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675 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Demonstration of μCHP in Light Commercial Hot Water Applications

Internal combustion engine driven combined heat and power (CHP) systems produce power while the waste heat is recovered and used for another purpose. For µCHP systems (less than 50kWe output) overall efficiencies can reach over 90% for products currently on the market throughout the world. On a fuel basis this offers an advantage over using grid-based power and another fuel for heat. Additionally, the cost of natural gas on an energy unit basis is significantly less expensive than electric power. This difference can lead to substantial savings for the end user of a CHP system. In some parts of the world, particularly Germany and Japan, µCHP has become a common part of the heat and distributed generation equipment mix. Market analysis conducted in 2012 showed that in North America there is potential of a 5,300 units per year market for µCHP, resulting in an annual energy savings of approximately 13.5 TBtu and more than $84 million in annual customer savings. However, µCHP still has not seen much market penetration in North America. This study helps to identify some of the reasons why, address roadblocks that still need to be overcome and provide experience to established best practices. Nine commercial sites were initially identified (fitness club, surgical center, senior community, resort and spa, commercial laundry, two multi-family housing, restaurant and manufacturing facility). Systems from two different manufacturers were installed at five sites total, but due to unforeseen circumstances, only three of those sites were finally commissioned: test data were collected by Oak Ridge National Laboratory. While not all systems were installed as intended, the project resulted in the following key findings: Micro combined heat and power is an unfamiliar technology for building owners and plumbing and electrical contractors that serve the buildings most suited for µCHP. Manufacturers will need to be aggressive in providing training and providing broad support to successfully bring the technology to market.; The proper integration of µCHP into other building systems is the most critical part of a successful installation. Manufacturers will need to be able to provide the expertise to train, advise and support the mechanical contractors during the design and installation of the heat integration system.; Regulations governing µCHP varies across the country. There are a few UL standards (UL 2200 and UL 1741) that apply nationally. Emissions are governed by EPA except in California where the California Air Resources Board (CARB) has established their own standard. Requirements that dictate installation and interconnection are dependent on local building codes and local utility processes and requirements. Some out of date building codes do not offer clear guidance for these requirements, leading to confusion. This makes developing training and determining broadly applicable best practices difficult.; Installation costs of µCHP are a key factor in making an installation successful. It is critical that these costs and all national, state and local regulations be understood and accounted for by all parties involved in the installation before a project is undertaken.; A robust customer service organization is important to meet the needs of the customers. These systems require annual maintenance and service and local capability is needed to keep costs inline.

03 NATURAL GAS↗
NASA NTRS2020

A Summary of Airframe Results from a Fokker F28 Full-Scale Crash Test

On June 20, 2019, a full-scale crash test was conducted on a Fokker F28 MK1000 aircraft as a part of a joint NASA / Federal Aviation Administration (FAA) research effort to investigate the crashworthiness characteristics of a Transport Category Aircraft (TCA), as defined by 14 Code of Federal Regulations, Part 25. The test was conducted at NASA Langley Research Center’s Landing and Impact Research Facility and was the third in a test series to further understand TCA crashworthiness characteristics. The test article featured 24 Anthropomorphic Test Devices (ATDs, a.k.a. crash test dummies), and over 700 channels of instrumentation covering major aircraft structures such as the wings, tail, nose, cockpit and cabin, along with recording seat, overhead bin and ATD accelerations. Five different U.S. Government agencies collaborated on the test including: NASA, the FAA, the U.S. Army Research Laboratory, the National Transportation Safety Board (NTSB) and the National Highway Traffic Safety Administration (NHTSA). This report will covertest article build up, which includes weight and balance measurements and pre-test laser scans. It will also cover the events of the test, which includes the test sequence of events and post-test damage inspections. Finally, it will show airframe level accelerations at all positions measured, with discussion on correlation to the airframe damage witnessed. The test build up consisted of outfitting the main cabin section of the aircraft with 24 ATDs seated in 12 rows of seats, overhead mass and the under floor cargo area with foam representing the luggage. The main cabin also included all of the onboard data system pallets, which recorded711 channels of data from the test. All major portions of the aircraft were instrumented, including locations at the floor / frame junction locations in the cabin where the ATDs were located along with other major exterior components such as the nose, the tail, each engine cowling, and at overhead hat rack ballast locations. The aircraft impacted a soil surface at65.3 ft/s horizontal and 31.8 ft/s vertical velocities. The aircraft plowed through the soil and slid a distance of 32.5 feet from the initial impact location. There was a secondary impact occurring 0.9 s due to the “slap down” of the nose during the post-impact response. The duration of the event from impact to rest was1.62 seconds. There was major structural damage in the lower fuselage areas around the Wingbox and Aft Fuselage sections. The Aft Fuselage section deformation caused some cabin intrusion from the keel beams pushing the aft cabin floor into the cabin. Other structural deformations occurred around the tail and at transition regions in the aircraft structure; mainly in locations of differing overall stiffness. The data obtained showed average vertical accelerations between 12 and 16 g with spikes reaching almost 40 g at certain floor locations. Average horizontal accelerations were approximately 10 g for all floor locations measured with spikes reaching approximately 25 g in some locations. The report includes a full set of results on aircraft deformation and accelerations along with discussions as to the effect on the aircraft structure.

