Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Design for Manufacture and Assembly”

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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Reduction of CO 2 Emissions Through Lightweight Body Panels (Project Final Report)

Lightweight construction is an integral part of Volkswagen’s overall strategy of reducing CO 2 emissions. Due to its low cost, steel is the most commonly used material for automotive exterior body panels today. Unfortunately, steel has a high density, resulting in a relatively low specific strength. Glass fiber based sheet molding compounds (SMC) provide high properties in combination with lower density. The high specific strength of SMC offers an enormous lightweight potential. To unlock the full potential of SMC materials in combination with cutting edge manufacturing processes, Volkswagen Group of America worked together with IACMI (Institute for Advanced Composites Manufacturing Innovation) and the academic partners: University of Tennessee Knoxville, Purdue University and Michigan State University; as well as the industry partners: Ashland, IDI, Owens Corning and Continental Structural Plastics. Leveraging the expertise of all project partners, reaching over the entire supply chain the project demonstrated the potential of these materials. This report will highlight the major steps in the development process on the way to technology readiness for SMC using the example of the Volkswagen Atlas Liftgate. Over the 36-month period of the project, the work focused on three R&D areas: material development, design and simulation, and development of the manufacturing process. Material selection included alternative fibers and resin systems, and accounted for material availability, properties, and cost-efficiency. The work undertaken in the field of design and simulation has pushed the envelope of short fiber reinforced thermoset molding compound process simulation. Design iterations were virtually tested, while the final design was used to validate the simulation software against physical parts. Manufacturing development used cutting-edge technology, while experts along the supply chain were working together to ensure the best possible results. In the final stage of the project, liftgates were molded, trimmed, bonded, painted and assembled before exhaustive testing. The result is an e-coat (electrophoretic dip coating) capable Class-A SMC liftgate, which is ready for high-volume production, and can be used as a technology demonstrator. The prototypes manufactured in the scope of this work have exhibited a mass reduction for the Volkswagen Atlas liftgate of up to 35% compared to the series production steel version, without a degradation of the functionalities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Floating Offshore Wind US Manufacturing and Commercialization (CRADA Final Report)

Create a detailed manufacturing, assembly, load-out, transportation, upending, turbine integration, and offshore transportation plan for a hypothetical project in one of the California lease areas off the central coast. Develop a detailed schedule and cost estimation for each step of the process and compare with conventional floating platform designs.

17 WIND ENERGY↗
NASA NTRS1977

Analysis of the Gas Core Actinide Transmutation Reactor (GCATR)

Design power plant studies were carried out for two applications of the plasma core reactor: (1) As a breeder reactor, (2) As a reactor able to transmute actinides effectively. In addition to the above applications the reactor produced electrical power with a high efficiency. A reactor subsystem was designed for each of the two applications. For the breeder reactor, neutronics calculations were carried out for a U-233 plasma core with a molten salt breeding blanket. A reactor was designed with a low critical mass (less than a few hundred kilograms U-233) and a breeding ratio of 1.01. The plasma core actinide transmutation reactor was designed to transmute the nuclear waste from conventional LWR's. The spent fuel is reprocessed during which 100% of Np, Am, Cm, and higher actinides are separated from the other components. These actinides are then manufactured as oxides into zirconium clad fuel rods and charged as fuel assemblies in the reflector region of the plasma core actinide transmutation reactor. In the equilibrium cycle, about 7% of the actinides are directly fissioned away, while about 31% are removed by reprocessing.

