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At least 433 records · Page 24

Surface Pressure Results for the NATO AVT-298 SWiFT Configuration in the National Transonic Facility

A high Reynolds number wind tunnel test of the Swept Wing Flow Test (SWiFT) configuration was conducted in the National Transonic Facility at the NASA Langley Research Center during the summer of 2023. The test campaign was the culmination of an international collaboration under the NATO AVT-298 research task group. The main objective of the test was to investigate Reynolds number scaling effects on the low-speed stability & control characteristics of the SWiFT model. Surface pressure results corroborate the force & moment results and help to provide more insight into the observed flow behavior. The effect of angle of attack and Reynolds number on the low-speed surface pressure results are analyzed particularly around the leading edge of the model. The onset and progression of flow separation on the wings particularly near the wing crank is also investigated, as well as the cause of an observed double-stall behavior. Finally, the transonic results showed a slight forward movement of the shock location with decreased shock strength as Reynolds number was increased. The data acquired from the test will ultimately help improve computational aerodynamic analysis and design tools for application to future BWB-type vehicle configurations.

NATO AVT-298↗

Surface Pressure Results for the NATO AVT-298 SWiFT Configuration in the National Transonic Facility

A high Reynolds number wind tunnel test of the Swept Wing Flow Test (SWiFT) configuration was conducted in the National Transonic Facility at the NASA Langley Research Center during the summer of 2023. The test campaign was the culmination of an international collaboration under the NATO AVT-298 research task group. The main objective of the test was to investigate Reynolds number scaling effects on the low-speed stability & control characteristics of the SWiFT model. Surface pressure results corroborate the force & moment results and help to provide more insight into the observed flow behavior. The effect of angle of attack and Reynolds number on the low-speed surface pressure results are analyzed particularly around the leading edge of the model. The onset and progression of flow separation on the wings particularly near the wing crank is also investigated, as well as the cause of an observed double-stall behavior. Finally, the transonic results showed a slight forward movement of the shock location with decreased shock strength as Reynolds number was increased. The data acquired from the test will ultimately help improve computational aerodynamic analysis and design tools for application to future BWB-type vehicle configurations.

NATO AVT-298↗

Research Plan and Preliminary Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms―Grain Coarsening Temperature Evaluation

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A component design in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, piping and forging using the available ART A709 materials. The objective of this A709 development work at ORNL in FY2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution annealing process. This report summarizes the work performed to identify the grain coarsening temperature for commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Flat Rolled Products.

36 MATERIALS SCIENCE↗

Composite Overwrapped Pressure Vessel (COPV) Life Test

Recent attention has been focused on how NASA and its commercial partners have been placing less emphasis on testing and have become more dependent on analytical methods when evaluating design margins for fracture-critical components. Of high concern is the possible misuse of such analytic models for thin-walled metallic liners for composite overwrapped pressure vessels (COPVs). The NASA Engineering and Safety Center (NESC) has initiated an assessment to understand the limitations of linear-elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate behavior of small cracks in thin metal liners for COPVs. It has been observed that fabrication of some thin metallic liners results in a wide variation in microstructure morphology, which results in varying microscale crack growth mechanisms. The ultimate goal is to develop and demonstrate a test-based methodology validating the safe-life requirements for COPVs with thin, elastically responding metal liners where LEFM methods are not appropriate.

Russell, Richard↗

Continued Investigations of Respirable Release Fractions for Stress Corrosion Crack-Like Geometries

The formation of a stress corrosion crack (SCC) in the canister wall of a dry cask storage system (DCSS) has been identified as a potential issue for the long-term storage of spent nuclear fuel. The presence of an SCC in a storage system could represent a through-wall flow path from the canister interior to the environment. Modern, vertical DCSSs are of particular interest due to the commercial practice of using relatively high backfill pressures (up to approximately 800 kPa) in the canister to enhance internal natural convection. This pressure differential offers a comparatively high driving potential for blowdown of any particulates that might be present in the canister. In this study, the rates of gas flow and aerosol transmission of a spent fuel surrogate through an engineered microchannel with dimensions representative of an SCC were evaluated experimentally using coupled mass flow and aerosol analyzers. The microchannel was formed by mating two gage blocks with a linearly tapering slot orifice nominally 13 μm (0.005 in.) tall on the upstream side and 25 μm (0.0010 in.) tall on the downstream side. The orifice is 12.7 mm (0.500 in.) wide by 8.89 mm (0.350 in.) long (flow length). Surrogate aerosols of cerium oxide, CeO 2 , were seeded and mixed with either helium or air inside a pressurized tank. The aerosol characteristics were measured immediately upstream and downstream of the simulated SCC at elevated and ambient pressures, respectively. These data sets are intended to demonstrate a new capability to characterize SCCs under well-controlled boundary conditions. Modeling efforts were also initiated that evaluate the depletion of aerosols in a commercial dry storage canister. These preliminary modeling and ongoing testing efforts are focused on understanding the evolution in both size and quantity of a hypothetical release of aerosolized spent fuel particles from failed fuel to the canister interior and ultimately through an SCC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A theory of post-stall transients in axial compression systems. II - Application

