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DOE OSTI2021

MOSAIC: An Effective FFT-based Numerical Method to Assess Aging Properties of Concrete

As the nuclear fleet in the United States ages and subsequent license renewal applications grow, the prediction of concrete durability at extended operation becomes more important. To address this issue, a Fast-Fourier Transform (FFT) method is utilized to simulate aging-related degradation of concrete within the Microstructure Oriented Scientific Analysis of Irradiated Concrete (MOSAIC) software. MOSAIC utilizes compositional phase maps to simulate damage from radiation-induced volumetric expansion (RIVE), applied force, creep, and thermal expansion. This compositional detail allows each mineral in the microstructure to be assigned specific material properties, allowing the simulation to be as accurate and representative as possible. The principal goal of MOSAIC is to simulate the effects of nonlinear aging mechanisms occurring in nuclear concrete on the macroscopic mechanical properties, using only the aggregate microstructure compositional information as a starting point. Here, several realistic example simulations are shown to demonstrate the utility and uniqueness of the MOSAIC software.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Compaction of crushed salt for safe containment – overview of the KOMPASS project

Abstract. In Germany, rock salt formations are possible host rock candidates for a repository for heat-emitting radioactive waste. The safety concept of a repository in salt bases on a multibarrier system consisting mainly of the geological barrier salt and geotechnical seals ensuring safe containment. Crushed salt will be used for backfilling of cavities and sealing measures in drifts and shafts due to its favourable properties and its easy availability (mined-off material). The creep of the rock salt leads to crushed salt compaction with time. Thereby, the crushed salts' porosity is reduced from the initial porosity of 30 %–40 % to a value comparable to the porosity of undisturbed rock salt (≤1 %). In such low porosity ranges, technical impermeability is assumed. The compaction behaviour of crushed salt is rather complex and involves several coupled THM processes (Kröhn et al., 2017; Hansen et al., 2014). It is influenced by internal properties like humidity and grain size distribution, as well as boundary conditions such as temperature, compaction rate or stress state. However, the current process understanding has some important gaps referring to the material behaviour, experimental database and numerical modelling. It needs to be extended and validated, especially in the low porosity range. The objective of the KOMPASS project was development of methods and strategies for the reduction of deficits in the prediction of crushed salt compaction leading to an improvement of the prognosis quality. Key results are as follows (KOMPASS Phase 1, 2020): selection of an easily available and permanently producible synthetic crushed salt mixture, acting as a reference material for generic investigations; development and proof of different techniques for producing pre-compacted samples for further investigations; establishment of a tool of microstructure investigation methods to demonstrate the comparability of grain structures of pre-compacted samples with in-situ compacted material for future investigations; execution of various laboratory experiments using pre-compacted samples, e.g. long-term creep tests which deliver reliable information about time- and stress-dependent compaction behaviour; development of a complex experimental investigation strategy to derive necessary model parameters considering individual functional dependencies. Its technical feasibility was successfully verified; benchmarking with various existing numerical models using datasets from three different triaxial long-term tests. The result was not entirely satisfactory; however, the number of influencing factors is small and further validation work has to be done. Overall, the KOMPASS project has made significant progress in the approaches to solving the outstanding question, building the basis for further investigations.

Friedenberg, Larissa↗

NASA NTRS2003

Numerical Simulations of Non-Newtonian Convection in Ice: Application to Europa

Numerical simulations of solid state convection in Europa's ice shell have so far been limited to consideration of Newtonian flow laws, where the viscosity of ice is strongly dependent upon temperature, predicting that a stagnant lid should form at the top (10-40%) of a convecting ice shell. Such large thicknesses seem to contradict estimates of the effective elastic thickness of Europa s ice shell during its geologically active period. Recent laboratory experiments characterize the rheology of ice as the sum of contributions from several temperature and strain rate-dependent creep mechanisms. We present the results of numerical simulations of convection within Europa s ice shell using the finite-element model Citcom, applying the non-Newtonian rheology of grain boundry sliding. Our calculations suggest a shallower brittle/ductile transition and larger interior convective velocities compared to Newtonian rheology. The flow field is time-dependent, with small, localized upwellings and downwellings at the thermal boundary layers that have minimal topographic expression at the surface.

