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At least 649 records · Page 36

Thermal Analysis of the Sirius-3 Nuclear Propulsion Fuel Experiments

To support long space missions, NASA is designing and testing different fuels for nuclear thermal propulsion. These designs include a number ceramic metallic fuels which are to be irradiated in the Tranisent Test Reactor to test the fuel’s performance at protypical conditions. The irradiation campaign of these fuels is referred to as the Sirius experiments, and includes single and stacked experiment samples. In this paper we present the thermal analysis of the Sirius-3 experiment. For this analysis, temperatures from a Bison finite element model are compared to the temperatures obtained from an experiment thermocouple where good agreement between the two are found. Because agreement of the thermocouple and Bison finite element model, insight into the heat flow is provided to experimenters as they design future experiments. As an example of this insight, the rods through the fuel specimen as shown in Sirius A and B [1] were removed and replaced with hold down rings for the Sirius-2C

33 ADVANCED PROPULSION SYSTEMS↗

Experimentation on Finned-Tube Microchannel Heat Exchanger Incorporating Phase Change Material and R-410A

Integrating latent heat thermal energy storage, particularly phase change materials (PCM), in building heating, ventilation, air conditioning, and refrigeration (HVAC&R) systems, offers substantial benefits for peak load shifting and energy efficiency. While numerous studies explore PCM-embedded heat exchangers (PCM-HX) using single-phase heat transfer fluids, there needs to be more investigation regarding PCM-HX utilizing two-phase refrigerant flow. This gap is even more pronounced for microchannel heat exchanger (MCHX) configurations. In this study, an MCHX-based PCM-HX was built and tested to analyze and evaluate the performance of a PCM-HX operating with a two-phase refrigerant as the working fluid. A commercially available MCHX condenser unit was embedded with 2.6 kg of RT35 PCM and tested using R-410A as the working fluid, using an in-house test loop to control the refrigerant inlet conditions precisely. Thin and minimally invasive T-type thermocouples traced the temperature evolution along MCHX channels and tube banks. Additional larger T-type thermocouple probes at the refrigerant inlet and outlet measured the average power of the PCM-HX during condensing tests, ranging from 0.7 kW to 1.6 kW based on mass flow rates varying from 3.5 g/s to 8 g/s. This experimental study on MCHX-based PCM-HX with a two-phase refrigerant has the potential to offer practical design guidelines for the direct integration of PCM-TES in HVAC&R systems without the use of a secondary loop, while caution is advised to avoid a substantial increase in the refrigerant charge amount.

