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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Development of an advanced ultrasonic phased array for the characterization of thick, reinforced concrete components (Final Scientific/Technical Report)

There are no nondestructive evaluation (NDE) tools capable of characterizing microscale damage throughout the thickness of concrete components, due to the multiphase, heterogeneous and multiscale nature of concrete. Ultrasound is only scattered by features at the same length scale, or smaller, than the wavelength of a wave’s dominant frequency. Successful imaging of microscale damage using ultrasound requires that the ultrasonic wavelength be on the order of a few millimeters (or smaller), yet the heterogeneous microstructure of concrete, with its fine and coarse aggregates, is on this same (and higher) micrometer/millimeter length scale, causing excessive ultrasonic wave scattering even in “good” concrete. The proposed solution applies non-collinear wave mixing to spatially image microscale damage, while still maintaining penetration through thick concrete components. This microscale imaging is possible by combining nonlinear wave mixing, with advanced phased array hardware and software to develop a breakthrough tool that will bring revolutionary changes in NDE of concrete infrastructure in terms of image resolution and depth of penetration. This work uses non-collinear wave mixing which exploits the physics that material nonlinearities such as microscale damage, cause interactions between two intersecting ultrasonic waves due to cross-mixing, which can lead to the generation of a third wave with a frequency and wave number of the sum or difference of the incident waves. The concrete material volume at this mixing point is characterized/imaged. This project delivered a single-sided nonlinear ultrasonic phased array imaging device, that can image microscale damage (microcracks of 100 micrometers) through a 0.5 m thick concrete component and assessed the commercial feasibility of such arrays for improved crack detection.

42 ENGINEERING↗
DOE OSTI2021

Microscopic characterization of alkali-silica reaction (ASR) affected recycled concrete mixtures induced by reactive coarse and fine aggregates

Alkali-silica reaction (ASR) is one of the most detrimental distress mechanisms leading to early deterioration of concrete infrastructure, creating large amounts of construction and demolition waste which however can be transformed into recycled concrete aggregates (RCA). Yet, as ASR is an ongoing distress mechanism, its potential of reoccurrence in RCA could cause adverse effects. Investigation of the crack propagation of RCA concrete revealed that the distress features vary widely thus, indicating different distress mechanisms in all RCA concrete. Concrete made of slightly damaged RCA shows the lease number of cracks yet, wider cracks at high expansion levels. Additionally, the distress in slightly damaged RCA concrete made of reactive coarse aggregate and RCA concrete made of reactive sand, regardless of original damage extent, is governed by cracks propagating through the residual cement paste whereas cracks propagate through the new cement paste in severely damaged RCA made of reactive coarse aggregate.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A mesoscale 3D model of irradiated concrete informed via a 2.5 U-Net semantic segmentation

The concrete biological shield in light-water reactors is exposed to neutron and gamma irradiation, which deteriorates the concrete’s mechanical properties in the long term. To assess the irradiation-induced damage, predictive mechanical models are developed and used in parallel with the characterization of irradiated concrete samples. Realistic 3D simulation domains can drastically improve a model’s prediction. In this work, we utilized x-ray computed tomography (XCT) data of a concrete specimen to reconstruct its 3D microstructure. The XCT data shows low contrast between the concrete’s aggregates and cement paste, resulting in poor image segmentation when using traditional unsupervised techniques. To address this issue, we developed and trained a 2.5D U-Net model on only 24 pre-labeled XCT layers to segment 651 layers of the XCT data. The overall F1-score of the model is approximately 96%. Then, we created a 3D finite element (FE) mesh based on the stack of segmented images. The FE model contains radiation-induced expansion, damage, and creep. The constitutive equations are adapted to each phase (aggregates and cement paste). Here, we simulated the effects of neutron irradiation in the concrete specimen as well as the specimen’s mechanical response to uniaxial compression. Finally, model validation was performed using experimental data on similar concrete specimens in the literature.

