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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Refined BISON-Griffin Workflow For Designing Targeted TRISO Transient Experiments In The Transient Reactor Test Facility

U.S. industry is expected to deploy tristructural isotropic (TRISO) particle fuel technologies for commercial reactors within the next decade. In our previous work, we defined a preliminary transient design space for TRISO fuels, identified potential gaps in the available data, and began to develop multiphysics modeling tools that could be applied to design targeted Transient Reactor Test Facility (TREAT) experiments to fill these gaps. This work builds on that foundation by (1) updating BISON fuel performance and Griffin reactor physics models to reflect the current TREAT experiment tube and capsule designs,(2) coupling the codes to improve the accuracy and usability of the transient design analyses, and (3) demonstrating their use over an expanded design space that includes fuel burnup. The simulated mechanical responses of the TRISO particles were complex functions of fission product accumulation, fission gas release, and irradiation-induced dimensional change in the pyrolytic carbon layers. Predicted tangential stresses in particle silicon carbide layers were least compressive for preheated tests involving fresh fuels but remained compressive throughout the ranges of temperature, heat rate, and burnup considered in this work. Finally, comparisons between the potential TREAT transients and historical test reactor irradiations showed that the TREAT tests would produce significantly lower average energy deposition rates, yielding less severe transients with greater relevance to near-term commercial applications. Use of these predictive capabilities has the potential to increase the value of each test, improving the overall efficiency and cost effectiveness of transient testing for TRISO and other advanced fuels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Thermoplastic Polymer from Lignin: Creating an Extended Polyamide Network through Reactive Kraft Lignin Derivatives

Thermoplastic polymers have many desirable properties for consumer applications and are complemented by efficient thermal processing techniques, reducing the cost of manufacturing. Lignin exists as an immense biobased carbon source but has largely been researched for its use in thermoset materials due to its own cross-linked, polyfunctional nature. In this study, a new reaction design is employed to create a thermoplastic polyamide network incorporating lignin that is tested to be 99% biobased carbon by radiocarbon analysis. Chemical analysis reveals the nature of lignin incorporation based on chain extension and cross-linking models. The thermal and rheological properties of the new polymers are thoroughly investigated to demonstrate the higher melt-strength capability of the lignin-based polymers facilitating their use in modern processing equipment. This analysis results in finding an optimal lignin loading ratio in the polymer composition reflected by improved tensile strength and stiffness. The results point to a promising polymer design for applying industrial kraft lignin in high-value thermoplastic polymer applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Affinity of LDR Organics to Cementitious Materials: Sorption and Leaching Tests

SRNL is working to identify and test the physiochemical interactions of organic contaminants of potential concern with minerals in grout/cementitious materials. Organic species may interact with cementitious minerals including slag, fly ash, cement, and other components/dopants like carbon in fly ash. The identification of such interactions will support the solidification process design, performance assessments for the chemicals of concern, and a proposed Resource Conservation and Recovery Act (RCRA) treatment variance specified for the Land Disposal Restriction (LDR) organics associated with Hanford tank waste. Inably expected to be present LDR organics associated with Hanford tank waste (RPP-RPT-63493, Rev 1a) was screened by functional groups, octanol-water partitioning coefficients, and detection frequency in Hanford tank waste samples. A subset of 10 compounds, spanning the identified properties, were tested using sorption and leachate tests. These compounds were subjected to traditional batch sorption tests and leaching tests on/from Cast Stone cementitious material with and without activated carbon (a potential organic adsorption additive). The interactions between organic compounds were observed in traditional batch sorption and modified Toxic Characteristic Leaching Procedure (TCLP) leachate tests for a surrogate Cast Stone material with and without an activated carbon addition. Specifically, phthalic acids (negatively charged) and 4-chloroaniline (polar) sorbed strongly to unmodified Cast Stone and a group of 3 phenolic compounds (2,4,6-Trichlorophenol, Pentachlorophenol, o-Cresol) were sorbed to and were retained by Cast Stone with a 1% activated carbon amendment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Predicting Safety Rod Reactivity Insertion in the Advanced Test Reactor