42 ENGINEERING↗

AGR-5/6/7 Irradiation Test Final As-run Report

This document presents the as-run analysis of the Advanced Gas Reactor (AGR)-5/6/7 irradiation experiment. AGR-5/6/7 is the last of a series of experiments conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory in support of the development and qualification of tri-structural isotropic low-enriched fuel for use in high-temperature gas-cooled reactors. The test train contained five separate capsules that were independently controlled and monitored. Each capsule contained multiple 24.91-mm-long and 12.25-mm-dimeter compacts filled with low-enriched uranium carbide/oxide tri-structural isotropic fuel particles. The objectives of the AGR-5/6/7 experiment were to: • Irradiate reference-design fuel particles to support fuel qualification. • Establish operating margins for the fuel, beyond normal operating conditions. • Provide irradiated-fuel performance data and irradiated-fuel samples for post-irradiation examination and safety testing. The primary objective of the AGR-5/6 test (Capsules 1, 2, 4, and 5) was to verify the successful performance of the reference-design fuel under normal operating conditions. The AGR-7 test (Capsule 3) was designed to explore fuel performance at higher temperatures. Its primary objective was to demonstrate the capability of the fuel to withstand conditions beyond normal operating conditions, in support of plant design and licensing. AGR-5/6/7 will also provide irradiated-fuel performance data based on the fission gas release from particles during irradiation. To achieve the test objectives, the AGR-5/6/7 experiment was irradiated in the northeast flux trap of the ATR with a planned duration of 500 effective full-power days. The northeast flux trap was selected because its larger diameter provided greater flexibility for test-train design compared to the Large B positions used for the AGR-1 and AGR-2 irradiations, significantly enhancing test capabilities for the combined irradiation campaigns. Due to delays in the ATR schedule, the AGR-5/6/7 irradiation was significantly shorter than the originally planned 13-cycle schedule. Irradiation began on February 16, 2018 and ended on July 22, 2020, spanning nine ATR cycles (162B–168A) over two and a half years. Thus, the AGR-5/6/7 fuel compacts were irradiated for a total of approximately 360.9 effective full-power days. Final burnup values, on a per-compact basis, ranged from 5.66 to 15.26% fissions per initial heavy metal atom, while fast fluence values ranged from 1.62 to 5.55 × 1025 n/m2 (E >0.18 MeV). Time-averaged volume-averaged fuel temperatures on a capsule basis at the end of irradiation ranged from 756°C in Capsule 5 to 1313°C in Capsule 3 excluding days with significantly lower temperature during the two short powered axial locator mechanism cycles, 163A and 167A. By the end of irradiation, 48 out of 54 installed thermocouples had failed (the bottom three capsules lost all thermocouples). During the first five cycles (162B – 165A), the fission-gas isotope release-rate-to-birthrate (R/B) ratios were stable in the 10-8–10-6 range, and no in-pile particle failures were observed based on the gross gamma counts. During this time, the high exposed kernel fraction and high fuel particle temperatures in Capsule 1 led to a maximum R/B value of around 2 ? 10-6 for Kr-85m. The fission gas release in all capsules started to increase from the second half of Cycle 166A, when a large number of in-pile particle failures occurred in Capsule 1 and a gas line problem in this capsule caused fission gas leakage at various degrees into the other four capsules. This gas line problem also prevented a fission gas release measurement for Capsule 1 during the last three cycles due to gas flow isolation. By the end of irradiation, it is estimated that approximately 15 particles failed in Capsule 3, which was considered possible because the experiment was designed to operate beyond the high-temperature gas-cooled reactor normal operating temperature range. A few hundred in-pile particle failures were estimated for Capsule 1 by the end of Cycle 166A, but the total number of failures is unknown due to the lack of fission gas release data in the later cycles. Additionally, four potential in-pile failures were identified for Capsule 2 during the last cycle, Cycle 168A. In contrast, no in-pile failures were identified in the top two capsules (4 and 5) based on the absence of the typical spikes in gross gamma counts and low failure estimates using the AGR-3/4 R/B per exposed kernel model.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Validation of Pronghorn for Natural-Circulation Molten Salt Loops

This paper presents the development and validation of a high-fidelity thermal-hydraulic model of a molten salt natural circulation flow loop, designed for integration within a digital twin framework. The study evaluates the performance of Idaho National Laboratory’s Pronghorn against experimental data from Texas A&M University Molten Salt Flow Loop (MSFL) four Hitec-salt test benchmark data. Natural circulation of high-Prandtl-number fluids exhibits complex, counter-intuitive flow patterns that make pointwise thermocouple readings unreliable. Experimental work at TAMU’s MSFL provides benchmark data, including flow visualization at a test-section and centerline steady-state temperature measurements along the loop. Validation includes four single-phase natural circulation test cases with Hitec salt. Key metrics include flow profile agreement and steady-state temperature accuracy. Pronghorn results for two-dimensional single-phase agree qualitatively with the experimental flow profile. This paper illustrates the importance of Computational Fluid Dynamics (CFD) in elucidating the behavior of high-Prandtl-number thermal-hydraulics, along with how misleading centerline temperature measurements can be. Pronghorn reproduces the axial and radial stratification that makes single thermocouple readings unreliable. Future research will focus on reduced-order modeling techniques to enable rapid simulation suitable for real-time digital twin applications. The validated cases provide a basis for developing reduced-order surrogates aimed at real-time digital-twin applications.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Treatment of Osteoid Osteomas Using a Navigational Bipolar Radiofrequency Ablation System

