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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

Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Stress-strain and failure properties of graphite/epoxy laminates

The results of a series of tensile tests on graphite/epoxy laminates at rates varying from 0.002 in/min to 2 in/min are reported. The loads are applied at various angles to the fiber directions in each case. The rate dependent behavior of the stress-strain response is assessed. Evidence is presented to indicate that failure first occurs on inner piles. Also, evidence is presented to indicate that, in some cases, moduli increase with increased stress or strain level. The lamination theory is used to predict moduli and comparisons with experiment are given. Also, the lamination theory is used in conjunction with three failure theories to predict ultimate strengths with varying degrees of success.

Yeow, Y. T.↗

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.

Feldman, Jay D.↗

Predictive Engineering of Interfaces and Cathodes for High-Performance All Solid-State Lithium-Sulfur Batteries

The primary goal of this project is to leverage data-driven methods and machine learning strategies to develop accurate multi-physics models for all-solid-state Li-S battery (ASLSB) materials that can capture electrochemical and transport phenomena over atomic to mesoscopic length/timescales. These models will be rigorously validated by synthesis and advanced characterization experiments. The team will leverage the predictive power of these models, alongside synthesis/characterization experiments and battery fabrication to address longstanding issues at the electrode/electrolyte interfaces in ASLSBs. The project’s proposed technology involves the following: (1) halide-doped solid sulfide electrolytes that can concurrently provide high Li + ion conductivity and suppress dendrite growth; (2) novel mesoporous cathode composed of super-P and carbon nanotubes co-infiltrated with sulfur and sulfide electrolyte, which hold potential to allow high sulfur loading and optimal ion/electron pathways; and (3) functionalization of sulfide electrolyte with ionic liquids to improve physical contact and minimize impedance at the cathode/electrolyte interface. Successful development of proposed predictive models (at multiple scales) will bridge this knowledge gap and will advance fundamental understanding of reaction chemistry, kinetics, charge transfer, and dendrite growth at electrified SSIs. This will enable predictive design of effective strategies to mitigate interfacial problems in ASSLSBs, including poor interfacial contact, interfacial impedance to Li + ion transport, and poor electron/ion conduction within cathodes. Ultimately, the fundamental knowledge gained will lead to development of high-performance ASSLSBs.

25 ENERGY STORAGE↗

The mitochondrial Cu + transporter PiC2 (SLC25A3) is a target of MTF1 and contributes to the development of skeletal muscle in vitro

The loading of copper (Cu) into cytochrome c oxidase (COX) in mitochondria is essential for energy production in cells. Extensive studies have been performed to characterize mitochondrial cuproenzymes that contribute to the metallation of COX, such as Sco1, Sco2, and Cox17. However, limited information is available on the upstream mechanism of Cu transport and delivery to mitochondria, especially through Cu-impermeable membranes, in mammalian cells. The mitochondrial phosphate transporter SLC25A3, also known as PiC2, binds Cu + and transports the ion through these membranes in eukaryotic cells, ultimately aiding in the metallation of COX. We used the well-established differentiation model of primary myoblasts derived from mouse satellite cells, wherein Cu availability is necessary for growth and maturation, and showed that PiC2 is a target of MTF1, and its expression is both induced during myogenesis and favored by Cu supplementation. PiC2 deletion using CRISPR/Cas9 showed that the transporter is required for proliferation and differentiation of primary myoblasts, as both processes are delayed upon PiC2 knock-out. The effects of PiC2 deletion were rescued by the addition of Cu to the growth medium, implying the deleterious effects of PiC2 knockout in myoblasts may be in part due to a failure to deliver sufficient Cu to the mitochondria, which can be compensated by other mitochondrial cuproproteins. Co-localization and co-immunoprecipitation of PiC2 and COX also suggest that PiC2 may participate upstream in the copper delivery chain into COX, as verified by in vitro Cu + -transfer experiments. These data indicate an important role for PiC2 in both the delivery of Cu to the mitochondria and COX, favoring the differentiation of primary myoblasts.

