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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Alternatives Analysis Amchitka Island Mud Pit Cap Repair, Amchitka, Alaska January 2016

The U.S. Department of Energy (DOE) Office of Legacy Management (LM) manages the Nevada Offsites program, which includes a series of reclaimed drilling mud impoundments on Amchitka Island, Alaska (Figure 1). Navarro Research and Engineering, Inc. is the Legacy Management Support contractor (the Contractor) for LM. The Contractor has procured Tetra Tech, Inc. to provide engineering support to the Amchitka mud pit reclamation project. The mud pit caps were damaged during a 7.9-magnitude earthquake that occurred in 2014. The goals of the current project are to investigate conditions at the mud pit impoundments, identify feasible alternatives for repair of the cover systems and the contents, and estimate relative costs of repair alternatives. This report presents descriptions of the sites and past investigations, existing conditions, summaries of various repair/mitigation alternatives, and direct, unburdened, order-of-magnitude (-15% to +50%) associated costs.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Light Water Reactor Sustainability Program: Complete Report on Development of Weld Repair Technology

This report summarizes recent post-welding activities on irradiated alloys at the Irradiated Materials Examination and Testing (IMET) and the Low Activation Materials Development and Analysis (LAMDA) facilities at Oak Ridge National Laboratory. Equipment and capabilities were developed jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program (and the Welding and Repair Technology Center), and Oak Ridge National Laboratory. The preliminary helium measurements and microstructure characterization revealed successful advanced laser and friction stir welding procedures on high helium content stainless steel. The significant, on-going effort to weld irradiated alloys with high helium concentrations and comprehensively analyze the results will eventually yield validated repair techniques and guidelines for use by the nuclear industry in extending the operational lifetimes of nuclear power plants. The nuclear industry welding workshop was successfully held at ORNL on September 18 – 19, 2018.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Investigation of Cold Spray as a Dry Storage Canister Repair and Mitigation Tool

The lack of a permanent spent nuclear fuel repository means utilities are faced with extending licenses for dry cask storage systems (DCSS) canisters far beyond their original 20-year license period. DCSS canisters are made from austenitic stainless steels (SSs) and fabricated using fusion welds. High heat input and melting associated with fabrication welds causes material around the weld to be susceptible to chloride-induced stress corrosion cracking (CISCC). The purpose of the work reported here is to investigate the use of cold spray for repair and mitigation of CISCC in DCSS canisters to ensure integrity far beyond their original license period. This report presents an analysis of cold spray for canister life extension, a summary of related efforts, relevant technology down selections, work accomplished, and future efforts relative to use of cold spray for repair and mitigation of CISCC in DCSS canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Development of Repair Techniques for Cast Iron Engine Blocks by Additive Manufacturing

ORNL partnered with Cummins Inc to demonstrate the feasibility of using additive manufacturing techniques to deposit large volume of new material on cast iron in the context of remanufacturing. Remanufacturing at Cummins Inc is carried out to repair any field damage and, in some cases, provide additional value by adding new features. Large volume deposition on difficult to weld materials is a challenging problem due to involved metallurgy. Phase-1 of this work evaluated the feasibility of using laser directed energy deposition technique to deposit new material layer by layer on cast iron engine blocks. During phase-1 deposits were made using Inconel-718, Nickel, Nr-Cr-B braze filler. Leveraging the knowledge gained during Phase-1, Phase-2 focused on developing a low- cost crack resistant ferrous alloy to repair cast iron via volume deposition techniques without preheating. Three different alloy chemistries were identified, and trials were performed on cast iron substrates to identify the optimal chemistry that provided adequate resistance to cracking in both, the deposits as well as the cast iron substrate.

42 ENGINEERING↗
DOE OSTI2022

Improve Performance and Cost for Steam Turbine Maintenance, Repair, and Overhaul Using Additive Manufacturing

The overall objective was to develop additive-manufacturing-enabled repair solutions for last stage bucket (LSB) and additive-manufacturing-enabled packing rings (PRs) for coal-fired steam turbines with the goal of reducing routine maintenance, repair, and overhaul (MRO) cost and improving the operating efficiency of steam turbines. GE Steam Power (GESP) and GE Gas Power (GEGP) provided technical and commercial consulting to GER with insights on steam turbine MRO design requirements, MRO duration and costs, and an overall commercialization strategy for the additive manufacturing technologies developed in the proposed effort.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Cold Spray for Mitigation and Repair of Spent Nuclear Fuel Dry Storage Canisters

The purpose of this work is to investigate the use of cold spray for repair and mitigation of chloride-induced stress corrosion cracking (CISCC) in dry cask storage system (DCSS) canisters to ensure their integrity far beyond their original license period. This report provides a viability analysis of cold spray for repair and mitigation of CISCC in DCSS canisters to extend canister life.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

