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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

3D pore structure reconstruction of fluff region in top of EBR-II irradiated fuel by X-ray micro-computed tomography

Metallic fuels comprised of U-Zr binary and U-Pu-Zr ternary alloys are a promising fuel candidate for sodium-cooled fast reactors and possess many advantages over ceramic fuels such as higher uranium density and improved thermal conductivity. Fluff is a highly porous structure forming at the top of metallic fuel slugs during irradiation and was extensively observed in past sodium-cooled fast reactor (SFR) experiments such as Idaho National Laboratory’s Experimental Breeder Reactor II (EBR-II). Previous investigations have shown that fluff is rich in fissile atoms and hence could have neutronics implications, but its formation mechanisms are not understood. In this work, two cube-shaped lift outs were taken from the fluff and bulk fuel regions of a high burnup U-19Pu-10Zr composition EBR-II fuel slug and characterized by micro computed tomography (Micro-CT) and energy dispersive x-ray spectroscopy (EDS). This was used to characterize differences in microscale porosity and composition between fluff and bulk fuel, and to support or oppose postulated fluff formation mechanisms. Surface EDS showed minimal differences between the elemental compositions of the fluff and fuel cubes. However, three-dimensional (3D) pore analysis from the tomography scans showed significant differences between the fluff and fuel cube pore size distributions at the microscale level. The high porosity and irregular pore distribution seen in macroscale fluff was also present within the micro-scale fluff cube, having a much higher porosity than the fuel cube which was concentrated in a few large pore networks. In conclusion, these results indicate support for a creep driven mechanism of fluff formation.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS

Computed Tomography Scanning and Petrophysical Measurements of Eastern Williston Basin Twin Buttes and Hagel Formations

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) in Morgantown, West Virginia, were used to characterize core from two wells that represent coal resources across North Dakota. These include the MC23080C Well in Mercer County and the 23-B001 Well in Oliver County. The primary impetus of this work was to capture a detailed digital representation of the core from the MC23080C and 23-B001 Wells. The collaboration between the NETL and the Energy and Environment Research Center (EERC) enables other research entities to access information about this potential carbon ore, rare earth, and critical mineral resource plays in the Williston Basin. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. Fractures, discontinuities, and millimeter-scale features were readily detectable with the medical CT scanner acquired images. Imaging with the NETL medical CT scanner was performed on entire cores. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), gamma density, and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for potential future analysis. Higher-resolution industrial and micro-CT images were acquired from selected zones along the depth of the core to visualize the structure in higher detail. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provides a multi-scale analysis of the core, with the resulting macro- and micro-descriptions relevant to many subsurface energy-related examinations traditionally performed at NETL.

01 COAL, LIGNITE, AND PEAT

Brady’s Geothermal Field Computed Tomography Core Characterization

We present a publicly accessible database centered around multi-scale Computed Tomographic (CT) imaging of samples from the BCH-03 well, supplemented by a wide range of supporting geological analyses (Brown, et al., 2022). The data include detailed petrologic descriptions of core samples, core-scale medical CT scans, high-resolution micro-CT scans, thin section photomicrographs, elemental abundance data from X-ray diffraction, velocity wave measurements, and helium porosimetry of the matrix.

computed tomography

K-3 Refractory Corrosion Test Results, HAL24M2

This report summarizes the refractory corrosion data of the high-Al matrix of Direct Feed High-Level Waste (DFHLW) glasses generated to expand glass compositional ranges. Design of a 20 high-Al glass matrix, HAL24M2, was reported in Russell et al. (2025, in progress). The HAL24M2 glasses were tested for K-3 corrosion and the results are presented in this report. Corrosion of Monofrax K-3 refractory materials in the HAL24M2 glass melts was measured using a crucible-scale method. Two test conditions, 1150 °C/7days and 1200 °C/7days were applied. The melt-line neck corrosion depth of the test coupons was measured by micro-computed tomography (micro-CT). The measured K-3 neck corrosion values were compared to predicted values using the model in Vienna et al. (2024). The model slightly over-predicted the neck corrosion depth of these glasses.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W

Non-Destructive, Three-Dimensional Imaging of Processes in the Rhizosphere Utilizing High Energy Photons