2.5D U-Net↗
DOE OSTI2020

Radiation Effects in Concrete for Nuclear Systems

Concrete is massively used in the construction of critical safety-related components in nuclear power plants. Among those, the concrete biological shield is exposed to high levels of neutron and gamma irradiation exiting the reactor pressure vessel. This article provides a comprehensive overview of the state-of-the-art knowledge on irradiated concrete. First, the fundamental irradiation-induced degradation mechanisms occurring at the level of the concrete constituents such as rock-forming minerals and hydrated cementitious phases are examined. The critical role of the mineralogical and chemical composition regarding concrete resistance against radiation effects such as amorphization, irradiation-induced expansion and radiolytic gas release are detailed. Second, the interactions between the varied irradiated phases are comprehensively analyzed and put in perspectives with the effects of prolonged irradiation on the structural properties of concrete aggregates, cement paste, and concretes. Finally, the significance of irradiation for the long-term operation of nuclear power plants is discussed in the light of the most recent knowledge and its limitations.

Le Pape, Yann↗
DOE OSTI2020

Development of an MEMS ultrasonic microphone array system and its application to compressed wavefield imaging of concrete

Abstract Although contactless ultrasonic wavefield imaging shows potential for effective nondestructive inspection of various engineering materials, it has been rarely applied to concrete materials owing to technical challenges including low signal-to-noise ratio (SNR) caused by inherent heterogeneity of concrete. This paper presents development of a multi-channel MEMS ultrasonic microphone array system and its application to compressed wavefield imaging of concrete materials. The developed multi-channel MEMS ultrasonic microphone array system contains eight MEMS ultrasonic microphone elements and a signal conditioning circuit that enables measurements of ultrasonic signals with high SNR. A compressed sensing approach, based on the multiple measurement vector (MMV) concept, is applied to reconstruct a full dense ultrasonic wavefield data from sparsely sampled ultrasonic wavefield data. Experiments are carried out on a laboratory concrete sample to verify the performance of the developed MEMS microphone array system and proposed compressed sensing approach and then large-scale concrete samples to demonstrate practical application. The experimental results demonstrate that the developed MEMS microphone array system provides high-quality (SNR > 20 dB) ultrasonic data collected from concrete elements; furthermore, the proposed compressed sensing approach provides accurate reconstruction of dense wavefield data, as determined by peak signal-to-noise ratio (PSNR), from sparsely measured wavefield data with compression ratios up to 85% and PSNR above 25 dB in data collected form realistic large-scale concrete samples. By combining the MEMS array system and compressed sensing approach, the total ultrasonic data acquisition time needed to produce dense wavefield data can be significantly reduced.

Instruments & Instrumentation↗
DOE OSTI2024

Assessment of Machine Learning for Ultrasonic Nondestructive Evaluation of Alkali–Silica Reaction in Concrete

Alkali–silica reaction (ASR) is a type of material degradation in concrete structures that leads to concrete cracking and rebar corrosion, thereby reducing the material’s structural integrity and the overall structure’s lifetime and raising safety concerns. Ultrasonic nondestructive evaluation (NDE) has been proven to be a valuable technique for assessing concrete properties and monitoring ASR progression in concrete. However, the deployment and analysis of ultrasonic NDE and its data requires specialized expertise, often relying on the engineer’s subjective interpretation. With the surge in computational power, artificial intelligence (AI) and machine learning (ML) algorithms have become popular in automating NDE data analysis. Various industrial sectors are increasingly adopting ML algorithms for NDE data analysis with a growing emphasis on AI–assisted automation. Regulatory agencies are also preparing for this technological shift, anticipating corresponding revisions in standards. Thus, there is an urgent need to identify the capabilities and limitations of current ML technologies for the evaluation of concrete material properties and damage status. Furthermore, the effects of various factors on ML model performance must be thoroughly investigated. The study summarized herein evaluated the effectiveness of two ML models (i.e., support vector regression (SVR) and deep neural network (DNN)) in predicting concrete material damage induced by ASR based on the long-term ultrasonic monitoring data. Four distinct concrete specimens were cast with artificially induced ASR, and over a period exceeding 500 days, ultrasonic signals and expansion data were continuously collected. For the SVR model, wave velocity and 12 other wave features were extracted from the ultrasonic signals, with 6 out of 13 features selected as input for the model. Different combinations of training and testing datasets were designed to explore factors influencing prediction performance, including the range of data within training and testing sets, in addition to various signal preprocessing methodologies. These findings suggest the importance of using a training dataset with a broader data range compared with testing datasets for improved model performance alongside consistent signal preprocessing across datasets.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Impact of Laboratory-Accelerated Aging Methods to Study Alkali–Silica Reaction and Reinforcement Corrosion on the Properties of Concrete