The Advanced Test Reactor (ATR), and complimentary zero-power ATR Critical (ATRC) reactor, located at Idaho National Labs (INL), are undergoing conversion from Highly Enriched Uranium (HEU) to Low Enriched Uranium (LEU). Both have a variety of testing locations that can receive large variations in flux due to its unique serpentine design, consisting of five lobes surrounding nine flux traps (see Figure 1). Initial criticality and power distribution throughout the core are controlled by core-external outer shim control cylinders (OSCCs). Distinct test loops allow for testing at specific temperatures, pressures, and irradiation conditions such as flux and fission density. The ATR is one of the key nuclear engineering research and testing facilities within the DOE National Laboratory Complex, and the ATRC supports its operation [1]. Currently, the Office of Material Management and Minimization (M3) within the National Nuclear Security Administration of the DOE is working to convert the remaining research reactors, including the ATR, from 93% HEU fuel to 19.75% LEU fuel (LEU) to support non-proliferation [2]. Extensive materials testing at INL and internationally has demonstrated that a high-density uranium molybdenum (U 10Mo) alloy can meet the performance requirements of the remaining high powered research reactors. The current LEU fuel element design is named the LOWE element. However, there are many technical challenges to address before the conversion to LEU can be successful, including the accurate characterization of the reactor core physics with LEU fuel. To ensure safe operation of the ATR, reactor engineers prepare a CSAP (Core Safety Assurance Package) before each cycle. The purpose of the CSAP is to verify the reactor performance calculation used to determine if the selected fuel loading meets operational, experimental, and safety criteria. Many of the criteria in the CSAP are limits on reactivity insertion in various accident scenarios.

42 ENGINEERING↗
DOE OSTI2020

Development of the 3 m{sup 3} Low Level Radioactive Waste Container in Taiwan - 20037

Chinshan Nuclear Power Plant stopped its business operation in July, 2019, and Kuosheng Nuclear Power Plant will also be permanently shut down in 2023. Nuclear Reactor Facilities Regulation Act requires a nuclear facility must be dismantled in 25 years after being permanently ceased operation. According to the approved decommissioning plan of Chinshan Nuclear Power Plant and the proposed one of Kuosheng Nuclear Power Plant, the 3 m{sup 3} low level radioactive waste container is planned to store the low level radioactive wastes with higher radiation produced during the decommissioning. However, 3 m{sup 3} low level radioactive waste containers are not used or developed in Taiwan before. To meet such need, Institute of Nuclear Energy Research develops a new type of 3 m{sup 3} low level radioactive waste container and performs the corresponding analyses and tests based on Guidelines of Applying the Usage License of Low Level Radioactive Waste Containers and Regulations for the Safe Transport of Radioactive Material. In this article, it provides the information of the low level radioactive waste containers that have been approved or is under reviewing in Taiwan, and so do the design specifications of the developed 3 m{sup 3} waste container. Besides, the numerical evaluation and test results of the developed 3 m{sup 3} waste container are also included in this article. Based on the evaluation and test results, the developed 3 m{sup 3} waste container satisfies the requirements of the storage container and industrial package type 2. Institute of Nuclear Energy Research will submit the usage license applications to the authority this year, and the usage licenses would be granted in 2021, expectedly. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2020

Parametric Design Study of a Power Electronics Package for Improving Solder Joint Reliability