Clement, J. D.↗
NASA NTRS2006

Control of Technology Transfer at JPL

Controlled Technology: 1) Design: preliminary or critical design data, schematics, technical flow charts, SNV code/diagnostics, logic flow diagrams, wirelist, ICDs, detailed specifications or requirements. 2) Development: constraints, computations, configurations, technical analyses, acceptance criteria, anomaly resolution, detailed test plans, detailed technical proposals. 3) Production: process or how-to: assemble, operated, repair, maintain, modify. 4) Manufacturing: technical instructions, specific parts, specific materials, specific qualities, specific processes, specific flow. 5) Operations: how-to operate, contingency or standard operating plans, Ops handbooks. 6) Repair: repair instructions, troubleshooting schemes, detailed schematics. 7) Test: specific procedures, data, analysis, detailed test plan and retest plans, detailed anomaly resolutions, detailed failure causes and corrective actions, troubleshooting, trended test data, flight readiness data. 8) Maintenance: maintenance schedules and plans, methods for regular upkeep, overhaul instructions. 9) Modification: modification instructions, upgrades kit parts, including software

Jet Propulsion Laboratory (JPL)↗
NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in the past year, including firing tests of both main propulsion elements, manufacturing of flight hardware, and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons (t) (154,000 pounds) of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 t (286,000 pounds) to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware, including flight hardware for Exploration Mission 1 (EM-1). This paper will provide an overview of the progress made over the past year and provide a glimpse of upcoming milestones on the way to a 2018 launch readiness date.

May, Todd↗
NASA NTRS2019

Assessment of Automated Fiber Placement for the Fabrication of Composite Wind Tunnel Blades

Composite wind tunnel blades are frequently fabricated by hand layup of prepreg fabrics. Though well proven, this fabrication method is laborious and expensive. The study described in this paper used the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at the NASA Langley Research Center to explore whether automated fiber placement (AFP) could reduce manufacturing time and cost for production of wind tunnel blades. Two blades, taken from two NASA wind tunnels, were investigated as representative geometries. Computer-aided design models of the blade surfaces were created, and AFP process planning and programming were employed to study the manufacturability of the shapes. A placement/cure tool was manufactured for the chosen blade surface from thermoplastic material using an additive manufacturing process. The present study revealed that the AFP head geometry, primarily the heater configuration of the ISAAC system, is the primary constraint that limits the ability to manufacture the selected wind tunnel fan blades using AFP.

Grenoble, Ray↗
DOE OSTI2022

Circularity in mixed-plastic chemical recycling enabled by variable rates of polydiketoenamine hydrolysis

Footwear, carpet, automotive interiors, and multilayer packaging are examples of products manufactured from several types of polymers whose inextricability poses substantial challenges for recycling at the end of life. Here, we show that chemical circularity in mixed-polymer recycling becomes possible by controlling the rates of depolymerization of polydiketoenamines (PDK) over several orders of magnitude through molecular engineering. Stepwise deconstruction of mixed-PDK composites, laminates, and assemblies is chemospecific, allowing a prescribed subset of monomers, fillers, and additives to be recovered under pristine condition at each stage of the recycling process. We provide a theoretical framework to understand PDK depolymerization via acid-catalyzed hydrolysis and experimentally validate trends predicted for the rate-limiting step. The control achieved by PDK resins in managing chemical and material entropy points to wide-ranging opportunities for pairing circular design with sustainable manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2010

