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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming↗
DOE OSTI2020

BISON Development and Validation for Priority LWR-ATF concepts

Over the years, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) (2015-2018, 2020) and Consortium for Advanced Simulation of Light Water Reactors (CASL) (2019) programs have provided support for development of Accident Tolerant Fuel (ATF) material models in the BISON fuel performance code. Since the beginning, the goal has been to utilize a multiscale modeling approach to gain a physical understanding of the fuel concepts of interest and to develop mechanistic models in the absence of a large amount of experimental data. This work builds upon that of previous years. In particular we present newly updated fission gas release models for both gas behavior in Cr 2 O 3 -doped UO 2 and U 3 Si 2 fuels, and a new creep model for U 3 Si 2 . The validation exercises completed last year are revisited with the latest models and the results updated. A brief summary of recent modeling activities for FeCrAl cladding is also provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

In-Situ Ion Irradiation to Add Irradiation Assisted Grain Growth to the Marmot Tool

In the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, the MARMOT mesoscale fuel performance tool is used to inform the development of mechanistic materials models for the BISON fuel performance tool. The grain size of the fuel has a large impact on its performance, directly impacting heat conduction, fission gas release, creep, and fracture. Thus, atomistic and mesoscale MARMOT simulations have been used to investigate grain boundary migration and grain growth in UO 2 . However, the current grain growth models in MARMOT does not consider the effect of irradiation on causing grain growth. This research project experimentally studied and implemented irradiation effects on grain growth of UO 2 into MARMOT.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1980

Initial comparison of SSPM ground test results and flight data to NASCAP simulations

The satellite surface potential monitor (SSPM) has been developed for the P78-2 SCATHA (Spacecraft Charging At The High Altitudes) satellite to determine the response of selected spacecraft materials to charged-particle environmental fluxes. Since the monitor infers total surface voltages from a single point on the interior side of insulators, a ground simulation program was undertaken to develop analytical techniques to model the monitors and to obtain an experimental calibration of the relationship between the flight measurement techniques and actual measurements. The experimental testing was conducted using monoenergetic electron beams irradiating samples in the dark. An analytical computer model was developed in the NASCAP (NASA Charging Analyzer Program) code. The analytical model material properties for Kapton that controlled backscatter and secondary yield were adjusted to obtain a single set of values that produced reasonable fits for both voltages and currents. The analytical techniques developed in the ground technology investigation have been applied to space flight conditions. Predictions were compared with limited flight data. The agreement is very good indicating that the technique, and NASCAP, can be used to predict spacecraft material charging behavior. Details of the testing, the analytical modelling technique and flight data comparisons are presented.

Stevens, N. J.↗
DOE OSTI2020

Sample problems for Section III, Division 5 design by inelastic analysis of Grade 91 components

This report works through two sample design analyses of representative Grade 91 components using the ASME Boiler & Pressure Vessel Code Section III, Division 5, Appendix HBB-T rules for the strain and deformation and creep-fatigue design criteria using a design by inelastic analysis approach. The component geometries and loadings were selected to span a wide variety of potential applications. The sample components are an endplate geometry, which is fairly representative of typical pressure vessel construction, and a core block, representing a critical component in a heat pipe microreactor, which has a complicated geometry and complex thermal stress history. These sample problems serve several functions. First, they are complete worked examples of how to apply the current design by inelastic analysis rules. Second, they serve as test cases to evaluate the current rules and provide feedback on how they could be optimized to deal with complicated component geometries or to be better automated in modern finite element analysis software. Finally, the analysis here uses an inelastic constitutive model for Grade 91 developed by Argonne National Laboratory and proposed for inclusion in the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules as a reference constitutive model. Using this constitutive model in the sample problem analyses tests the model in the context of the ASME Code rules. The final conclusions of this report are that the material model and the current Code rules are satisfactory, but that the Code rules could be optimized to simplify automation and reduce over conservatism. Future work should address the specific optimization topics discussed in this report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1973

Experimental stress analysis of large plastic deformations in a hollow sphere deformed by impact against a concrete block

An experimental plastic strain measurement system is presented for use on the surface of high velocity impact test models. The system was used on a hollow sphere tested in impact against a reinforced concrete block. True strains, deviatoric stresses, and true stresses were calculated from experimental measurements. The maximum strain measured in the model was small compared to the true failure strain obtained from static tensile tests of model material. This fact suggests that a much greater impact velocity would be required to cause failure of the model shell structure.