Justin D Littell↗
NASA NTRS2003

Case for Deploying Complex Systems Utilizing Commodity Components

When the International Space Station (ISS) finally reached an operational state, many of the Payload Operations and Integration Facility (POIF) hardware components were reaching end of life, COTS product costs were soaring, and the ISS budget was becoming severely constrained. However, most requirement development was complete. In addition, the ISS program is a fully functioning program with at least fifteen years of operational life remaining. Therefore it is critical that any upgrades, refurbishments, or enhancements be accomplished in realtime with minimal disruptions to service. For these and other reasons, it was necessary to ensure the viability of the POIF. Due to the to the breadth of capability of the POIF (a NASA ground station), it is believed that the lessons to be learned by other complex systems are applicable and any solutions garnered by the POIF are applicable to other complex systems as well. With that in mind, a number of new approaches have been investigated to increase the portability of the POIF and reduce the cost of refurbishment, operations, and maintenance. These new approaches were directed at the Total Cost of Ownership (TCO); not only the refurbishment but also current operational difficulties, licensing, and anticipation of the next refurbishment. Our basic premise is that technology had evolved dramatically since the concept of the POIF ground system and we should leverage our experience on this new technological landscape. Fortunately, Moore's law and market forces have changed the landscape considerably. These changes are manifest in five (5) ways that are particularly relevant to POIF: 1. Complex Instruction Set Computing (CISC) processors have advanced to unprecedented levels of compute capacity with a dramatic cost break, 2. Linux has become a major operating system supported by most vendors on a broad range of platforms, 3. Windows(TradeMark) based desktops are pervasive in the office environment, 4. Stable and affordable WindowsTM development environments and tools are available and offer a rich set of capabilities, 5. The WindowsTM 2000 provides a stable client platform, Therefore, five studies were proposed, developed, and are in the current process of deployment which dramatically reduces the cost of operations, maintenance, refurbishment, and deployment of a ground system. Restating and refining the basic premise stated earlier, it is possible to enhance operations through the replacement of hardware and software components with commodity based items wherever applicable. This will dramatically reduce the overall lifecycle cost of the project. The first study leveraged the POIF S secure, three-tier, web architecture to replace the client workstations with lower cost PC platforms. A second study initiated a review of COTS products to examine the level of added value of each product. This study included replacement of some COTS products with custom code, deletions, substitutions, and consolidation of COTS products. Studies three and four reviewed the server architectures of the data distribution systems and Enhanced HOSC System (EHS) command and telemetry system to propose migration to new platforms, both software and hardware. The final study reviewed current IP communication technologies, developed an operational model for flight operations, and demonstrated that voice over IP was practical and could be integrated into operations.

Bryant, Barry S.↗
DOE OSTI2025

MOSCATO Development and Integration in Fiscal Year 2025: Implementation of Multiphase, Multiphysics Modeling Capabilities for Molten Salt Systems

