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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Initial Core Physics and Safety Analyses Supporting the Versatile Test Reactor

The Versatile Test Reactor (VTR) is a proposed integrated facility for investigations into the behavior of fuels and materials subjected to high, fast neutron fluxes prototypical of fast reactor environments. Detailed design of the reactor is currently being performed by a group of U.S. National Laboratories, including Argonne National Laboratory. The current design of the reactor is a 300 MW sodium-cooled pool-type fast reactor fueled with ternary U-20Pu-10Zr metallic fuel. This report documents reactor core physics and preliminary safety analyses that have been performed. The reference VTR core has 313 assembly positions, 66 of which contain fuel assemblies. The remaining assembly positions are loaded with reflector, shield, control rod duct, and test assemblies. Ten positions are available in the reference design for experimental or test assemblies, however the VTR will support test assemblies in any position in the core for alternate core loadings. The performance of the reference VTR core has been assessed for an assumed equilibrium cycle. The core power distribution and reactivity feedback coefficients have been calculated. Preliminary assessments of the reactivity coefficients have shown that each of them results in a negative reactivity change for increasing temperatures. Safety analysis of a VTR layout has been performed using the SAS4A/SASSYS-1 fast reactor safety analysis code. A model has been developed to represent the current core design and a reference heat transport system design. The model has been used to simulate and perform analysis of protected and unprotected loss of heat sink, station blackout, and transient overpower accident scenarios. These scenarios represent the three main ways to perturb the reactor core, through changes to the core inlet temperature, mass flow rate, or reactivity insertions and are credible bounding scenarios for the evaluated transient categories. The results of these simulations have been assessed against simplified criteria for Anticipated Operational Occurrences for the protected transients and for Beyond Design Basis Events for the unprotected transients. Because the primary heat transport system is able to transition quickly and effectively to natural circulation and because the shutdown heat removal system provides sufficient heat rejection capability, large margins for all criteria were predicted for all protected transients. Large margins were also predicted for the unprotected loss of heat sink and station blackout transients due to the strong negative reactivity feedbacks generated by the core. Because of the high power density in the reactor, smaller fuel melting margins are predicted for the unprotected transient overpower accident.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Comparison of Nuclear Thermal Propulsion Reactor Cores Using Different Fuel Forms, Neutron Spectra, and Uranium Enrichments

A comparison of 300 MWt HEU and HALEU NTP cores using different fuel forms is presented to demonstrate trends and potentially inform fuel development. Compared to HEU, HALEU cores require additional in-core moderation. Beryllium was chosen as the reference in-core moderator material; metal hydrides may also be considered. Typical NTP fuel forms such as carbide and carbonitride solid solutions, carbide-graphite composites, CERMETs and CERCERs were considered together with less typical fuel forms such as UC and U metal. Be-moderated HALEU cores are heavier than HEU cores (1.9-2.7 and 0.9-2.0 metric tons, respectively). Furthermore, HALEU loading is very sensitive to the amount of in-core moderation which translates into tight fabrication tolerances. HALEU cores requires more reactivity control mechanisms than HEU cores to compensate for temperature feed-back. Using enrichments only slightly above HALEU (e.g., 25%) may provide a compromise between the administrative preference for using HALEU and the engineering preference for simplifying the reactor systems by, for example, not using in-core moderators.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Core Physics Characteristics of Extended Enrichment and High Burnup Boiling Water Reactor Fuel