Using the theory developed in Part I, calculations have been carried out to show the evolution of the mass flow, pressure rise, and rotating-stall cell amplitude during compression system post-stall transients. In particular, it is shown that the unsteady growth or decay of the stall cell can have a significant effect on the instantaneous compressor pumping characteristic and hence on the overall system behavior. A limited parametric study is carried out to illustrate the impact of different system features on transient behavior. It is shown, for example, that the ultimate mode of system response, surge or stable rotating stall, depends not only on the B parameter, but also on the compressor length-to-radius ratio. Small values of this latter quantity tend to favor the occurrence of surge, as do large values of B. Based on the analytical and numerical results, several specific topics are suggested for future research on post-stall transients.

Greitzer, E. M.↗

Overview of LIDS Docking Seals Development

NASA is developing a new docking system to support future space exploration missions to low-Earth orbit, the Moon, and Mars. This mechanism, called the Low Impact Docking System (LIDS), is designed to connect pressurized space vehicles and structures including the Crew Exploration Vehicle, International Space Station, and lunar lander. NASA Glenn Research Center (GRC) is playing a key role in developing the main interface seal for this new docking system. These seals will be approximately 147 cm (58 in.) in diameter. GRC is evaluating the performance of candidate seal designs under simulated operating conditions at both sub-scale and full-scale levels. GRC is ultimately responsible for delivering flight hardware seals to NASA Johnson Space Center around 2013 for integration into LIDS flight units.

Dunlap, Pat↗

Regenerative Life Support Systems for Exploration Habitats: Unique Capabilities and Challenges to Enable Long-Duration-Mission Habitats Beyond Low Earth Orbit

The Artemis I launch of NASA’s Space Launch System and Orion crew vehicle will mark a major milestone in the agency’s efforts to return humans to the Moon. Work is underway on the Human Landing System that will carry the next astronauts to the lunar surface, and the lunar orbiting Gateway that will host science and serve as a platform to support sustained human presence on the Moon and ultimately crewed missions to Mars. Two decades of continuous human presence on the International Space Station has provided a wealth of experience operating, upgrading, and demonstrating advanced Regenerative Environmental Control and Life Support Systems (Regen ECLSS). However, habitats that enable sustained lunar surface presence and transit to Mars will encounter many unique conditions and challenges. System characteristics including reliability, maintainability, mass, and power become significantly more critical. Operating environments associated with lower total pressure, low gravity, contingency protocols, and extensive un-crewed and dormant periods impose additional functionality requirements and alter the performance of certain critical systems. Integration and combined operations with other elements such as orbiting outposts, logistics suppliers, and mobility platforms impact capability and interface requirements. Limits on allocated water and oxygen consumable mass influence the need for higher levels of water and oxygen recovery from waste products. Impacts and challenges these unique exploration circumstances impose on the suite of Regen ECLSS systems are explored and discussed herein.

David F Howard↗

Effect of insulator surface conditioning on the pinch dynamics and x-ray production of a Ne-filled dense plasma focus

The dense plasma focus (DPF) can be an intense source of x rays, wherein the insulator sleeve strongly dictates the electrical breakdown, which subsequently affects the formation of a plasma sheath and a collapse phase. Experiments on a 25 kJ DPF (operated at 4.4 kJ) are carried out to demonstrate the influence of insulator surface morphology on the pinch structure, dynamics, and x-ray yield using a Ne fill. Two borosilicate insulators are directly compared, one with a smooth finish and the other machined with four circumferential grooves traversing the perimeter of the exterior insulator surface. Comparisons are made through same-shot imaging diagnostics of the evolving plasma sheath during breakdown, rundown, and at the pinch in addition to the time-resolved measurements of emitted x rays via filtered photodiodes. The presence of structures on the insulator sleeve reduces x-ray production across all fill pressures by a factor of 2.8 ± 2.4 on average and reduces the highest x ray producing shots by a factor of 5. ± 1.8. Observations of sheath asymmetry and inhomogeneity at lift-off are observed and correlated with subsequent observations of off-axis radial collapse. Taken together, this suggests that local variations in the insulator surface decrease the spatial uniformity of the sheath, leading to an azimuthally asymmetric focus, reduced electron densities, and, ultimately, degraded x-ray production.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Tidal Turbine Test, Downeast Turbines, July 12, 2021