MOSCATO (Molten Salt Chemistry and Transport) is a multiphysics code that provides high-fidelity, coupled simulations of fluid flow, heat transfer, mass transfer, chemistry, electrochemical phenomena, and alloy corrosion for molten salt systems. In FY25, significant developments were made to the code package, enhancing its capabilities for modeling all relevant phenomena within operating moltens salt reactors (MSRs). The developments and activities in FY25 included: 1. Implementation of Level-Set methods to enable modeling of single-bubble behavior in molten salts. In FY25, the Level-Set two-phase flow modeling implementation was improved to simulate single bubble behavior with molten salt media. The large density and viscosity ratios between typical gases and molten salt liquids present challenges for these types of numerical solvers. With enhancements to the pressure projection method, MOSCATO’s Level-Set solver was able to be successfully validated to experiments related to helium bubble rise in stagnant molten salt. The simulated bubble rising velocity showed reasonable good agreement with experimental measurements. The bubble shape and dynamics were also visually compared with experimental snapshots, demonstrating a good qualitative match. 2. Generation of mass transfer correlations for multiphase flow systems. To enable calculations of the tritium transport across the interface between gas bubbles and salt, we modeled high- Schmidt-number mass transfer around a sphere across a broad range of Reynolds numbers. The mesh near the sphere surface was highly refined to resolve steep concentration gradients caused by the low diffusion coefficient. Literature-based mass transfer correlations were compared with the numerical results, and modifications were proposed to improve agreement, particularly at higher Schmidt numbers. These mass transfer correlations were subsequently provided to other national laboratories to help enable high quality mass transfer simulations using lower-order solvers under development within the NEAMS program. 3. Preliminary implementation of a bubbly flow solver. To model bubbly flow in molten salt, we implemented a bubbly flow solver for void fractions less than 5%. To do so, an algebraic relative velocity model that assumes small bubbles with rapid momentum equilibration was added to MOSCATO to compute bubble velocities. Preliminary comparisons with experimental data showed reasonable agreement, and further improvements are underway. 4. Generation of mass transfer correlations for MSRE subchannel The Molten-Salt Reactor Experiment (MSRE) was a landmark historical project that demonstrated the feasibility of molten-salt reactor technology. The MSRE campaign also generated a significant body of experimental data and reports that continue to support molten-salt–related research. In this report, the MSRE core subchannel was used as the reference geometry for a mass transfer study performed with MOSCATO. The geometry and computational mesh were adapted from a previous study, providing adequate resolution for the relatively low Reynolds number in this case. Additional mesh refinement was applied to reach higher Schmidt numbers, enabling the derivation of a reliable mass-transfer correlation for the present scenario. 5. Simulations of oxygen ingressions into molten salt. In the previous fiscal year, we initiated a study to simulate oxygen ingression in stagnant salt. As oxygen enters the salt through its surface, it reacts with Ce 3+ to form solid CeO 2 and other reaction products. To more fully capture the complex diffusion-convection-reaction mechanisms, capabilities for modeling natural convection in the salt vessel were added. These were needed as the flow of the ingressed gas induced flow in the salt caused by surface shear and non-isothermal effects. With these updated physics in place, we were able to successfully reproduce the experimental results for the rate of change of CeCl 3 concentrations versus time. 6. Flow corrosion model validation. In FY24, MOSCATO’s corrosion model was validated against static corrosion experiments. In FY25, this work was extended to a flow corrosion experiment, where FLiNaK salt was driven by natural convection, with initial salt impurities to initiate corrosion. Despite uncertainties in parameters such as elemental diffusion coefficients in the alloy and unknown H + concentrations, the simulations achieved good agreement with experimental results, especially in predicting sample mass losses.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRSDate not supplied