Barr, A. C.↗

DOE OSTI2023

A structural model of the long-term degradation of the concrete biological shield

The concrete biological shield (CBS) of light water reactors is exposed to high neutron radiation dose in the long term, which may lead to the degradation of the concrete’s mechanical properties. Given the important shielding role of the CBS, it is necessary to investigate the irradiation effects at the structural scale and provide estimates of the damage extent from the wall’s inner surface to study potential license renewals. For this purpose, we developed a mechanical model accounting for radiation-induced expansion, creep, and damage in concrete using the Grizzly finite element code, informed by ex-core neutron flux calculations using the VERA tool. The model was applied to a 3D CBS structure represented by the CBS wall, a steel liner, reinforcement bars, and a concrete base mat and evaluated damage at 40, 60, and 80 years of operation. The VERA model predicted a maximum fluence of approximately 2 x 10 19 ncm -2 at 80 years of operation. The results showed that damage is highest at the inner surface of the CBS wall and gradually decreases with depth. It extends beyond the rebar after 60 years and reaches a depth of approximately 12 cm at 80 years.

42 ENGINEERING↗

DOE OSTI2023

Compare Mechanistic Predictions for Doped UO 2 Mechanical Response and Other Properties with Empirical Models and Experimental Measurements

The U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation program develops predictive capabilities using computational methods for the analysis and design of advanced reactor and fuel cycle systems. This program has been supporting the development of BISON, a high-fidelity, high resolution fuel performance tool at the engineering scale. As part of its development, additional modeling capabilities and improvements have been developed for relevant fuel forms. In this work, a fuel creep deformation model for Cr-doped fuel has been implemented into BISON, along with improvements to the empirical UO 2 fuel creep model based on experimental data and improvements to the radial power factor calculation for doped fuels. This work allows for more accurate simulation analyses for both UO 2 and doped-UO 2 fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1993

Recent advances in computational structural reliability analysis methods

The goal of structural reliability analysis is to determine the probability that the structure will adequately perform its intended function when operating under the given environmental conditions. Thus, the notion of reliability admits the possibility of failure. Given the fact that many different modes of failure are usually possible, achievement of this goal is a formidable task, especially for large, complex structural systems. The traditional (deterministic) design methodology attempts to assure reliability by the application of safety factors and conservative assumptions. However, the safety factor approach lacks a quantitative basis in that the level of reliability is never known and usually results in overly conservative designs because of compounding conservatisms. Furthermore, problem parameters that control the reliability are not identified, nor their importance evaluated. A summary of recent advances in computational structural reliability assessment is presented. A significant level of activity in the research and development community was seen recently, much of which was directed towards the prediction of failure probabilities for single mode failures. The focus is to present some early results and demonstrations of advanced reliability methods applied to structural system problems. This includes structures that can fail as a result of multiple component failures (e.g., a redundant truss), or structural components that may fail due to multiple interacting failure modes (e.g., excessive deflection, resonate vibration, or creep rupture). From these results, some observations and recommendations are made with regard to future research needs.

Thacker, Ben H.↗

DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗

NASA NTRS1984

Materials for Advanced Turbine Engines (MATE): Project 3: Design, fabrication and evaluation of an oxide dispersion strengthened sheet alloy combustor liner, volume 1

The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Incoloy MA 956 (FeCrAl base) and Haynes Developmental Alloy (HDA) 8077 (NiCrAl base) were evaluated. Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. Both alloys demonstrated a +167C (300 F) advantage of creep and oxidation resistance with no improvement in thermal fatigue capability compared to a current generation combustor alloy (Hastelloy X). MA956 alloy was selected for further demonstration because it exhibited better manufacturing reproducibility than HDA8077. Additional property tests were conducted on MA956. To accommodate the limited thermal fatigue capability of ODS alloys, two segmented, mechanically attached, low strain ODS combustor design concepts having predicted fatigue lives or = 10,000 engine cycles were identified. One of these was a relatively conventional louvered geometry, while the other involved a transpiration cooled configuration. A series of 10,000 cycle combustor rig tests on subscale MA956 and Hastelloy X combustor components showed no cracking, thereby confirming the beneficial effect of the segmented design on thermal fatigue capability. These tests also confirmed the superior oxidation and thermal distortion resistance of the ODS alloy. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components was designed and constructed.

Henricks, R. J.↗

NASA NTRS1992

Computational simulation of coupled material degradation processes for probabilistic lifetime strength of aerospace materials

The research included ongoing development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subjected to a number of effects or primative variables. These primative variable may include high temperature, fatigue or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation has been randomized and is included in the computer program, PROMISS. Also included in the research is the development of methodology to calibrate the above described constitutive equation using actual experimental materials data together with linear regression of that data, thereby predicting values for the empirical material constraints for each effect or primative variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from the open literature for materials typically of interest to those studying aerospace propulsion system components. Material data for Inconel 718 was analyzed using the developed methodology.

