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DOE OSTI2020

Selective Electrocatalysis Imparted by Metal-Insulator Transition for Durability Enhancement of Automotive Fuel Cells.

Repetitive start-up and shut-down events in polymer electrolyte membrane fuel cells for automotive applications lead to serious corrosion of the cathode due to an instantaneous potential jump that results from unintended air leakage into the anodic flow field followed by a parasitic oxygen reduction reaction (ORR) on the anode. Here we report a solution to the cathode corrosion issue during the start-up/shut-down events whereby intelligent catalyst design is used to selectively promote the hydrogen oxidation reaction (HOR) while concomitantly suppressing the ORR on the anode. Platinum thin layers supported on hydrogen tungsten bronze (Pt/HxWO3) suppressed the ORR by converting themselves into an insulator following exposure to oxygen, while selectively promoting the HOR by regaining metallic conductivity following subsequent exposure to hydrogen. The HOR-selective electrocatalysis imparted by a metal-insulator transition in Pt/HxWO3 demonstrated a remarkably enhanced durability of membrane electrode assemblies compared to those with commercial Pt/C catalysts.

Jung, Sang-Mun↗

NASA NTRS1992

Activities of the Boom and Chassis Group

Group One of the NASA Lunar Enabler Project has designed the primary chassis and boom structures for the lunar vehicle. Both components also feature V-clamps that were adapted to interface connections within the structure. The chassis features a front end, rear end section, middle cross-section, and face plate. The rear section contains an extra compartment for the engine, hydraulic pump, fuel bottles, and oil reservoir necessary for the wheel drives. Each section consists of tubular aluminum 6061-T6. The boom features four degrees of freedom system, where the minimum factor of safety of any part is 1.5 (but, normally much higher). It consists of a tapered upper boom, lower boom, and three elbows that complement the articulation joints. Each section of the boom has been constructed from aluminum 6061-T6. There are four joints and eight V-clamps in the boom assembly. The V-clamps feature support rings that prevent axial rotation. They provide easy adaptability and assembly.

Dell, Jason Scott↗

DOE OSTI2024

Interface-modulated kinetic differentials in electron and hole transfer rates as a key design principle for redox photocatalysis by Sb2VO5/QD heterostructures

The efficient conversion of solar energy to chemical energy represents a critical bottleneck to the energy transition. Photocatalytic splitting of water to generate solar fuels is a promising solution. Semiconductor quantum dots (QDs) are prime candidates for light-harvesting components of photocatalytic heterostructures, given their size-dependent photophysical properties and band-edge energies. A promising series of heterostructured photocatalysts interface QDs with transition-metal oxides which embed midgap electronic states derived from the stereochemically active electron lone pairs of p-block cations. Here, we examine the thermodynamic driving forces and dynamics of charge separation in Sb2VO5/CdSe QD heterostructures, wherein a high density of Sb 5s2-derived midgap states are prospective acceptors for photogenerated holes. Hard-x-ray valence band photoemission spectroscopy measurements of Sb2VO5/CdSe QD heterostructures were used to deduce thermodynamic driving forces for charge separation. Interfacial charge transfer dynamics in the heterostructures were examined as a function of the mode of interfacial connectivity, contrasting heterostructures with direct interfaces assembled by successive ion layer adsorption and reaction (SILAR) and interfaces comprising molecular bridges assembled by linker-assisted assembly (LAA). Transient absorption spectroscopy measurements indicate ultrafast (<2 ps) electron and hole transfer in SILAR-derived heterostructures, whereas LAA-derived heterostructures show orders of magnitude differentials in the kinetics of hole (<100 ps) and electron (∼1 ns) transfer. The interface-modulated kinetic differentials in electron and hole transfer rates underpin the more effective charge separation, reduced charge recombination, and greater photocatalytic efficiency observed for the LAA-derived Sb2VO5/CdSe QD heterostructures.