Soil structure, which can be described as the aggregation and distribution of pore spaces, regulates carbon, nutrient, and water cycling across the Earth system. Yet the inability to make quantitative, dynamic, in situ measurements of soil structure and rhizosphere carbon flow has prevented meaningful incorporation of soil structural processes into Earth System Models (ESMs). The key limitations are: (i) Lack of scale integration between micron-scale soil structure and ecosystem-scale models, (ii) Poor functional linkage between soil structural properties and biogeochemical processes, and (iii) Absence of dynamic 3D measurements of rhizosphere structural changes and carbon transformations. To address these challenges, we developed a new integrated positron emission tomography (PET) - microcomputed tomography (CT) imaging platform that enables the first 4D (spatial 3D and time), non-invasive, quantitative imaging of carbon allocation and rhizosphere structural dynamics in living plants and intact soils. The system combines: • Rhizo-PET (R-PET): a high-resolution positron emission tomography scanner optimized for 11 CO 2 tracing in plant roots. • a-Se micro-CT: a high-contrast, high-spatial resolution CT system based on amorphous selenium (a-Se) direct conversion technology, enabling micron-scale visualization of soil structure and root–soil interfaces. Together, these advances allow us to quantify how carbon exudates move, transform, and stabilize within the rhizosphere, directly informing missing processes in BER-relevant carbon cycle models.

42 ENGINEERING

Permeability Prediction Using Vision Transformers

Accurate permeability predictions remain pivotal for understanding fluid flow in porous media, influencing crucial operations across petroleum engineering, hydrogeology, and related fields. Traditional approaches, while robust, often grapple with the inherent heterogeneity of reservoir rocks. With the advent of deep learning, convolutional neural networks (CNNs) have emerged as potent tools in image-based permeability estimation, capitalizing on micro-CT scans and digital rock imagery. This paper introduces a novel paradigm, employing vision transformers (ViTs)—a recent advancement in computer vision—for this crucial task. ViTs, which segment images into fixed-sized patches and process them through transformer architectures, present a promising alternative to CNNs. We present a methodology for implementing ViTs for permeability prediction, its results on diverse rock samples, and a comparison against conventional CNNs. The prediction results suggest that, with adequate training data, ViTs can match or surpass the predictive accuracy of CNNs, especially in rocks exhibiting significant heterogeneity. This study underscores the potential of ViTs as an innovative tool in permeability prediction, paving the way for further research and integration into mainstream reservoir characterization workflows.

58 GEOSCIENCES

Applications of Computed Tomography to Evaluate Cellular Solid Interfaces

The major morphological features - foam cells, voids, knit lines, and the bondline interface were evaluated. The features identified by micro-CT correlate well to those observed by SEM. 3D reconstructions yielded volumetric dimensions for large voids (max ~ 30 mm). Internal voids and groupings of smaller cells at the bondline are concluded to be the cause of the indications noted during the NDE prescreening process.

Maisano, Josephine

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon (RCC)

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.

NDE for Characterizing Oxidation Damage in Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter s thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using NDE methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating. The results of that study are briefly reviewed in this article as well. Additionally, a short discussion on the future role of simulation to aid in these studies is provided.

Roth, Don J.

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 C and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3mm. Single-sided NDE methods were used because they might be practical for on-wing inspection, while X-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally cracked coating and subsequent oxidation damage was also studied with X-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.

Preserving the Science Legacy from the Apollo Missions to the Moon

Six Apollo missions landed on the Moon from 1969-72, returning to Earth 382 kg of lunar rock, soil, and core samples-among the best documented and preserved samples on Earth that have supported a robust research program for 45 years. From mission planning through sample collection, preliminary examination, and subsequent research, strict protocols and procedures are followed for handling and allocating Apollo subsamples. Even today, 100s of samples are allocated for research each year, building on the science foundation laid down by the early Apollo sample studies and combining new data from today's instrumentation, lunar remote sensing missions and lunar meteorites. Today's research includes advances in our understanding of lunar volatiles, lunar formation and evolution, and the origin of evolved lunar lithologies. Much sample information is available to researchers at curator.jsc.nasa.gov. Decades of analyses on lunar samples are published in LPSC proceedings volumes and other peer-reviewed journals, and tabulated in lunar sample compendia entries. However, for much of the 1969-1995 period, the processing documentation, individual and consortia analyses, and unpublished results exist only in analog forms or primitive digital formats that are either inaccessible or at risk of being lost forever because critical data from early investigators remain unpublished. We have initiated several new efforts to rescue some of the early Apollo data, including unpublished analytical data. We are scanning NASA documentation that is related to the Apollo missions and sample processing, and we are collaborating with IEDA to establish a geochemical database called Moon DB. To populate this database, we are working with prominent lunar PIs to organize and transcribe years of both published and unpublished data. Other initiatives include micro-CT scanning of complex lunar samples to document their interior structure (e.g. clasts, vesicles); linking high-resolution scans of Apollo film products to samples; and new procedures for systematic high resolution photography of samples before additional processing, enabling detailed 3D reconstructions of the samples. All of these efforts will provide comprehensive access to Apollo samples and support better curation of the samples for decades to come.