FY2022 Status Report: Cold Spray for Canister SCC Mitigation and Repair

This progress report describes work performed during FY22 at Sandia National Laboratories (SNL) to assess the corrosion performance of cold spray coatings to enable optimization of cold spray for the purposes of mitigation and/or repair of potentially susceptible regions, corrosion, or stress corrosion cracking (SCC) in austenitic stainless steel for spent nuclear fuel (SNF) storage. Of particular concern is SCC, by which a through-wall crack could potentially form in a canister outer wall over time intervals that may be shorter than possible dry storage times. In FY21, initial corrosion explorations of cold spray coating were evaluated and in FY22, an expanded set of cold spray coatings with in-depth analysis of post-exposure accelerated testing was explored. Additionally, relevant atmospheric exposure testing was carried out and initial results are presented herein. The corrosion attack from the accelerated testing and more realistic atmospheric exposures environments were compared to identify potentially deleterious factors for corrosion as well as help to understand the applicability of accelerated testing for cold spray optimization. This initial analysis will help to enable optimization of the corrosion resistance cold spray, one of the more promising coating and repair techniques, for potential application in an SNF environment. Learnings from both are summarized, and implications and future work are presented in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Corrosion-Resistant Coatings on Spent Nuclear Fuel Canisters to Mitigate and Repair Potential Stress Corrosion Cracking (FY22 Status)

This report summarizes the activities performed by Sandia National Laboratories in FY22 to identify and test coating materials for the prevention, mitigation, and/or repair of potential chloride-induced stress corrosion cracking in spent nuclear fuel dry storage canisters. This work continues efforts by Sandia National Laboratories that are summarized in previous reports in FY20 and FY21 on the same topic. The previous work detailed the specific coating properties desired for application and implementation to spent nuclear fuel canisters (FY20) and identified several potential coatings for evaluation (FY21). In FY22, Sandia National Laboratories, in collaboration with four industry partners through a Memorandum of Understanding, started evaluating the physical, mechanical, and corrosion-resistance properties of 6 different coating systems (11 total coating variants) to develop a baseline understanding of the viability of each coating type for use to prevent, mitigate, and/or repair potential stress corrosion on cracking on spent nuclear fuel canisters. This collaborative R&D program leverages the analytical and laboratory capabilities at Sandia National Laboratories and the material design and synthesis capabilities of the industry collaborators. The coating systems include organic (polyetherketoneketone, modified polyimide/polyurea, modified phenolic resin), organic/inorganic ceramic hybrids (silane-based polyurethane hybrid and a quasi-ceramic sol-gel polyurethane hybrid), and hybrid systems in conjuncture with a Zn-rich primer. These coatings were applied to stainless steel coupons (the same coupons were supplied to all vendors by SNL for direct comparison) and have undergone several physical, mechanical, and electrochemical tests. The results and implications of these tests are summarized in this report. These analyses will be used to identify the most effective coatings for potential use on spent nuclear fuel dry storage canisters, and also to identify specific needs for further optimization of coating technologies for their application on spent nuclear fuel canisters. In FY22, Sandia National Laboratories performed baseline testing and atmospheric exposure tests of the coating samples supplied by the vendors in accordance with the scope of work defined in the Memorandum of Understanding. In FY23, Sandia National Laboratories will continue evaluating coating performance with a focus on thermal and radiolytic stability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Elucidating mechanisms of Photosystem I assembly and repair (Final Technical Report)

Oxygenic photosynthesis generates the carbohydrates and oxygen that support life on earth. Central to this process are photosystems I and II (PSI and PSII), large protein-pigment complexes that are among the most complex macromolecular structures in nature. Impressive advances have been made in understanding the structure and photochemical mechanisms of PSI and PSII. However, less is known about the mechanisms underlying their biogenesis. The overarching goal of this project was to elucidate mechanisms of photosystem assembly. Several proteins that are not found in mature PSI or PSII are essential for their assembly, but the assembly pathways and the role of each assembly factor are just starting to emerge. During the course of this project, we advanced understanding of this problem in several ways. First, we addressed the spatial organization of photosystem assembly by localizing many known assembly factors to specific subdomains of thylakoid membranes in plant chloroplasts. This work revealed that the "curvature" domain - the highly curved periphery of stacked granal membrane disks - is a center of photosystem assembly. However, whereas some PSI assembly factors localized exclusively to the curvature domain, another was found exclusively in granal margins and unstacked membranes. This spatial partitioning suggests an assembly line along which different assembly intermediates are physically segregated. Most assembly factors localized similarly in dark-adapted and illuminated plants, but one PSII assembly factor shifted from the curvature domain to unstacked membranes upon illumination, suggesting an unanticipated role in the repair of light-induced PSII damage. Whereas most PSII subunits were found primarily in grana stacks (as expected), one PSII subunit, PsbP, was prominent also in the curvature fraction, suggesting that PsbP has functions beyond its role in mature PSII, possibly in biogenesis or repair.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Fermilab 2025 Summer Internship: Repairing Pre-Amplifiers with Mu2e Electronics Installation Team