This study focuses on two separate investigations of the main aging mechanisms: alkali–silica reactivity (ASR) and the corrosion of reinforcing steel (rebar) concrete, both of which may result in a premature failure to meet the serviceability or strength requirements of a concrete structure. However, these processes occur very slowly, spanning decades. The impact of direct chemical additives to fresh concrete to accelerate ASR and the corrosion of reinforcing steel on the fresh and hardened properties of the ensuing material are investigated to inform the potential use of chemicals in large-scale studies. The deterioration of reinforced concrete (RC) is determined by means of expansion, cracking, bulk diffusivity and surface resistivity measurements, and compressive, split tensile and flexural strength tests. The results indicate that the addition of sodium hydroxide and calcium chloride can effectively accelerate the crack formation and propagation in concrete due to ASR and the corrosion of rebar, respectively. The ASR-induced cracks maintained a constant crack width from 0.05 mm to 0.1 mm over the measurement period regardless of the intensity of aging acceleration. Adding 4% chloride by weight of cement for accelerating rebar corrosion resulted in an average crack that was 82% larger than in the case of ASR accelerated with the addition of sodium hydroxide. The addition of alkali resulted in an increase in early-age (7-day) strength. At a total alkali loading of 2.98 kg/m3, 3.84 kg/m3 and 5.57 kg/m3, the 28-day compressive strength of concrete decreased by 3%, 10% and 24%, respectively. Similarly, a higher early-age strength and a lower later-age strength was observed for the concrete in the presence of corrosive calcium chloride. The results from this research are expected to inform future studies on the long-term performance of RC structures under accelerated ASR and corrosion.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Mechanical Properties and Durability of "Waterless Concrete"

Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and by oxidation soil iron and sulfur can be produced. Iron can be used to reinforce the sulfur concrete. Sulfur concrete specimens were cycled between liquid nitrogen (approximately 191 C) and room temperature (approximately 21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (approximately 21 C) and approximately 101 C. Test results showed that due to temperature cycling, compressive strength of cycled specimens was 20% of those non-cycled. Microscopic examination of the fracture surfaces from the cycled samples showed clear de-bonding of the sulfur from the aggregate material whereas it was seen well bonded in those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibers. The glass fibers from lunar regolith simulant was melted in a 25 cc Pt-Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to 1 hour. Glass fibers were cast from the melt into graphite crucibles and were annealed for a couple of hours at 600 C. Glass fibers and small rods were pulled from the melt. The glass melt wets the ceramic rod and long continuous glass fibers were easily hand drawn. The glass fibers were immediately coated with a protective polymer to maintain the mechanical strength. The glass fibers were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Prisms beams strengthened with glass fibers were tested in 4-point bending test. Beams strengthened with glass fiber showed to exhibit an increase in the flexura strength by as much as 45%.