59 BASIC BIOLOGICAL SCIENCES↗

Temperature Humidity and Sea Level Pressure Increments Induced by 1DVAR Analysis of GPS Refractivity

The Global Positioning System (GPS) transmitted signals are affected by the atmosphere. Using the radio occultation technique, where a receiver is placed on a low-Earth-orbiting platform. it is possible to perform soundings. by measuring the bending angles of the rays. The information can be converted into atmospheric refractivity. We have developed a one dimensional variational (1DVAR) analysis that uses GPS/MET 1995 refractivity and 6-hour FVDAS (Finite Volume Data Assimilation System) forecasts as background information to constrain the retrievals. The analysis increments are defined as 1DVAR minus background temperature, humidity and sea level pressure. Before assimilating the 1DVAR profiles into the FVDAS. the increments need to be understood. First, some bias could be induced in the retrievals when confronted with actual biased data: second. bias in the back-round could create undesired bias in the retrievals. Anv bias in the analyses will ultimately change the climatology of the model the retrievals will be assimilated into. We relate the increments to the reduction of the difference between observed minus computed refractivity profiles. We also point out the difference in the mean increments using backgrounds which have assimilated either NESDIS TIROS Operational Vertical Sounder (TOVS) operational retrievals or Data Assimilation Office (DAO) TOVS interactive retrievals. The climatology of the model in terms of refractivity is significantly different and this impacts the GPS 1DVAR increments. This testifies that changing the basic load of assimilated data has an influence on the impact the GPS data may have in a DAS.

Poli, Paul↗

Artificial Generation of 2-D Fiber Reinforced Composite Microstructures with Statistically Equivalent Features

Fiber reinforced composites are used widely for their high strength and low weight advantages in various aerospace and automotive applications. While their use may be sought after, modeling of these material requires increasing fidelity at the lower scales to capture accurate material behavior under loading. The first steps in creating statistically equivalent models to real life cases is developing a method of rapid evaluation and artificial microstructure generation. The outlined work is capable of tracking microscale fiber positions and determining regions of localized volume fraction extrema (high and low end). Groupings of high and low volume fraction regions are called clusters and their geometry is used to characterize the microstructure. These cluster features can be evaluated for both artificial models and actual scans, allowing correlation to be established which can ultimately be used to regenerate statistically equivalent models. The results of this work show that if one feature is to be correlated, a model can be generated which matches almost exactly. But once more features are equally taken into account, the regeneration loses accuracy.

micromechanics↗

G2 Autonomous Control for Cryogenic Delivery Systems

The Independent System Health Management-Autonomous Control (ISHM-AC) application development for cryogenic delivery systems is intended to create an expert system that will require minimal operator involvement and ultimately allow for complete autonomy when fueling a space vehicle in the time prior to launch. The G2-Autonomous Control project is the development of a model, simulation, and ultimately a working application that will control and monitor the cryogenic fluid delivery to a rocket for testing purposes. To develop this application, the project is using the programming language/environment Gensym G2. The environment is an all-inclusive application that allows development, testing, modeling, and finally operation of the unique application through graphical and programmatic methods. We have learned G2 through training classes and subsequent application development, and are now in the process of building the application that will soon be used to test on cryogenic loading equipment here at the Kennedy Space Center Cryogenics Test Laboratory (CTL). The G2 ISHM-AC application will bring with it a safer and more efficient propellant loading system for the future launches at Kennedy Space Center and eventually mobile launches from all over the world.

cryogenic fluids↗

Room temperature shear properties of the strain isolator pad for the shuttle thermal protection system

Tests were conducted at room temperature to determine the shear properties of the strain isolator pad (SIP) material used in the thermal protection system of the space shuttle. Tests were conducted on both the .23 cm and .41 cm thick SIP material in the virgin state and after fifty fully reversed shear cycles. The shear stress displacement relationships are highly nonlinear, exhibit large hysteresis effects, are dependent on material orientation, and have a large low modulus region near the zero stress level where small changes in stress can result in large displacements. The values at the higher stress levels generally increase with normal and shear force load conditioning. Normal forces applied during the shear tests reduces the low modulus region for the material. Shear test techniques which restrict the normal movement of the material give erroneous stress displacement results. However, small normal forces do not significantly effect the shear modulus for a given shear stress. Poisson's ratio values for the material are within the range of values for many common materials. The values are not constant but vary as a function of the stress level and the previous stress history of the material. Ultimate shear strengths of the .23 cm thick SIP are significantly higher than those obtained for the .41 cm thick SIP.