BackgroundPercutaneous CT-guided radiofrequency ablation is a safe and effective minimally invasive treatment for osteoid osteomas. This technical case series describes the use of a recently introduced ablation system with a probe that can be curved in multiple directions, embedded thermocouples for real-time monitoring of the ablation volume, and a bipolar design that obviates the need for a grounding pad.MethodsMedical records of all patients who underwent radiofrequency ablation of an osteoid osteoma with the STAR Tumor Ablation System (DFINE; San Jose, CA) were reviewed. The location of each osteoid osteoma, nidus volume, and procedural details were recorded. Treatment efficacy and long-term complications were assessed at clinical follow-up.ResultsDuring the study period, 18 osteoid osteomas were radiofrequency ablated with the multidirectional bipolar system. Lesion locations included the femur (50 %; 9/18), tibia (22 %; 4/18), cervical spine (11 %; 2/18), calcaneus (5.5 %; 1/18), iliac bone (5.5 %; 1/18), and fibula (5.5 %; 1/18). The median nidus volume of these cases was 0.33 mL (range 0.12–2.0 mL). All tumors were accessed via a single osseous channel. Median cumulative ablation time was 5 min and 0 s (range 1 min and 32 s–8 min and 50 s). All patients with clinical follow-up reported complete symptom resolution. No complications occurred.ConclusionSafe and effective CT-guided radiofrequency ablation of osteoid osteomas can be performed in a variety of locations using a multidirectional bipolar system.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

Non-isothermal Crystallization Kinetics of Mold Fluxes for Casting High-Aluminum Steels

This paper investigates the crystallization behavior of CaO-SiO{sub 2}- and CaO-Al{sub 2}O{sub 3}-based mold fluxes for casting high-aluminum steels using single hot thermocouple technology, developed kinetic models, and scanning electron microscope. The results showed that the crystallization ability of the typical CaO-SiO{sub 2}-based Flux A (CaO/SiO{sub 2} 0.62, Al{sub 2}O{sub 3} 2 mass pct) is weaker than that of CaO-Al{sub 2}O{sub 3}-based Flux B (CaO/SiO{sub 2} 4.11, Al{sub 2}O{sub 3} 31.9 mass pct) because of its higher initial crystallization temperature. The crystallization kinetics of Flux A was “surface nucleation and growth, interface reaction control” in the overall non-isothermal crystallization process, whereas that of Flux B was “constant nucleation rate, 1-dimensional growth, diffusion control, in the primary crystallization stage, and then transformed into constant nucleation rate, 3-dimensional growth, interface reaction control in the secondary crystallization stage.” The energy dispersive spectroscopy results for Flux B suggested that the variations in the crystallization kinetics for Flux B are due to different crystals precipitating in the primary (BaCa{sub 2}Al{sub 8}O{sub 15}) and secondary (CaAl{sub 2}O{sub 4}) crystallization periods during the non-isothermal crystallization process.

36 MATERIALS SCIENCE↗

Effect of Slag Composition on the Crystallization Kinetics of Synthetic CaO-SiO{sub 2}-Al{sub 2}O{sub 3}-MgO Slags

The crystallization kinetics of CaO-SiO{sub 2}-Al{sub 2}O{sub 3}-MgO (CSAM) slags was studied with the aid of single hot thermocouple technique (SHTT). Kinetic parameters such as the Avrami exponent (n), rate coefficient (K), and effective activation energy of crystallization (E{sub A}) were obtained by kinetic analysis of data obtained from in situ observation of glassy to crystalline transformation and image analysis. Also, the dependence of nucleation and growth rates of crystalline phases were quantified as a function of time, temperature, and slag basicity. Together with the observations of crystallization front, they facilitated establishing the dominant mechanisms of crystallization. In an attempt to predict crystallization rate under non-isothermal conditions, a mathematical model was developed that employs the rate data of isothermal transformation. The model was validated by reproducing an experimental continuous cooling transformation diagram purely from isothermal data.