Chemistry↗

NASA NTRS2004

Micro-Tubular Fuel Cells

Micro-tubular fuel cells that would operate at power levels on the order of hundreds of watts or less are under development as alternatives to batteries in numerous products - portable power tools, cellular telephones, laptop computers, portable television receivers, and small robotic vehicles, to name a few examples. Micro-tubular fuel cells exploit advances in the art of proton-exchange-membrane fuel cells. The main advantage of the micro-tubular fuel cells over the plate-and-frame fuel cells would be higher power densities: Whereas the mass and volume power densities of low-pressure hydrogen-and-oxygen-fuel plate-and-frame fuel cells designed to operate in the targeted power range are typically less than 0.1 W/g and 0.1 kW/L, micro-tubular fuel cells are expected to reach power densities much greater than 1 W/g and 1 kW/L. Because of their higher power densities, micro-tubular fuel cells would be better for powering portable equipment, and would be better suited to applications in which there are requirements for modularity to simplify maintenance or to facilitate scaling to higher power levels. The development of PEMFCs has conventionally focused on producing large stacks of cells that operate at typical power levels >5 kW. The usual approach taken to developing lower-power PEMFCs for applications like those listed above has been to simply shrink the basic plate-and-frame configuration to smaller dimensions. A conventional plate-and-frame fuel cell contains a membrane/electrode assembly in the form of a flat membrane with electrodes of the same active area bonded to both faces. In order to provide reactants to both electrodes, bipolar plates that contain flow passages are placed on both electrodes. The mass and volume overhead of the bipolar plates amounts to about 75 percent of the total mass and volume of a fuel-cell stack. Removing these bipolar plates in the micro-tubular fuel cell significantly increases the power density.

Kimble, Michael C.↗

DOE OSTI2020

(Oxy)hydroxides Formed on Aluminum Fuel Materials After Irradiation and Long-Term Wet Storage - 20354

The aluminum cladding of research-reactor fuel experiences general corrosion when in contact with water during in-reactor service and post-discharge wet storage, resulting in the formation of adherent aluminum (oxy)hydroxide films. These (oxy)hydroxides contain chemically-bound water that poses challenges for extended dry storage due to the risk of thermal or radiolytic decomposition releasing free water and/or hydrogen and oxygen gases. This study describes characterization of the (oxy)hydroxides present on several aluminum materials used in reactor operation and subsequently stored wet in the L-Basin storage facility at the Savannah River Site (SRS) for an extended period. Characterization data providing insight into the loading, composition, and morphology of (oxy)hydroxides to be expected on service-exposed aluminum cladding provides valuable benchmarks for designing adequate drying and dry-storage approaches. This work is part of a broader investigation to address knowledge gaps and technical data needs for dry storage of aluminum-clad spent nuclear fuel (ASNF), which included in-lab growth of (oxy)hydroxide films on aluminum alloy substrates to investigate formation behavior, investigation of drying methods to remove existing (oxy)hydroxides from ASNF cladding, and measurement of radiolytic yield of hydrogen from (oxy)hydroxide powders and films. In this study, (oxy)hydroxide films were characterized for three aluminum-alloy materials used in reactors and subsequently stored wet for up to approximately 40 years in L-Basin at SRS: one cropping from a Missouri University Research Reactor (MURR) fuel element (Al-6061 alloy), one cropping from a Universal Sleeve Housing (USH) (Al-6063 alloy), and one Mark-16B fuel assembly (either Al-6061 or Al- 6063). The USH and Mark-16B were used in SRS production reactors. Characterization of the as-received (oxy)hydroxides included scanning electron microscopy (SEM) in both plan-view and cross-section to characterize the (oxy)hydroxide layer's morphology, thickness, and structure. X-ray diffraction (XRD) was used to identify the chemical composition and distinguish between the various aluminum (oxy)hydroxides known to form under reactor and storage conditions. XRD analysis revealed both bayerite (Al(OH)3) and boehmite (AlOOH) on the surface of the MURR and USH samples, as well as bayerite, boehmite, and gibbsite (another Al(OH)3 polymorph) on the surface of the Mark-16B sample. The aluminum trihydroxides, bayerite and gibbsite, are typically associated with corrosion in low-temperature (<80 deg. C) water, while boehmite is expected to form at higher water temperature (>80 deg. C). The presence of bayerite on the USH, which is believed to have operated close to 90 deg. C, suggests that boehmite formed during in-reactor exposure was not protective against further hydroxide growth in low-temperature wet storage. Cross-section scanning electron microscopy (SEM) showed total (oxy)hydroxide layer thicknesses of ∼5- 10 μm for the MURR and ∼5-15 μm for the Mark-16B. The thickness of the USH's (oxy)hydroxide layer was indiscernible by the current mounting and imaging method, despite plan-view SEM and XRD confirming the presence of an (oxy)hydroxide layer. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Computational Thermal Hydraulics of a High-Performance Low-Enriched-Uranium Annular Target for HFIR Irradiation

