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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Fluorine-Free Precise Polymer Electrolyte for Efficient Proton Transport: Experiments and Simulations

Designing polymers with controlled nanoscale morphologies and scalable synthesis is of great interest in the development of fluorine-free materials for proton-exchange membranes in fuel cells. This study focuses on a precision polyethylene with phenylsulfonic acid branches at every fifth carbon, p5PhSA, with a high ion-exchange capacity (4.2 mmol/g). The polymers self-assemble into hydrophilic and hydrophobic co-continuous nanoscale domains. In the hydrated state, the hydrophilic domain, composed of polar sulfonic acid moieties and water, serves as a pathway for efficient mesoscopic proton conductivity. The morphology and proton transport of p5PhSA are evaluated under hydrated conditions using in situ X-ray scattering and electrochemical impedance spectroscopy techniques. Additionally, at 40 °C and 95% relative humidity, the proton conductivity of p5PhSA is 0.28 S/cm, which is four times greater than Nafion 117 under the same conditions. Atomistic molecular dynamics (MD) simulations are also used to elucidate the interplay between the structure and the water dynamics. The MD simulations show strong nanophase separation between the percolated hydrophilic and hydrophobic domains over a wide range of water contents. The percolated hydrophilic nanoscale domain facilitates the rapid proton transport in p5PhSA and demonstrates the potential of precise hydrocarbon-based polymers as processible and effective proton-exchange membranes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Assembly of MiniFuel Targets for Irradiation of TRISO Fuel Compacts in the High Flux Isotope Reactor

To support the development of Kairos Power’s fluoride-salt-cooled high-temperature reactor, irradiation testing of tristructural isotropic (TRISO) fuel compacts was performed at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR) to collect experimental data on TRISO fuel during high particle-power operation and validate fuel performance models. Fuel compacts containing enriched uranium oxycarbide (UCO), natural UCO (NUCO), or uranium dioxide (UO 2 ) TRISO particles were fabricated at ORNL and inserted into MiniFuel targets for HFIR irradiation. Five MiniFuel targets were successfully assembled, welded, tested, and delivered to HFIR, along with their quality assurance documentation. The targets were inserted into HFIR’s inner vertical experiment facility within the permanent beryllium reflector. Each target contains six fuel compacts and will be irradiated in HFIR for four cycles, with target temperatures of 500, 700, and 900°C. This report summarizes the experiment design, test matrix, and fabrication. This work was performed under the Nuclear Science User Facility program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Summary of DASSH-CFD Inter-Assembly Heat Transfer Comparison

Fast reactor core design requires integration of detailed power distributions obtained from neutronics models and thermal fluids calculations to determine temperature distributions and flow conditions. During the design phase, calculations may be repeated as specifications change and computational expense must be balanced with solution accuracy, creating an opportunity for the use of intermediate-fidelity codes. To that end, the Ducted Assembly Steady-State Heat Transfer Software (DASSH) has been developed at Argonne National Laboratory to perform full-core, steady state coolant and fuel pin temperature calculations in reactors consisting of hexagonal, ducted assemblies. DASSH is a first-order, finite volume subchannel code based on methodologies initially introduced in the legacy thermal hydraulics codes SUPERENERGY-2 and SE2-ANL. It can work coupled with the Argonne Reactor Computational (ARC) code suite to obtain neutron and gamma power distributions based on neutron transport solutions and features many improvements and new capabilities compared to its predecessors. DASSH calculates temperatures by balancing energy between subchannels and relies on correlations to account for flow distribution and coolant mixing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

IER305: Molybdenum Sleeve Experiments in the Sandia Critical Experiments Facility [Slides]

This presentation is on the Molybdenum (Mo) sleeve experiments at the Sandia Critical Experiments Facility. The Institut de Radioprotection et de Sûreté Nucléaire (IRSN) performed the preliminary design of the experiment. IRSN performed the final nuclear design of the experiment. Sandia performed the detailed design of the experiment to make it work in the critical assembly and Sandia also oversaw the fabrication and installation of the hardware. The slides include cutaway and overall views and a look into the results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Tailoring catalyst layer structures for anion exchange membrane fuel cells by controlling the size of ionomer aggreates in dispersion

The development of anion exchange membranes and ionomers plays a critical role in performance of anion exchange membrane fuel cells. However, the optimal design of catalyst layer structures still remains unexplored despite its significance. Herein, the rational design guide is presented for cathode and anode catalyst layers using m-TPN1 ionomer by controlling the size of ionomer aggregates in dispersion and comparing various catalyst layer structures. The size of m-TPN1 aggregates decreases, creating a more uniform ionomer distribution and a larger triple-phase-boundary. As ionomer distribution of the cathode catalyst layer becomes more uniform, the power density of membrane-electrode-assembly is enhanced. Also, the power density at fully humidified condition strongly correlates with the porosity of anode catalyst layer due to the limitation of hydrogen transport at anode by water flooding.

