Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Voids”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Bio-treatment of poplar via amino acid for interface control in biocomposites

Advanced biocomposites reinforced by abundant biomass-derived fillers can add a revenue stream to enhance the economic viability of biofuel production chains and the energy efficiency of the composite industry. However, the low stiffness of biopolymers limits their use in structural applications. Poplar fibers (mesh size: <180 μm, Populus spp.), an abundant waste from the wood industry, were used as bio-filler to fabricate high-performance biocomposites based on polylactic acid (PLA), in which the poplar fibers were modified by an amino acid (l-lysine). As a benefit of the amino acid treatment, the tensile Young's moduli of the lysine/poplar/PLA composites increased by up to 68% with the addition of a small amount of lysine, compared with neat PLA. At the same time, the tensile strength, failure strain, and Young's modulus of the poplar/PLA composites all increased after adding only 0.1 wt % of lysine. It has been observed that the lysine content has a significant effect on the decomposition temperature, complex viscosity, storage modulus, crystallization temperature, and crystallinity of composites. The fracture surfaces of the composites with an optimum lysine content had fewer voids and were more compact compared with composites without any lysine. The pores on the surfaces of poplar fibers became more available for the penetration of PLA molecules as a result of lysine addition. Finally, this study presents a facile method for reinforcing biocomposites with extremely low-cost and environmentally friendly biofillers.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Light-weight construction, design freedom, integration of functions, and compelling cost element are desired by Original Equipment Manufacturers (OEMs) and their suppliers. The emergence of overmolding of continuous-discontinuous reinforcement enables design freedom and ability to tailor stiffness, strength, and damage tolerance for structural applications. In this work, long fiber thermoplastics (LFT) are overmolded with continuous fiber-reinforced thermoplastic (CFRTP) tape are combined using extrusion compression molding process to evaluate the structural performance. The CFRTP tape overmolded LFT samples were characterized using nondestructive and destructive techniques to track fiber alignment, fiber distribution, manufacturing defects, interfacial bonding of the tape – LFT and effect of CFRTP tape on LFT. Mode 1 fracture toughness, G 1c for tape overmolded LFT was higher by 25–30% compared to literature reported G 1c . This response was attributed to excellent fiber distribution, good fiber wetting, and absence of voids at the interface. Three-point bend test indicated that CFRTP tape overmolded LFT composites were better able to resist damage under the bending load compared to constituent LFT composite. Flexural strength of the overmolded composite was higher by 119–142%, and modulus higher by 77–65% compared to constituent LFT composite. Simulated flexural results accurately represents the mechanical behavior of composites. Here, the penetration energy of tape overmolded LFT composites determined by LVI test was in the range of 27.66–30.15 J, which is significantly higher than constituent LFT composite, 7.76 J. CFRTP tape overmolded LFT composite exhibits progressive fiber fracture, matrix cracking, and interfacial debonding failure, whereas, constituent LFT composite showed catastrophic fiber fracture.

42 ENGINEERING↗
DOE OSTI2021

Hydrogen embrittlement of additively manufactured austenitic stainless steel 316 L

Additive manufacturing (AM) is a promising means of production of austenitic stainless steel (SS) parts for hydrogen service. The hydrogen embrittlement resistance of SS 316 L parts manufactured by powder-bed-fed selective laser melting (SLM) and directed energy deposition (DED) was examined using slow strain rate tensile testing. The influence of the hierarchical AM microstructures on mechanical response, microstructural evolution, and void formation were analyzed using multiscale electron microscopy. Furthermore, the presence of hydrogen reduced ductility in as-built DED materials, but did not significantly influence the response in as-built SLM material or heat-treated materials. Microstructural features driving these different responses are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Understanding a novel form of intergranular corrosion of stainless steel 316L exposed to molten LiCl-Li 2 O-Li

We report stainless steel 316 L exposed to LiCl-Li2O molten salt containing Li metal for 500 and 1000 h experiences deep intergranular attack and bulk void formation. This degradation is due to a synergistic corrosion mechanism, different than other forms of molten salt corrosion, where Cr and Mn oxides and carbides form along grain boundaries and are dissolved by Li metal. Synchrotron transmission X-ray microscopy 3D imaging is used to show corrosion morphology and Cr enrichment and depletion in a novel format that has not previously been used for bulk corrosion samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Perspectives and challenges of ultra-high temperature ceramics for fusion plasma-facing applications

