabrication of the test article have been drafted and are being reviewed to add part tolerances and we have started ordering off-the-shelf components. The report will summarize the development of the Bearing Test Article design starting with an overview of the entire test article, then a more detailed examination of the bearing test section, loading mechanisms, test article ports and seals, and support structures, including analysis that went into significant design choices.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Advanced Monitoring and Control in the ANL METL Facility Using an Engineering Digital Twin

The potential benefits of using an engineering digital twin to achieve greater autonomy for monitoring and control functions in advanced reactors was investigated for the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The METL sodium purification system served as a representative system as it requires significant human in-the-loop interaction to accomplish its design function. The objective was to demonstrate how real-time operation could be automated while preserving oversight of the operator for ensuring that the system design functions are met. A digital twin model of the purification system was developed for both the cold trap purification loop and plugging meter diagnostic loop using information from the METL piping and instrumentation diagram (P&ID). Automated monitoring and diagnosis of component degradation in the METL facility was demonstrated in tests using the PRO-AID health monitoring software with the digital twin model incorporated in the library of components. Component failures were introduced and were successfully diagnosed in real time. These tests serve to demonstrate an advanced monitoring capability able to differentiate sensor degradation from component degradation, to generate a rank ordering of probabilities of different failure mechanisms that serves to circumvent the false alarm problem with current anomaly detection methods, and how facility monitoring can be transformed from anomaly detection to identification of a specific fault. Automated control of the purification system was demonstrated through simulations that exercised a model predictive controller designed using the digital twin model. Results of these simulations compared favorably with experimental data showing very good reference tracking response with negligible overshoot. In conclusion, these pilot tests and simulations successfully demonstrated the use of a digital twin for improved automation of monitoring and control. It was shown how the digital twin enables switching between control modes from cold trap operation where impurities are removed to plugging meter operation where impurity concentrations are measured.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

A709 Qualification Plan Update and Mechanical Properties Data Assessment

This report provides a summary of the development effort for the qualification of Alloy 709, an advanced austenitic stainless steel, in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. It provides an assessment of the mechanical properties data generated to date from the tensile, creep, fatigue and creep-fatigue tests of the precipitation-treated Alloy 709 from two commercial heats in plate product form. It was concluded that the mechanical properties of Alloy 709 with the precipitation treatment continued to outperform those of Type 316 stainless steel. This affirms the recommendation to Code qualification this alloy as a replacement for Type 316 stainless steel to support the objective of reducing the construction and operating costs to incentivize advanced reactor deployment. The data also demonstrated that the precipitation treatment is effective in enhancing the creep-fatigue resistance of Alloy 709 while maintaining a significant creep strength advantage over Type 316 stainless steel. This report also provides an update to the test conditions for the creep, fatigue and creep-fatigue test matrices in order to cover the Code Case data package more effectively. Finally, it is recommended to continue the Alloy 709 Code Case Testing Program to develop the data package needed for the determination of the material-specific design parameters for inclusion in the Alloy 709 Code Case.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

A Summary of the Microstructural Characterization Results for the A709 Commercial Heats

To improve high temperature strength for advanced nuclear reactors, it is necessary to qualify additional structural materials for introduction into the American Society of Mechanical Engineers (AMSE) Boiler and Pressure Vessel Code (BPVC). Specifically, Alloy 709 was identified as a material for Sodium-cooled Fast Reactors to enhance time-dependent mechanical properties compared to 316H stainless steel, a code qualified high temperature alloy. Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) performed initial microstructure and mechanical property testing on a third, commercial heat of Alloy 709 stainless steel. The Alloy 709 plate was produced by Allegheny Technology Inc. (ATI) and in the solution annealed condition. The chemical composition was within the limits for an American Society of Testing and Materials (ASTM) A213 specification for seamless tube for material UNS S31025. Grain size was measured as an average ASTM size of 6.5, which was larger than the ASTM 7 required according to ASTM A213 for seamless tube. The chemical composition was within the limits for an ASTM A213, and the room temperature tensile tests and hardness data met ASTM A213 specifications. Creep-fatigue results showed similar behavior to previous heats of Alloy 709.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

LLMs for Mfg.—On the State of Large Language Models and Applications to Manufacturing

Additive Manufacturing (AM), referred to as 3D printing, has emerged as a key pillar of Industry 4.0 enabling layer-by-layer fabrication of intricate geometries from CAD models. In parallel, Large Language Models (LLMs), deep learning models for natural language generation trained on vast text corpora, have demonstrated unprecedented capabilities in understanding and generating human-like text. The convergence of these trends opens new opportunities at the intersection of AM and AI/ML, where LLMs can assist engineers and researchers in design, manufacture planning, and knowledge discovery. Recent academic work has begun to explore LLM applications in AM and adjacent fields, such as material science, mechanical engineering, and design for additive manufacturing. This exploration ranges from intelligent process planning to domain-specific knowledge retrieval. This survey provides a comprehensive review of current developments, focusing on peer-reviewed literature contributions that apply, adapt, and advance LLMs in general and domain-specific domains. We analyze state-of-the-art (SOTA) techniques, such as fine-tuning foundational models for specific domains, retrieval-augmented generation (RAG) pipelines, knowledge graph integration, and delve into the architectures and evaluation methods employed. The goal of this survey is to inform researchers and practitioners of the current capabilities and limitations of LLMs in general and in domain-specific applications, and to outline how these models are being tailored to meet the requirements of these applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Preliminary Experimental Results in Support of the Development of EPP and SMT Design Methods and Viscoplastic Model for A709