The lifetime of a power electronics package is, to a large extent, determined by the reliability of its bonded interfaces under major loading conditions in an operational environment. Based on the application-level requirements of the package, bonded interface material is selected based on the results obtained from accelerated tests such as thermal cycling and power cycling. In addition to evaluating the reliability through accelerated tests, it is important to consider the impact of other component layers on the thermomechanical performance of the interface material, both from a material and geometric perspective. The co-efficient of thermal expansion (CTE) mismatch introduced by the use of different materials within a package and its structural design plays a critical role in determining the interface material reliability. In this paper, we present the results of a parametric modeling study of a power electronics package under thermal cycling in which the materials and geometric design of the different component layers were varied with respect to a baseline design to understand their impact on the reliability of the interface material. We chose the volume-averaged strain energy density per cycle computed at the corner region of the interface material as the metric for the reliability comparisons. Our results indicate that in addition to the CTE mismatch, the stiffness of individual component layers has a major impact on reliability. Among the different baseplates that we studied, aluminum silicon-carbide baseplates offered superior reliability over their copper and aluminum counterparts. We also found that the magnitude of the impact of stiffness variation—amongst the adjacent layers—on the reliability of the solder joint is dependent on the inherent CTE mismatch between the layers.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Developing reactors for electrifying bio-methanation: a perspective from bio-electrochemistry

The integration of microbial synthesis with renewable electricity is an emerging route for both CO 2 utilization and seasonal energy storage in the form of stored bio-electrofuels. The major benefits of electrifying bioreactors include: using highly selective bio-catalysts for CO 2 conversion under mild reaction conditions; decoupling the production of more facile electrochemical intermediates, such as hydrogen, at the electrode from the production of bio-catalyzed multi-electron and/or carbon products, such as methane or acetate; using microbes as robust and self-regenerating catalysts enabling higher efficiency and durability in CO 2 conversion systems compared to inorganic catalysis. In this Perspective, we propose research aimed at developing electro-bioreactor components that will increase the productivity of the reactor while maintaining high energy efficiency and biocompatible reaction conditions to fully realize the benefits of electrified bioreactors. Furthermore, these developments include: flow reactors with tailored 3D electrodes to optimally use the reactor volume, electrocatalysts designed for peak performance in neutral pH electrolytes, high conductivity microbial media, and new membrane separator materials with high ion conductivity and low gas permeability. Production of methane via a hybrid electrical-biological approach is taken as a case study to motivate these developments. Finally, an iterative design–manufacture–test cycle, enabled by additive manufacturing and 3D printing technologies, is proposed to rapidly prototype components prior to large-scale manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Cost-Effective Thermally Activated Building Systems to Support a Power Grid System With High Penetrations Of As-Available Renewable Energy Resources

With a goal to reduce the energy cost for building operation as well as to support renewable energy sources (RES) for the power grid reliability, quality, resilience, and dispatchability, this project developed and demonstrated a novel thermally activated building envelope system that integrates Phase Change Material (PCM)-based Thermal Energy Storage (TES) and the hydronic activation into the building envelope. The main objectives of this study are: 1) to design and laboraorty-test a novel thermally activated building envelope system that integrate PCM-based TES and the hydronic activation into building envelope, and 2) to exploit this new system to significantly reduce the energy cost of operating buildings and manage and support renewable energy sources (RES), e.g., solar and wind for the power grid reliability, quality, resilience, and dispatchability. To achieve the project objectives, a new low-cost, fire-retardant PCM packaging technology (CenoPCM) was developed specifically for high-volume building applications.