Morris, R. E.↗
NASA NTRS1981

Use of two-dimensional transmission photoelastic models to study stresses in double-lap bolted joints

The stress distribution in two hole connectors in a double lap joint configuration was studied. The following steps are described: (1) fabrication of photoelastic models of double lap double hole joints designed to determine the stresses in the inner lap; (2) assessment of the effects of joint geometry on the stresses in the inner lap; and (3) quantification of differences in the stresses near the two holes. The two holes were on the centerline of the joint and the joints were loaded in tension, parallel to the centerline. Acrylic slip fit pins through the holes served as fasteners. Two dimensional transmission photoelastic models were fabricated by using transparent acrylic outer laps and a photoelastic model material for the inner laps. It is concluded that the photoelastic fringe patterns which are visible when the models are loaded are due almost entirely to stresses in the inner lap.

Hyer, M. W.↗
DOE OSTI2020

Accelerating Finite-temperature Kohn-Sham Density Functional Theory\ with Deep Neural Networks

We present a numerical modeling workflow based on machine learning (ML) which reproduces the the total energies produced by Kohn-Sham density functional theory (DFT) at finite electronic temperature to within chemical accuracy at negligible computational cost. Based on deep neural networks, our workflow yields the local density of states (LDOS) for a given atomic configuration. From the LDOS, spatially-resolved, energy-resolved, and integrated quantities can be calculated, including the DFT total free energy, which serves as the Born-Oppenheimer potential energy surface for the atoms. We demonstrate the efficacy of this approach for both solid and liquid metals and compare results between independent and unified machine-learning models for solid and liquid aluminum. Our machine-learning density functional theory framework opens up the path towards multiscale materials modeling for matter under ambient and extreme conditions at a computational scale and cost that is unattainable with current algorithms.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Further buffeting tests in a cryogenic wind tunnel

Further measurements of buffeting, using wing-root strain gauges, were made in the NASA Langley 0.3 m Cryogenic Wind Tunnel to refine techniques which will be used in larger cryogenic facilities such as the United States National Transonic Facility (NTF) and European Transonic Wind Tunnel (ETW). The questions addressed included the relative importance of variations in frequency parameter and Reynolds number, the choice of model material (considering both stiffness and damping) and the effects of static aeroelastic distortion. The main series of tests was made on half models of slender 65 deg delta wings with a sharp leading edge. The three delta wings had the same planform but widely different bending stiffness and frequencies (obtained by varying both the material and the thickness of the wings). It was known that the flow on this configuration would be insensitive to variations in Reynold number. Additional tests were made on one unswept half-wing of aspect ratio 1.5 with an NPL 9510 aerofoil section, known to be sensitive to variations in Reynolds number at transonic speeds. For brevity the test Mach numbers were restricted to M = 0.21 and 0.35 for the delta wings and to M = 0.30 for the unswept wing.

Mabey, D. G.↗
NASA NTRS1994

Modeling of outgassing and matrix decomposition in carbon-phenolic composites

Work done in the period Jan. - June 1994 is summarized. Two threads of research have been followed. First, the thermodynamics approach was used to model the chemical and mechanical responses of composites exposed to high temperatures. The thermodynamics approach lends itself easily to the usage of variational principles. This thermodynamic-variational approach has been applied to the transpiration cooling problem. The second thread is the development of a better algorithm to solve the governing equations resulting from the modeling. Explicit finite difference method is explored for solving the governing nonlinear, partial differential equations. The method allows detailed material models to be included and solution on massively parallel supercomputers. To demonstrate the feasibility of the explicit scheme in solving nonlinear partial differential equations, a transpiration cooling problem was solved. Some interesting transient behaviors were captured such as stress waves and small spatial oscillations of transient pressure distribution.