Ultra-high temperature ceramics (UHTCs) offer several potential advantages as plasma-facing components (PFCs) in fusion reactors due to their extreme melting points, tailorable thermal conductivity, and attractive unirradiated mechanical properties including fracture toughness comparable or superior to tungsten. Here, recent developments and material properties of UHTCs are briefly reviewed, along with an overview of limited studies on their responses to neutron irradiation and an evaluation of plasma-surface interactions. Five key research pathways, primarily focused on irradiation effects, for advancing UHTCs in PFC applications are discussed: (1) assessing irradiation effects on the coupled thermal–mechanical performance (2) addressing the lack of studies on irradiation, plasma-surface interactions, and their synergistic effects; (3) investigating high-temperature (>1000 °C) neutron irradiation effects critical for PFC performance; (4) optimizing multi-component UHTC compositions or composites to improve thermal or mechanical properties; (5) enhancing radiation resistance to mitigate microcracking and void swelling through strategies such as increasing sink strength by reducing grain size, introducing fine particles, and leveraging complex concentrated alloy concepts.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A new self-adaptive reconstruction method to identify defects through Wigner–Seitz approach

A new self-adaptive reconstruction method based on local atomic structure at any given molecular dynamics (MD) step has been developed in this article. The method can be used in Wigner–Seitz defect analysis approach to correctly and efficiently explore the information of both point defects and complex defect clusters (e.g. dislocation loops and voids) formed after a displacement cascade where the cascade interacts with grain boundaries and/or dislocations. The algorithm and validation are provided in detail. Results for identification of radiation defects during and after cascades interacting with a dislocation network show that the new method can well recognize all simple and complex defects and defect clusters. Thus, this new method provides a totally new way to explore the density and size of radiation defects at atomic scale after complex MD evolution processes, providing correct information to understand and predict radiation damage in materials through atomic simulations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Sequence2Self: Self-supervised image sequence denoising of pixel-level spray breakup morphology

Optical imaging of fast and transient phenomena such as the turbulent breakup of liquid sprays exhibit low signal-to-noise ratios due to the limited illumination intensity relative to the short exposure time. Image denoising is required to facilitate physical studies over these data but is challenging due to the absence of clean ground-truths and the stringency of the denoising task (e.g., strong and complex noise, limited resolution, preserving physical fidelity), preventing supervised and existing un-/self-supervised deep learning methods. To this end, Sequence2Self (Seq2S) is proposed, an extension of Self2Self (S2S) to image sequences that leverages both the signal’s spatial and temporal correlation. Seq2S is demonstrated on time-resolved x-ray phase contrast imaging of liquid jet fuel sprays in a gas turbine combustor, which possesses all of challenges detailed above. Experiments are conducted across four fuels with different breakup morphology using various state-of-the-art methods. Overall, many of the methods failed and Seq2S was most successful: (1) Accurate spray structures were reconstructed with consistent evolution across frames void of artifacts. (2) The performance was robust, invariant to the hyperparameter choice. (3) Computational time is short and can be made eligible for real-time denoising. In particular, the images denoised by Seq2S showed spray droplet diameter distributions with near-zero Kullback–Leibler divergence (0.01 ± 0.01) to a cleaner reference, whereas the second best method yielded 0.06 ± 0.03. In conclusion, this suggests that Seq2S can be reliably used prior to subsequent quantitative spray analyses as it retains (if not, improves) the statistical physical properties of the data.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

The deformation and burst behavior of Zircaloy-4 cladding tubes with hydride rim features subject to internal pressure loads