Current Status of NASA's Heavy Lift Plans

Numerous studies since the Apollo Program of the 1960s have highlighted the benefits of - and the need for - a national heavy lift launch capability to support human exploration, science, national security, and commercial development of space. NASA's most recent and most refined effort to develop that heavy lift capability is the Ares V. Ares V is a key element of NASA's Constellation Program. It s overall goal s part of approved national space policy is to retire the Space Shuttle and develop its successor, complete the International Space Station, and resume human exploration beyond low Earth orbit (LEO), beginning with exploration of the Moon as a step to other destinations in the Solar System. Ares V s first role is that of cargo vehicle to carry a lunar lander into Earth orbit, rendezvous with astronauts launched on the smaller Ares I crew launch vehicle, and perform the trans lunar injection (TLI) mission to send the mated crew and lander vehicles to the Moon. The design reference missions (DRMs) envisioned for it also include direct lunar cargo flights and a human Mars mission. Although NASA's priority from the start of the Constellation Program to the present has been development of the Ares I and Orion crew vehicle to replace the retiring Shuttle fleet, the Ares team has made significant progress in understanding the performance, design trades, technology needs, mission scenarios, ground and flight operations, cost, and other factors associated with heavy lift development. The current reference configuration was selected during the Lunar Capabilities Concept Review (LCCR) in fall 2008. That design has served since then as a point of departure for further refinements and trades among five participating NASA field centers. Ares V development to date has benefited from progress on the Ares I due to commonality between the vehicles. The Ares I first stage completed a successful firing of a 5-segment solid rocket motor. The Ares I-X launch Numerous studies since the Apollo Program of the 1960s have highlighted the benefits of and the need for - a national heavy lift launch capability to support human exploration, science, national security, and commercial development of space. NASA s most recent and most refined effort to develop that heavy lift capability is the Ares V. Ares V is a key element of NASA s Constellation Program. It s overall goal s part of approved national space policy is to retire the Space Shuttle and develop its successor, complete the International Space Station, and resume human exploration beyond low Earth orbit (LEO), beginning with exploration of the Moon as a step to other destinations in the Solar System. Ares V s first role is that of cargo vehicle to carry a lunar lander into Earth orbit, rendezvous with astronauts launched on the smaller Ares I crew launch vehicle, and perform the trans lunar injection (TLI) mission to send the mated crew and lander vehicles to the Moon. The design reference missions (DRMs) envisioned for it also include direct lunar cargo flights and a human Mars mission. Although NASA s priority from the start of the Constellation Program to the present has been development of the Ares I and Orion crew vehicle to replace the retiring Shuttle fleet, the Ares team has made significant progress in understanding the performance, design trades, technology needs, mission scenarios, ground and flight operations, cost, and other factors associated with heavy lift development. The current reference configuration was selected during the Lunar Capabilities Concept Review (LCCR) in fall 2008. That design has served since then as a point of departure for further refinements and trades among five participating NASA field centers. Ares V development to date has benefited from progress on the Ares I due to commonality between the vehicles. The Ares I first stage completed a successful firing of a 5-segment solid rocket motor. The Ares I-X launch successfully demonstrated in suborbital flighhe ability to assemble, prepare, launch, control and recover the Ares I configuration and compare performance to computer models. Component tests continue on the J-2X engine, which will put both the Ares I and Ares V upper stages into orbit. In addition, more than 100,000 parts have been manufactured or on the assembly line for the first J-2X powerpack and the first two development engines, with hot fire tests to begin in 2011. This paper will further detail the progress to date on the Ares V and planned activities for the remainder of 2010. In addition, the Ares V team has continued its outreach to potential user communities in science and national security. Through the Constellation Program, NASA has amassed an enormous knowledge base in the design, technologies, and operations of heavy lift launch vehicles that will be a national asset for any future launch vehicle decision. This early phase of the design presents the best opportunity to incorporate where possible the insights and needs of other users.

Creech, Steve↗
NASA NTRS1978

Advanced manufacturing development of a composite empennage component for l-1011 aircraft

Tooling concepts were developed which would permit co-couring of the hat stiffeners to the skin to form the cover assembly in a single autoclave cycle. These tooling concepts include the use of solid rubber mandrels, foam mandrels, and formed elastometric bladders. A simplification of the root end design of the cover hat stiffeners was accomplished in order to facilitate fabrication. The conversion of the 3D NASTRAN model from level 15 to level 16 was completed and a successful check run accomplished. A detailed analysis of the thermal load requirement for the environmental chambers was carried out. Based on the thermal analysis, best function requirements, load inputs and ease of access, a system involving four chambers, two for the covers containing 6 and 4 specimens, respectively, and two for the spares containing 6 and 4 specimens, respectively, evolved.