42 ENGINEERING↗
DOE OSTI2023

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gas removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components for system integration needed to advance its TRL.

Magalhaes, Duarte↗
DOE OSTI2023

Development of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gases removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components needed to advance its TRL.

Magalhaes, Duarte↗
NASA NTRS2010

Tight Fits for Americas Next Moon Rocket, Ares V

America has begun the development of a new heavy lift rocket which will enable humans to return to the moon and reach even farther destinations. Five decades ago, the National Aeronautics and Space Administration designed a system (called Saturn/Apollo) to carry men to the moon and back; the rocket which boosted them to the moon was the Saturn V. Saturn V was huge relative to contemporary rockets and is still the largest rocket ever launched. The new moon rocket is called Ares V. It will insert 40% more payload into low earth orbit than Saturn V; and after docking with the crew spacecraft, it will insert 50% more payload onto the translunar trajectory than Saturn V. The current design of Ares V calls for two liquid-fueled stages and 2 "strap-on" solid rockets. The solid rockets are extended-length versions of the solid rockets used on the Shuttle. The diameter of the liquid stages is at least as large as the first stage of the Saturn V; the height of the lower liquid stage (called the core stage) is longer than the external tank of the Shuttle. Huge rockets require huge infrastructure and, during the Saturn/Apollo era, America invested significantly in manufacturing, assembly and launch facilities which are still in use today. Since the Saturn/Apollo era, America has invested in additional infrastructure for the Shuttle program. Ares V must utilize this existing infrastructure, with reasonable modifications. Building a rocket with 50% more capability in the same buildings, testing it in the same test stands, shipping on the same canals under the same bridges, assembling it in the same building, rolling it to the pad on the same crawler, and launching it from the same launch pad is an engineering and logistics challenge which goes hand-in-hand with designing the structure, tanks, turbines, engines, software, etc. necessary to carry such a large payload to earth orbit and to the moon. This paper quantitatively discusses the significant "tight fits" that are constraining Ares V. The engineers designing and building the infrastructure for the Saturn/Apollo program usually added margins and growth capability; sometimes the size of existing facilities (such as the width of a draw bridge) was not a constraint. Ares V may utilize the "extra" space in the existing facilities and expand other tight fits. Some of the tight fits cannot be overcome without great expense; raising the roof on the Vertical Assembly Building for example. Other tight fits are easily overcome; the transporter at the manufacturing facility for the core stage can pass under low ceilings and later over a dike (without dragging the middle) by retracting or extending the struts which support the stage. Tight fits discussed in this paper include manufacturing (jigs, widths, heights, and local transportation), testing (test stand sizes and crane capability), transportation to the test stands and the launch site (barge, waterway, and rail), assembly (VAB internal dimensions and door size), roll-out limits, and launch pad size.

Jaap, John↗
NASA NTRS2007

Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing

This viewgraph presentation reviews the development of a simulator for non-nuclear tests for the development of a space nuclear power system. The development of the Instrumented Thermal Simulator is to assist in developing an understanding of individual components and integrated system operation without the cost, time, safety concerns associated with nuclear testing. The presentation shows the design, the electrical integration, the hardware, and the assembly of the simulators. There are slides that show the test plan, the analysis, and the initial results.