Boyce, Lola↗

NASA NTRS1992

Computational simulation of probabilistic lifetime strength for aerospace materials subjected to high temperature, mechanical fatigue, creep, and thermal fatigue

The results of a fourth year effort of a research program conducted for NASA-LeRC by The University of Texas at San Antonio (UTSA) are presented. The research included on-going development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subjected to a number of effects or primitive variables. These primitive variables may include high temperature, fatigue, or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation was randomized and is included in the computer program, PROMISC. Also included in the research is the development of methodology to calibrate the above-described constitutive equation using actual experimental materials data together with regression analysis of that data, thereby predicting values for the empirical material constants for each effect or primitive variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from industry and the open literature for materials typically for applications in aerospace propulsion system components. Material data for Inconel 718 was analyzed using the developed methodology.

Boyce, Lola↗

NASA NTRS2019

Characterizing Damage Accumulation in CMCs

Silicon carbide / silicon carbide ceramic matrix composites (SiC/SiC CMCs) are structural ceramics that are well-suited for the extreme environment conditions of aerospace applications largely due to their low weight, creep resistance, damage tolerance, and high specific strength. In CMCs, the initiation and evolution of damage is influenced by a number of factors including characteristics of the constituent landscape (porosity, interfacial properties, and geometric distribution of CMC constituents), thermo-mechanical loading parameters, and environmental conditions. However, much is still unknown about these factors and the interactions between them. In order to accurately predict the lifetimes of these advanced composites, it is critical to understand the evolution of damage and to characterize which early damage mechanisms (and their relationship to key microstructural features) subsequently lead to crack coalescence and macroscopic failure. This research focuses on the use of a multi-modal, experimental approach to examine the relative activity of surface and subsurface damage mechanisms in CMCs. The impact of fabrication choices on the evolution of damage to final failure, and the influence of constituent architecture on early damage mechanisms, are investigated. This approach combines acoustic emission (AE) with microscale deformation tracking via digital image correlation inside a scanning electron microscope (SEM-DIC). The potential application of this combined approach towards characterization of damage in SiC/SiC CMCs under more complex testing conditions is explored.

Swaminathan, Bhavana↗

DOE OSTI2020

HDG-1 Graphite Preirradiation Data Package Report

This report documents all pre-irradiation examination material-property measurement data for graphite specimens that are going to be used within the first high dose graphite (HDG) -1 irradiation capsule. The two new HDG capsules signify a major change to the AGC Experiment. HDG-1 and HDG-2 will replace the last two Advanced Graphite Creep (AGC) capsules (AGC-5 and AGC-6) which were designed to irradiate graphite at the extreme upper operational temperatures for a very-high-temperature reactor (VHTR) design, 1100°C. These very high temperature AGC-5 and AGC-6 capsules have been repurposed to re-irradiated specimens (from AGC-2, AGC-3, and AGC-4) at the lower temperatures of 600°C and 800°C. HDG-1 will be irradiated at 600°C and HDG-2 will be irradiated at 800°C. By re-irradiating the previous AGC specimens a total maximum neutron dose of around 15 dpa (displacements per atom) can be achieved for all major graphite grades at irradiation temperatures of 600°C and 800°C. Specimens in the HDG-1 capsule are made up of previously irradiated specimens from the AGC-2 capsule and unirradiated specimens prepared for the now discontinued AGC-5 capsule. Utilizing the irradiated specimens, a maximum neutron dose of around 15 dpa is anticipated. These new maximum dose levels will provide irradiated material property data over a total neutron dose range of 1-15 dpa at a temperature of 600°C when combined with the previous AGC-1 and AGC-2 irradiation data. This will provide quantitative data necessary for predicting the irradiation behavior and operating performance of new nuclear graphite grades for use within high temperature reactor designs. Similar to previous AGC test trains, HDG-1 includes the major graphite grades (IG-110, NBG-17, NBG-18, PCEA, and 2114) as well as adding the very fine-grain grade IG-430 which is of interest to the Molten Salt Reactor (MSR) designs. Also new to the HDG-1 capsule are 90 smaller geometry specimens designated as pencil specimens. These specimens take up only one third the space of a standard creep size specimen. This increased number of specimens will enhance property measurement statistics because they will provide 3 times the control specimen data at a position that would otherwise only have a single measurement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

HDG-1 Graphite Preirradiation Data Package Report

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1976

Experimental and theoretical investigation of fatigue life in reusable rocket thrust chambers

During a test program to investigate low-cycle thermal fatigue, 13 rocket combustion chambers were fabricated and cyclically test fired to failure. Six oxygen-free, high-conductivity (OFHC) copper and seven Amzirc chambers were tested. The failures in the OFHC copper chambers were not typical fatigue failures but are described as creep rupture enhanced by ratcheting. The coolant channels bulged toward the chamber centerline, resulting in progressive thinning of the wall during each cycle. The failures in the Amzirc alloy chambers were caused by low-cycle thermal fatigue. The zirconium in this alloy was not evenly distributed in the chamber materials. The life that was achieved was nominally the same as would have been predicted from OFHC copper isothermal test data.