This paper presents the highlights of boiling water reactor (BWR) core physics studies performed at Oak Ridge National Laboratory as part of a series of studies conducted to compare low-enriched uranium (LEU) with LEU+ fuel. The studies analyzed isotopic fuel content, lattice parameters (Phase 1), and core physics (Phase 2) to identify challenges in operation, storage, and transportation for BWRs and pressurized water reactors (PWRs). Because of a lack of publicly available lattice and core designs for modern BWR fuel assemblies and reactor cores, several optimized lattice designs were generated, and different core loading strategies were investigated. Twelve optimized lattice designs with 235 U enrichments ranging from 1.6% to 9% and gadolinia loadings ranging from 3 to 8 wt% were used to model axial enrichment and geometry variations in fuel assemblies for core designs. Each core shares a common set of approximations in design and analysis to allow for consistent comparisons between LEU and LEU+ fuel. The objective is to highlight anticipated changes in core behavior with respect to the reference LEU core. The results of this study show that the differences in LEU and LEU+ core reactor physics characteristics are less significant than the differences in lattice physics characteristics reported in the Phase 1 studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1971

Qualitative responses of a vortex core to tip blowing and intersecting airfoils

The qualitative responses of a trailing vortex core to change in its convective velocity produced by injection of air into the vortex core and by the flow field of a lifting surface in the path of the core are discussed. Flow pictures of the vortex core and vorticity measurements in the core show that an axial momentum injection of approximately 35% of the total wing drag alters the vortex structure and behavior quite drastically by effectively inducing a more rapid dispersion of the vorticity in the core. The data indicate that the phenomenon is governed by the rate of injection of the momentum rather than the mass flow rate. There also seems to be an optimum rate of injection beyond which increased injection does not bring about equally significant changes in the vortex core. Flow patterns of the region of interaction between the flow field of a lifting surface and the vortex core show two modes of vortex response; (1) the vortex core bends, following the streamline shape until it intercepts the wake of the wing where it is abruptly dispersed, or (2) the vortex core may be sliced into two similar vortices when the vortex hits the leading edge of the wing.

Kantha, H. L.↗
NASA NTRS1991

Heat transfer and core neutronics considerations of the heat pipe cooled thermionic reactor

The authors summarize the results of detailed neutronic and thermal-hydraulic evaluations of the heat pipe cooled thermionic (HPTI) reactor design, identify its key design attributes, and quantify its performance characteristics. The HPTI core uses modular, liquid-metal core heat transfer assemblies to replace the liquid-metal heat transport loop employed by in-core thermionic reactor designs of the past. The nuclear fuel, power conversion, heat transport, and heat rejection functions are all combined into a single modular unit. The reactor/converter assembly uses UN fuel pins to obtain a critical core configuration with in-core safety rods and reflector controls added to complete the subassembly. By thermally bonding the core heat transfer assemblies during the reactor core is coupled neutronically, thermally, and electrically into a modular assembly of individual power sources with cross-tied architecture. A forward-facing heat pipe radiator assembly extends from the reactor head in the shape of a frustum of a cone on the opposite side of the power system from the payload. Important virtues of the concept are the absence of any single-point failures and the ability of the core to effectively transfer the TFE waste heat load laterally to other in-core heat transfer assemblies in the event of multiple failures in either in-core and radiator heat pipes.