Molybdenum-99 has historically been generated via isolation from fissioned highly enriched uranium (HEU) targets. Here, this isotope is in high demand due to its daily use across the world in radiopharmaceutical medical procedures. The primary objective of this work was to design and analyze an experimental target assembly containing one low-enriched-uranium (LEU) annular target for irradiation at the High Flux Isotope Reactor (HFIR). Efforts included incorporating spatially dependent energy sources from neutron and gamma interactions, quantifying thermal contact conductance at material interfaces, performing grid-independent studies, comparing turbulence models, and simulating various steady-state and transient scenarios relevant for irradiation qualification and eventual insertion. These models provide velocity, pressure, and temperature distributions in both space and time. Such results enable the selection of an appropriate irradiation location, fission rate density, and flow-limiting orifice size and demonstrate compliance with HFIR safety requirements such that insertion into the reactor can be approved. This analysis shows that across all scenarios, wetted surface temperatures remain below the coolant saturation temperature with no net vapor formation in the coolant. In every scenario, all components stay below 30% of the aluminum 6061 melting temperature. Computational fluid dynamics and system-level models predict peak target temperatures that agree within 4%, though the predicted axial location of the peak differs by about 10% of the heated length due to differences in flow development length. These results de-risk the irradiation of LEU (annular targets) and strengthen a domestic, HEU-independent 99 Mo supply by providing important fuel performance data to form the foundation for a robust licensing basis.

Molybdenum-99↗

DOE OSTI2022

A multiphysics model of the versatile test reactor based on the MOOSE framework

The traditional modeling approach for sodium fast reactor cores relies on separate physics models, where the fuel performance, thermal–hydraulics, and neutronics calculations required to predict the core physics characteristics for nominal conditions are decoupled by relying on user-imposed boundary conditions. Here, this paper aims at evaluating the impact of multiphysics simulations for predicting the core characteristics of the Versatile Test Reactor, which is being designed as a 300-MWt sodium-cooled fast reactor. The purpose of the Versatile Test Reactor is to accelerate the testing of advanced nuclear materials in the United States. The proposed multiphysics model relies on the Griffin reactor physics code, the SAM thermal–hydraulic system code, the BISON fuel performance code, as well as generic Multiphysics Object-Oriented Simulation Environment capabilities implemented in the open-source tensor mechanics module. For k eff calculations, the introduction of a tight coupling between the neutronics, thermo-mechanical and thermal–hydraulics models induces a change of around 543 pcm in the eigenvalue, compared to the traditional standalone neutronics calculation where approximate temperature profiles are used. The multiphysics model is then employed for quantifying the impact of the thermal conductivity uncertainties on some of the key figures of merit, such as the fuel centerline temperature, assembly powers, and keff for nominal core conditions. As anticipated, uncertainties on fuel thermal conductivity mostly impact the fuel centerline temperature, and to a lesser extend the k eff .

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Evaluation of flow-induced plate deflection for University of Missouri research reactor low-enriched uranium fuel element

The University of Missouri Research Reactor (MURR), located on the campus of the University of Missouri in Columbia, Missouri, is one of the six United States (U.S.) High Performance Research Reactors (USHPRR), including one critical facility, that are actively collaborating with the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Office of Material Management and Minimization (M3) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥20 wt% U-235) fuel to low-enriched uranium (LEU, <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow conversion of some USHPRR, including MURR. In the design of its fuel elements, MURR is using thin parallel curved fuel plates separated by coolant channels. In this work, fluid-structure interaction (FSI) analysis of the MURR LEU fuel element is performed at the element level (as compared to the plate level analysis), which models all components of the LEU fuel element, including fuel plates and the supporting structures. Therefore, the effect of supporting structures on the flow distribution within the element and the fuel plate deflection are evaluated. In addition to the element nominal flow rate and dimensions, the tolerances in the geometry of the coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are evaluated. For the LEU fuel plates, which are thinner than the current HEU plates, the predicted plate deflection is found to be small compared to the fabrication and assembly tolerances. Thus, the FSI-induced deflections are not expected to noticeably reduce the coolant flow rate or predicted safety margins in the limiting channels for the MURR LEU fuel element. In addition to the simulation work, a hydraulic performance test of the MURR LEU fuel element is currently being planned to support conversion to the use of LEU fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