Bragg-Sitton, Shannon↗
DOE OSTI2023

Recent advancements in high performance polymer electrolyte fuel cell electrode fabrication – Novel materials and manufacturing processes

The global effort to introduce polymer electrolyte fuel cells for clean and renewable energy to the market is increasing the demand for high performance, robust and affordable membrane electrode assemblies (MEAs). There is not yet a standard method for large scale production of MEAs, or the methods employed are generally unsatisfactory in terms of quality and performance. A large number of published data of newly developed catalyst and electrolyte materials, claim to improve the state of the art, but are often not fully comparable due to different experimental studies and experimental designs. This article summarizes the trends in material developments and emerging MEA-manufacturing techniques. The materials and techniques are systematically compared in terms of cell performance and scalability. Current and future scientific challenges are identified and analysed based on published findings over the past five years. Finally, the results of the cited papers have been quantitatively compared to each other and to the internal benchmarks used in each cited work to provide a complete picture of the state of the art in PEFC MEA manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2022

The CWS Experiments – An Experimental Study of the Effects of Chlorine on Thermal Neutron Absorption

The Chlorine Worth Study (CWS) experiments consist of layers of Zero Power Physics Reactor plates moderated by high density polyethylene, polyvinyl chloride, and chlorinated polyvinyl chloride with the goal to produce a thermal critical experiment. A thick high density polyethylene reflector surrounds the experiments. Aluminum fuel trays and frames were used to conduct the intrinsic heat generation of the plutonium plates away from the core and out to the top plate and the platen, both acting as heat sinks. The goal of the CWS experiments was to provide benchmark critical experiments that were sensitive to chlorine and matched the sensitivity of criticality safety applications for aqueous chloride operations at PF-4 at Los Alamos National Laboratory. The specific aqueous chloride PF-4 applications were solutions of 30 g/L plutonium, 300 g/L plutonium, and 600 g/L plutonium. The CWS experiments were designed using prototype methods developed by the ARCHIMEDES and EUCLID projects at Los Alamos National Laboratory. The CWS experiments were performed in December of 2021 at the National Criticality Experiments Research Center at the Nevada Nuclear Security Site on the Planet critical assembly. It is intended that the CWS experiments will be evaluated and submitted to the ICSBEP in the future as criticality safety benchmarks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

A strategy for automated core design to increase economic viability and minimize fuel fragmentation, relocation, and dispersal susceptibility in high-burnup cores

The nuclear industry aims to increase the cycle length of pressurized water reactors from 18 to 24 months to increase power plant capacity factors and economic viability. These cycle length extensions will inherently require fuel rods to exceed the current peak rod average burnup limit of 62 GWd/MTU. A chief concern of operating beyond the current burnup limit is the fuel fragmentation, relocation, and dispersal (FFRD) phenomenon in which pulverized fuel fragments can axially relocate and escape through a burst in the cladding formed during a loss-of-coolant accident. In this work, we demonstrate an approach for automating core design employing an optimization tool based on a penalty-free, parallel simulated annealing algorithm to produce pressurized water reactor core designs with two different optimization objectives. The two objectives were to produce core designs with (1) mitigated FFRD susceptibility while achieving 24-month cycle lengths (2) maximum cycle length with no regard for the likelihood of FFRD. Batch size was considered in tandem with both cases to maximize economic viability. The PARCS nodal model was the primary reactor physics tool used in the optimizations and used nuclear cross sections calculated with 2D Polaris lattice physics models. Reactor performance and safety characteristics of the optimized cores were verified using high-fidelity Virtual Environment for Reactor Applications models. The core designs produced by the optimization tool are compared with each other and to a high-burnup core design produced and analyzed in previous works to highlight the fuel management strategies that may enhance high-burnup reactor safety and economic viability. The optimized cores satisfied their respective objective functions, producing a maximum cycle length of 720 effective full-power days in one core design and one that may reduce FFRD susceptibility by up to 50% based on the first-order approximation to FFRD risk formulated in this work. The optimized cores met most constraints but exceeded the hot channel factor limit, especially in FFRD cases where fresh fuel carried more power. Furthermore, this highlights the need for future lattice-level optimizations and broader assembly options.

Cycle length↗
DOE OSTI2025

Understanding the Quadrupole Mass Filter and Testing a High-Resolution QMS RGA for ITER

A common type of residual gas analyzer is the quadrupole mass spectrometer. One of the main components within this instrument is a mass filter known as the quadrupole. It is responsible for the selective throughput of the ionized gas particles - by ascending mass number - prior to ion impacts on the analyzer (or detector) surface from which the ion current signal is generated for processing. However, the quadrupole is not fully described in relation to the electric field characteristics and the function as an ion mass separator. This paper describes the basic origins of the electrical design, the intricate assembly criteria, and performance of the quadrupole within the spectrometer. A specialized quadrupole mass spectrometer is part of a configuration for a diagnostic gas analyzer system planned for ITER, a fusion research machine. It has a verified capability, essential as a diagnostic criterion for this reactor project, to successfully deconvolute the mass signals of Helium-4 and deuterium (reactor fuel exhaust gases, separated by only 0.026 atomic mass units), down to a relative three-percent concentration of the former gas. The associated preliminary testing, performed at the Oak Ridge National Laboratory, is also addressed. Finally, one of the key parameters used to express gas concentration, the relative sensitivity factor, will be explained, including an evaluation of dependency on other variables.