Determan, W. R.↗
NASA NTRS1992

Research core drilling in the Manson impact structure, Iowa

The Manson impact structure (MIS) has a diameter of 35 km and is the largest confirmed impact structure in the United States. The MIS has yielded a Ar-40/Ar-39 age of 65.7 Ma on microcline from its central peak, an age that is indistinguishable from the age of the Cretaceous-Tertiary boundary. In the summer of 1991 the Iowa Geological Survey Bureau and U.S. Geological Survey initiated a research core drilling project on the MIS. The first core was beneath 55 m of glacial drift. The core penetrated a 6-m layered sequence of shale and siltstone and 42 m of Cretaceous shale-dominated sedimentary clast breccia. Below this breccia, the core encountered two crystalline rock clast breccia units. The upper unit is 53 m thick, with a glassy matrix displaying various degrees of devitrification. The upper half of this unit is dominated by the glassy matrix, with shock-deformed mineral grains (especially quartz) the most common clast. The glassy-matrix unit grades downward into the basal unit in the core, a crystalline rock breccia with a sandy matrix, the matrix dominated by igneous and metamorphic rock fragments or disaggregated grains from those rocks. The unit is about 45 m thick, and grains display abundant shock deformation features. Preliminary interpretations suggest that the crystalline rock breccias are the transient crater floor, lifted up with the central peak. The sedimentary clast breccia probably represents a postimpact debris flow from the crater rim, and the uppermost layered unit probably represents a large block associated with the flow. The second core (M-2) was drilled near the center of the crater moat in an area where an early crater model suggested the presence of postimpact lake sediments. The core encountered 39 m of sedimentary clast breccia, similar to that in the M-1 core. Beneath the breccia, 120 m of poorly consolidated, mildly deformed, and sheared siltstone, shale, and sandstone was encountered. The basal unit in the core was another sequence of sedimentary clast breccia. The two sedimentary clast units, like the lithologically similar unit in the M-1 core, probably formed as debris flows from the crater rim. The middle, nonbrecciated interval is probably a large, intact block of Upper Cretaceous strata transported from the crater rim with the debris flow. Alternatively, the sequence may represent the elusive postimpact lake sequence.

Anderson, R. R.↗
NASA NTRS1993

Composition and maturity of the 60013/14 core

The 60013/14 double drive tube (62 cm deep) is one of three regolith cores taken 35-40 m apart in a triangular array on the Cayley plains at station 10' (LM/ALSEP), Apollo 16. This trio, which includes double drive tube 60009/10 (59 cm deep) and deep drill core 60001-7 (220 cm), is the only such array of cores returned from the Moon. The top 45 cm of 60013/14 is mature, as is surface reference soil 60601 taken nearby. Maturity generally decreases with depth, with soil below 45 cm being submature. The zone of lowest maturity (34 is less than or equal to I(sub s)/FeO is less than 50) extends from 46 to 58 cm depth, and corresponds to the distinct region of light-colored soil observed during core processing. In the other two cores, most of the compositional variation results from mixing between fine-grained, mature soil with 10-11 micro-g/g Sc and coarse-grained ferroan anorthosite consisting of greater than 99% plagioclase with less than 0.5 micro-g/g Sc. This is most evident in 60009/10 which contains a high abundance of plagioclase at about 54 cm depth (minimum Sc: 3-4 micro-g/g); a similar zone occurs in 60001-7 at 17-22 cm (MPU-C), although it is not as rich in plagioclase (minimum Sc: 6-7 micro-g/g). Compositional variations are less in 60013/14 than in the other two cores (range: 7.9-10.0 micro-g/g Sc), but are generally consistent with the 'plagioclase dilution' effect seen in 60009/10, i.e., most 60013/14 samples plot along the mixing line of 60009/10. However, a plagioclase component is not the cause of the lower maturity and lighter color of the unit at 46-58 cm depth in 60013/14. Many of the samples in this zone have distinctly lower Sm/Sc ratios than typical LM-area soils and plot off the mixing trend defined by 60009/10. This requires a component with moderately high Sc, but low-Sm/Sc, such as feldspathic fragmental breccia (FFB) or granulitic breccia. A component of Descartes regolith, such as occurs at North Ray Crater (NRC) and which is rich in FFB, could account for the composition of these soils (i.e., a 3:1 mixture of 60601 and NRC soil). It seems unlikely that NRC ejecta would occur half a meter deep at the LM station, thus this low-Sm/Sc component may result from an older, local crater that penetrated the Cayley surface layer and excavated underlying Descartes material, as did North Ray Crater. There is no evidence for such a unit or component in the other two cores. Soil below the light-colored unit (58-62) cm has 'typical' Sm/Sc ratios, but the lowest absolute Sc concentrations, i.e., it is compositionally equivalent to a mixture of surface soil and plagioclase such as that in ferroan anorthosite. This is the only soil that might be related to the plagioclase-rich units in the other two cores. Except for the mature soil at the top of each core and, perhaps, the plagioclase-rich layers, there is little compositional evidence for any common unit among the three cores. Soil corresponding to the mare-glass-bearing unit (MPU-B) and regolith-breccia-bearing unit (MPU-A) of 60001-7 do not occur in 60013/14 or 60009/10.