An Experimental Feasibility Study on Applying Neutron Tomography to Encapsulated Spent Nuclear Fuel - 20050

Visual inspection makes easier to ensure the integrity and safety of spent nuclear fuel (SNF) than any classical techniques. Various classical techniques have been applied but there are no reliable methods to qualitatively and quantitatively verify spent fuel in dry storage. Thus, the present authors have developed the prototype safeguards apparatus for dry storage employing the array of He-4 gas scintillation detectors (S670E, Arktis Radiation Detectors Ltd., Switzerland), newly designed to simultaneously measure thermal and fast neutrons without any moderators. The S670E detector has a cylindrical shape with a diameter of 52 mm and active length of 600 mm (total length: 875 mm). The detector is filled by He-4 gas with an approximate pressure of 180 bar for fast neutron detection, and its inner wall is coated by Li-6 for thermal neutron detection. The scintillation lights generated via Li-6 nuclear reaction and elastic scattering are collected by 24 SiPMs linearly paired at the center of the detector. The detector delivers a TTL (Transistor-Transistor Logic) output for pulse readout and UART (Universal Asynchronous Receiver Transmitter) for device control. In order to assess feasibility of the apparatus, an experimental system has been designed, built, and optimized via computational studies. Cf-252 neutron sources and linearly arrayed detectors, working as a single detector, were occupied for this study due to the difficulties in working with SNF. The laboratory scale cask (diameter: 0.67 m, height: 1.5 m), minimized by a factor of 10 compared to the actual thickness of a commercial TN-32 cask, was also manufactured. The detector array was designed to rotate the lab-scale cask and obtain 36 image profiles at every 10 degrees. All profiles were aligned in single frame image called a sinogram, and the cross-sectional image was then fabricated by the inverse radon transform algorithm. These experiments have been repeated with different configurations and numbers of sources. Some gamma-ray sources were also measured with neutron sources in order to distinguish between neutron and gamma-ray pulses. Basically, a He-4 detector is designed to run on Linux OS so it is difficult to directly apply to Windows-based equipment widely used in S. Korea. Therefore, a new data acquisition board working on Windows OS was designed and built. The board mainly consists of FPGA (Field Programmable Gate Array) and SoC (System on Chip) for TTL pulse readout, sorting measured data, and transferring data to a user interface. In conclusion, the tomographic system at lab-scale has shown considerable potential to detect a partial or gross defect of encapsulated assemblies in dry storage. Next steps of this study will be to 1) repeatedly carry out experiments to demonstrate scientific reliability and validity, and 2) numerically integrate signals with weight factors to enhance the image quality since the suggested system based on passive interrogation method requires longer measurement time. Finally, the system will apply to a commercial dry storage phased out soon in S. Korea. (authors)