Evans, Cindy

Small Particle Impact Damage on Different Glass Substrates

Impact experiments using sand particles were performed on four distinct glass substrates. The sand particles were characterized using the X-Ray micro-CT technique; 3-D reconstruction of the particles was followed by further size and shape analyses. High-speed video footage from impact tests was used to calculate the incoming and rebound velocities of the individual sand impact events, as well as particle volume. Further, video analysis was used in conjunction with optical and scanning electron microscopy to relate the incoming velocity and shape of the particles to subsequent fractures, including both radial and lateral cracks. Analysis was performed using peridynamic simulations.

Waxman, R.

From Tomography to Material Properties of Thermal Protection Systems

A NASA Ames Research Center (ARC) effort, under the Entry Systems Modeling (ESM) project, aims at developing micro-tomography (micro-CT) experiments and simulations for studying materials used in hypersonic entry systems. X-ray micro-tomography allows for non-destructive 3D imaging of a materials micro-structure at the sub-micron scale, providing fiber-scale representations of porous thermal protection systems (TPS) materials. The technique has also allowed for In-situ experiments that can resolve response phenomena under realistic environmental conditions such as high temperature, mechanical loads, and oxidizing atmospheres. Simulation tools have been developed at the NASA Ames Research Center to determine material properties and material response from the high-fidelity tomographic representations of the porous materials with the goal of informing macroscopic TPS response models and guiding future TPS design.

Tomography

Effect of Ex Vivo Ionizing Radiation on Static and Fatigue Properties of Mouse Vertebral Bodies

For a variety of medical and scientific reasons, human bones can be exposed to a wide range of ionizing radiation levels. In vivo radiation therapy (0.05 kGy) is used in cancer treatment, and ex vivo irradiation (25-35 kGy) is used to sterilize bone allografts. Ionizing radiation in these applications has been shown to increase risk of fracture, decrease bone quality and degrade collagen integrity. Past studies have investigated the deleterious effects of radiation on cortical or trabecular bone specimens individually, but to date no studies have examined whole bones containing both cortical and trabecular tissue. Furthermore, a clear relationship between the dose and the mechanical and biochemical response of bone's extracellular matrix has yet to be established for doses ranging from cancer therapy to allograft sterilization (0.05-35 kGy). To gain insight into these issues, we conducted an ex vivo radiation study to investigate non-cellular (i.e. matrix) effects of ionizing radiation dose on vertebral whole bone mechanical properties, over a range of radiation doses (0.05-35 kGy), with a focus on any radiation-induced changes in collagen. With underlying mechanisms of action in mind, we hypothesized that any induced reductions in mechanical properties would be associated with changes in collagen integrity. METHODS: 20-week old female mice were euthanized and the lumbar spine was dissected using IACUC approved protocols. The lumbar vertebrae (L1- S1) were extracted from the spine via cuts through adjacent intervertebral discs, and the endplates, posterior processes, surrounding musculature, and soft tissues were removed (approx. 1.5mm diameter, approx. 2mm height). Specimens were randomly assigned to one of five groups for ex vivo radiation exposure: x-ray irradiation at 0.05, 1, 17, or 35 kGy, or a 0 kGy control. Following irradiation, the vertebrae were imaged using microcomputed tomography (micro-CT) and then subjected to either monotonic compressive loading to failure or uniform cyclic compressive loading. During cyclic testing, samples were loaded in force control to a force level that corresponded to a strain of 0.46%, as determined in advance by a linearly elastic micro-CT-based finite element analysis for each specimen. Tests were stopped at imminent fracture, defined as a rapid increase in strain. The main outcome for the monotonic test was the strength (maximum force); for cyclic testing it was the fatigue life (log of the number of cycles of loading at imminent failure). A fluorometric assay was used on the S1 vertebrae to measure the number of non-enzymatic collagen crosslinks[4]. A one-way ANOVA was performed on mechanical properties and collagen crosslinks; means were compared with controls using Dunnett's method, with a Tukey-Kramer post-hoc analysis when significance was found (p < or = 0.05). RESULTS: Compared to the unirradiated control group, the concentration of non-enzymatic collagen crosslinks was significantly increased for all irradiated groups (p < 0.0001), and being higher by at least 50% (Figure 1a). By contrast, the radiation effects on the collagen were only evident at the higher doses. For irradiation exposures of 17 kGy or more, strength decreased substantially as the radiation level was increased, but no effect was evident below 17 kGy (Figure 1b). There was no significant change in the stiffness or maximum displacement for any radiation dose (p>0.05). The finite element analysis prescribed force level for cyclic loading exceeded the measured (monotonic) strength of the 17 and 35 kGy irradiated groups (mean +/- SD, 20.6 +/- 5.6 N; 13.2 +/- 3.7 N, respectively) and therefore these groups were eliminated from the fatigue study. The fatigue life for the 0.05 and 1 kGy groups were similar to each other and were not statistically significantly different from the control group (Figure 1c).