Mcmanus, Hugh L.↗
DOE OSTI2021

Phase Stability of Yttrium Titanium Oxide

This proposed study aims at elevating Idaho National Laboratory (INL)’s portfolio in nuclear material research on two major fronts: 1) expanding INL’s material characterization capabilities to provide holistic microstructural and microchemical characterization ranging from atomic scale to millimeter scale, and 2) filling the knowledge gap on the effect of microstructural evolution on material phase stability at extreme conditions resembling those inside nuclear reactors, using Yttrium-Titanium-Oxide (YTO) as a model material. Previous research indicated the kinetics of phase transition of YTO materials varies between bulk samples and powder samples, suggesting that microstructural characteristics such as defect, micro-strain, and crystallite size could play a significant role in phase transition. The effect of crystallite size on the thermodynamics of phase transition has been well documented for other ceramic materials at nanometer crystallite size, with potential impacts from surface and strain energy and defects. In this proposed study, we will perform microstructural (micro-strain, crystallite size, defects, phase) and microchemical (elemental mapping) analyses through in-situ high temperature measurements using X-ray diffraction (XRD; at millimeter scale for powder and bulk samples) and transmission electron microscopy (TEM, at nanometer scale and atomic scale for powder and thin foil samples), to provide a comprehensive view of the effect of microstructural and microchemical evolution on phase transition and phase stability of YTO materials. These findings will also establish a roadmap and provide new insights on the phase stability of other materials that are critical to nuclear energy and other renewable energy infrastructure. Besides advancing our understanding of this fundamental material science question, this project will also enable the development of state-of-the-art material characterization capabilities at INL/MFC for microstructural and microchemical analysis at high temperature conditions. The new collaboration between the High-Resolution Materials Characterization group at INL and the Electron Microscopy group at the University of Florida (UF) in this project will open the possibilities for more fruitful and synergetic cutting-edge nuclear material research in the future.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Buffeting tests in a cryogenic windtunnel

Measurements of wing buffeting, using root strain gages, were made in the NASA Langley 0.3 m cryogenic wind tunnel to refine techniques which will be used in larger cryogenic facilities such as the United States National Transonic Facility (NTF) and the European Transonic Wind Tunnel (ETW). The questions addressed included the relative importance variations in frequency parameter and Reynolds number, the choice of model material (considering both stiffness and damping) and the effects of static aeroelastic distortion. The main series of tests was made on three half models of slender 65 deg delta wings with a sharp leading edge. The three delta wings had the same planform but widely differing bending stiffnesses and frequencies (obtained by varying both the material and the thickness of the wings). It was known that the steady flow on this configuration would be insensitive to variations in Reynolds number. On this wing at vortex breakdown the spectrum of the unsteady excitation is unusual, having a sharp peak at particular frequency parameter. Additional tests were made on one unswept half-wing of aspect ratio 1.5 with an NPL 9510 aerofoil section, known to be sensitive to variations in Reynolds number at transonic speeds. The test Mach numbers were M = 0.21 and 0.35 for the delta wings and to M = 0.30 for the unswept wing. On this wing the unsteady excitation spectrum is fairly flat (as on most wings). Hence correct representation of the frequency parameter is not particularly important.

Mabey, D. G.↗
DOE OSTI2024

Preliminary Experimental Results in Support of the Development of EPP and SMT Design Methods and Viscoplastic Model for A709

The ASME code qualification effort for Alloy 709 (A709) is currently underway to qualify it for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5. The United States (U.S.) Department of Energy (DOE) national laboratories are collaborating in the advanced materials development initiative to investigate the mechanical performance of A709 in support of its code qualification. As part of the A709 code qualification effort, this report summarizes ORNL’s initial experimental findings that support the integration of A709 into the elastic-perfectly plastic (EPP) strain limits code case. It also covers thermomechanical fatigue testing conducted to develop viscoelastic material models, along with the preliminary results of creep-fatigue experiments at 816°C using the Simplified Model Test (SMT) method.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Accelerating Finite-Temperature Kohn-Sham Density Functional Theory with Deep Neural Networks

We present a numerical modeling workflow based on machine learning (ML) which reproduces the total energies produced by Kohn-Sham density functional theory (DFT) at finite electronic temperature to within chemical accuracy at negligible computational cost. Based on deep neural networks, our workflow yields the local density of states (LDOS) for a given atomic configuration. From the LDOS, spatially-resolved, energy-resolved, and integrated quantities can be calculated, including the DFT total free energy, which serves as the Born-Oppenheimer potential energy surface for the atoms. We demonstrate the efficacy of this approach for both solid and liquid metals and compare results between independent and unified machine-learning models for solid and liquid aluminum. Our machine-learning density functional theory framework opens up the path towards multiscale materials modeling for matter under ambient and extreme conditions at a computational scale and cost that is unattainable with current algorithms.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2011