Korotev, Randy L.↗
NASA NTRS1998

Element Partitioning Constraints on Formation and Composition of the Earth's Core

Element partitioning study provides a number of constraints on the formation and composition of the core. First, partitioning of siderophile elements between the core and mantle should explain the "excess" siderophile elements in the mantle. Second, partitioning of light element(s) between the core and mantle should supply the core with the right amount of light element(s) to account for the density deficit in the core. Third, partitioning of light element(s) between the inner and outer core should be consistent with the observed difference in density deficits (relative to pure Fe) between these two reservoirs. In this study, high-pressure and high-temperature experiments have been conducted to investigate the pressure, temperature, and composition effects on partitioning of siderophile elements Ni and Co between core-forming Fe alloy and mantle silicate melt and minerals, partitioning of light elements S, O, and Si between core-forming Fe alloy and mantle silicate melt and minerals, and partitioning of light elements S and C between solid and liquid Fe. The implications of these results for mechanism of core formation and the composition of the core are discussed.

Li, J.↗
NASA NTRS1996

Evolutionary status of the pre-protostellar core L1498

L1498 is a classic example of a dense cold pre-protostellar core. To study the evolutionary status, the structure, dynamics, and chemical properties of this core we have obtained high spatial and high spectral resolution observations of molecules tracing densities of 10(3)-10(5) cm-3. We observed CCS, NH3, C3H2, and HC7N with NASA's DSN 70 m antennas. We also present large-scale maps of C18O and 13CO observed with the AT&T 7 m antenna. For the high spatial resolution maps of selected regions within the core we used the VLA for CCS at 22 GHz, and the Owens Valley Radio Observatory (OVRO) MMA for CCS at 94 GHz and CS (2-1). The 22 GHz CCS emission marks a high-density [n(H2) > 10(4) cm -3] core, which is elongated with a major axis along the SE-NW direction. NH3 and C3H2 emissions are located inside the boundary of the CCS emission. C18O emission traces a lower density gas extending beyond the CCS boundary. Along the major axis of the dense core, CCS, NH3 and C3H2 emission show evidence of limb brightening. The observations are consistent with a chemically differentiated onion-shell structure for the L1498 core, with NH3 in the inner and CCS in the outer parts of the core. The high angular resolution (9"-12") spectral line maps obtained by combining NASA Goldstone 70 m and VLA data resolve the CCS 22 GHz emission in the southeast and northwest boundaries into arclike enhancements, supporting the picture that CCS emission originates in a shell outside the NH3 emitting region. Interferometric maps of CCS at 94 GHz and CS at 98 GHz show that their emitting regions contain several small-scale dense condensations. We suggest that the differences between the CCS, CS, C3H2, and NH3 emission are caused by a time-dependent effect as the core evolves slowly. We interpret the chemical and physical properties of L1498 in terms of a quasi-static (or slowly contracting) dense core in which the outer envelope is still growing. The growth rate of the core is determined by the density increase in the CCS shell resulting from the accretion of the outer low-density gas traced by C18O. We conclude that L1498 could become unstable to rapid collapse to form a protostar in less than 5 x 10(6) yr.

