Multiphase-Tolerant Turbine (MuTT) Development for an sCO₂ PTES System
Summary of initial multiphase nozzle testing and the test loop design for a multiphase tolerant turbine.
25 ENERGY STORAGE↗
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Results for “Test Loop”
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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UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers
The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Cold Trap Replacement Project Report
This report documents the replacement of the Mechanisms Engineering Test Loop (METL) cold trap. The work involved preparation of the facility to replace the cold trap, removal of the existing welded cold trap from the sodium purification circuit, installation of a new replacement cold trap, completion of associated welds and examinations, restoration of instrumentation and heaters, and controlled return of the cold trap circuit to service. The replacement represented a significant maintenance evolution because the cold trap is an integral welded component of the sodium system. As a result, the work required coordinated control of sodium chemistry, deliberate formation of freeze plugs, inert gas management, precision cutting and welding, and a staged reheating and refill sequence. The activity was executed using procedural controls intended to protect personnel, preserve system cleanliness, and maintain the integrity of the sodium boundary throughout the work. This report provides a narrative summary of the milestone, including the purpose of the work, the pre-job system condition, the major field activities performed, observations made during execution, and the resulting post-work condition of the METL cold trap circuit.
42 ENGINEERING↗
Captan+X Data Converter Integration
Fermi National Accelerator Laboratory's CAPTAN (Compact And Programmable daTa Acquisition Node) series provides a flexible hardware platform for data acquisition across a range of experiments and facilities. The latest iteration, CAPTAN+X, is built around a Kintex-7 FPGA supporting four FPGA Mezzanine Card (FMC) connections. As part of a broader laboratory effort to bring facility systems under a Model-Based Systems Engineering (MBSE) framework, CAPTAN+X is one of several systems slated to be incorporated into this modeling environment in the near term. A necessary step toward that goal is incorporating the platform's core functionality, which centers on integration with the LXD31K4 FMC, a data converter module combining dual AD9652 analog-to-digital converters and dual AD9142A digital-to-analog converters. Achieving compatibility required resolving pin-mapping conflicts between the LXD31K4's High Pin Count connector and the CAPTAN+X's available pin types, adapting a Board Support Project originally written for an UltraScale-class evaluation board to the Kintex-7 architecture, replacing incompatible primitives, restructuring clock distribution, and manually configuring chip initialization in place of an unsupported soft-processor-based approach. Functional verification of the ADC and DAC channels, followed by closed-loop testing combining both converters with real-time filtering, confirmed correct operation of the integrated system. These results establish a working hardware and firmware baseline for the CAPTAN+X platform, positioning it for future inclusion in the laboratory's growing MBSE modeling effort.
Espinoza, David [Illinois U., Urbana (main)]↗
Anomaly Detection in Liquid Sodium Cold Trap Operation with Multisensory Data Fusion Using Long Short-Term Memory Autoencoder
Sodium-cooled fast reactors (SFR), which use high temperature fluid near ambient pressure as coolant, are one of the most promising types of GEN IV reactors. One of the unique challenges of SFR operation is purification of high temperature liquid sodium with a cold trap to prevent corrosion and obstructing small orifices. We have developed a deep learning long short-term memory (LSTM) autoencoder for continuous monitoring of a cold trap and detection of operational anomaly. Transient data were obtained from the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The cold trap purification at METL is monitored with 31 variables, which are sensors measuring fluid temperatures, pressures and flow rates, and controller signals. Loss-of-coolant type anomaly in the cold trap operation was generated by temporarily choking one of the blowers, which resulted in temperature and flow rate spikes. The input layer of the autoencoder consisted of all the variables involved in monitoring the cold trap. The LSTM autoencoder was trained on the data corresponding to cold trap startup and normal operation regime, with the loss function calculated as the mean absolute error (MAE). The loss during training was determined to follow log-normal density distribution. During monitoring, we investigated a performance of the LSTM autoencoder for different loss threshold values, set at a progressively increasing number of standard deviations from the mean. The anomaly signal in the data was gradually attenuated, while preserving the noise of the original time series, so that the signal-to-noise ratio (SNR) averaged across all sensors decreased below unity. Results demonstrate detection of anomalies with sensor-averaged SNR < 1.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Voltage Service Limits Smart Contract Using Distributed Ledger Technology for Electrical Utility Grid with Customer-Owned Generator
Modern electrical grids face growing stability risks from customer-owned generators, especially at points of common couplings (PCCs). Disruptive behavior from power-electronic sources can cause protective relays to isolate problematic generators, making measurement integrity critical. This article presents a distributed ledger technology (DLT) approach that uses smart contracts to evaluate PCC voltage measurements and trigger backup breaker operations. The approach is framed as a verifiable, multi-organization attestation and audit layer, not as a real-time control security mechanism. In the proposed architecture, voltage measurements from a hardware protective relay are anchored on a DLT through the Cyber Grid Guard (CGG) system for attestation by both the grid utility and customer-owned generator. A Voltage Service Limits (VSLs) smart contract evaluates the on-chain measurements against allowable phase-voltage limits derived from the ANSI C84.1 standard. The framework is validated in a hardware-relay-in-the-loop test bed under sustained-undervoltage, sustained-overvoltage, and transient line-to-line fault scenarios. The results show that the VSL smart contract can process these measurements and issue backup breaker actions consistent with the defined service-limit criteria, demonstrating the DLT potential as a verifiable audit layer at the PCC that complements primary protection.