The author spent nine weeks over summer 2025 working on the tracker electronics installation team for the Mu2e experiment. One of her main responsibilities was repairing high voltage (HV) and calibration (Cal) pre-amplifiers (pre-amps). During installation, the fragile wires connecting the two sockets to the pre-amp board must be bent, often leading to breakage. During production, the sockets and wires were initially soldered to the board at UC Berkely, then the whole pre-amp was coated in parylene before transport to Fermilab. The interns were able to expedite the repairs, and thus whole installation process, by using an alternative method on-site with epoxy. Another task they were responsible for, not included in the original project specifications, was attaching copper clips to specific vias on the Cals to reduce noise. The talk will give listeners insight into the daily problem-solving required by the novel technologies in the Mu2e project. The author would like to acknowledge her fellow Monmouth College undergraduate interns, Lizzie Durfee and Gianna Maughan, advisor and PI of the DOE RENEW Grant Dr. Christopher G. Fasano, and the Mu2e team lead by co-spokesperson Dr. Bob Bernstein and tracker L2 manager Dr. Brendan Kiburg.

de Zwart, Bronte [Monmouth Coll.]↗
DOE OSTI2025

Emergency vacuum repairs in an aging accelerator: Case studies and lessons learned

Jefferson Lab operates the CEBAF electron accelerator at energies to 12 GeV for the Department of Energy Nuclear Physics program. The CEBAF injector beamline was designed and built in the early 1990s. Although we’ve upgraded and replaced many of the vacuum systems, we still have unique original components installed which operate daily. Over the past 3 years, we have had several vacuum leaks in ageing components leading to emergency repairs on a tight timeline. I’ll discuss the nature of these vacuum component failures, the difficulties in repair due to their ages, the lessons we’ve learned, and how we hope to minimize similar failures going forward.

Stutzman, Marcy [Thomas Jefferson National Acceler↗
DOE OSTI2023

Repairing High γ’ Hot Section Gas Turbine Components Using Advanced Manufacturing

This article describes the ability to use laser-blown powder deposition to repair high γ' IN-100 superalloy gas turbine components. The influence of various process conditions on the ability to make crack-free IN-100 deposits over surrogate high γ' alloys was investigated to identify cracking mechanisms in the deposit and heat-affected zones (HAZs). The various crack formation mechanisms, such as solidification cracking and liquation cracking, were evaluated using multiscale characterization and numerical simulation. The cracking in the deposit region was predominantly solidification cracking, while those observed in the HAZ were liquation cracking. The results showed that controlling thermally induced residual stresses is the key to eliminating cracking, and the optimum preheat temperature was determined. In conclusion, the results were then contrasted with those in published literature and an approach to effectively repair hot section parts was presented.

36 MATERIALS SCIENCE↗
NASA NTRS1969

Welded repairs of punctured thin-walled aluminum pressure vessels

Punctures in thin-walled aluminum pressure vessels are repaired by plugging the hole with an interference-fit disc and welding the unit. The repaired vessels withstood test pressures in excess of vessel ultimate design values for 2-, 4-, and 6-inch holes in 0.202-inch-thick aluminum alloy parent material.

Jones, D. J.↗
NASA NTRS1969

Repair of honeycomb panels with welded breakaway studs

Damaged metallic honeycomb panels can be repaired by drilling holes and welding breakaway studs to both facing sheets. Minimal heat required for welding reduces distortion of highly stressed panels. Repairs can be made without the use of doublers and with greater strength when doublers are used.

Bruce, D. F.↗
NASA NTRS1976

Repairing a communications satellite on orbit

A review of past failures indicates that module exchange can satisfy most repair requirements of communications satellites. Emphasis is placed on the design of a serviceable communications satellites with 20 modules, on the development of an on-orbit servicer designed to remove failed modules from a body-stabilized spacecraft and to replace them with good modules, and on servicing operations. Benefits of servicing or repair include increased satellite availability, increased reliability, decreased life cycle costs, replacement of worn-out items, installation of updated equipment, and correction of design failures. The use of servicing instead of replacement could result in cost savings in excess of 40 percent. Significant savings are possible when the lifetime of a program is long relative to the satellite lifetime.

Gordon, G. D.↗
NASA NTRS1979

Repairing pin-fin cold plates

Inexpensive technique avoids high temperatures that deform thin stainless steel plates. Because repair disks have small diameters, repaired area can sustain greater loads that larger unsupported areas of faceplate.

Ruppe, E. P.↗