This study is motivated by the desire to conduct a separate effects test replicating specific aspects of an in-pile pulse reactor test on high exposure light water reactor (LWR) fuel rods. The principal purpose of the tests was to determine whether temperature and or hydrogen concentration thresholds exist in assessing the vulnerability of a stress relieved zirconium alloy cladding tubes to low strain ruptures. A secondary objective was to determine whether observations of the cladding stress during deformation could aid in the understanding of the crack formation and propagation in cladding tubes with hydride rim features. Here, the study utilized artificially hydrided Zircaloy-4 cladding tubes and an isothermal, internal pressure test that was controlled with an in-situ strain measurement. The test results show a clear transition in failure vulnerability between room temperature and 150 °C. Below 150 °C, cladding tubes rupture at very low uniform plastic strain—even at relatively modest cladding hydrogen levels. At and above 150 °C, cladding tubes only rupture at low uniform plastic strain if the cladding hydrogen content is greater than 500 ppm and usually experience at least some modest amount of plastic deformation prior to rupture. Post-test metallographs from non-ruptured cladding tubes show numerous primary cracks forming in the hydride rim and arresting at the metal/hydride interface. This observation combined with the decrease in bulk yielding of hydrided cladding tubes when compared to fresh non-hydrided tubes leads to the conclusion that the fracture stress of the hydride rims is related to and bounded by the yield stress of the zirconium metal. Some evidence is presented for a change in crack propagation mechanism from one of void formation on hydride plates and linkage at temperatures below 150 °C to more classical ductile shearing beneath the primary crack tip at temperatures above 150 °C. This apparent change in crack propagation mechanism may help explain the observed temperature and hydrogen concentration thresholds.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Water reactive polyurethane grouting for deep vadose zone contaminant immobilization

Contaminants in the deep vadose zone (DVZ) pose a long-term threat to groundwater, human health, and the environment. Polyurethane grouting is a type of chemical grouting that is potentially advantageous in immobilizing contaminants in DVZs. Polyurethane resin has low viscosity that makes it feasible to penetrate and fill the pore space between fine particles. Here, in this study a series of laboratory pressure grouting and leaching tests were conducted to simulate and assess the effectiveness of polyurethane grouting for immobilizing contaminants in DVZs. Soil with fine particles was prepared with 127 I (as iodide) that served as a non-radioactive surrogate for radioactive 129 I. After grouting and curing, leaching tests were used to measure and compare contaminant diffusivity and leachability index values. Additionally, changes in porosity and saturated hydraulic conductivity of grouted soil were measured. X-Ray Computer Tomography (XCT) results showed that the cured polyurethane was distributed nearly homogeneously and approximately half of the voids were filled with cured polyurethane. Grouting reduced the saturated hydraulic conductivity of soil by 37 %. The effective diffusivity decreased by more than 80 % as compared with the ungrouted soil. The leachability index of the grouted soil was 6.5; meeting the criteria established by the U.S. Nuclear Regulatory Commission (NRC) standard. The results obtained in this study provide a valuable assessment of polyurethane grouting for iodide immobilization in the DVZ and indicate this approach may be a viable method for contaminant remediation in DVZ soils.

Contaminant Diffusion↗
DOE OSTI2021

Aerodynamic effects on outer ash deposition rates in second generation atmospheric pressure oxy-coal combustion systems

Recent measurements in scenarios representative of second generation atmospheric pressure oxy-coal combustion systems have shown a significant increase in ash deposition rates in comparison to combustion in air. However, the causative mechanisms behind this increase have not been well understood. To fill this void, well-characterized experiments including fuel and deposit particle size distributions (PSDs) were coupled with highly resolved numerical simulations to isolate the aerodynamic effects impacting the deposition process such that mechanisms could be hypothesized. Three combustion scenarios (AIR, OXY27, OXY70) spanning a factor of three variation in flue gas volumetric flow rates were simulated and the deposition characteristics (impaction rates, deposit PSD, temperature, residence times, capture rates) tracked/predicted using a customized deposition module. The measured deposit PSD was significantly different from the PSD of the parent fuel indicating significant physio-chemical transformations (coalescence and particle growth in particular) at play. The use of simplistic modeling approaches (swelling parameter variations) to model particle growth led to inaccurate deposit ash PSD and rate predictions. A more satisfactory agreement between the measurements and simulations was obtained when the functional form of the parent fuel PSD (spread parameter) was modified to conform closely to the deposit PSD while still ensuring the fidelity of temperature and velocity predictions. Based on the measured ash compositions, identical capture criteria were employed across all three scenarios. Here this study further supports the theory that the ash deposition rates in these systems are dominated by aerodynamic effects with the ash PSD playing a dominant role.