Downeast Turbines tested a tidal turbine prototype with novel rotor/channel system and lateral effluent discharge apparatus (LEDA), during five days of testing in the flume at Alden Lab. Three days of testing (July 12-14, 2021) focused on turbine power metrics of torque and rpm, which were low, and then two days of follow-up testing (July 27-28, 2021) focused on LEDA performance metrics of pressure differential and rates of volumetric flow, with encouraging results. Next step is to to characterize, and even optimize, configurations of the LEDA, using 3D-CFD as a helpful tool, to refine its shape and explore its limits of performance as a means of effluent discharge that augments performance of an instream turbine. An improved configuration of the LEDA will be re-combined with the rotor/channel system of the turbine prototype, and ultimately, the rotor will be re-sized (enlarged), to better match the LEDA's performance capabilities in drawing through a rate of volumetric flow. This submission is Downeast Turbines' Post Access Report for the test event. It includes the files described here (next below), and several reference links. "Downeast TEAMER-Post-Access-Report...docx" is a document file containing the report. "Appendices A, B, and C" are included in this file, and so are "Figures #1-7." "Appendix D - Test Data Workbooks.zip" is an archive file containing all post access data (raw data tables, calculating tables, and graphs), presented in fourteen Excel workbooks as described in the report. "Appendix E - Post Access Figures.zip" is an archive file containing "Figures #8-52," of the report.

16 TIDAL AND WAVE POWER↗

Studies of Westward Electrojets and Field-Aligned Currents in the Magnetotail During Substorms: Implications for Magnetic Field Models

This section outlines those tasks undertaken in the final year that contribute integrally to the overarching project goals. Fast, during the final year, it is important to note that the project benefited greatly with the addition of a Boston University graduate student, Ms. Karen Hirsch. Jointly, we made substantial progress on the development of and improvements to magnetotail magnetic field and plasma models. The ultimate aim of this specific task was to assess critically the utility of such models for mapping low-altitude phenomena into the magnetotail (and vice-versa). The bulk of this effort centered around the finite-width- magnetotail convection model developed by and described by Spence and Kivelson (J. Geophys. Res., 98, 15,487, 1993). This analytic, theoretical model specifies the bulk plasma characteristics of the magnetotail plasma sheet (number density, temperature, pressure) across the full width of the tail from the inner edge of the plasma sheet to lunar distances. Model outputs are specified by boundary conditions of the source particle populations as well as the magnetic and electric field configuration. During the reporting period, we modified this code such that it can be interfaced with the auroral particle precipitation model developed by Dr. Terry Onsager. Together, our models provide a simple analytic specification of the equatorial distribution of fields and plasma along with their low-altitude consequences. Specifically, we have built a simple, yet powerful tool which allows us to indirectly 'map' auroral precipitation signatures (VDIS, inverted-V's, etc.) measured by polar orbiting spacecraft in the ionosphere, to the magnetospheric equatorial plane. The combined models allow us to associate latitudinal gradients measured in the ion energy fluxes at low-altitudes with the large-scale pressure gradients in the equatorial plane. Given this global, quasi-static association, we can then make fairly strong statements regarding the location of discrete features in the context of the global picture. We reported on our initial study at national and international meetings and published the results of our predictions of the low-altitude signatures of the plasma sheet. In addition, the PI was invited to contribute a publication to the so-called 'Great Debate in Space Physics' series that is a feature of EOS. The topic was on the nature of magnetospheric substorms. Specific questions of the when and where a substorm occurs and the connection between the auroral and magnetospheric components were discussed in that paper. This paper therefore was derived exclusively from the research supported by this grant. Attachment: Empirical modeling of the quite time nightside magnetosphere.' 'CRRES observations of particle flux dropout event.' The what, where, when, and why of magnetospheric substorm triggers'. and 'Low altitude signature of the plasma sheet: model prediction of local time dependence'.

Spence, Harlan E.↗

Application of System Identification to Parachute Modeling

Parachute models are used in numerous flight simulation tools to predict a wide range of parachute flight performance characteristics (e.g., parachute inflation loads, parachute stability and dynamics, vehicle touchdown conditions, and, ultimately, the safety and survivability of the system using the parachute). The current state of the art in developing parachute models is to initially estimate the parachute characteristics based on the parachute geometry and historical data and then add increased model fidelity based on data from wind tunnel and/or flight tests. This approach, however, can be deficient in identifying which parachute states (e.g., angle of attack, sideslip, angular rates, flyout angles, descent rate, dynamic pressure, proximity to other parachutes) are responsible for the parachute motion, and the relationship between those states and the forces on the parachute.