Marcus, Chris [ORNL] (ORCID:0000000190139636)↗
NASA NTRS1989

Mars mission effects on Space Station evolution

The permanently manned Space Station scheduled to be operational in low earth by the mid 1990's, will provide accommodations for science, applications, technology, and commercial users, and will develop enabling capabilities for future missions. A major aspect of the baseline Space Station design is that provisions for evolution to greater capabilities are included in the systems and subsystems designs. User requirements are the basis for conceptual evolution modes or infrastructure to support the paths. Four such modes are discussed in support of a Human to Mars mission, along with some of the near term actions protecting the future of supporting Mars missions on the Space Station. The evolution modes include crew and payload transfer, storage, checkout, assembly, maintenance, repair, and fueling.

Askins, Barbara S.↗
NASA NTRSDate not supplied

Design of Space Systems to Enable In-space Assembly and Servicing

For several decades, NASA has employed in-space systems to enhance the performance and extend the useful life of operational orbital assets. In at least one case, an operational mission was not only enhanced, but enabled – the International Space Station was made possible by crewed and robotic in-space assembly, and continues to support installation and operation of new science and technology payloads. In several cases (Hubble Space Telescope, Intelsat 401, Westar and Palapa), major operational assets were rescued or repaired soon after launch when otherwise mission-ending anomalies occurred or were detected. In addition to the original rescue, Hubble was upgraded four times, enabling high-demand, world class science over four decades. More recently, two Northrop Grumman Mission Extension Vehicles have captured two Intelsat spacecraft near the end of their life and fuel capacity, to take over maneuvering duties. In spite of these recent operational achievements, and with the exception of large human exploration vehicles and large space telescopes, space architects rarely consider in-orbit servicing and assembly capabilities in their future planning. Technologies such as multi-launch mission architectures (and rendezvous and proximity operations systems), docking systems, external robotics, advanced tools, modular systems and structures, and fluid transfer systems are available today to support these missions. In-space manufacturing will soon be operational to enable resilient missions that recover from on-orbit failures, and expand the utilization of space. We envision a future that includes these capabilities, and discuss the cultural, engineering, and technological challenges to achieving this vision. We discuss the vision, the proverbial chicken and the egg (which came first, the serviceable spacecraft or the servicer?), the cost, risk, and perceptions thereof of in-space operations, a “spectrum” of cooperative servicing design considerations, and the current status of the space industry’s slow but steady march to widespread operational use of on-orbit servicing, assembly, and manufacturing.

Bo Naasz↗
NASA NTRS2015

Low Cost Upper Stage-Class Propulsion (LCUSP)

NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.

Vickers, John↗
DOE OSTI2021

SCALE 6.2.4 Validation for Light Water Reactor Decay Heat Analysis

Energy release from the decay of radionuclides in nuclear fuel after its discharge from reactor is a critical parameter for design, safety, and licensing analyses of used nuclear fuel storage, transportation, and repository systems. Well-validated computational tools and nuclear data are essential for decay heat prediction. This paper summarizes the validation of the SCALE nuclear analysis code system version 6.2.4, used with ENDF/B-VII.1 libraries, for decay heat analysis of light water reactor used fuel. The experimental data used for validation include full-assembly decay heat measurements that cover assembly burnups of 5 to 51 GWd/tonne U, cooling times after discharge in the 2- to 27-year range, and initial fuel enrichments up to 4 wt% 235U. The comparison between calculated (C) and experimental (E) decay heat showed very good agreement, with an average C/E over all considered measurements of 1.006 (σ = 0.016) for pressurized water reactor and 0.984 (σ = 0.077) for boiling water reactor assembly measurements. The effect of using assembly-average versus axially varying modeling data on the calculated decay heat, important to thermal analyses for used fuel transportation and storage systems, is discussed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