42 ENGINEERING↗
DOE OSTI2020

Nuclear response of additive manufactured GRCop-84 copper for use in Lower hybrid launchers in a fusion environment

Recent advances in selective laser melting (SLM) 3D printing technology allow additive manufacture of lower hybrid current drive (LHCD) RF launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr 2 Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. Tensile strength and thermal conductivity are compared to other competing high conductivity copper alloys for fusion use. Swelling and conductivity at 100 DPA when exposed to the Hanford Fast Flux Test Facility neutron spectrum is predicted in the 1–2 % and 65-70% IACS range, respectively, by comparison to copper alloys with similar precipitate and grain size. Finally, self-similar ion irradiation of a GRCop-84 target at 430 °C to 20 DPA resulted in no noticeable void formation in FIB cross sections or TEM lamella.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

Quantitative proton radiography and shadowgraphy for arbitrary intensities

Charged-particle radiography and shadowgraphy data can be directly inverted to obtain a line-integrated transverse Lorentz force or a line-integrated transverse refractive index gradient if intensity modulations due to scattering and absorption are negligible, and angular deflections are small. We develop a new direct-inversion algorithm based on plasma physics and compare it to a new Monge–Ampère code and an existing power diagram code. The measured or source intensity is represented by electrons subject to drag, and the other intensity by fixed ions. The decrease in kinetic plus electrostatic energy determines convergence. The displacement of the electrons from their initial to their equilibrium positions determines the line-integrated force or refractive index gradient. We have implemented two approaches: PIC (particle in cell) and Lagrangian fluid, in 1-D and 2-D. The PIC code works for arbitrary intensities, can work efficiently in parallel, and can make use of existing codes. The Lagrangian code requires less memory and is faster than the PIC code without massively parallel processing, but fails in 2-D for large intensity modulations. The Monge–Ampère code is by far the fastest in 2-D, without massively parallel processing, but fails for intensities with large voids, high contrast ratios and large deflections across the boundaries, and could not obtain the degree of convergence possible with the PIC code. As a result, the power diagram code was by far the slowest and most memory intensive, and failed for large peaks in the measured intensity.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Influences of shock imprinting on mix in a 3D-printed porous media

Mixing of materials in porous media can cause a significant impact on fusion yield as previously demonstrated by the National Ignition Facility (NIF) MARBLE Campaign. Initially, the reactants are separated, with deuterium in the lattice struts and a tritium gas fill in the voids. Lattice parameters such as the strut thickness and relative pitch, provide a control for the mix parameters in the experiment. Los Alamos National Laboratory’s (LANL) BOSQUE project looks to better understand how the mix of the reactants and shell materials impact the fusion burn and resultant yield on various laser platforms. xRAGE’s Eulerian hydrodynamics and adaptive mesh refinement (AMR) provide the unique ability to study the impacts of multiscale features of complex lattice structures. This modeling provides the ability to measure shock front variations as the wave progress’ through a given media. Initial conditions of the lattice are essential to accurately model mix and burn measured by experiment. By varying the initial orientation and densities of these lattice regions the early time dynamics of how the shock is launched into the system is changed and advocates for the study of resulting effects. In this work, we will study the sensitivities of shock effects in varying 3D printed geometric systems and how these shocks alter the structure and mix in the lattice. We will discuss both preliminary experimental results and simulations to help plan and constrain future experiments where we will study the impact of different lattice geometries and lattice bulk densities. This work concludes with the relative impacts of lattice geometries on shock speeds at different bulk densities and the resultant mix widths due to those shock interactions. We see agreement with theory at the higher end of our bulk density study, however, as we approach lower bulk density systems the dynamics of these interactions begin to change.

2 Photon Polymerization↗
DOE OSTI2020

Temperature statistics in a radiatively heated particle-laden turbulent square duct flow

Radiation absorption by preferentially concentrated particles in a turbulent square duct flow is studied experimentally. The particle-laden flow is exposed to near-infrared radiation, and the gas phase temperature statistics are measured along the wall bisector of the duct. It is found that the instantaneous temperature fluctuations are comparable to the overall mean temperature rise. The temperature statistics at the duct centerline and near the wall are qualitatively different. The former reflects preferential concentration in isotropic flows while the latter displays evidence of particle clustering into streamwise elongated streaks. Comparison of the experimental data to a simplified heat transfer model suggests that the Lagrangian evolution of particle clusters and voids, and turbulent mixing in the vicinity of particle clusters, are important. This work was motivated by particle solar receiver technology, but the findings are also relevant to systems where there is localized heat release or mass transfer from disperse particles or droplets. It shows that obtaining Lagrangian histories of particle trajectories is an important next step towards understanding thermal transport phenomena in particle-laden turbulent flows.

