Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “THERMOCOUPLES”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Extended Storage of High Burn-up Fuel Cask R and D Project - 17145

Under contract by EPRI and DOE, AREVA Federal Services LLC (AFS) is leading a team consisting of AREVA Inc. and Dominion Virginia Power (Dominion) to develop and conduct a full-scale confirmatory Research project with HBU fuel. A test plan was developed using an existing TN Americas (TN) TN-32 bolted storage cask with a modified, specially instrumented lid to be engineered and then loaded with multiple cladding types of HBU pressurized water reactor (PWR) UNF from Dominion's North Anna Power Station (this modified cask is identified as TN-32B). Seven specially designed thermocouple lances, each containing nine detectors, will be inserted into the designated fuel assembly guide tubes through the modified cask lid. The loaded cask with the monitoring system will be placed into dry storage on the existing North Anna Independent Spent Fuel Storage Installation (ISFSI) pad for a period of extended monitoring. In addition, design modifications to the lid have been incorporated to permit periodic gas sampling of the cask internals during the storage period on the ISFSI pad. The fuel selected for this research project ranges in average assembly burnup between 50 GWD/MTU to 67 GWD/MTU. The instrumentation used to collect the thermal data is very similar to in-core thermocouple detectors used at nuclear power plants and is considered very reliable for this application. Prior to cask loading at North Anna, a series of 'fit up' tests will be performed at the fabricator to ensure proper alignment, fit and function of the modified cask and related instrumentation and equipment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Extended Storage of High Burn-up Fuel Cask R and D Project - 16591

Under contract by EPRI and DOE, AREVA Federal Services LLC (AFS) is leading a team consisting of AREVA Inc. and Dominion Virginia Power (Dominion) to develop and conduct a full-scale confirmatory Research project with HBU fuel. A test plan was developed using an existing AREVA Transnuclear (TN) TN-32 bolted storage cask with a modified, specially instrumented lid to be engineered and then loaded with multiple cladding types of HBU pressurized water reactor (PWR) UNF from Dominion's North Anna Power Station (this modified cask is identified as TN-32B). Seven specially designed thermocouple lances, each containing nine detectors, will be inserted into the designated fuel assembly guide tubes through the modified cask lid. The loaded cask with the monitoring system will be placed into dry storage on the existing North Anna Independent Spent Fuel Storage Installation (ISFSI) pad for a period of extended monitoring. In addition, design modifications to the lid have been incorporated to permit periodic gas sampling of the cask internals during the storage period on the ISFSI pad. The fuel selected for this research project ranges in average assembly burnup between 50 GWD/MTU to 67 GWD/MTU. The instrumentation used to collect the thermal data is very similar to in-core thermocouple detectors used at nuclear power plants and is considered very reliable for this application. Prior to cask loading at North Anna, a series of 'fit up' tests will be performed at the fabricator to ensure proper alignment, fit and function of the modified cask and related instrumentation and equipment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Measurement of heat flow through cast slabs of calcium sulfate dihydrate

Slabs of cast calcium sulfate dihydrate have been used for decades as a heat transfer barrier in commercial and residential construction and are assessed in accordance with the parameters defined by ASTM C1396. The study described herein hypothesizes that minor impurities have significant effects on the high–temperature performance of these casts. Five thermocouples are cast into a 20–mm–thick slab at approximately 4–mm intervals are measured between ambient and approximately 1000°C in a furnace. Thermal diffusivity and inertia are estimated from this temperature profile. This study compares natural, flue gas desulfurized (FGD) and reagent grade hemihydrates that have been converted into the dihydrate form with distilled water; the common additives kaolin and borax are used to modify the cast. The thermocouple data allow an effective thermal diffusivity (α') and an effective thermal inertia (I') to be calculated. Furthermore, the hemihydrate source and kaolin content are found to affect the high–temperature performance; the FGD source increases the thermal inertia, and kaolin inhibits the formation of other borate compounds through intercalation.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Instrument for stable high temperature Seebeck coefficient and resistivity measurements under controlled oxygen partial pressure