radiation

Curating NASA's Past, Present, and Future Extraterrestrial Sample Collections

As codified in NASA Policy Directive 7100.10F, the Astromaterials Acquisition and Curation Office at NASA Johnson Space Center (hereafter JSC Curation) is charged with curation of all extraterrestrial material under NASA control, including future NASA missions. JSC Curation curates all or part of nine astromaterial collections in seven clean room suites: (1) Apollo Samples (1969; ISO 6-7), (2) Luna Samples (from USSR; 1972; ISO 7), (3) Antarctic Meteorites (1976; ISO 7), (4) Cosmic Dust (1981; ISO 5), (5) Microparticle Impact Collection (formerly called Space Exposed Hardware; 1985; ISO 5), (6) Genesis Solar Wind Atoms (2004; ISO 4); (7) Stardust Comet Particles (2006; ISO 5), (8) Stardust Interstellar Particles (2006; ISO 5), (9) Hayabusa Asteroid Particles (from JAXA; 2010; ISO 5). In addition to the labs that house the samples, we have installed and maintained a wide variety of facilities and infrastructure required to support the clean-rooms: more than 10 different HEPA-filtered air-handling systems, ultrapure dry gaseous nitrogen systems, an ultrapure water system (UPW) and cleaning facilities to provide clean tools and equipment for the labs. We also have sample preparation facilities for making thin sections, microtome sections, and even focused ion-beam (FIB) sections to meet the research requirements of scientists. To ensure that we are keeping the samples as pristine as possible, we routinely monitor the cleanliness of our clean rooms and infrastructure systems. This monitoring includes: daily monitoring of the quality of our UPW, weekly airborne particle counts in the labs, monthly monitoring of the stable isotope composition of the gaseous N2 system, and annual measurements of inorganic or organic contamination in processing cabinets. We track within our databases the current and ever-changing characteristics of more than 250,000 individual samples across our various collections (including the 19,141 samples on loan to 433 Principal Investigators in 24 countries). The next sample return missions that NASA will participate in are Hayabusa2 and OSIRIS-REx (Origins Spectral Interpretation Resource Identification Security - Regolith Explorer). The designs for a new state-of-the-art suite of clean rooms to house these samples at JSC have been finalized. This includes separate ISO class 5 clean rooms to house each collection, a common ISO class 7 area for general use, an ISO class 7 microtome laboratory, and a separate thin section lab. Additionally, a new cleaning facility is being designed and procedures developed that will allow for enhanced cleaning of cabinets and tools in an inorganically, organically, and biologically clean manner. We are also designing a large multi-purpose Advanced Curation laboratory that will allow us to develop the techniques necessary to fully support the Hayabusa2 and OSIRIS-REx missions, as well as future possible sample return missions (e.g., Lunar Polar Volatiles, Mars, Comet Surface). A micro-CT (micro Computed Tomography) laboratory dedicated to the study of astromaterials has come online within JSC Curation, and we plan to add additional facilities that will enable non-destructive (or minimally-destructive) analyses of astromaterials in the near future (e.g., micro-XRF (micro X-Ray Fluorescence), confocal imaging Raman Spectroscopy). These facilities will be available to: (1) develop sample handling and storage techniques for future sample return missions, (2) be utilized by PET (Positron Emission Tomography) for future sample return missions, (3) for retroactive PET-style analyses of our existing collections, and (4) for periodic assessments of the existing sample collections.

Zeigler, Ryan A.

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson

Gas pore correlations in laser powder bed fusion of Al6061

Additive manufacturing (AM) of metal materials based on powder bed fusion technology is widely used now in many industries. A known limitation of this type of manufacturing is the formation of gas pores in the bulk material. Here we present a combined X-ray imaging and mid-infrared pyrometry study of pore formation in side-by-side tracks of Al6061 for different processing conditions using both in-situ and post-processing analysis. By carefully quantifying the distributions and correlations of pore positions, we show that an existing pore in one track often catalyzes the formation of another pore in an adjacent track. In a raster scan strategy commonly used to construct bulk material, this phenomenon has the result of forming subsurface perforations, or lines of pores transverse to the scanning direction in a rastered patch. If controlled, this effect can be eliminated to improve the yield strength of the build, or exploited to create programmable failures for specific purposes.

36 MATERIALS SCIENCE

Impacts of Small-Scale Heterogeneity on Large-Scale Subsurface Flow

Discussion of NETL's CT scanning and core characterization capabilities, followed by a rapid review of several recent publications that utilize these capabilities to answer reservoir questions at the micro scale with relevance to field scale operations.

core characterization