Toutanji, Houssam↗
NASA NTRS2010

Performance of Waterless Concrete

The development of permanent lunar bases is constrained by performance of construction materials and availability of in-situ resources. Concrete seems a suitable construction material for the lunar environment, but water, one of its major components, is an extremely scarce resource on the Moon. This study explores an alternative to hydraulic concrete by replacing the binding mix of concrete (cement and water) with sulfur. Sulfur is a volatile element on the lunar surface that can be extracted from lunar soils by heating. Sulfur concrete mixes were prepared to investigate the effect of extreme environmental conditions on the properties of sulfur concrete. A hypervelocity impact test was conducted, having as its target a 5-cm cubic sample of sulfur concrete. This item consisted of JSC-1 lunar regolith simulant (65%) and sulfur (35%). The sample was placed in the MSFC Impact Test Facility s Micro Light Gas Gun target chamber, and was struck by a 1-mm diameter (~1.4e-03 g) aluminum projectile at 5.85 km/s. In addition, HZTERN code, provided by NASA was used to study the effectiveness of sulfur concrete when subjected to space radiation.

Toutanji, Houssam↗
DOE OSTI2023

Thermal energy storage in concrete: Review, testing, and simulation of thermal properties at relevant ranges of elevated temperature

This study examines the thermal performance of concrete used for thermal energy storage (TES) applications. The influence of concrete constituents (aggregates, cementitious materials, and fibers) on the thermal conductivity and specific heat are summarized based on literature and via experimentation at elevated temperatures. It is indicated that concrete with siliceous aggregate, low water/cement ratios, and steel fibers produces better overall thermal properties. The results of literature review and laboratory testing are used for numerical simulation to evaluate the impact of concrete thermal property variability on TES capabilities. The TES module consists of the heat exchanger and surrounding concrete as the storage media. Both idealized cases without heat loss and realistic cases with insulation and heat losses are considered. Furthermore, the result shows that conventional concrete mixes can be tailored to decrease the module charge/discharge durations and increase the amount of thermal energy storage.

25 ENERGY STORAGE↗
DOE OSTI2021

Meso-scale modelling of compressive fracture in concrete with irregularly shaped aggregates

This paper presents a meso-scale modelling framework to investigate the fracture process in concrete subjected to uniaxial and biaxial compression accounting for its mesostructural characteristics. 3D mesostructure of concrete consisting of coarse aggregates, mortar and interfacial transition zone between them was developed using an in-house code based on the Voronoi tessellation and splining method, which enables to generate the realistic-look aggregates with controllable structural features such as content, location, size and shape. Based on the generated 3D mesostructure, the concrete damage plasticity approach was employed to simulate the compressive fracture behaviour of concrete in terms of crack morphology and stress-strain response against the shape parameters of aggregate. Results indicate that the shape of aggregate has a negligible effect on compressive strength of concrete, which is highly associated with the random location and size distribution of aggregate. The aggregate irregularity has a significant influence on crack initiation and growth of concrete.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modelling the development of capillary pressure in freshly 3D-printed concrete elements

3D concrete printing is a promising technology recently developed to automate construction. Since no formwork is used in this technology to support and protect fresh concrete, there are two aspects which considerably accelerate the development of capillary pressure in 3D-printed concrete in comparison to conventionally placed concrete: i) high stiffness of 3D-printed needed to provide sufficient buildability, and ii) very early and fast evaporation of pore water. Accelerated development of capillary pressure may lead to severe plastic shrinkage cracking in 3D-printed elements and, hence, need to be mitigated. This investigation aims at providing a poromechanical model for capillary pressure development in 3D-printed elements. To simulate the development of capillary pressure and plastic shrinkage, environmental factors, material properties, and element geometry need to be considered as a whole. The model inputs – coefficient of permeability, static bulk modulus, air entry pressure and chemical shrinkage rate – were determined experimentally. The model was validated for two fine-grained concretes. Both 3D-printed materials yielded faster capillary pressure increase in comparison to cast concrete, while partial substitution of cement with silica fume further accelerated the capillary pressure development. Furthermore, due to the lower permeability of the mixture containing silica fume, the gradient of capillary pressure between 3D-printed layers increased, as did the gradient of plastic shrinkage.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of Interlayer Time-Lapse and Workability Retention on Printed Concrete Performance