The transport properties of ceramic materials strongly depend on oxygen activity, which is tuned by changing the partial oxygen pressure (pO 2 ) prior to and during measurement. Within, we describe an instrument for highly stable measurements of Seebeck coefficient and electrical resistivity at temperatures up to 1300 K with controlled oxygen partial pressure. An all platinum construction is used to avoid potential materials instabilities that can cause measurement drift. Two independent heaters are employed to establish a small temperature gradient for Seebeck measurements, while keeping the average temperature constant and avoiding errors associated with pO 2 -induced drifts in thermocouple readings. Oxygen equilibrium is monitored using both an O 2 sensor and the transient behavior of the resistance as a proxy. A pO 2 range of 10 -25 –10 0 atm can be established with appropriate gas mixtures. Seebeck measurements were calibrated against a high purity platinum wire, Pt/Pt–Rh thermocouple wire, and a Bi 2 Te3 Seebeck coefficient Standard Reference Material. To demonstrate the utility of this instrument for oxide materials we present measurements as a function of pO 2 on a 1 % Nb-doped SrTiO 3 single crystal, and show systematic changes in properties consistent with oxygen vacancy defect chemistry. Thus, an approximately 11% increase in power factor over a pO 2 range of 10 -19 –10 -8 atm at 973 K for the donor-doped single crystals is observed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Failure Analysis of Gas Spray Atomization Crucible Materials

An attempted induction melt for gas spray atomization of a Pd alloy at Savannah River National Laboratory experienced a series of faulty thermocouple readings leading to failure of multiple alumina ceramic components and the loss of the metal charge. The spherical powders are used in research and development efforts for hydrogen storage applications. The failure of the thermocouples led to high operating temperatures exceeding the expected operating temperatures. Estimated temperatures of the liquid metal were established by the comparison of the radio frequency power output and multiple temperature readings and determined to have exceeded the functional temperature range of the alumina components. Failure analyses of the event included characterization of the components using visual observation and X-Ray computed tomography of the frozen ingot.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Accurate and inexpensive thermal time-of-flight sensor for measuring refrigerant flow in minichannels

Thermal flow meters are good candidates for measuring flow rates in small diameter channels because they can be integrated into compact geometries and consist of only a few simple components. A new thermal time-of-flight (TOF) flow sensor is developed in this report for measuring liquid refrigerant velocities in minichannels. The sensor consists of a small heater and two downstream thermocouples. The heater is pulsed to induce a temperature rise in the fluid, and the time for the temperature pulse to reach the downstream thermocouples is measured. Insights from the data and a simplified one-dimensional transient model are used to calibrate the device. The calibration relates the time of flight to both the average refrigerant velocity and local temperature gradients in the fluid. The calibrated TOF device can detect refrigerant velocities between 1 and 20, mm s -1 , measuring 98.7% of the data to within ±3% of the full scale (±0.6 mm s -1 ).

42 ENGINEERING↗
DOE OSTI2025

Investigation of residual stress distribution in wire-arc directed energy deposited refractory molybdenum alloy utilizing numerical thermo-mechanical analysis and neutron diffraction method