NASA Discipline Exobiology↗
NASA NTRS2010

Core-Noise

This presentation is a technical progress report and near-term outlook for NASA-internal and NASA-sponsored external work on core (combustor and turbine) noise funded by the Fundamental Aeronautics Program Subsonic Fixed Wing (SFW) Project. Sections of the presentation cover: the SFW system level noise metrics for the 2015, 2020, and 2025 timeframes; the emerging importance of core noise and its relevance to the SFW Reduced-Noise-Aircraft Technical Challenge; the current research activities in the core-noise area, with some additional details given about the development of a high-fidelity combustion-noise prediction capability; the need for a core-noise diagnostic capability to generate benchmark data for validation of both high-fidelity work and improved models, as well as testing of future noise-reduction technologies; relevant existing core-noise tests using real engines and auxiliary power units; and examples of possible scenarios for a future diagnostic facility. The NASA Fundamental Aeronautics Program has the principal objective of overcoming today's national challenges in air transportation. The SFW Reduced-Noise-Aircraft Technical Challenge aims to enable concepts and technologies to dramatically reduce the perceived aircraft noise outside of airport boundaries. This reduction of aircraft noise is critical for enabling the anticipated large increase in future air traffic. Noise generated in the jet engine core, by sources such as the compressor, combustor, and turbine, can be a significant contribution to the overall noise signature at low-power conditions, typical of approach flight. At high engine power during takeoff, jet and fan noise have traditionally dominated over core noise. However, current design trends and expected technological advances in engine-cycle design as well as noise-reduction methods are likely to reduce non-core noise even at engine-power points higher than approach. In addition, future low-emission combustor designs could increase the combustion-noise component. The trend towards high-power-density cores also means that the noise generated in the low-pressure turbine will likely increase. Consequently, the combined result from these emerging changes will be to elevate the overall importance of turbomachinery core noise, which will need to be addressed in order to meet future noise goals.

Hultgren, Lennart S.↗
NASA NTRS2005

Improvements in Fabrication of Sand/Binder Cores for Casting

Three improvements have been devised for the cold-box process, which is a special molding process used to make sand/binder cores for casting hollow metal parts. These improvements are: The use of fiber-reinforced composite binder materials (in contradistinction to the non-fiber-reinforced binders used heretofore), The substitution of a directed-vortex core-blowing subprocess for a prior core-blowing process that involved a movable gassing plate, and The use of filters made from filtration-grade fabrics to prevent clogging of vents. For reasons that exceed the scope of this article, most foundries have adopted the cold-box process for making cores for casting metals. However, this process is not widely known outside the metal-casting industry; therefore, a description of pertinent aspects of the cold-box process is prerequisite to a meaningful description of the aforementioned improvements. In the cold-box process as practiced heretofore, sand is first mixed with a phenolic resin (considered to be part 1 of a three-part binder) and an isocyanate resin (part 2 of the binder). Then by use of compressed air, the mixture is blown into a core box, which is a mold for forming the core. Next, an amine gas (part 3 of the binder) that acts as a catalyst for polymerization of parts 1 and 2 is blown through the core box. Alternatively, a liquid amine that vaporizes during polymerization can be incorporated into the sand/resin mixture. Once polymerization is complete, the amine gas is purged from the core box by use of compressed air. The finished core is then removed from the core box.

Bakhitiyarov, Sayavur I.↗
NASA NTRS2016

Carbon Solubility in Silicon-Iron-Bearing Metals during Core Formation on Mercury