36 MATERIALS SCIENCE↗

Modified DHTT Equipment for Crystallization Studies of Mold Slags

The double hot thermocouple technique (DHTT) enables simulations of the temperature gradient at near-service conditions during continuous casting of steel. With the equipment applied so far, a rectangular slag film of even thickness often cannot be achieved. Further, the minimum temperature frequently lies within the slag film. Modified equipment can avoid these disadvantages via the following design features. The entire furnace chamber is heated to the selected temperature of the cold wire, and the minimum temperature is not located within the slag film. Furthermore, the shape of the heating wire is improved, which enables mounting of a thin, rectangular slag film between four platinum wires. This modification allows for investigations on transparent and translucent slags. So far, the results from DHTT investigations were represented via snapshots of the samples at certain experimental times. Therefore, appropriate methods for the graphical representation of the results were suggested: the maximum crystallinity, the time related to certain crystallinities with a dependence on the position within the slag film, and the crystal growth rate. The CaO-MgO-Al{sub 2}O{sub 3}-SiO{sub 2} slag investigated with this equipment was mineralogically examined additionally, and based on thermodynamic calculations, the allocation of temperatures to certain positions within the crystallized slag film was possible.

36 MATERIALS SCIENCE↗

Experimental Investigations on Solidification of 500-kg Steel Ingots with Laboratory Trials

The present work focuses on the solidification process of large steel ingots. Several complex solidification phenomena in large ingots were investigated by means of experimental hot modeling and cold modeling. In hot modeling, a 500 kg ingot solidified slowly in a specially insulated mold and this slow solidification process simulates the solidification of industrial scale ingots with a weight between 3 and 6 t. Temperature was measured by thermocouples during solidification and curves were plotted, and as-cast structure and macrosegregation of alloying elements were quantified. The A segregates were produced in the laboratory hot trials and quantitatively investigated. Meanwhile, water modeling (cold modeling) using NH{sub 4}Cl solution was conducted with different cooling/heating conditions. Macroscopic crystal growth phenomena, such as dendritic growth, sedimentation of crystals, and convective fluid flow, were directly observed and analyzed, and flow channels were also observed and compared with A segregates in the hot modeling.

36 MATERIALS SCIENCE↗

Effect of Li{sub 2}O on the Behavior of Melting, Crystallization, and Structure for CaO-Al{sub 2}O{sub 3}-Based Mold Fluxes

The effect of Li{sub 2}O content on the behavior of melting, crystallization, and molten structure for CaO-Al{sub 2}O{sub 3}-based mold fluxes was investigated in this article, through use of single hot thermocouple technology (SHTT), Fourier transform infrared spectroscopy (FTIR), Raman spectroscopy, and X-ray diffraction (XRD). The SHTT results showed that the melting temperature range of the designed mold fluxes decreases and the crystallization of mold fluxes is inhibited first and then becomes enhanced when the Li{sub 2}O content increases from 1 to 6 mass pct. The FTIR and Raman spectroscopy results suggested that Li{sub 2}O could release O{sup 2−} ions to break the complex Al-O-Al structural unit into Al-O{sup −} structure. Meanwhile, Li{sub 2}O could also stabilize the structural unit of Si-O-Al by link aluminate and Q{sub 0}{sup Si} structure through providing Li{sup +} ions to merge into the network and compensate for the charges between Al{sup 3+} and Si{sup 4+}. Besides, the XRD results indicated that the precipitation of LiAlO{sub 2} in molten slag would enhance the crystallization behavior of mold flux when Li{sub 2}O content is over 4.5 mass pct.

36 MATERIALS SCIENCE↗

Effect of MgO on Crystallization and Heat Transfer of Fluoride-Free Mold Fluxes

The effect of MgO on crystallization and heat transfer of fluoride-free mold fluxes was studied using single/double-hot thermocouple technique (SHTT/DHTT) and infrared emitter technique (IET), respectively. SHTT experiments demonstrated that the increase of MgO concentration promoted the crystallization tendency of mold fluxes. XRD analysis showed that the dominant phases changed from CaSiO{sub 3} to CaSiO{sub 3}/Ca{sub 2}MgSi{sub 2}O{sub 7}/Ca{sub 11}Si{sub 4}B{sub 2}O{sub 22}, and to Ca{sub 2}MgSi{sub 2}O{sub 7} as the MgO content was increased. The heat flux across mold flux disks was reduced from 671 to 615 kW/m{sup 2} in IET experiments when MgO concentration was increased from 0.9 to 4.9 mass pct.