Directed energy deposition (DED), a metal additive manufacturing (AM) technique, offers higher deposition rates and energy efficiency, making it suitable for fabricating components from refractory molybdenum alloys, such as molybdenum-titanium-zirconium (TZM). However, large thermal gradients and non-equilibrium thermal cycles in DED could generate high residual stress in the component, potentially deteriorating quality and performance. Thus, this study aims to investigate residual stress generation and its distribution in wire-arc DED of TZM thin-wall, utilizing thermo-mechanical analysis and high-fidelity neutron diffraction (ND) method. Two interpass temperatures (50°C and 200°C) have been considered to investigate their impact on residual stress formation. During experiments, in-situ thermal data has been recorded using thermocouples, which have been utilized for calibrating the thermal model. Thermocouple data shows a good agreement with the simulation results, having a difference of less than 10 %. Post-deposition part deformation has been observed, which is measured using a coordinate measuring machine, showing maximum values of 0.93 mm and 0.78 mm for interpass temperatures of 50°C and 200°C, respectively. Numerical predictions of distortion deviated by less than 15% from the experimental results. ND measurement and simulation results indicate that residual stress magnitude and evolution vary across the TZM deposits, revealing microstructural anisotropy in both conditions. Notably, lower interpass temperatures resulted in higher residual stresses, confirmed by experimental and simulation data. Further, this study demonstrated that an integrated experimental and thermo-mechanical analysis can potentially reveal the temperature history, part deformation, and residual stress formation in wire-arc DED TZM alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Analysis of iron-chromium-aluminum samples exposed to accident conditions followed by quench in the QUENCH-19 experiment

The QUENCH-19 experiment was a first-of-its-kind full-bundle test simulating accident conditions followed by water quench on accident-tolerant fuel (ATF) cladding. Here, a type of FeCrAl(Y) alloy, B136Y3, was developed at Oak Ridge National Laboratory and tested at the Karlsruhe Institute of Technology using Kanthal APM corner rods, a shroud, and Kanthal AF spacer grids. Testing conditions were similar to those in QUENCH-15—which tested ZIRLO cladding behavior—so that B136Y3 and ZIRLO cladding could be compared. QUENCH-19 consisted of an initial pre-oxidation heating followed by a transient. Then, a maximum power hold, which was not present in QUENCH-15, was executed to extend the heating period for the FeCrAl(Y) rods. Finally, a rapid water quench was executed that was similar to emergency core coolant system (ECCS) actuation. Compared with the ZIRLO rods in QUENCH-15, the bundle in QUENCH-19 released significantly less H 2 (9.2 g vs. 47.6 g) and achieved a much lower maximum temperature (1455°C vs. 1880°C). Furthermore, no breakaway oxidation was observed in QUENCH-19. Metallographic mounts revealed that despite the symmetry of the setup, at elevations near the maximum temperature, cladding and thermocouples were heavily damaged, substantial melting and oxidation occurred, and the cladding underwent chemical interaction with the thermocouple sheaths. Additionally, the ZrO 2 spacers detrimentally interacted with the cladding, leading to mixed oxide debris and the full destruction of some rods. Additional failure was found in certain cooler rods that may have risen due to the high thermal expansion coefficient of FeCrAl alloys. This paper presents an analysis of this work, which suggests that FeCrAl cladding can chemically survive anticipated loss-of-coolant accident events followed by rapid ECCS quench if the correct geometry and core design are present.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Improving Thermal Model Prediction Through Statistical Analysis of Irradiation and Post-Irradiation Data from AGR Experiments

As part of the High Temperature Reactors (HTR) R&D program, a series of irradiation tests, designated as Advanced Gas-cooled Reactor (AGR), have been defined to support development and qualification of fuel design, fabrication process, and fuel performance under normal operation and accident conditions. The AGR tests employ fuel compacts placed in a graphite cylinder shrouded by a steel capsule and instrumented with thermocouples (TC) embedded in graphite blocks enabling temperature control. While not possible to obtain by direct measurements in the tests, crucial fuel conditions (e.g., temperature, neutron fast fluence, and burnup) are calculated using core physics and thermal modeling codes. This paper is focused on AGR test fuel temperature predicted by the ABAQUS code's finite element-based thermal models. The work follows up on a previous study, in which several statistical analysis methods were adapted, implemented in the NGNP Data Management and Analysis System (NDMAS), and applied for qualification of AGR-1 thermocouple data. Abnormal trends in measured data revealed by the statistical analysis are traced to either measuring instrument deterioration or physical mechanisms in capsules that may have shifted the system thermal response. The main thrust of this work is to exploit the variety of data obtained in irradiation and post-irradiation examination (PIE) for assessment of modeling assumptions. As an example, the uneven reduction of the control gas gap in Capsule 5 found in the capsule metrology measurements in PIE helps identify mechanisms other than TC drift causing the decrease in TC readings. This suggests a more physics-based modification of the thermal model that leads to a better fit with experimental data, thus reducing model uncertainty and increasing confidence in the calculated fuel temperatures of the AGR-1 test.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Effects of break geometry and orientation on helium-air mixing in simulated reactor cavities of high temperature gas reactors