Murri, Daniel G.↗

Probability of Decompression Sickness and Venous Gas Emboli from 49 NASA Hypobaric Chamber Tests with Reference to Exploration Atmosphere

Introduction: Decompression sickness (DCS) is a complex biophysical event; it combines human perception of pain, for instance, and the presence of a gas phase in the tissues. Living tissues are complex and dynamic. Micronuclei and later bubbles may or may not form given what appears to be the same conditions. Even when bubbles grow, symptoms may or may not develop under what appears to be the same conditions. Therefore, at this time it is appropriate to consider DCS as a probabilistic rather than a deterministic event. Methods: Probabilistic models about hypobaric DCS and venous gas emboli (VGE) require a large amount of quality research data, a definition of decompression dose using physical and physiologic variables, and a flexible analytical approach that can quantify the association between each outcome and all covariates of interest (assuming independence between DCS and VGE) and then ultimately be extended to acknowledge dependencies between DCS and VGE. Our DCS and VGE data are from 1,031 hypobaric decompressions from 1983 to 2016. A total of 577 humans participated in 49 hypobaric chamber tests to evaluate denitrogenation procedures used by astronauts in the Space Shuttle and International Space Station programs. We defined decompression dose as the ratio of computed nitrogen tension in a theoretical 360-minute half-time compartment to ambient pressure, which accounts for denitrogenation and exposure pressure as well as explanatory variables such as age, sex, body mass index, and the presence or absence of ambulation as part of exercise at the exposure pressure. A parametric survival model, using a log-logistic distribution, was used to quantify the time to development of DCS, VGE, and Grade IV VGE. Results: Our survival estimates are applicable to simple hypobaric decompressions, such as depressurizations in 5 to 30 minutes to exposure pressures between 4 and 10 pounds per square inch absolute (psia) and after minutes to hours of denitrogenation, either under resting or exercise conditions to accelerated denitrogenation. The regressions are applicable to exposures between 2 to 6 hours and under conditions of ambulation or no ambulation as part of exercise at the test pressure. We estimate that an exposure to 4.3 psia with simulated extravehicular activity (EVA) that includes ambulation after equilibration to the exploration atmosphere at 8.2 psia with a 34% oxygen atmosphere will result in 3.1% DCS (1.8% to 5.2 95% confidence interval), 23.2% VGE (16.7 to 31.2%), and 8.5% Grade IV VGE (4.7 to 14.7%) in equal samples of men and women exposed for 6 hours. Discussion: Probabilistic models for DCS, VGE, and Grade IV VGE can be used to inform those that plan future EVAs. Their applications are useful to quantify the risk of DCS and VGE in astronauts that perform EVAs in low-pressure space suits while in space or while exploring the surfaces of the moon or Mars.

Johnny Conkin↗

Report on FY 2023 Experimental Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME 2023). In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, pipes, and forgings using the available ART A709 materials. The objective of this A709 development work in FY 2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution-annealing process, which was reported in Y. Wang et al., 2023. This report summarizes the results of the high-speed dilatometry project to develop the CCP diagram using the commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Specialty Rolled Products.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

The giant impact produced a precipitated Moon

The author's current simulations of Giant Impacts on the protoearth show the development of large hot rock vapor atmospheres. The Balbus-Hawley mechanism will pump mass and angular momentum outwards in the equatorial plane; upon cooling and expansion the rock vapor will condense refractory material beyond the Roche distance, where it is available for lunar formation. During the last seven years, the author together with several colleagues has carried out a series of numerical investigations of the Giant Impact theory for the origin of the Moon. These involved three-dimensional simulations of the impact and its aftermath using Smooth Particle Hydrodynamics (SPH), in which the matter in the system is divided into discrete particles whose motions and internal energies are determined as a result of the imposed initial conditions. Densities and pressures are determined from the combined overlaps of the particles, which have a bell-shaped density distribution characterized by a smoothing length. In the original series of runs all particle masses and smoothing lengths had the same values; the matter in the colliding bodies consisted of initial iron cores and rock (dunite) mantles. Each of 41 runs used 3,008 particles, took several weeks of continuous computation, and gave fairly good representations of the ultimate state of the post-collision body or bodies but at best crude and qualitative information about individual particles in orbit. During the last two years an improved SPH program was used in which the masses and smoothing lengths of the particles are variable, and the intent of the current series of computations is to investigate the behavior of the matter exterior to the main parts of the body or bodies subsequent to the collisions. These runs are taking times comparable to a year of continuous computation in each case; they use 10,000 particles with 5,000 particles in the target and 5,000 in the impactor, and the particles thus have variable masses and smoothing lengths (the latter are dynamically adjusted so that a particle typically overlaps a few tens of its neighbors). Since the matter in the impactor provides the majority of the mass left in orbit after the collision, and since the masses of the particles that originated in the impactor are smaller than those in the target, the mass resolution in the exterior parts of the problem is greatly improved and the exterior particles properly simulate atmospheres in hydrostatic equilibrium.