The ASME code qualification effort for Alloy 709 (A709) is currently underway to qualify it for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5. The United States (U.S.) Department of Energy (DOE) national laboratories are collaborating in the advanced materials development initiative to investigate the mechanical performance of A709 in support of its code qualification. As part of the A709 code qualification effort, this report summarizes ORNL’s initial experimental findings that support the integration of A709 into the elastic-perfectly plastic (EPP) strain limits code case. It also covers thermomechanical fatigue testing conducted to develop viscoelastic material models, along with the preliminary results of creep-fatigue experiments at 816°C using the Simplified Model Test (SMT) method.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The 2020 Nonlinear Mechanics and Dynamics Research Institute

The 2020 Nonlinear Mechanics and Dynamics (NOMAD) Research Institute was successfully held from June 15 to July 30, 2020. NOMAD brings together participants with diverse technical backgrounds to work in small teams to cultivate new ideas and approaches in engineering mechanics and dynamics research. NOMAD provides an opportunity for researchers – especially early career researchers - to develop lasting collaborations that go beyond what can be established from the limited interactions at their institutions or at annual conferences. A total of 11 students participated in the seven-week long program held virtually due to the COVID-19 health pandemic. The students collaborated on one of four research projects that were developed by various mentors from Sandia National Laboratories, the University of New Mexico, and other academic and research institutions. In addition to the research activities, the students attended weekly technical seminars, various virtual tours, and socialized at virtual gatherings. At the end of the summer, the students gave a final technical presentation on their research findings. Many of the research discoveries made at NOMAD 2020 are published as proceedings at technical conferences and have direct alignment with the critical mission work performed at Sandia.

42 ENGINEERING↗
DOE OSTI2025

Structural Design and Modeling of MARVEL Primary Coolant System Using the ASME Section III, Division 5, Code

This paper presents the structural design and supporting analysis for the Microreactor Applications Research Validation and Evaluation (MARVEL) primary coolant system (PCS) using the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III, Division 5, rules. MARVEL is a liquid metal–cooled microreactor intended to provide experimental capabilities for the rapid testing and development of microreactor technologies. The PCS utilizes high-temperature sodium-potassium liquid metal as the primary coolant and operates at a design temperature of 570°C, necessitating the consideration of creep-related failure mechanisms. The base metal for the PCS is 316H stainless steel, and the weldments are made with a 16-8-2 filler. The design approach incorporates the current base code rules along with ASME code cases N-924, N-861, and N-862 to address primary load, ratcheting, and creep-fatigue evaluations, respectively. The reactor’s operation involves complex thermal and mechanical interactions due to natural convective flow and differential thermal expansion between components. In conclusion, this paper discusses the structural engineering challenges encountered, such as managing thermal stresses in the distribution plenum and guard vessel, and outlines the strategies implemented to meet the code requirements, including design modifications and operational constraints.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

Report on the Integration of Experimental and Modeling Data for Initial Equivalence Study of Mechanical Performance in Irradiated LPBF 316 Stainless Steel

To ensure the rapid development, deployment, and use of advanced nuclear technologies, faster qualification approaches are needed. Typically, the primary pathway uses traditional data packages consistent with the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, which does not consider the environmental effects the material will experience such as corrosion and radiation damage. Examining radiation effects requires a significant amount of space in US facilities at the Advanced Test Reactor and the High Flux Isotope Reactor (HFIR) and suffers from natural gradients in temperature and neutron flux profiles. Ion irradiation may enable rapid assessment of radiation-induced damage to a material and is proposed as part of an accelerated materials qualification framework through the Advanced Materials and Manufacturing Technologies program. To enhance the utility of ion irradiation as an examination tool, this report provides the initial assessment of engineering-relevant properties of microstructures produced from ion irradiation in the near-surface volume. Nanoindentation, Vickers hardness, and known tensile properties were brought together with simple mathematical models and experimental data for an initial equivalence study of the mechanical performance of irradiated laser powder bed fusion (LPBF) 316 stainless steels across length scales. Direct observation of the calculated ion irradiation yield stress and measured neutron irradiation yield stress at 2 dpa showed that both datasets exhibit the same trend with irradiation temperature and overlap within an acceptable band of stress values. Ion irradiations at 10 dpa serve as a prediction of properties to compare to postirradiation examination of HFIR-irradiated LPBF 316H further in the program. This work is a significant demonstration of the Licensing Approach with Ions and Neutrons, which uses ion irradiations to generate mechanical property information more rapidly than through neutron irradiations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Sulfate Promotes Compact CaCO 3 Formation and Protects Portland Cement from Supercritical CO 2 Attack

Supercritical (sc) CO 2 in geologic carbon sequestration (GCS) can chemically and mechanically deteriorate wellbore cement, raising concerns for long-term operations. In contrast to the conventional view of “sulfate attack” on cement, we found that adding 0.15 M sulfate to the acidic brine can significantly reduce the impact of scCO 2 attack on Portland cement, resulting in stronger cement than that found in a sulfate-free system. Scanning electron microscopy revealed a decreased total attack depth in reacted cement in the presence of sulfate. With a newly defined minimum porosity term in reactive transport modeling, our model suggests that sulfate caused CaCO 3 to fill more nanopore spaces in the cement. Small angle X-ray scattering experiments also showed that sulfate can decrease the pore sizes of the carbonate layer. The results suggest that the interactions between sulfate and cement can generate a less porous CaCO 3 layer, which better resists acidic brine. Using this mechanism as a proof-of-concept, we tested the incorporation of sodium sulfate into Portland cement and synthesized new cement composites that show stronger resistance against scCO 2 attacks. Finally, these newly discovered interfacial interactions between CaCO 3 and sulfate provide new insights into engineering mechanically strong and green materials for safer GCS.

54 ENVIRONMENTAL SCIENCES↗