The rapid advancement of additive manufacturing technologies for concrete construction requires further understanding of material performance and its relationship with print parameters such as interlayer time-lapse and workability retention during the print. Here this study addresses the effects of the time delay between consecutive extruded layers on the mechanical performance of printed concrete using a mix designed by Quikrete. A series of specimens were prepared with printing delays of 10, 15, 30, and 60 min. This work correlates the change in fracture properties, mechanical performance, and workability retention with the interlayer time-lapse between two consecutive concrete layers. Interlayer time-lapse is defined as the time difference in printing of two consequent layers of concrete. It affects individual properties differently based on the loading direction and test types, but it is consistent in terms of interlayer performance. The understanding of the effect of interlayer time-lapse on the fracture properties between two consecutive printed layers fills the knowledge gaps in printed concrete research. Therefore, this study can help researchers perform required optimization and safely estimate the performance of printed concrete.

3D printing↗
DOE OSTI2022

Nondestructive Damage Detection of Concrete With Alkali-Silica Reactions Using Coda Wave and Anomaly Detection

An anomaly detection model for early damage detection for concrete structures undergoing alkali-silica reaction (ASR) is presented. It is difficult to detect ASR initiation and early damage without a reference expansion measurement. Coda waves, or the multiply scattered portion of ultrasonic waves, have been found to be indicative of small changes in complex material such as concrete. The relationship between concrete damage and relative velocity change and decorrelation of coda waves has been studied, but a generalized model which detects when damage occurs in a concrete structure is still lacking. The presented method uses features extracted from coda waves to detect early damage in concrete structures. The model uses unsupervised learning and only requires data from undamaged structures for training. During the training process, the reconstruction error of the training data is minimized. When the data collected from damaged concrete structures is used as an input of the model, it returns high reconstruction errors that indicate the occurrence of damage in the structures. The performance of the model is validated using experimental studies and has been shown to generalize across two different ASR specimens.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Preliminary Nuclear Containment Vessel Modeling for Multi-Hazard Probabilistic Risk Assessment under Seismic Hazards and Concrete Degradation

The current practice for natural phenomena hazards (NPH) risk assessment of nuclear facilities is to compute the risk for each hazard independently and then compound the total risk as a combination of single hazard risks. This state of practice does not consider correlations between hazards and the cascading impacts to structures, systems, and components (SSCs), and could thus underestimate the NPH risk or overestimate the nuclear facility safety. Events such as the Fukushima Daiichi accident have highlighted the importance of multi-hazard risk considerations to nuclear power plants (NPPs) that quantify the cascading damage effects to SSCs in the risk models. Moreover, the current fleet of NPPs in the United States is aging; these NPPs are now expected to operate well beyond their initially planned design life. Aging-related deterioration can potentially decrease the capacity of critical structures such as containment vessels to withstand NPH. Such aging considerations may not be adequately accounted for by the current NPH risk assessment guidelines. This paper presents a preliminary modeling and simulation of a representative reinforced concrete containment vessel subjected to seismic mainshock and aftershock considering concrete degradation due to alkali silica reaction. The broader aim is to develop multi-hazard time-dependent fragility functions that could be subsequently used in the probabilistic risk assessment (PRA) model. The multi-hazard component comes into play due to the consideration of damage to the containment vessel under seismic loads and concrete degradation. Consideration of concrete degradation also brings into play the time-dependent nature of the containment vessel response. The response of the containment vessel under varying degrees of concrete degradation to seismic loads is investigated. The results presented are simulated using the Multi-hazard Analysis for STOchastic time-DOmaiN phenomena (MASTODON) software for seismic analysis and the Blackbear software for concrete degradation and damage modeling. Both software are open source and developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE).