25 ENERGY STORAGE↗
DOE OSTI2026

A meshing framework for digital twins for extrusion based additive manufacturing

Additive manufacturing (AM) allows for manufacturing of complex three-dimensional geometries not typically realizable with standard manufacturing practices. The internal microstructure of AM components has a significant impact on mechanical, vibrational, and shock properties and permits richer design space when this is controllable. Due to complex interactions of internal geometry of an extrusion-based AM component, it is common practice to assume homogeneous behavior or to perform characterization testing on specific toolpath configurations. To avoid testing or material waste, it is necessary to develop a consistently accurate numerical simulation framework with relevant boundary value problems that can handle the complicated geometry of internal material microstructure present in AM components. Herein, a framework is proposed to directly create computational meshes suitable for finite element analysis (FEA) of the fine-scale features generated from extrusion-based AM tool paths to maintain a strong process–structure–property-performance linkage. This mesh can be manually or automatically analyzed using standard FEA simulations such as quasi-static preloading or modal analysis. The framework allows an in-silico assessment of a target AM geometry where fine-scale features greatly impact quantities of design interest such as in soft elastomeric lattices where toolpath infill can greatly influence the self-contact of a structure in compression, which we use as a motivating exemplar. This approach greatly reduces both time and resource waste present in traditional build and test design cycles for non-intuitive design spaces, and acts as a tool for use in the production of a key component of a digital twin, a mesh suitable for finite element analysis. In conclusion, it also further allows for the exploration of toolpath infill to optimize component properties beyond simple linear properties such as density and stiffness.

Additive manufacturing↗
DOE OSTI2024

Lattice Design and Advanced Modeling to Guide the Design of High-Performance Lightweight Structural Materials

Lightweight structural materials are required to increase the mobility of fission batteries. The materials must feature a robust combination of mechanical properties to demonstrate structural resilience. The primary objective of this project is to produce lightweight structural materials whose strength-to-weight ratios exceed those of the current widely used structural materials such as 316L stainless steels (316L SS). To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structures models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The preliminary results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison with the solid material and that the unit cell size of the lattice had a minimal effect. The novelty here is to apply up-front modeling to determine the best structure for the application before actually producing the sample. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for material development.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Yttrium Hydride Post-Irradiation Examination Plan

Micro nuclear reactors are expected to use metal hydride moderators to ensure thier compact design for the flexible operational purposes. Department of Energy’s Microreactor program therefore aims to provide infrasture and qualification bed for the development of micro nuclear reactors. Because micro nuclear reactors must be compact to offer a flexible operational purposes, metal hydrides are expected to be used as neutron moderator materials due to their high hydrogen number density. Los Alamos National Laboratory (LANL) directed by the DOE to provide a qualified fabrication techniques of metals hydride, especially the yttrium hydride (YHx) which provides advantages over other metal hydride candiates. Qualification of YHx involves fabrication, property, and performance pillars, which must be met for the deployment of microreactors. In the support of the qualification process metal hydride, LANL has developed fabrication techniques based in direct hydriding and powder compacting. For both manufacturing techniques, fresh material properties of metal hydrides have been reported in the literature. To establish the performance limits and the qualification parameters, an irradiation campaign has been initated at Idaho National Laboratory (INL). The irradation campaign aims to investigate the critical irradiated YHx properties as a function of neutron fluence and temperaute. The first phase of the irradiation campaign includes the effect of the operating temperature under neutron irradiation which provides initial data on the metal hydrides and informs the manufacturing processes. So that, drop-in irradations in Advanced Test Reactor (ATR) has been designed. This document depicts the post-irradation examination (PIE) plan of the ATR irradiated YHx. Objective of the PIE plan is to serve as a qualification basis for YHx as a neutron moderator material by understanding the impacts irradiation has on the physical and thermophysical properties; to establish a link between fabrication and the irradiated YHx properties; to institute a PIE strategy for other solid-state neutron moderator candidates, and; to inform micro nuclear reactor fuel performance and safety codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Status of EM Pump Modeling Capability for VTR