Source record↗
DOE OSTI2023

ADDITIVE MANUFACTURING AND REGULATORY TESTING OF CANISTERS FOR SPENT NUCLEAR FUEL MANAGEMENT

The back end of the fuel cycle focuses on the interim storage, transportation, and final disposition of the spent nuclear fuel from nuclear reactors. Commercial light water nuclear power stations across the United States operate with fuel assemblies being irradiated for up to 6 years (planned) in the reactor pressure vessel. After their planned irradiation, the fuel assemblies are moved to a spent fuel pool within the facility complex. After the spent nuclear fuel is removed from the fuel pool, it is typically inserted into a welded metal canister that can be transferred between overpacks for storage, transportation and possibly disposal. Most dry storage systems being used by industry today use dual purpose canisters (DPCs), designed for use in storage and transportation overpacks, but not specifically designed for disposal. Triple purpose-canisters, designed for disposal in addition to storage and transportation, have also been researched. Traditional manufacturing methods for spent fuel canisters involve fusion welding along the length or circumference of the canister which results in high tensile residual stresses in the joint weld zone (WZ) and heat affected zone (HAZ). In this paper, spent fuel canister designs were printed by wire arc additive manufacturing (AM) using the 316L SS welding wire to demonstrate: 1. Feasibility of spent nuclear fuel canister fabrication using this advanced manufacturing method, 2. Dynamic response of the additive manufacture canister design when subjected to the federally mandated Normal Conditions of Transport (NCT) and Hypothetical Accident Conditions (HAC) physical tests for Type B packages. This paper will focus on the canister printing design and structural tests. The AM 3D printed design, regulatory testing, and post-test evaluation of the canister tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. One AM canister design was subjected to the penetration, free drop, and puncture test. Before and after the dynamic structural tests, the AM canister design was scanned with a handheld scanner to capture a 3D CAD geometry to compare to the 3D printed canister design in the deformed shape. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeated results of the deformed shape of the AM canister design.

Martinez, Oscar↗
NASA NTRS2010

Cost Estimate for Molybdenum and Tantalum Refractory Metal Alloy Flow Circuit Concepts

The Early Flight Fission-Test Facilities (EFF-TF) team at NASA Marshall Space Flight Center (MSFC) has been tasked by the Naval Reactors Prime Contract Team (NRPCT) to provide a cost and delivery rough order of magnitude estimate for a refractory metal-based lithium (Li) flow circuit. The design is based on the stainless steel Li flow circuit that is currently being assembled for an NRPCT task underway at the EFF-TF. While geometrically the flow circuit is not representative of a final flight prototype, knowledge has been gained to quantify (time and cost) the materials, manufacturing, fabrication, assembly, and operations to produce a testable configuration. This Technical Memorandum (TM) also identifies the following key issues that need to be addressed by the fabrication process: Alloy selection and forming, cost and availability, welding, bending, machining, assembly, and instrumentation. Several candidate materials were identified by NRPCT including molybdenum (Mo) alloy (Mo-47.5 %Re), tantalum (Ta) alloys (T-111, ASTAR-811C), and niobium (Nb) alloy (Nb-1 %Zr). This TM is focused only on the Mo and Ta alloys, since they are of higher concern to the ongoing effort. The initial estimate to complete a Mo-47%Re system ready for testing is =$9,000k over a period of 30 mo. The initial estimate to complete a T-111 or ASTAR-811C system ready for testing is =$12,000k over a period of 36 mo.