36 MATERIALS SCIENCE↗

Nonisothermal Crystallization Kinetics of Glassy Mold Fluxes

Crystallization of the solid glassy mold flux film occurring in the gap between the initial shell and mold wall is important, as it determines the in-mold heat transfer and mold lubrication during the process of continuous casting. In order to study the nonisothermal crystallization behavior of the glassy mold flux film in the continuous casting mold, the continuous heating transformation diagram, crystallization mechanism, and precipitate phases were investigated using the single hot thermocouple technique, kinetic models, a scanning electron microscope, and an energy-dispersive spectrometer (EDS). The results show that the initial crystallization temperature for CaO-SiO{sub 2} based flux A ranges from [1086 K to 1147 K (813 °C to 874 °C)], which is lower than the case of CaO-Al{sub 2}O{sub 3} based flux B ranging from [1205 K to 1245 K (932 °C to 972 °C)]. The crystallization kinetics for flux A are constant nucleation rate, two-dimensional growth, and control by diffusion. For flux B, they are constant nucleation rate, three-dimensional growth, and control by interface reaction. Besides, the EDS results indicate that the precipitate crystals in fluxes A and B are CaSiO{sub 3} and Ca{sub 2}AlSiO{sub 4}, respectively.

36 MATERIALS SCIENCE↗

Effects of B{sub 2}O{sub 3} on Crystallization, Structure, and Heat Transfer of CaO-Al{sub 2}O{sub 3}-Based Mold Fluxes

The reaction between traditional CaO-SiO{sub 2}-based mold fluxes and high-Al steel inevitably changes flux composition, and, consequently, flux properties. This problem can be mitigated by using CaO-Al{sub 2}O{sub 3}-based mold fluxes. To maintain appropriate melting properties, CaO-Al{sub 2}O{sub 3}-based mold fluxes contain B{sub 2}O{sub 3}, which is an effective fluxing agent that decreases the liquidus temperature. In this article, the effects of B{sub 2}O{sub 3} on crystallization behavior, structure, and heat transfer of CaO-Al{sub 2}O{sub 3}-based mold fluxes were studied using single/double hot thermocouple technique, Raman spectroscopy, and infrared emitter technique. The increase of B{sub 2}O{sub 3} content from 7.6 to 13.1 mass pct suppressed the crystallization tendency of mold fluxes in continuous cooling experiments and isothermal experiments conducted over 1273 K (1000 °C). The isothermal crystallization below 1273 K (1000 °C) was also inhibited when B{sub 2}O{sub 3} content increased from 7.6 to 9.6 mass pct; but a further increase of B{sub 2}O{sub 3} content to 13.1 mass pct did not show a visible effect on the crystallization tendency. The increase of B{sub 2}O{sub 3} content from 9.6 to 13.1 mass pct improved the heat fluxes under an incident thermal radiation of 1.6 MW/m{sup 2}; however, the increase of B{sub 2}O{sub 3} content from 7.6 to 9.6 mass pct slightly decreased the heat transfer rate. Crystallization of fluxes and heat transfer were discussed in relation to flux structure.

36 MATERIALS SCIENCE↗

TTT Diagram of 10 pct CaO-90 pct Fe{sub 2}O{sub 3} in Low-Temperature Region Below 1499 K

The important property of a sinter is its ability to withstand the load in a blast furnace (BF). During the cooling process, many compounds among CaO(C), FeO(W), and Fe{sub 2}O{sub 3}(F) precipitate, thereby affecting the quality of the sinter. In a previous study, the compounds that precipitated at a high quenching rate (7600 K/s) were clarified. In this study, a 10 pct CaO-90 pct Fe{sub 2}O{sub 3} sample was melted and held at the desired temperatures from 1 minute to 168 hours using the hot thermocouple (HTC) method. The precipitated compounds were clarified by X-ray diffraction (XRD), while a time-temperature-transformation (TTT) diagram for the 10 pct CaO sample was determined below 1499 K. Unstable compounds (C{sub 2}W{sub 4}F{sub 9} and WF{sub SS}) were precipitated together with CF and F in the low-temperature region below 1428 K (1155 °C). However, the unstable compounds disappeared when the holding time was long. In the temperature region from 1428 K to 1499 K (1155 °C to 1226 °C), the rate of formation of CF{sub 2} was low; over a period longer than 168 hours, CF disappeared. Therefore, the reaction, CF + F = CF{sub 2}, is very slow because the locations of CF and F are separated during precipitation from the melt.