Sawyer, J. W.↗

Plate and butt-weld stresses beyond elastic limit, material and structural modeling

Ultimate safety factors of high performance structures depend on stress behavior beyond the elastic limit, a region not too well understood. An analytical modeling approach was developed to gain fundamental insights into inelastic responses of simple structural elements. Nonlinear material properties were expressed in engineering stresses and strains variables and combined with strength of material stress and strain equations similar to numerical piece-wise linear method. Integrations are continuous which allows for more detailed solutions. Included with interesting results are the classical combined axial tension and bending load model and the strain gauge conversion to stress beyond the elastic limit. Material discontinuity stress factors in butt-welds were derived. This is a working-type document with analytical methods and results applicable to all industries of high reliability structures.

Verderaime, V.↗

New Alloys for Electroformed Replicated X-Ray Optics

The process of electroforming x-ray mirror shells off a superpolished mandrel has been widely used. The recently launched XMM mission is a good example of this, containing 174 such mirror shells of diameters ranging from 0.3-0.7 m and thicknesses of 0.47-1.07 mm. To continue to utilize this technique for the next generation of x-ray observatories, where ever-larger collecting areas will be required within the constraints of tight weight budgets, demands that new alloys be developed that can withstand the large stresses imposed on very thin shells by the replication and handling processes. Towards this end, we began a development program in late 1997 to produce a high-strength alloy suitable for electroforming very thin high-resolution x-ray optics. The requirements for this task are quite severe; not only must the electroformed deposit be very strong, it must also have extremely low residual stresses to prevent serious figure distortions in large thin-walled shells. Further, the electroforming must be performed at near room temperature, as large temperature changes will modify the figure of the mandrel, in an environment that is not corrosive for the mandrel. The figure of merit for the strength of the electroformed deposit is its Precision Elastic Limit (PEL). This is a measure of permanent strain, at the few parts per million level, under applied stress. Pure nickel is very ductile and will permanently deform, at the parts-per-million level under loads of a few x 10(exp 7) Pa. These stresses are easily exceeded when thin-walled shells (150 micron thick) are replicated. Our goal was to develop an alloy an order of magnitude stronger than this. We will present the results of our development program, showing the evolution of our plating baths through to our present 'glassy' nickel alloy that satisfies the goals above. For each we will show the electroforming characteristics of the bath and the PEL measurements for the resulting alloys. We estimate the ultimate limit on shell thickness and mass for x-ray mirrors produced in these baths.

Engelhaupt, D.↗

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

Crycooling↗

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heaters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

cryocooling↗

3D Printed Ceramic Reinforced Polymer Composites Microstructure and Mechanical Properties

In Fused Filament Fabrication (FFF) 3D printing a part is made by extruding material layer by layer. Benefits of FFF are the ability to print complex shapes quickly and at a lower cost compared to other manufacturing methods. In this work, filaments composed of either silicon carbide (SiC) or zirconium silicate ceramic particulates in a polylactic-acid (PLA) matrix were used to print specimens for microstructural analysis and mechanical testing. Pure PLA samples were also printed and tested as a baseline for comparison. A Design of Experiments approach was used to test the interactions between three different parameters and their effect on ultimate strength, Young’s modulus, and yield strength. For compression test specimens, these parameters were infill percentage, number of shells, and print orientation angle. For tensile test specimens, the parameters were layer height, number of shells, and infill orientation angle. Pre- and post-compression test samples were evaluated by scanning electron microscopy for microstructural analysis. Infill percentage had the greatest effect on mechanical properties while number of shells and print orientation angle had minor effects. When changing the layer lines from perpendicular to parallel, relative to the loading direction, SiC-PLA had higher mechanical properties while pure PLA properties had decreased, and zirconium silicate-PLA had mix results.