Recent results obtained from the MErcury Surface, Space ENvironment, GEochemistry, and Ranging (MESSENGER) spacecraft showed the surface of Mercury has high S abundances (approximately 4 wt%) and low Iron(II) Oxide abundances (less than 2 wt%). Based on these extreme values, the oxygen fugacity of Mercury's surface materials was estimated to be approximately 3 to 7 log(sub 10) units below the IW buffer (Delta IW-3 to Delta IW-7). This highly reducing nature of the planet has resulted in a large core and relatively thin mantle, extending to only approximately 420 km depth (corresponding to a core-mantle boundary pressure of approximately 4-7 GPa) within the planet. Furthermore, MESSENGER results have suggested the presence of carbon on the surface of the planet. Previous experimental results from have also suggested the possibility of a primary floatation crust on Mercury composed of graphite, produced after a global magma ocean event. With these exotic conditions of this compositional end-member planet, it begs the question, what is the core composition of Mercury? Although no definitive conclusion has been reached, previous studies have made advances towards answering this question. Riner et al. and Chen et al. looked at iron sulfide systems and implemented various crystallization and layered core scenarios to try and determine the composition and structure of Mercury's core. Malavergne et al. examined core crystallization scenarios in the presence of sulfur and silicon. Hauck et al. used the most recent geophysical constraints from the MESSENGER spacecraft to model the internal structure of Mercury, including the core, in a iron-sulfur-silicon system. More recently, Chabot et al. conducted a series of metal-silicate partitioning experiments in a iron-sulfur-silicon system. These results showed the core of Mercury has the potential to contain more than 15 wt% silicon. However, with the newest results from MESSENGER's low altitude campaign, carbon is another potential light element that could be incorporated into Mercury's core. The goal of this study is to determine the carbon concentration at graphite saturation in various silicon-iron bearing metals relevant to possible mercurian core compositions. Future experiments will include the addition of sulfur into these metals.

Vander Kaaden, Kathleen E.↗
NASA NTRS2019

Computational Performance of Progressive Damage Analysis of Composite Laminates using Abaqus/Explicit with 16 to 512 CPU Cores

The computational scaling performance of progressive damage analysis using Abaqus/ Explicit is evaluated and quantified using from 16 to 512 CPU cores. Several analyses were conducted on varying numbers of cores to determine the scalability of the code on five NASA high performance computing systems. Two finite element models representative of typical models used for progressive damage analysis of composite laminates were used. The results indicate a 10 to 15 times speed up scaling from 24 to 512 cores. The run times were modestly reduced with newer generations of CPU hardware. If the number of degrees of freedom is held constant with respect to the number of cores, the model size can be increased by a factor of 20, scaling from 16 to 512 cores, with the same run time. An empirical expression was derived relating run time, the number of cores, and the number of degrees of freedom. Analysis cost was examined in terms of software tokens and hardware utilization. Using additional cores reduces token usage since the computational performance increases more rapidly than the token requirement with increasing number of cores. The in- crease in hardware cost with increasing cores was found to be modest. Overall the results show relatively good scalability of the Abaqus/Explicit code on up to 512 cores.

Bergan, A. C.↗
NASA NTRSDate not supplied

Clearance Sensitivity Mitigation in Small Core Compressors

As future aircraft become lighter and more aerodynamically efficient, thrust requirements will decrease, reducing the core size of the engine. Furthermore, in the pursuit of improved fuel burn, engine overall pressure ratio and bypass ratio will increase, further driving down engine core size. These drivers together mean that the core size, or corrected mass flow rate at the compressor exit, for future single-aisle aircraft applications will shrink below 3.0 lbm/s. Traditionally, this small core compressor size is in the domain of axi-centrifugal designs, machines that are typically less efficient and limited to pressure ratios of ~25 due to stress and thermomechanical fatigue in the centrifugal impeller. In this light, NASA, Pratt & Whitney and the Raytheon Technologies Research Center embarked upon a program to develop technologies to enable an all-axial high-pressure compressor with a core size below 3.0 lbm/s and an overall pressure ratio greater than 50. One of the challenges with an all-axial high-pressure compressor at this core size is the small span at the rear of the compressor. As core size is scaled down, the rotor tip clearances do not scale with span, leading to significant efficiency penalties. This paper documents a numerical and experimental effort to mitigate this penalty through design optimization and technology insertion, enabling an estimated 5 to 10% fuel burn reduction relative to 2020 best-in-class. The experimental program consisted of two builds of a high-speed rig: a baseline build and a second build to insert technology to manage large rotor tip gap/span ratios. The results demonstrated a reduction in the sensitivity of the compressor to large clearance ratios, which would be likely at the end-of-life of a small core application. The test campaign demonstrated that, with the insertion of technology, small core compressors can maintain a similar efficiency to current best-in-class large core size compressors. In addition to advancing the state-of-the-art of technology, the program also advanced the modeling standards for multistage compressors with large clearance-to-span ratios. The validation of this approach is described in the paper.