cyber security↗
Corrosion of advanced refractory alloys in lithium
Static and thermal convection loop tests for refractory alloy corrosion in lithium
STATIC TESTING↗
SEDAN - SNAP-8 data analysis program
SEDAN series of IBM 7094 computer programs for analyzing steady state data from SNAP-8 test loops
SNAP-8↗
Nuclear design data for experiments to be conducted in Horizontal Through Hole 1 of the Plum Brook Reactor
Design data for gas cooled test loop, and inpile capsule facility from mockup reactor experiments
Ciesla, E. J.↗
Automatic transmission line monitor
Monitor improves complex network reliability in computer data links and command transmission lines. System evaluates circuit performance against preselected criteria, identifies and stores data indicating out-of-tolerance conditions, conducts closed loop testing, and provides for operation under command of digital computer that determines restoration priorities.
Parsons, W. E.↗
Motor start of a 2- to 10-kilowatt Brayton rotating unit operating on gas bearings in a closed loop
Motor start of 2 to 10 kilowatt Brayton rotating unit operating on gas bearings in closed loop test facility
Evans, R. C.↗
Shock and vibration tests of a SNAP-8 NaK pump
The pump used for reactor cooling in the SNAP 8 space power system was subjected to the expected vehicle launch vibration, and shock loading in accordance with the SNAP 8 environmental specification. Subsequent disassembly revealed damage to the thrust bearing pins, which should be redesigned and strengthened. The unit was operational, however, when run in a test loop after reassembly.
Stromquist, A. J.↗
Design and operation of a 1000 C lithium-cesium test system
A 100 kWt cesium-lithium test loop fabricated of niobium-1% zirconium for experiments on erosion and two-phase system operation at temperatures of 980 C and velocities of 150 m/s. Although operated at design temperature for 100 hours, flow instabilities in the two-phase separator interfered with the achievement of the desired mass flow rates. A modified separator was fabricated and installed in the loop to alleviate this problem.
Hays, L. G.↗
Summary of NASA Lewis Research Center solar heating and cooling and wind energy programs
Plans for the construction and operation of a solar heating and cooling system in conjunction with a office building being constructed at Langley Research Center, are discussed. Supporting research and technology includes: testing of solar collectors with a solar simulator, outdoor testing of collectors, property measurements of selective and nonselective coatings for solar collectors, and a solar model-systems test loop. The areas of a wind energy program that are being conducted include: design and operation of a 100-kW experimental wind generator, industry-designed and user-operated wind generators in the range of 50 to 3000 kW, and supporting research and technology for large wind energy systems. An overview of these activities is provided.
Vernon, R. W.↗
Summary of NASA-Lewis Research Center solar heating and cooling and wind energy programs
NASA is planning to construct and operate a solar heating and cooling system in conjunction with a new office building being constructed at Langley Research Center. The technology support for this project will be provided by a solar energy program underway at NASA's Lewis Research Center. The solar program at Lewis includes: testing of solar collectors with a solar simulator, outdoor testing of collectors, property measurements of selective and nonselective coatings for solar collectors, and a solar model-systems test loop. NASA-Lewis has been assisting the National Science Foundation and now the Energy Research and Development Administration in planning and executing a national wind energy program. The areas of the wind energy program that are being conducted by Lewis include: design and operation of a 100 kW experimental wind generator, industry-designed and user-operated wind generators in the range of 50 to 3000 kW, and supporting research and technology for large wind energy systems. An overview of these activities is provided.
Vernon, R. W.↗
Aliasing filter for multirate systems
Rolloff filter is inexpensive way of reducing aliasing in digital control systems. Rolloff filter operating at faster sample rate (or rates) of system with 2:1 rate ratio gives infinite attenuation at half-sample rate of fast-rate loop. Tested successfully on Space Shuttle primary flight-control systems, filter technique could be applied to other multirate sampled-data systems.
Lee, J. F. L.↗
A drive unit for the instrument pointing system
The requirements, capabilities, and unique design features of the instrument pointing system drive units (DU) are presented. The DU's are identical for all three gimbal axes (elevation, cross elevation, and azimuth) and provide alternating rotation of shaft versus the housing of + or - 180 deg. The design features include: two ball bearing cartridges using cemented carbide balls coated with TiC a layer; redundant brushless torque motors and resolvers; a load by-pass mechanism driven by a dc torque motor to off-load the bearings during ascent/descent, ground transportation, and to provide an emergency breaking capability; and cabling over each gimbal axis by means of cable follow-up consisting of 13 signal and 15 power flat band cable loops. Test results of disturbance torque characteristics are presented.
Birner, R.↗
Cell module and fuel conditioner development
The design features and plans for fabrication of Stacks 564 and 800 are described. The results of the OS/IES loop testing of Stack 562, endurance testing of Stack 560 and the post test analysis of Stack 561 are reported. Progress on construction and modification of the fuel cell test facilities and the 10 kW reformer test station is described. Efforts to develop the technical data base for the fuel conditioning system included vendor contacts, packed bed heat transfer tests, development of the BOLTAR computer program, and work on the detailed design of the 10 kW reformer are described.
Hoover, D. Q., Jr.↗