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2021

Advanced PGM-free Cathode Engineering for High Power Density and Durability

Polymer electrolyte fuel cells (PEFCs) are among the most promising technologies for future electric vehicles by using clean H2 with much-improved energy conversion efficiency, longer range, and rapid refueling. However, due to a large amount of platinum group metal (PGM) catalyst used in their electrodes, their prohibitively high cost hinders broad commercialization of PEFCs for transportation. Therefore, there is a critical need to develop low-cost, high-performance PGM-free cathode catalysts that have the potential to dramatically transform the economics of PEFC commercialization by reducing catalyst costs by one to two orders of magnitude. However, before PGM-free cathodes become viable, several technical challenges associated with PGM-free cathodes must be addressed, including insufficient activity and stability of the catalysts, as well as severe water flooding and large transport losses in the electrodes. Overcoming those barriers and ultimately meeting the challenging automotive PEFC performance targets was the focus of this comprehensive research and development effort on new PGM-free cathodes. To this end, we assembled a team including leading researchers from universities and industry with different but complementary expertise and capabilities. The project combined three novel and promising approaches: Advanced metal-organic framework (MOF)-derived M-N-C catalysts with a high activity and impressive durability, Novel PGM-free specific cathode architectures and fabrication strategies capable of addressing the substantial flooding and transport resistances in thicker cathodes by introducing engineered hydrophobicity through additives and support layers, and Advanced electrode ionomers with high proton conductivity for low ohmic losses across the electrode and more uniform catalyst utilization. The implementation of these new materials and electrode designs was supported by a suite of advanced experimental and simulation tools that allows us to identify performance and durability bottlenecks, devise solutions, and establish rational material design and synthesis targets. These methods include advanced electrochemical characterization, high-resolution imaging, and multi-scale modeling. In addition, the project team leveraged a broad cross-section of the ElectroCat consortium’s national laboratory facilities and expertise in advancing these materials and design strategies. Finally, the industry partners on the project facilitated the evaluation of scaled-up synthesis and manufacturing in the United States. Over its four-year period, the project made significant year-over-year advances in PGM-free cathode performance and viability. A combination of high activity and highly durable catalysts were developed through novel catalyst synthesis strategies, which met several performance and durability targets. More specifically, a catalyst prepared from MOFs and Fe2O3 nanoparticles with ammonium chloride and chemical vapor deposition treatments yielded a significant advancement in PGM-free cathode durability. Several novel strategies for fabricating cathodes were demonstrated, including those designed to reduce flooding and thickness of the cells for significantly increased volumetric power density. An optimized cathode with high conductivity ionomer and tuned ink processing for hydrophobicity yielded high fuel cell performance with new levels power density and maximum current. The scientific studies and modeling assessment also provided an outlook for future efforts, including a focus on catalysts with an increased density of the highly stable active sites developed in this project.

08 HYDROGEN↗

DOE OSTI2020

Low temperature, ambient pressure electrochemical ammonia synthesis in alkaline media — Mechanistic studies and catalyst design. Final Report

Ammonia synthesis via the Haber-Bosch process is a pillar of modern agriculture, which converts the abundant but inert dinitrogen in the atmosphere to nitrogen-based fertilizers. Despite more than a century of optimization, the Haber-Bosch process remains energy intensive and reliant on fossil fuels and produces large amounts of CO 2 . Distributed and modular ammonia synthesis via the electrochemical nitrogen reduction reaction (ENRR) at or close to ambient conditions, powered by renewable electricity is an attractive alternative because it allows as needed production of ammonia, and in turn fertilizers. However, selective ENRR catalysts remain lacking. In this project, we systematically investigated two categories of catalytic materials, i.e., precious metals and transition metal nitrides, in the ENRR. Precious metals exhibit low activity and selectivity in the ENRR, which is in agreement with recent computational studies. Transition metal nitrides, especially VN, has been demonstrated as active and selective ENRR catalysts. We developed the first quantitative method to determine the amount of ammonia produced in the ENRR on N-containing containing catalysts in the membrane electrode assembly configuration. An initial ammonia production rate of 6.6 × 10 -10 mol s -1 mg -1 and a Faradaic efficiency of 6.0% at -0.1 V were reached on VN. After the initial deactivation, VN was shown to be stable in the ENRR for 116 hours with a steady state ammonia production rate of 1.1 × 10 -10 mol s -1 cm -2 . A vanadium oxynitride species was identified as the active phase in the ENRR via a combination of operando and ex situ characterization techniques. In addition, we established that the ENRR proceeded on transition metal nitrides via the Mars van Krevelen mechanism and determined the initial and steady state active site densities by developing a quantitative isotopic exchange method.

42 ENGINEERING↗

NASA NTRS2011

Attitude Control and Orbital Dynamics Challenges of Removing the First 3-Axis Stabilized Tracking and Data Relay Satellite from the Geosynchronous ARC