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analyses of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. Most recently, SAS4A/SASSYS-1 has been selected as the safety analysis software for the Versatile Test Reactor (VTR), a new materials testing Sodium Fast Reactor (SFR) to be built by the Department of Energy. In order to support analysis of the VTR, which will utilize ElectroMagnetic (EM) pumps as the primary coolant pumps, the development of new EM pump modeling capabilities has been initiated for SAS4/SASSYS-1. The new physics-based EM pump model captures systems-level transient performance based on equivalent circuit theory and is highly flexible to model a wide range of electromagnetic pumps of the three-phase linear induction type subject to changes in power supply and plant conditions. Within the equivalent circuit framework, two sub-models are developed to provide options for analysts both with and without a detailed geometric characterization of their pump such that minimal information is required to achieve a realistic working model, but specific details of a particular pump design may be captured if sufficient information is provided. In addition, heat generated from pump operation and its transport through the plant system can be modeled to better capture the behavior of certain transients. This paper will outline the model and derive the governing equations of the new EM pump model. An initial comparison between the simple EM pump model and experimental data is made. This comparison shows that the equivalent circuit model can capture pump performance, with greater accuracy near the rated conditions. In order to demonstrate the transient behavior of the new model, a simple transient with an EM pump replacing the centrifugal pumps in the Advanced Burner Test Reactor is included.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Status of EM Pump Modeling Capability for VTR

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analyses of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. Most recently, SAS4A/SASSYS-1 has been selected as the safety analysis software for the Versatile Test Reactor (VTR), a new materials testing Sodium Fast Reactor (SFR) to be built by the Department of Energy. In order to support analysis of the VTR, which will utilize ElectroMagnetic (EM) pumps as the primary coolant pumps, the development of new EM pump modeling capabilities has been initiated for SAS4/SASSYS-1. The new physics-based EM pump model captures systems-level transient performance based on equivalent circuit theory and is highly flexible to model a wide range of electromagnetic pumps of the three-phase linear induction type subject to changes in power supply and plant conditions. Within the equivalent circuit framework, two sub-models are developed to provide options for analysts both with and without a detailed geometric characterization of their pump such that minimal information is required to achieve a realistic working model, but specific details of a particular pump design may be captured if sufficient information is provided. In addition, heat generated from pump operation and its transport through the plant system can be modeled to better capture the behavior of certain transients. This paper will outline the model and derive the governing equations of the new EM pump model. An initial comparison between the simple EM pump model and experimental data is made. This comparison shows that the equivalent circuit model can capture pump performance, with greater accuracy near the rated conditions. In order to demonstrate the transient behavior of the new model, a simple transient with an EM pump replacing the centrifugal pumps in the Advanced Burner Test Reactor is included.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Printed Strain Gauges for Anthropomorphic Test Dummies for Vehicle Crash Testing

In Phase 1 of the technical collaboration between Oak Ridge National Laboratory (ORNL) and Humanetics, additive manufacturing was studied as a method to produce high strain – strain gauges that are embedded in an additively manufactured (AM) anthropomorphic crash test dummy (ATD) to provide high fidelity data to significantly improve vehicle safety. In this study commercially available conductive filament was acquired and the mechanical properties were tested for use in this application. The design space of embedded printed strain gauges was explored with multiple configurations printed and tested for performance. The testing resulted in finding that commercially available filament materials were unable to meet the performance requirements. Finally, an extensive literature survey was performed on advanced manufacturing techniques and novel high strain conductive materials to manufacture strain gauges that can be embedded in to the AM ATD. Humanetics have taken the literature survey and have reached out to material suppliers such as Techmer to provide custom blends of materials for testing. Humanetics will continue to build off of the research that was performed and test custom materials for use in AM ATDs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

VTR Casting Furnace Conceptual Design

This TEV describes the development of a conceptual design for a fuel casting system to be used in the development and demonstration of fuel designs for the new Versatile Test Reactor (VTR). This system will be installed in the Fuel Manufacturing Facility (FMF). The system will be in a shielded glovebox and will be used to melt fuel materials and injection cast these materials into fuel slugs, which will further be used to fabricate fuel elements for the VTR. This TEV covers only the injection casting system itself. Operations such as removing the castings from the injection molds, trimming of the castings, and installation of the castings into fuel element cladding are beyond the scope of the TEV. The conceptual design herein is principally concerned with the mechanical portion of the casting system and does not include details of the control or power supply systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