Here, this study experimentally examined the spatial and temporal variations in air and helium concentrations and temperature fields within simulated reactor cavities of a High Temperature Gas Reactor (HTGR) following helium discharge into an initially air-filled reactor cavity system. Detailed temperature maps were generated using a combination of fiber optics temperature sensor and multiple thermocouple probes within the simulated reactor cavities. The research scenario involved a hypothetical small pipe break in the Reactor Pressure Vessel, resulting in the release of high-temperature helium into the surrounding cavity. A scaled multi-compartment experimental facility, modeled after the General Atomics Modular High Temperature Gas Reactor (GA-MHTGR) design, was constructed for helium and air mixing experiments. Oxygen sensors and thermocouple probes were installed in all five cavities to measure the concentrations of oxygen (or helium) and the temperature distributions of the gas mixture. The experimental findings highlighted the significant impact of the injected helium jet velocity on the gas mixing process and demonstrated how the direction of the helium jet influences the air-helium temperature profiles within the cavities.

Air-ingress↗
DOE OSTI2020

Direct-Write Printing Copper–Nickel (Cu/Ni) Alloy with Controlled Composition from a Single Electrolyte Using Co-Electrodeposition

Although various processes for metal printing at the micro- and mesoscale have been demonstrated, printing functional devices such as thermocouples, thermopiles, and heat flux sensors that function based on interfaces between an alloy and another alloy/metal demands processes for printing alloys. Furthermore, a high-quality and crystalline alloy is required for acceptable function of these devices. This article reports for the first time co-electrodeposition-based printing of single-phase solid solution nanocrystalline copper/nickel (Cu/Ni) alloy with various controllable compositions (Cu100Ni0 to Cu19Ni81) from a single electrolyte. Additionally, the printed alloy is nanocrystalline (<35 nm), continuous, and dense with no apparent porosity, with remarkable mechanical and magnetic properties, without any postprocessing annealing such as heat treatment. In addition, a functional thermocouple fabricated using this process is demonstrated. Such a process can not only be used for fabrication of functional devices, it may also facilitate fundamental studies on alloys by printing a continuous library of alloy composition for material characterization.

36 MATERIALS SCIENCE↗
DOE OSTI2025

In Situ Atmospheric Plume Thermometry via Carbon Monoxide Spectral Profile: Laboratory and Field Validation

For small molecules with large rotational constants, knowing the relative intensities of the ro-vibrational transitions can be used to determine the temperature within a gas plume. We demonstrate the use of carbon monoxide (CO) as an in situ spectroscopic probe of gas plume temperature by application of both laboratory and standoff Fourier transform infrared spectroscopy to monitor the CO spectral response at different temperatures. Here, the measured CO rotational contours were analyzed using a simple Boltzmann model to deduce the population distribution of the J-levels, from which the in-plume temperature is deduced. The method was vetted by comparing deduced temperatures in both static laboratory measurements of known temperatures, as well as field measurements using a simulated smokestack release. For the smokestack experiments, spectroscopically deduced temperatures were compared to readings from a series of thermocouples placed at strategically sampled distances along the plume trajectory. Both the spectroscopically-derived and thermocouple-measured temperatures revealed an expansion-induced (mixing) rapid cooling of the plume, with the infrared thermometry values displaying greater temperature values which are believed to better represent the actual plume temperatures.