Launched on April 4, 1983 onboard STS 6 (Space Shuttle Challenger), the First Tracking and Data Relay Satellite (TDRS 1) was retired above the Geosynchronous Orbit (GEO) on June 27, 2010 after having provided real-time communications with a variety of low-orbiting spacecraft over a 26-year period. To meet NASA requirements limiting orbital debris 1, a team of experts was assembled to conduct an End-Of-Mission (EOM) procedure to raise the satellite 350 km above the GEO orbit. Following the orbit raising via conventional station change maneuvers, the team was confronted with having to deplete the remaining propellant and passivate all energy storage or generation sources. To accomplish these tasks within the time window, communications (telemetry and control links), electrical power, propulsion, and thermal constraints, a spacecraft originally designed as a three-axis stabilized satellite was turned into a spinner. This paper (a companion paper to Innovative Approach Enabled the Retirement of TDRS 1, paper # 1699, IEEE 2011 Aerospace Conference, March 5-12, 2011 sup 2) focuses on the challenges of maintaining an acceptable spinning dynamics, while repetitively firing thrusters. Also addressed are the effects of thruster firings on the orbit characteristics and how they were mitigated by a careful scheduling of the fuel depletion operations. Periodic thruster firings for spin rate adjustment, nutation damping, and precession of the momentum vector were also required in order to maintain effective communications with the satellite. All operations were thoroughly rehearsed and supported by simulations thus lending a high level of confidence in meeting the NASA EOM goals.

Benet, Charles A.↗

NASA NTRSDate not supplied

Ideas For Infusing In-Space Servicing, Assembly and Manufacturing Concepts into Nuclear Electric Propulsion Architectures

NASA is currently investigating nuclear electric propulsion (NEP) for human Mars transport within the space nuclear propulsion portfolio. NEP spacecraft have the following characteristics, they: 1) include very large structures (~100-meter length); 2) are comprised of many components/modules; and 3) have very long lifetimes (e.g., 50 years for fuel rods). Thus, NEP spacecraft can be classified as a “persistent asset,” which is any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. NEP spacecraft will benefit from taking advantage of, and incorporating, In-space Servicing, Assembly, and Manufacturing (ISAM) capabilities in the spacecraft architecture from the onset, enabling system maintenance, repair, and evolution. ISA has a long history of being proposed for, and studied as, a means for achieving large systems in space. More recently, the benefits of ISA have been recognized by NASA, the Department of Defense (DOD), other government agencies, and commercial space companies, and thus, ISAM is being actively pursued at a national level. Past and current strategies for achieving large structures in space have relied largely on two strategies; the first is to launch monolithic structures (designed to meet launch vehicle requirements for payload size and mass) that are docked or berthed to other monolithic structures on-orbit to form a larger structure (e.g., the International Space Station [ISS]); the second is folding and packaging large structures to fit inside a payload fairing and deploying the full-sized structure (unaided) once on-orbit (e.g., the James Webb Space Telescope [JWST]). To date, conceptual architecture studies performed for NEP spacecraft capable of human-rated Mars transport have only included a combination of the two previously mentioned strategies. This paper will propose ideas for infusing ISAM strategies into NEP vehicle architectures that leverage existing and near future technologies and enable the resulting NEP systems to be realized in a more time- and cost-efficient manner.

in-space assembly↗

NASA NTRSDate not supplied

Ideas for Infusing In-Space Servicing, Assembly, and Manufacturing Concepts into Nuclear Electric Propulsion Architectures

in-space assembly↗

DOE OSTI2026

Zero-CO Residential Natural Gas Furnace

Residential natural gas furnaces are widely used in the US homes. Manufacturers dedicate significant design and testing resources to meet requirements of design standards. One area of these standards is controlling flue gas carbon monoxide (CO) emissions. To more effectively reduce CO emissions at the flue, we developed a novel catalyst-assisted approach that integrated a low Pt/Rh loading acidic gas reduction (AGR) catalyst with three-way catalyst (TWC) or diesel oxidation catalyst (DOC) components. Compact catalysts were fabricated and assembled into tubular components, which can be seamlessly incorporated into the primary heat exchanger of a representative commercially available condensing furnace. The retrofitted furnace was demonstrated and tested following ANSI/ASHRAE Standard 103-2017. Experimental results showed that both AGR/TWC and AGR/DOC configurations achieved near-zero CO emissions under steady-state and cold-start conditions, compared with up to 500 ppm at a cold start and 17 ppm in a steady state in the OEM furnace. The catalyst-assisted furnaces also exhibited an annual fuel utilization efficiency improvement of more than 1.5% relative to the baseline unit, with a manageable pressure drop of 2.0−2.5 in. of water column. These results demonstrate that the catalyst-assisted approach can effectively eliminate CO emissions and improve energy efficiency. The technology has broad applicability for residential and commercial gas-fired heating systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