Hickman, Robert R.↗
NASA NTRS2018

The Second European Service Module (ESM-2) Evolutions, Production and Challenges

This paper presents an overview of the Second European Service Module (ESM-2), the second in a series of European Service Modules produced as part of the Barter agreement between NASA and ESA for the Orion Program. The European Industrial consortium is led by the ESA prime contractor Airbus Defence and Space in Bremen. ESA and Airbus signed the ESM-2 contract on 16 February 2017, for this key element of the Orion Exploration Mission 2 (EM-2). EM-2 is the first crewed mission for Orion and will take astronauts farther into the solar system than humanity has ever travelled. EM-2 will also be a historic mission for Europe, as the ESM-2 will be the first European spacecraft to be part of a human transportation system carrying humans beyond low Earth orbit. ESM-2 is mainly a recurring production following ESM-1. Nevertheless, there are a number of important changes being implemented, for example, to incorporate upgrades to further enhance safety and reliability. The challenging delivery schedule for ESM-2 has driven the need to commence manufacturing prior to completion of the qualification on ESM-1. In addition, some requirement deviations and non-compliances approved for ESM-1 have resulted in modifications for ESM-2. In order to manage the competing constraints effectively, the ESM-2 Team has put in place a number of novel approaches to manage schedule, risk, and technical changes. Airbus has set up multi-functional teams according to an approach known as "Major Spacecraft Deliveries" consisting of quality assurance, engineering and procurement. The risk of starting manufacturing prior to qualification is managed through a special risk share agreement. This agreement necessitates rigorous risk reviews across the board for all manufacturing, assembly, integration and test milestones. The ESM-2 changes are managed by Configuration Management, but Airbus has also introduced the Technical Baseline Matrix to provide a transparent top-level overview of the changes from ESM-1 to ESM-2. The tool provides the basis for ESM-2 design and development needs, decisions, as well as the input for the Orion EM-2 Critical Design Review (CDR). The main technical evolutions, status of the production and the novel management approaches for ESM-2 are presented and discussed in the paper.

Orion European Service Module Programme↗
DOE OSTI2021

Development of dispensing hardware for safe fueling of heavy duty vehicles

The development of safe dispensing equipment for the fueling of heavy duty (HD) vehicles is critical to the expansion of this newly and quickly expanding market. This paper discusses the development of a HD dispenser and nozzles assembly (nozzle, hose, breakaway) for these new, larger vehicles where flow rates are more than double compared to light duty (LD) vehicles. This equipment must operate at nominal pressures of 700 bar, -40o C gas temperature, and average flow rate of 5-10 kg/min at a high throughput commercial hydrogen fueling station without leaking hydrogen. The project surveyed HD vehicle manufacturers, station developers, and component suppliers to determine the basic specifications of the dispensing equipment and nozzle assembly. The team also examined existing codes and standards to determine necessary changes to accommodate HD components. From this information, the team developed a set of specifications which will be used to design the dispensing equipment. In order to meet these goals, the team performed computational fluid dynamic, pressure modelling, and temperature analysis in order to determine the necessary parameters to meet existing safety standards modified for HD fueling. The team also considered user, operational, and maintenance requirements, such as freeze lock which has been an issue which prevents the removal of the nozzle from LD vehicles. The team also performed a failure mode and effects analysis (FMEA) to identify the possible failures in the design. The dispenser and nozzle assembly will be tested separately, and then installed on an innovative, HD fueling station which will use a HD vehicle simulator to test the entire system.

08 HYDROGEN↗
DOE OSTI2025

Restructuring and Optimizing Reactor Building Lifting Processes & Designing a Solution for an Overhead Door Handling Forklift Attachment

This poster presents two innovative projects aimed at enhancing operational efficiency and safety at the Advanced Test Reactor (ATR) Complex. The first project focuses on restructuring the existing lift book used for hoisting operations within the ATR Reactor Building. The current lift book, a cumbersome 150+ page document, is being transformed into a more efficient format using charts that allow for quick identification of maximum lift heights based on object footprint and weight. This new method also considers various parameters such as floor integrity and reactor status, dividing entries into four distinct charts to improve usability and safety during lifts. The second project involves designing a specialized forklift attachment for handling an overhead door at the ATR Reactor Building. The attachment is engineered to securely lift and lower a 1200lb, 14ft long door, ensuring safe replacement operations. The design process included research on forklift attachment codes, modeling in Autodesk Inventor, and testing through Finite Element Analysis (FEA) and hand calculations to confirm the attachment's structural integrity. Future work includes completing detailed drawings and an Engineering Calculations Analysis and Review (ECAR) document to proceed with manufacturing and assembly. Together, these projects demonstrate a commitment to optimizing reactor building operations through innovative engineering solutions and safety considerations.