42 ENGINEERING↗
DOE OSTI2020

A multi-dimensional dataset for two-phase instability in low pressure natural circulation based on direct transient local measurement

Thermal hydraulic instability can challenge the control and the safety of nuclear reactors. This experimental research captures and investigates the instability in a low-pressure (1–10 atmospheres) natural circulation loop with an adiabatic chimney installed above the heated section. Direct transient local measurement of two-phase flow is performed at multiple axial locations along the flow channel with thermocouples and conductivity probes traversed by customized high-precision mechanisms. Based on the periodicity of oscillations, a post-processing method is proposed to align the data captured non-simultaneously to reconstruct the instability behavior in one representative period. The averaging operation over multiple oscillation cycles is performed to reduce the random errors. Cyclic phenomena are clearly demonstrated by the post-processed data, and rapid void fraction change induced by the flashing is observed to be significant in the driving mechanism for low pressure oscillations. Parametric effects of inlet subcooling, heat flux, inlet flow restriction and system pressure are studied within the experiment range, and qualitative results are explained and compared with existing literature. The ratio between the oscillation period and the travelling time of the fluid particle through the test section is compared with the theoretical value for the density wave oscillation. The new dataset contains directly measured transient multi-dimensional two-phase data along the flow channel for natural circulation under density wave oscillations. The generated dataset is valuable for the validation of system analysis codes and CFD codes in the simulation of natural circulation phenomena and dynamic two-phase flow.

42 ENGINEERING↗
DOE OSTI2023

Development of experimental and computational frameworks to predict subcooled flow boiling in the LANL Isotope Production Facility

Cooling is crucial to maintain the integrity of target systems in isotope production facilities. At Los Alamos National Laboratory (LANL)’s Isotope Production Facility (IPF), multiple encapsulated targets are stacked and irradiated in tandem with a 100 MeV, ~250μA proton beam. To facilitate effective heat removal, these stacked targets are separated and cooled via a series of water channels. At these beam currents, this high-energy proton beam heats the target system, likely initiating subcooled flow boiling in the cooling channels. However, in-beam monitoring of the IPF target system is not possible due to the extreme radiation environment, and the necessarily significant shielding. To better understand high-power target performance, we developed ex-situ experimental and computational frameworks to predict the behavior of subcooled flow boiling at IPF. Subcooled flow boiling experiments on Inconel 625 samples under IPF conditions (2 bar pressure, 10 GPM flow rate (i.e., 2249 kg/m 2 /s), 85 K subcooling) revealed that IPF's average operating power is at the early stage of boiling with a heat transfer coefficient of 48,000 W/m 2 /s. The proposed modeling framework enables us to predict a complete boiling curve, i.e., single-phase heat transfer, onset of nucleate boiling, two-phase heat transfer, and critical heat flux (CHF), with specification of input boiling parameters up to intermediate heat flux levels. The estimated CHF under IPF conditions is 5.2 MW/m 2 . Experimental data under reduced conditions (2 bar pressure, 1.5 GPM flow rate (i.e., 337 kg/m 2 /s), 45 K subcooling) served as validation cases for the computational modeling. This computational model can be further extended to more complicated systems replicating the real IPF configuration, for instance, to study void distribution as a function of the incident proton beam profile and coolant velocity profile of multiple cooling channels. Finally, the proposed experimental and computational frameworks provide a means to better understand cooling systems in the isotope production facilities at different accelerators, where in-beam monitoring of the cooling process is not available.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2020

Macrovoid-free high performance polybenzimidazole hollow fiber membranes for elevated temperature H 2 /CO 2 separations

Thermally robust membranes are required for H 2 production and carbon capture from hydrocarbon fuel derived synthesis (syn) gas. Polybenzimidaole (PBI) materials have exceptional thermal, chemical and mechanical characteristics and high H 2 perm-selectivity for efficient syngas separations at process relevant conditions. The large gas volumes processed mandate the use of a high-throughput, small footprint hollow fiber membrane (HFM) platform. Here in this work, an industrially attractive spinning protocol is developed to fabricate PBI HFMs with unprecedented H 2 /CO 2 separation performance. A unique dope composition incorporating an acetonitrile diluent is discovered enabling asymmetric macro-void free PBI HFM fabrication using a water coagulant. The influences of dope viscosity, coagulant chemistry, and air gap on HFM morphology are evaluated. Elevated temperature (up to 350 °C) H 2 permeances of 400 GPU with H 2 /CO 2 selectivities > 20 are achieved. This unprecedented separation performance is a ground breaking achievement at temperatures traditionally considered out-of-reach for polymeric membranes.

08 HYDROGEN↗