NASA NTRS1986

Large-Scale Advanced Prop-Fan (LAP) pitch change actuator and control design report

In recent years, considerable attention has been directed toward improving aircraft fuel consumption. Studies have shown that the high inherent efficiency previously demonstrated by low speed turboprop propulsion systems may now be extended to today's higher speed aircraft if advanced high-speed propeller blades having thin airfoils and aerodynamic sweep are utilized. Hamilton Standard has designed a 9-foot diameter single-rotation Large-Scale Advanced Prop-Fan (LAP) which will be tested on a static test stand, in a high speed wind tunnel and on a research aircraft. The major objective of this testing is to establish the structural integrity of large-scale Prop-Fans of advanced construction in addition to the evaluation of aerodynamic performance and aeroacoustic design. This report describes the operation, design features and actual hardware of the (LAP) Prop-Fan pitch control system. The pitch control system which controls blade angle and propeller speed consists of two separate assemblies. The first is the control unit which provides the hydraulic supply, speed governing and feather function for the system. The second unit is the hydro-mechanical pitch change actuator which directly changes blade angle (pitch) as scheduled by the control.

Schwartz, R. A.↗

NASA NTRS2004

Prototype Morphing Fan Nozzle Demonstrated

Ongoing research in NASA Glenn Research Center's Structural Mechanics and Dynamics Branch to develop smart materials technologies for aeropropulsion structural components has resulted in the design of the prototype morphing fan nozzle shown in the photograph. This prototype exploits the potential of smart materials to significantly improve the performance of existing aircraft engines by introducing new inherent capabilities for shape control, vibration damping, noise reduction, health monitoring, and flow manipulation. The novel design employs two different smart materials, a shape-memory alloy and magnetorheological fluids, to reduce the nozzle area by up to 30 percent. The prototype of the variable-area fan nozzle implements an overlapping spring leaf assembly to simplify the initial design and to provide ease of structural control. A single bundle of shape memory alloy wire actuators is used to reduce the nozzle geometry. The nozzle is subsequently held in the reduced-area configuration by using magnetorheological fluid brakes. This prototype uses the inherent advantages of shape memory alloys in providing large induced strains and of magnetorheological fluids in generating large resistive forces. In addition, the spring leaf design also functions as a return spring, once the magnetorheological fluid brakes are released, to help force the shape memory alloy wires to return to their original position. A computerized real-time control system uses the derivative-gain and proportional-gain algorithms to operate the system. This design represents a novel approach to the active control of high-bypass-ratio turbofan engines. Researchers have estimated that such engines will reduce thrust specific fuel consumption by 9 percent over that of fixed-geometry fan nozzles. This research was conducted under a cooperative agreement (NCC3-839) at the University of Akron.

Lee, Ho-Jun↗

DOE OSTI2021

Feasibility of full-core pin resolved CFD simulations of small modular reactor with momentum sources

Complex flow structure interactions and heat transfer processes take place in nuclear reactor cores. Given the extreme pressure/temperature and radioactive conditions inside the core, numerical simulations offer an attractive and sometimes more feasible approach to study the related flow and heat transfer phenomena in addition to the experiments. Under the Exascale Computing Project, the full-core simulation of a small modular reactor (SMR) has been pursued coupling Computational Fluid Dynamics (CFD) and neutronics. A key aspect of the modeling of SMR fuel assemblies is the presence of spacer grids and the mixing promoted by mixing vanes or the equivalent. A reduced order methodology is adopted based on momentum sources to mimic the mixing of the vanes. The momentum sources have been carefully calibrated with detailed Large Eddy Simulations (LES) of spacer grids performed with Nek5000. Modeling the spacer grid and mixing vanes (SGMV) effect without body-fitted computational grid avoids the excessive costs in resolving the local geometric details, and thus supports the simulation to be scaled up to the full core. Besides the progress on momentum source modeling, this paper also features the first full-core pin resolved CFD simulation ever performed to the authors' knowledge. This represents a significant advancement in capability for the CFD of nuclear reactors, which will hopefully serve as an inspiration for further integrating high-fidelity numerical simulations in actual engineering designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