Axial Compressors↗
NASA NTRSDate not supplied

Clearance Sensitivity Mitigation in Small Core Compressors

As future aircraft become lighter and more aerodynamically efficient, thrust requirements will decrease, reducing the core size of the engine. Furthermore, in the pursuit of improved fuel burn, engine overall pressure ratio and bypass ratio will increase, further driving down engine core size. These drivers together mean that the core size, or corrected mass flow rate at the compressor exit, for future single-aisle aircraft applications will shrink below 3.0 lb/s. Traditionally, this small core compressor size is in the domain of axi-centrifugal designs, machines that are typically less efficient and limited to pressure ratios of ~25 due to stress and thermomechanical fatigue in the centrifugal impeller. In this light, NASA, Pratt & Whitney and the Raytheon Technologies Research Center embarked upon a program to develop technologies to enable an all-axial high-pressure compressor with a core size below 3.0 lb/s and an overall pressure ratio greater than 50. One of the challenges with an all-axial high-pressure compressor at this core size is the small span at the rear of the compressor. As core size is scaled down, the rotor tip clearances do not scale with span, leading to significant efficiency penalties. This paper documents a numerical and experimental effort to mitigate this penalty through design optimization and technology insertion, enabling an estimated 5 to 10% fuel burn reduction relative to 2020 best-in-class. The experimental program consisted of two builds of a high-speed rig: a baseline build and a second build to insert technology to manage large rotor tip gap/span ratios. The results demonstrated a reduction in the sensitivity of the compressor to large clearance ratios, which would be likely at the end-of-life of a small core application. The test campaign demonstrated that, with the insertion of technology, small core compressors can maintain a similar efficiency to current best-in-class large core size compressors. In addition to advancing the state-of-the-art of technology, the program also advanced the modeling standards for multistage compressors with large clearance-to-span ratios. The validation of this approach is described in the paper.

Axial Compressors↗
DOE OSTI2014

Highly-­laminated, high-­saturation-flux-­density, magnetic cores for on-­chip inductors in power converter applications

The objective of this project is development of a manufacturing process to realize thick highly-laminated metallic magnetic cores with suppressed eddy current losses for power applications and demonstration of integrated magnetic components using the process. The continual reduction in size and increase in functionality of portable electronic devices drives the development of ultracompact electrical power converters and therefore their associated inductors, which typically occupy the largest volume within the converter. This inductor size reduction can be achieved by increasing both the converter switching frequency as well as inductor operating flux density by utilizing appropriate magnetic core materials. Magnetically soft metallic alloys (e.g., NiFe and CoNiFe) are good core material candidates due to their superior magnetic properties (e.g., high saturation flux density and low coercivity) compared to conventional ferrite. However, to minimize eddy current losses, the core thickness is limited to the skin depth (typically less than 3 µm for 10 MHz operation); cores of this thickness are likely insufficient for handling high power (> 10W). Therefore, there is great interest in the development of highly-laminated metallic alloy cores with single lamination thickness in the sub-micron range to achieve suppressed eddy-current losses and high power handling capacity simultaneously. During the project, highly-laminated metallic alloy cores comprising up to 2000 layers of permalloy (Ni 80 Fe 20 ) or CoNiFe materials with single lamination thickness less than 1 µm have been fabricated based on automated multilayer electrodeposition technology compatible with CMOS manufacturing. The developed highly-laminated metallic cores preserve the high saturation flux density and low coercivity characteristics of metallic alloys, while suppressing eddy-current losses less than 1 W/cm3 at operation flux density of 0.5 T and frequency over 1 MHz. The developed highly-laminated metallic alloy cores have been further integrated into microfabricated windings to realize compact, on-chip inductors. Utilizing CMOS-compatible integration techniques, circular (toroid) and bar-shape (solenoid) microinductors have been fabricated exhibiting a constant inductance higher than 1 µH up to 50 MHz with peak quality factor as high as 35 at 5 MHz. The microfabricated inductor with highly-laminated core was tested in a power converter and demonstrated a converter efficiency of 93% at 5.5 MHz and 42 W under 100V input and 35V output operation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2012