Fused filament fabrication↗

Requirements Document for a Replacement Data Acquisition System

A flight vehicle is in the developmental stages. While in development flight testing is required by both the manufacturer and customer to rate design performance. The performance of the vehicle must fulfill the agreed upon requirements. Testing of a flight vehicle during operation requires various sensors in order to record and monitor performance for evaluation. A Data Acquisition System (DAQ) is needed in order to control and capture data from various sensors placed throughout the vehicle during flight. This DAQ will receive the analog data from the suite of sensors and convert them to a digital signal that can be transmitted to a recording station where the data will later be analyzed by test experts. Some of the key features to be included in the DAQ will be a self-check operation to verify the health of all sensors including the DAQ. The DAQ will also have the capability to store sensor calibration data files loaded during assembly and transmit those files to the recording station during flight. Breakthroughs in new technologies has allowed for higher resolution recording systems and faster sampling rates. Improved sensor data using a new Data Acquisition System (DAQ) can provide important answers to questions discovered during the last few flight tests. These questions arose when the flight system expressed unexpected behaviors. Having the capability of the new DAQ in flight tests would allow for more high-fidelity data to be captured from the system during flight tests and ultimately reducing the number of required flight test. Reducing the number of flight tests also reduce developmental cost and schedule.

42 ENGINEERING↗

Subcomponent Validation of Composite Joints for the Marine Energy Advanced Materials Project

The Marine Energy Advanced Materials project is an ongoing multi-year, multi-lab project with the main goals of addressing barriers and uncertainties facing marine energy developers in adopting advanced materials for structural applications. NREL's goals of the project were to address subcomponents testing needs for marine energy materials, to improve understanding of design allowables at the full-scale and provide near net-scale static and fatigue data of composite subcomponents using materials applicable to the marine energy industry. In the long term, the test method development and data generated would be used to inform standards development. This report outlines perhaps one of the largest-scale studies conducted with regards to saltwater conditioning of various composite material subcomponents and their subsequent structural validation, specifically directed at the marine renewable energy industry. A variety of fiberglass composite panels with epoxy and vinyl ester epoxy resin systems were manufactured at Montana State University, which were then used to manufacture an array of different types of subcomponent test specimens at the National Renewable Energy Laboratory's Flatirons Campus. These subcomponents were in the form of T-bolt and double-ended-insert specimens, which were intended to represent bonded and mechanical bolted connections for thick composite laminates, metal-metal and composite lap shear specimens to evaluate adhesion of constituent materials, and adhesive beam-shear specimens as part of an effort to better evaluate the characteristics of thick adhesive bondlines. Overall, the materials used were fiberglass reinforced epoxy and vinyl ester matrix composites, epoxy and methacrylate adhesives, and 316 and 2507 stainless steels. Specimens were then conditioned in salt water at various temperatures and for various periods of time at Florida Atlantic University and Pacific Northwest National Laboratory. All specimens were then mechanically characterized and validated using various test methods under static and fatigue loading conditions at NREL's Structural Technology Laboratory. Throughout the conditioning and mechanical validation process, valuable experience was gained, which will help guide future test method development for marine energy materials. In many instances, the results indicated similar observations as to what had been observed during previous coupon scale characterization efforts that provided a vital understanding of the scale up process. However in some instances, unexpected phenomena were observed, such as interactions between the adhesives and 316 steel. Furthermore, some materials exhibited significant degradation due to the saltwater conditioning. Ultimately, this report provides a detailed summary of the specimens that were designed, the subcomponent test methods that were developed, and the results that were generated, which will serve as important guidance for marine renewable energy developers and researchers for future structural designs and validation.

16 TIDAL AND WAVE POWER↗

Hindlimb suspension diminishes femoral cross-sectional growth in the rat

Growth, functional adaptation, and torsional strength were examined in the femora of 39-day-old male Sprague-Dawley rats subjected to hindlimb suspension for 0, 1, 2, 3, or 4 weeks and were compared with measurements for age-matched control animals. Our goal was to understand the effect of reduced loading on the normal age-related changes in femoral properties during growth. The control animals exhibited growth-related increases in all geometric and torsional properties of the femur. The mean body mass and femoral length of the hindlimb-suspended rats were similar to those of the controls throughout the experiment. Over 4 weeks, the femoral cross-sectional and torsional measurements from the hindlimb-suspended rats demonstrated increases in comparison with the basal values (+33% cross-sectional area, +64% polar moment of inertia, +67% ultimate torque, and +181% torsional rigidity), but the age-matched controls showed significantly greater growth-related increases (+71% cross-sectional area, +136% polar moment of inertia, +127% ultimate torque, and +367% torsional rigidity). The differences in femoral structural strength between the hindlimb-suspended animals and the age-matched controls were attributable to differences in altered cross-sectional geometry.

NASA Discipline Musculoskeletal↗