Response of Honeycomb Core Sandwich Panel with Minimum Gage GFRP Face-Sheets to Compression Loading After Impact

A compression after impact study has been conducted to determine the residual strength of three sandwich panel constructions with two types of thin glass fiber reinforced polymer face-sheets and two hexagonal honeycomb Nomex core densities. Impact testing is conducted to first determine the characteristics of damage resulting from various impact energy levels. Two modes of failure are found during compression after impact tests with the density of the core precipitating the failure mode present for a given specimen. A finite element analysis is presented for prediction of the residual compressive strength of the impacted specimens. The analysis includes progressive damage modeling in the face-sheets. Preliminary analysis results were similar to the experimental results; however, a higher fidelity core material model is expected to improve the correlation.

McQuigg, Thomas D.↗
DOE OSTI2024

Exploring the Feasibility of INCONEL® ALLOY 740H® for Power Plant Headers: Integrating Machine Learning with Computational Fluid Dynamics (CFD)

This keynote presentation explores the behavior of headers—essential components of pipeline systems—using ANSYS simulation software and machine learning techniques. The study aims to predict the thermal and mechanical performance of headers under diverse conditions through both steady-state and transient simulations. We investigate critical parameters such as heat transfer coefficient, fluid velocity, and temperature to optimize header design. Conducted as part of a DOE project led by NCAT in collaboration with UNC Charlotte, this research encompasses multiple key topics. The initial section focuses on the behavior of header systems under steady-state conditions using ANSYS simulation. It underscores the importance of headers in industrial infrastructure, especially in the energy sector, and examines the implications of material selection and flow direction on heat transfer dynamics. Methodologically, we employ Computational Fluid Dynamics (CFD) analysis through ANSYS, detailing the development of models, material properties, geometry specifications, boundary conditions, and meshing strategies. Our simulations explore various operational parameters, including temperature and mass flow rates, crucial for predicting heat transfer coefficients and enhancing header design. Results from the study include parametric investigations into mesh sensitivity, viscosity model evaluations, and the effects of heat transfer locations, all validated against theoretical calculations. We conclude with insights on mesh optimization, the suitability of viscosity models, and recommendations for future research aimed at improving header system efficiency and sustainability in industrial applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Characterization of modeling and experimental data inconsistencies from burst testing for high-burnup commercial fuel rod applications

Fuel fragmentation, relocation, and dispersal are some of the largest issues remaining in the nuclear industry before rod-average burnup can be increased beyond 62 GWd/tU. The issue is primarily related to the potential for fuel to be dispersed into the reactor primary system, which may increase public risk. One way to prevent dispersal is to avoid cladding burst. The objective of this work is to support the high burnup safety case by evaluating cladding burst under high-burnup, full-length fuel rods and to identify uncertainties that could improve model predictions. The results of this analysis will evaluate realistic, prototypic loss-of-coolant accident (LOCA) conditions; support future cladding burst test designs; and inform the development of mechanistic material models. Realistic high-burnup operating conditions were implemented in the BISON fuel performance code to simulate steady-state and LOCA transient fuel rod evolution to the point at which cladding burst occurred. Parametric studies are performed to assess code response to changes in rod internal pressures and heating rates. Results were compared with simulated LOCA experiments to identify inconsistencies between commercial fuel rod analysis and experimental validation. The representative full-length fuel rod LOCA simulation results did not agree with cladding burst tests. Cladding burst tests indicated burst occurring well below (100–150 °C) those calculated in the full-length fuel rod LOCA analysis. Further investigation indicated that the cladding burst tests do not appear to be representative for full-length fuel rods. The inconsistency investigated in this work showed that the differences between the BISON simulation and the experiment's cladding burst conditions arise from an incomplete characterization of the cladding surface temperature, detailed rodlet characterization, lack of cladding strain measurements, and uncertainty in the cladding creep and failure models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