36 MATERIALS SCIENCE↗

Development of an Austenitization Kinetics Model for 22MnB5 Steel

This paper presents a first-order austenitization kinetics model for 22MnB5 steel, commonly used in hot forming die quenching. Model parameters are derived from constant heating rate dilatometry measurements. Vickers hardness measurements made on coupons that were quenched at intermediate stages of the process were used to verify the model, and the Ac{sub 1} and Ac{sub 3} temperatures inferred from dilatometry are consistent with correlations found in the literature. The austenitization model was extended to consider non-constant heating rates typical of industrial furnaces and again showed reasonable agreement between predictions and measurements. Finally, the model is used to predict latent heat evolution during industrial heating and is shown to be consistent with values inferred from thermocouple measurements of furnace-heated 22MnB5 coupons reported in the literature.

36 MATERIALS SCIENCE↗

On the Phase with an Unreported Ternary Composition Found in the P-Pt-Rh System

This work reports a ternary structure in the P-Pt-Rh system, which has a composition not reported in the literature. The structure formed in the Pt-6 wt.% Rh alloy which was partially melted in a P-enriched CO environment near 1000 °C isothermally and non-isothermally as part of the type B thermocouple assembly. A composition and a crystal structure of this phase were investigated by utilizing SEM, EPMA, XRD and TEM techniques to discuss the potential of this structure being a true ternary phase. The EPMA indicated chemistries of the ternary structure from both isothermal and non-isothermal samples were about 23P-52Pt-25Rh (at.%) and, 22P-54Pt-24Rh (at.%) respectively. TEM diffraction patterns identified this ternary structure to be crystalline with a complex non-cubic structure, and confirmed it was not amorphous. Finally, by superimposing the compositions in the ternary phase diagram, it was concluded this phase was not extensions of any binary phases known in the respective binary systems.

36 MATERIALS SCIENCE↗

Real-time measurements of temperature, pressure and moisture profiles in High-Performance Concrete exposed to high temperatures during neutron radiography imaging

High-Performance Concrete (HPC) is particularly prone to explosive spalling when exposed to high temperature. Although the exact causes that lead to spalling are still being debated, moisture transport during heating plays an important role in all proposed mechanisms. In this study, slabs made of high-performance, low water-to-binder ratio mortars with addition of superabsorbent polymers (SAP) and polypropylene fibers (PP) were heated from one side on a temperature-controlled plate up to 550 °C. A combination of measurements was performed simultaneously on the same sample: moisture profiles via neutron radiography, temperature profiles with embedded thermocouples and pore pressure evolution with embedded pressure sensors. Spalling occurred in the sample with SAP, where sharp profiles of moisture and temperature were observed. No spalling occurred when PP-fibers were introduced in addition to SAP. The experimental procedure described here is essential for developing and verifying numerical models and studying measures against fire spalling risk in HPC.

42 ENGINEERING↗

Ultrasensitive Photothermal Spectroscopy: Harnessing the Seebeck Effect for Attogram-Level Detection

Molecular-level spectroscopy is crucial for sensing and imaging applications, yet detecting and quantifying minuscule quantities of chemicals remain a challenge, especially when they surface adsorb in low numbers. Here, we introduce a photothermal spectroscopic technique that enables the high selectivity sensing of adsorbates with an attogram detection limit. Our approach utilizes the Seebeck effect in a microfabricated nanoscale thermocouple junction, incorporated into the apex of a microcantilever. We observe minimal thermal mass exhibited by the sensor, which maintains exceptional thermal insulation. The temperature variation driving the thermoelectric junction arises from the nonradiative decay of molecular adsorbates’ vibrational states on the tip. We demonstrate the detection of photothermal spectra of physisorbed trinitrotoluene (TNT) and dimethyl methylphosphonate (DMMP) molecules, as well as representative polymers, with an estimated mass of 10 -18 g.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