Hannum, N. P.↗

NASA NTRS1992

Computational simulation of probabilistic lifetime strength for aerospace materials subjected to high temperature, mechanical fatigue, creep and thermal fatigue

This report presents the results of a fourth year effort of a research program, conducted for NASA-LeRC by the University of Texas at San Antonio (UTSA). The research included on-going development of methodology that provides probabilistic lifetime strength of aerospace materials via computational simulation. A probabilistic material strength degradation model, in the form of a randomized multifactor interaction equation, is postulated for strength degradation of structural components of aerospace propulsion systems subject to a number of effects or primitive variables. These primitive variables may include high temperature, fatigue or creep. In most cases, strength is reduced as a result of the action of a variable. This multifactor interaction strength degradation equation has been randomized and is included in the computer program, PROMISS. Also included in the research is the development of methodology to calibrate the above-described constitutive equation using actual experimental materials data together with regression analysis of that data, thereby predicting values for the empirical material constants for each effect or primitive variable. This regression methodology is included in the computer program, PROMISC. Actual experimental materials data were obtained from industry and the open literature for materials typically for applications in aerospace propulsion system components. Material data for Inconel 718 has been analyzed using the developed methodology.

Boyce, Lola↗

NASA NTRS2004

A Constitutive Equation for Stratospheric Balloon Materials

The selection of a suitable material for use as a reliable stratospheric balloon gas barrier and structural component is based on a variety of properties. Due to a more desirable combination of properties, the low density polyethylene that has been used for the last half century has been replaced during the last decade by linear low density polyethylene (LLDPE). This paper describes the effort to characterize the time dependent properties of a 38 micron coextrusion of LLDPE. The nonlinear viscoelastic constitutive equation presented may be used to accurately describe the creep and/or relaxation of this film when subjected to a biaxial state of stress, such as might be required for an extended balloon flight. Recent laboratory data have been used to mod@ an existing model of LLDPE to account for differences caused by the coextrusion process. The new model will facilitate structural design optimization and reliability assessment, and may be further utilized as a predictive tool to benefit in-flight operations. Current structural analysis tech&ques based on linear elastic properties have predicted stresses in excess of those which would actually exist.

Rand, J. L.↗

NASA NTRS2006

Using ABAQUS Scripting Interface for Materials Evaluation and Life Prediction

An ABAQUS script has been written to aid in the evaluation of the mechanical behavior of viscoplastic materials. The purposes of the script are to: handle complex load histories; control load/displacement with alternate stopping criteria; predict failure and life; and verify constitutive models. Material models from the ABAQUS library may be used or the UMAT routine may specify mechanical behavior. User subroutines implemented include: UMAT for the constitutive model; UEXTERNALDB for file manipulation; DISP for boundary conditions; and URDFIL for results processing. Examples presented include load, strain and displacement control tests on a single element model. The tests are creep with a life limiting strain criterion, strain control with a stress limiting cycle and a complex interrupted cyclic relaxation test. The techniques implemented in this paper enable complex load conditions to be solved efficiently with ABAQUS.

Powers, Lynn M.↗

DOE OSTI2021

Evaluation of external tubular configurations for a high-temperature chloride molten salt solar receiver operating above 700°C

Next-generation concentrating solar power (CSP) tower technologies target operating temperatures exceeding 700°C to increase the thermal-to-electric conversion efficiency. Molten chloride salts are one possible alternative to current commercial molten nitrate salts to enable the higher operating temperature. This paper analyzes the predicted optical, thermal-fluids, and structural performance of traditional external tubular solar receiver configurations applied with a chloride salt heat transfer fluid (HTF) and inlet/outlet temperatures of 500°C/735°C, and considers sensitivity analysis and optimization relative to receiver sizing, tube sizing, number of panels, flow circuit configurations, and solar flux concentration under constraints on internal velocity, pressure drop, wall thickness, and required creep-fatigue lifetime. The high temperature conditions increase the significance of inelastic deformation mechanisms such as creep relative to that expected in commercial 565°C nitrate salt designs. High-temperature creep and creep-fatigue damage in the metal alloy tubes are the key factors that limit allowable solar flux concentration and achievable receiver thermal efficiency at the near-800°C wall temperature conditions. For a traditional external cylindrical receiver configuration, the design parameters and conditions capable of satisfying all constraints produced, at best, a design point receiver efficiency of 78.2%, or 80.5% when excluding receiver intercept efficiency. Variation in the optimal receiver performance relative to uncertainty in the binding maximum velocity, minimum wall thickness, and minimum lifetime constraints is presented.

14 SOLAR ENERGY↗