42 ENGINEERING↗
DOE OSTI2025

Nondestructive Evaluation of Concrete: Elastic Property Imaging Through Full-Waveform Inversion

Concrete is a vital material in construction—especially in the nuclear industry, where it is used in critical structures such as containment vessels. Over time, concrete can degrade due to harsh operational and environmental conditions, necessitating that its elastic properties be accurately evaluated to ensure structural integrity and safety. Traditional nondestructive evaluation methods such as ultrasound-based techniques often rely on simplifying assumptions that may not hold true for concrete. This paper presents an advanced ultrasound-based method that uses elastic full-waveform inversion (EFWI) to create detailed images of concrete’s mechanical properties. By accurately modeling wave behaviors such as scattering and reflection, we aim to overcome the limitations of conventional ultrasonic-based methods. In this work, the imaging problem involved reconstructing the various elastic properties of a heterogenous concrete block with three steel rebars embedded in it. The ultrasonic measurements were synthetically generated from multiple sources and receivers, and the reconstruction process was performed using a gradient-based optimization algorithm. Our approach leveraged EFWI to reconstruct high-resolution images of the pressure wave speed, shear wave speed, and density. Multiple misfit functions—including L2-norm, cross-correlation (CC), and L1-norm—combined with total variation (TV) regularization and parameter constraints using a Sigmoid function—were explored for the reconstruction. The results demonstrated that using the L1-norm misfit function in conjunction with TV regularization and Sigmoid constraints significantly improved the reconstruction quality in comparison to traditional methods. This approach provided clearer images with fewer artifacts and better captured background heterogeneity. Our findings highlight that, when properly designed, EFWI carries great potential for providing comprehensive, more accurate, and more reliable assessments of concrete conditions, as is crucial for the maintenance and safety of nuclear power plant structures.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Nonlinear Impact-Echo Test for Quantitative Evaluation of ASR Damage in Concrete

Nonlinear acoustic methods demonstrate high sensitivity for concrete damage evaluation. Among these methods, nonlinear resonance acoustic methods have been widely used in laboratory tests on small scale test samples. In this study, a nonlinear impact-echo (IE) method for concrete damage evaluation was introduced, in which the IE frequency shift was measured at different impact force levels. The nonlinear IE test and the nonlinear impact resonance acoustic spectroscopy (NIRAS) test share similarities in the experimental setup and analysis method. However, the nonlinear IE test excites a local thickness resonance mode of a member instead of the global resonance vibration. Therefore, the analyzed mode is unaffected by member boundary conditions and is applicable to large concrete structural members. To identify the fundamental IE frequencies, multiple impacts were applied along the members. Once the fundamental IE frequencies were determined, the effectiveness of the nonlinear IE method was evaluated by testing seven concrete beam specimens with varying levels of alkali-silica reaction (ASR) damage. In conclusion, the nonlinear IE test demonstrates high sensitivity to concrete damage and allows for quantitative assessment of the damage state of concrete without a baseline measurement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Deterioration of concrete due to ASR: Experiments and multiscale modeling

The process of ASR (Alkali-Silica Reaction) induced expansion and damage in pavement concrete specimens is investigated using laboratory experiments and computational modeling. In the experimental program, the concrete specimens are subject to CS-CPT (climate simulation concrete prism test) to obtain ASR induced expansion with and without external supply of alkali. The dissolution rates of the granodiorite used in the concrete mix and the gel formation rates are determined under concrete-like conditions (pH 13.8, with/without Ca(OH){sub 2} and NaCl) at different temperatures. A micromechanics based computational model with aggregate-scale diffusion and reaction kinetics coupled to an Eigenstrain based micromechanics damage model is developed for the simulation of ASR induced expansion and damage. Data from the experimental program are used to calibrate and validate the computational model. Model predictions show that for the given concrete mixture, ASR induced expansion in the specimen exposed to water is predominantly governed by microcracking in the aggregate, while the expansion in the specimen subjected to external alkali supply is governed by microcracking in both the aggregates and the cement paste.

36 MATERIALS SCIENCE↗