42 - ENGINEERING↗
NASA NTRS2010

Ares I-X Flight Test Development Challenges and Success Factors

The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.

Askins, Bruce↗
DOE OSTI2020

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume I – Predicting Initial Microstructures

This report summarizes the current state of modeling and simulation methods for predicting the initial structure and properties of material in components assembled using advanced manufacturing technologies (AMTs). The report is the first volume in a two-volume series. This first volume focuses on predicting initial microstructures of AM material. The second volume discusses predicting material properties given the initial microstructure. The focus is on technologies of particular relevance to the design and manufacture of nuclear reactor components. The purpose of the report is to help develop the technical knowledge base to support regulatory decisions that will be needed to assess nuclear components manufactured with AMTs as these components are installed at nuclear power plants (NPPs). The report develops a list of AMTs of particular interest to the NRC and summarizes the key microstructural features and corresponding processing parameters relevant to each technology. Further sections describe available physically-based and data-driven prediction methods and survey widely available software tools. The report concludes with a summary of gaps that may be of particular interest to the NRC when evaluating modeling and simulation methods for AMTs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2011

Demonstration/Validation of Environmentally-Preferable Coatings for Launch Facilities

Kennedy Space Center (KSC) is responsible for a number of facilities/structures with metallic structural and non-structural components in a highly corrosive environment. Metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. Applied coating systems work via a variety of methods (barrier, galvanic and/or inhibitor) and adhere to the substrate through a combination of chemical and physical bonds. Maintenance at KSC and other NASA Centers is governed by NASA-STD-50088 (Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment) which establishes practices for the protective coating of ground support equipment and related facilities used by or for NASA programs and projects. The Standard is for the design of non-flight hardware used to support the operations of receiving, transportation, handling, assembly, inspection, test, checkout, service, and launch of space vehicles and payloads at NASA launch, landing, or retrieval sites. These criteria and practices contained within the Standard may be used for items used at the manufacturing, development, and test sites upstream of the launch, landing, or retrieval sites. The objective of this effort is to demonstrate and validate environmentally-preferable alternatives in accordance with NASA-STD-50088 and KSC requirements which can then be added to the Approved Products List. This Test Protocol contains the critical requirements and tests necessary to qualify alternatives for structural steel applications. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of KSC participants. A Test Report will document the results of the testing as well as any test modifications made during the execution of the testing. Users of this Test Protocol should check the project's Test Report for additional test details or minor modifications that may have been necessary in the execution of the testing. The technical stakeholders will have agreed upon test procedures modifications documented in the Test Report.

Lewis, Pattie↗
DOE OSTI2024

Specification of EBR-II Fabricated Fuel Diameter Data

All IFR EBR-II fuel pins were fabricated at one of the related fuel fabrication facilities at Argonne National Laboratory-West, at the EBR-II site [1]. U-Pu-Zr experimental pins were fabricated at the Experimental Fuels Laboratory (EFL), which was established in April of 1984 after the positive acceptance of the IFR concept, while the U-Zr experimental pins were fabricated at the Fuel Manufacturing Facility (FMF), along with the driver fuel pins [2]. The injection-casting fabrication process is described in detail in ref [1]. All the fuel pins that were loaded into EBR-II were examined after fabrication to ensure that they met the design dimensional requirements and tolerances prior to assembly. Fuel slug diameter was measured with either a laser profilometer (at FMF) or a hand micrometer (at EFL), at a minimum of 1-inch intervals over the length of the fuel slug, as shown in Figure 1 [2]. In all cases the average fuel diameter is reported, in some cases with additional summary statistics (e.g., minimum, maximum), and in rare cases the complete record of axially-varying fuel diameters is available. It should be noted that in cases where axial varying data is available, in general the orientation of the slug was not recorded or carried over to loading of the pin, so a diameter measurement at the bottom of the fabricated slug does not necessarily correspond to the bottom of the loaded slug, as it may have been loaded in either orientation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