Analysis of rotational structure↗
DOE OSTI2021

A tungsten external heater for BX90 diamond anvil cells with a range up to 1700 K

Resistive heating of a sample in a diamond anvil cell (DAC) can generate a homogeneous temperature field across the sample chamber with reliable temperatures measured by a thermocouple. It is of importance in experiments aiming at exploring phase diagrams and quantifying thermoelastic properties of materials. Here, we present a ring-heater design developed for BX90 diamond anvil cells (DACs). Furthermore, it is made of a ring-shaped aluminum oxide holder hosting a tungsten wire coil inside and coupled with Ar + 2% H 2 gas to prevent oxidation during experiment. This modular plug-and-play design enables in situ studies of samples via x-ray diffraction up to a temperature of 1700 K. Temperature in the BX90 sample volume as measured through a thermocouple was calibrated using the melting point of gold. As an application of this design, we report the thermal expansion coefficient of MgO at 9.5(1) GPa.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Thermal conductivity of energetic materials

Here, thermal conductivity has been confirmed for a variety of energetic materials (EMs) using finite element analysis (FEA) and cookoff data from the Sandia Instrumented Thermal Ignition (SITI) experiment. Materials studied include melt-cast, pressed, and low-density explosives. The low-density explosives were either prills or powders with some experiments run at pour density (not pressed). We have viewed several of our thermal conductivities with those in the literature as well as investigated contact resistance between the confining aluminum and explosive, multidimensional heat transfer effects, and uncertainty in the thermocouple bead positions. We have determined that contact resistance is minimal in the SITI experiment, the heat transfer along the midplane is one-dimensional, and that uncertainty in the thermocouple location is greatest near the heated boundary. Our values of thermal conductivity can be used with kinetic mechanisms to accurately predict thermal profiles and energy dissipation during the cookoff of explosives.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Alpert multi-wavelets for functional inverse problems: direct optimization and deep learning

Computational engineering models often contain unknown entities (e.g. parameters, initial and boundary conditions) that require estimation from other measured observable data. Estimating such unknown entities is challenging when they involve spatio-temporal fields because such functional variables often require an infinite-dimensional representation. Here, we address this problem by transforming an unknown functional field using Alpert wavelet bases and truncating the resulting spectrum. Hence the problem reduces to the estimation of few coefficients that can be performed using common optimization methods. We apply this method on a one-dimensional heat transfer problem where we estimate the heat source field varying in both time and space. The observable data is comprised of temperature measured at several thermocouples in the domain. This latter is composed of either copper or stainless steel. The optimization using our method based on wavelets is able to estimate the heat source with an error between 5% and 7%. We analyze the effect of the domain material and number of thermocouples as well as the sensitivity to the initial guess of the heat source. Finally, we estimate the unknown heat source using a different approach based on deep learning techniques where we consider the input and output of a multi-layer perceptron in wavelet form. We find that this deep learning approach is more accurate than the optimization approach with errors below 4%.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Advancing Temperature Monitoring of the Bottom Anode in a Direct Current Electric Arc Furnace Operations with Distributed Optical Fiber Sensors.

The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.

42 ENGINEERING↗
DOE OSTI2019

Convolutional Neural Networks for Heat Flux Model Validation on NSTX-U

To demonstrate the use of embedded thermocouples in new National Spherical Tokamak eXperiment Upgrade (NSTX-U) graphite plasma-facing components (PFCs), a convolutional neural network (CNN) has been trained using the ANSYS simulations to predict the scrape-off layer (SOL) heat flux width, λ q , given various machine operational parameters and diagnostic data as inputs. Here, the proof-of-concept CNN was trained on the thermocouple data generated by the approximated NSTX-U heat loads applied to real PFC designs in ANSYS. Once trained, the CNN is capable of high precision reconstruction of parameterized heat flux profiles expected in NSTX-U. In addition, to test the system's ability to cope with noise and systematic error, pseudonoise was injected into the simulated data. CNN can accurately predict the incident heat flux despite this noise and error.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