Cameron, A. G. W.↗

Resolution of the buoyancy in the 8-foot high temperature tunnel combustor

Currently, the 8-Foot High Temperature Tunnel (8-Ft. HTT) combustor produces a good profile at only one point (2000 psia and 3650 R with oxygen enrichment). Air is enriched with oxygen (liquid) so that the combustor product gas will contain the volumetric amount of oxygen normally found in air. The oxygen enriched air has a large fraction that is not reacted and flows through the outer periphery of the fuel injector. This ring of cold air in addition to the relatively cold walls of the combustor set up buoyancy forces that produce a segregation of relatively cool gases at the bottom of the combustor exit. The basic problem is to produce a test gas that has uniform properties at all combustor conditions. The combustor temperature may be as high as 3700 R or as low as 2000 R. Combustor pressures can be as high as 3500 psia (no oxygen enrichment) and as low as 600 psia. The segregation is most severe with oxygen enriched air, since its temperature is lower and its density is high. The combustor is lined with nickel 201 and can be operated at about 1600 R maximum. A global mixing process is desired that produces an acceptable profile of temperature, species, and velocity at the exit of the combustor. The ultimate goal is a temperature profile with about 100 R variance and about 2 percent variance in oxygen. The exit total temperature must not be lowered significantly by the mixing apparatus or mechanisms employed. If immersed bodies are used, they must also be kept very hot. All combustor wall modifications must be able to survive the heat and structural conditions of the varied operating conditions. Our approach to resolving this issue is being conducted in three stages: (1) Consider mixing exclusively, (2) Resolve the heat transfer concerns resulting from the chosen mixing strategy, and (3) Solve the material and structural problems resulting from stages (1) and (2). Since the 8-Ft. HTT is unavailable for experimentation, the study is conducted exclusively with computational fluid dynamic (CPD) codes (Fluent/Uns and Rampant 3.1) using unstructured grid through body fitted coordinates. Both CFD codes are general purpose Navier-Stokes solution packages that can solve integral conservation equations for conservation of mass, momentum and energy. The governing equations are discretized using a control-volume finite-element method on unstructured triangular 2-D grids. In the interest of time, a 3-D tetrahedral grid was used to check the 2-D results on one mixing strategy and the 2-D results were confirmed. Preliminary results indicate that excellent mixing can be achieved with a body placed in the center of the flowing hot fluid with a minor modification to the combustor wall similar to a model positioned in the test section of a wind tunnel. The concept here, is to create longitudinal vortices strong enough to bring both fluids into intimate contact with each other near the wall where the cold fluid resides. However, there may be a trade-off in the choice of mixing strategy, heat transfer and structural requirements. Currently, we are examining the more promising geometries for heat transfer concerns and developing strategies for the material of construction of the center body.

Loney, Norman W.↗

Ultimate Temperature of Pulse Tube Cryocoolers

An ideal pulse tube cryocooler using an ideal gas can operate at any temperature. This is not true for real gases. The enthalpy flow resulting from the real gas effects of 3He, 4He, and their mixtures in ideal pulse tube cryocoolers puts limits on the operating temperature of pulse tube cryocoolers. The discussion of these effects follows a previous description of the real gas effects in ideal pulse tube cryocoolers and makes use of models of the thermophysical properties of 3He and 4He. Published data is used to extend the analysis to mixtures of 3He and 4He. The analysis was done for pressures below 2 MPa and temperatures below 2.5 K. Both gases and their mixtures show low temperature limits for pulse tube cryocoolers. These limits are in the 0.5-2.2 K range and depend on pressure and mixture. In some circumstances, even lower temperatures may be possible. Pulse tube cryocoolers using the ha-fluid properties of dilute 3He in superfluid 4He appear to have no limit.

Kittel, Peter↗

Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