Coupled 3D-neutronics / thermal-hydraulics analysis of an unprotected loss-of-flow accident for a 3600 MWth SFR core

The core behaviour of a large (3600 MWth) sodium-cooled fast reactor (SFR) is investigated in this paper with the use of a coupled TRACE/PARCS model. The SFR neutron spectrum is characterized by several performance advantages, but also leads to one dominating neutronics drawback - a positive sodium void reactivity. This implies a positive reactivity effect when sodium coolant is removed from the core. In order to evaluate such feedback in terms of the dynamics, a representative unprotected loss-of-flow (ULOF) transient, i.e. flow run-down without SCRAM in which sodium boiling occurs, is analyzed. Although analysis of a single transient cannot allow general conclusions to be drawn, it does allow better understanding of the underlying physics and can lead to proposals for improving the core response during such an accident. The starting point of this study is the reference core design considered in the framework of the Collaborative Project on the European Sodium Fast Reactor (CP-ESFR). To reduce the void effect, the core has been modified by introducing an upper sodium plenum (along with a boron layer) and by reducing the core height-to-diameter ratio. For the ULOF considered, a sharp increase in core power results in melting of the fuel in the case of the reference core. In the modified core, a large dryout leads to melting of the clad. It seems that, for the hypothetical event considered, fuel failure cannot be avoided with just improvement of the neutronics design; therefore, thermal-hydraulics optimization has been considered. An innovative assembly design is proposed to prevent sodium vapour blocking the fuel channel. This results in preventing a downward propagation of the sodium boiling to the core center, thus limiting it to the upper region. Such a void map introduces a negative coolant density reactivity feedback, which dominates the total reactivity change. As a result, the power level and the fuel temperature are effectively reduced, and a large dryout is prevented. As a next step, the classical sodium plenum is replaced by a fission gas plenum (with lower sodium fraction), thus improving flow stability. Stable boiling at a steady power level is achieved in this final configuration. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Assessing the inner core nucleation paradox with atomic-scale simulations

We investigate the conditions required to freeze liquid iron and iron alloys near the centre of Earth's core. It is usually assumed that inner core growth begins once the ambient core temperature falls below the melting temperature of the iron alloy at Earth's centre; however, additional (under)cooling is required to overcome the energy barrier associated with creating a solid–liquid interface. Predictions based on Classical Nucleation Theory (CNT) have estimated a required undercooling of ~1000 K, which cannot be reconciled with predicted core cooling rates of ~100 K Gyr -1 . This apparent contradiction has been called the ‘inner core nucleation paradox’. Here we address three major uncertainties in the application of CNT to inner core nucleation using atomic-scale simulations. First, we simulate freezing in Fe and Fe-O liquids at core conditions to self-consistently constrain all parameters required by the CNT equations. Second, we test the basic validity of CNT by directly calculating the waiting time to observe freezing events in Fe and Fe-O liquids. Third, we investigate the influence of wave-like forcings applied to the atomic simulations, which have been suggested as a means to significantly reduce the energy barrier. Our results are consistent with CNT in the computationally accessible parameter regime, though error estimates on the waiting time can reach 50% of the measurement at the largest undercooling temperatures. Using CNT to extrapolate to inner core conditions yields estimated undercooling of 730 ± 20 K for the pure iron system and 675 ± 35 K for the Fe-O system. Forcings corresponding to large pressure variations of O(10) GPa reduce these values by ~100 K. While our undercooling estimates are significantly lower than previous estimates they are not low enough to resolve the inner core nucleation paradox.

58 GEOSCIENCES↗