A Multi-Disciplinary Analysis Framework for the Design of Small Launch Vehicles

Between the years of 1995 and 2014 the number of small satellites (1-500 kg) went up from 20 to 180. [1] Out of the 180 launched in 2014 66% were Nano satellites (1-10 kg). [1] With this trend of smaller satellites, one would expect a rise in number of small launch vehicles (SLVs are defined by capability to carry 1-100 kg to orbit), but this has not happened: [3] only 8% of all small satellites are launched on SLVs and the others become secondary payloads on regular launch vehicles. [1] This results in small satellites being placed into either suboptimal orbits or waiting for launch schedules to align with bigger launches, resulting in long waiting times. Dedicated SLVs could improve the responsiveness of small satellite launches, but SLV design is complicated by the large architecture space needed to be explored in order to find efficient and affordable designs. The SLV architecture trade space contains many discrete options, e.g. solid vs. liquid fuels, air launch vs. ground launch, number of stages, etc. [2][3] Performing detailed analysis for all the options at once would be prohibitive. Thus, a sizing environment/framework that is capable of providing necessary information for conceptual-level trade studies and can rapidly explore the vast SLV architecture space is necessary. The framework, illustrated in Figure 1, consists of four disciplines central to the sizing and synthesis of launch vehicles: propulsion, aerodynamics, structures, and trajectory. For the aerodynamics and trajectory disciplines, Missile DATCOM and POST2 are used, respectively. The propulsion and structures disciplines are represented in the framework with tools developed at ASDL Georgia Tech. For propulsion, the Solid Motor Analysis Code (SMAC) is a physics-based conceptual design tool for solid rocket motors. SMAC is capable of geometric burn simulation, ballistic analysis, and prediction of thrust performance. [4] For structures, Launch Vehicle Structural Analysis (LVSA) tool is a physics-based tool that focuses on structural dynamic analysis with sizing capability. These tools are integrated into the framework illustrated in Figure 1 with the corresponding connections described in Table 1. The process flow is as follows: first, SMAC sizes insulation and calculates maximum operating pressures for each vehicle stage. The MEOP and insulation thickness values from SMAC are fed to LVSA which then utilizes this information to size the motor casing. This creates a feedback loop between LVSA and SMAC that converges on the radius available for fuel, casing, and insulation thickness. Once the stage sizing is converged on SMAC creates an engine deck that is passed to POST2. Next, the data from SMAC and LVSA goes into Missile DATCOM which generates an aerodynamics database for POST2. Finally, POST2 performs a targeting optimization while maximizing the payload mass to orbit. Within the framework, POST2 is automated in order to be robust to a wide variety of possible designs by performing a Monte Carlo simulation over the initialization vector of the POST2 optimization variables. To demonstrate the capability of this framework, a sample problem of exploring the design space of an SLV capable of placing satellites into a low Earth orbit (inclination=47 deg, 196.5 by 211.3 nm) is used. This sample problem is a ground-launched SLV consisting of four in-line SRM stages. The multidisciplinary design analysis (MDA) environment is utilized to explore a design space consisting of 22 continuous and 12 discrete variables, shown by Table 1 by blocks 1,2,3. Running a full factorial design of experiments (DOE) would have been prohibitively expensive even with this reduced design space, thus a space filling design with 3,502 and then additional expansion of 2,602 cases was used. The first DOE consisted of 3,502 cases, and all of the variables were varied. These input variables are listed in blocks 1, 2, and 3 in Table 1. Most of the variables are propulsion related with stage lengths determining the delta-V split of the SLV. The expansion consisted of 2,602 cases, and the continuous variables were set to be equal to the most promising designs from the sizing of first DOE. For each set of continuous variables, the discrete variables (grain type, star points, and propellant) were to varied. The results of the DOE can be seen in Figure 2; each of the points in this plot represents a closed launch vehicle that reaches the targeted orbit. For each of the cases, there is information on flown trajectory, structural, and propulsion properties of the SLV. For example, Figure 3 shows changes in altitude and velocity with time for a particular case. The right side of Figure 3 clearly shows the coasting (slow decrease) and burning phases (sharp increase) of the SLV mission. LV mass is positively correlated with the optimized payload mass to orbit because heavier LVs carry more fuel and thus have more stored chemical energy. Furthermore, for any given payload mass to orbit, the most efficient design would result in the smallest LV. The results as visualized in Figure 2 shows this tradeoff, and the Pareto frontier of the efficient designs can be seen along the dotted line. Figure 2 can be divided into regions with the lowest mass vehicles corresponding to the minimum bound on radius, and the highest mass vehicles corresponding to the maximum bound on radius. Within a mass region, the discrete variables, such as propellant type and propellant grain arrangement, have the most effect on payload mass. This paper presents an MDA framework that can perform an automated physics-based sizing of SLV designs and a corresponding methodology to utilize the MDA to explore the design space of SLVs. The proposed methodology was applied to a perform a design space exploration for a four stage SLV. The outputs show the expected pareto frontier forming and provide detailed information about the SLV performance and staging. Using the produced data, it will be possible to select a set of pareto optimal designs that can then be further explored in subsequent design cycles. This demonstration shows that automated design space exploration should be used in the early phase design of future SLV concepts.

Nikita S Birbasov↗
NASA NTRS2017

Validation of Minimum Display Requirements for a UAS Detect and Avoid System

The full integration of Unmanned Aircraft Systems (UAS) into the National Airspace System (NAS), a prerequisite for enabling a broad range of public and commercial UAS operations, presents several technical challenges to UAS developers, operators and regulators. A primary barrier is the inability for UAS pilots (situated at a ground control station, or GCS) to comply with Title 14 Code of Federal Regulations sections 91.111 and 91.113, which require pilots to “see and avoid” other aircraft in order to maintain well clear. UAS pilots’ removal from the flight deck of the aircraft necessitates the development of a UAS-specific system for detecting nearby traffic and displaying traffic information to the pilot to support their ability to maintain an objectively defined “DAA well clear” threshold from other aircraft. This new UAS-specific function of remaining DAA well clear is called traffic avoidance. The resulting Detect and Avoid (DAA) system, however, will be subject to a collection of requirements that manufacturers will be obligated to meet in order to certify their equipment. RTCA Special Committee 228 (SC-228), a consortium of representatives from government, industry and academia, is responsible for developing and documenting the Minimum Operational Performance Standards (MOPS) for UAS DAA systems. The present study is the final in a series of human-in-the-loop (HITL) experiments designed to explore and test the various display and alerting requirements being incorporated into the DAA MOPS. Whereas the prior DAA HITLs examined a wide variety of DAA display features and concepts, the current experiment aims to validate the latest minimum display requirements for Phase 1 of the DAA MOPS. Rather than test different display concepts, this study tests two configurations of a MOPS-compatible DAA display: a version that is integrated into the primary navigation and control display of the GCS and a version that is physically separated from the primary display. This manipulation tests the draft minimum requirement that allows the DAA traffic display to be a separate, or standalone, configuration. This type of configuration is a more achievable near-term technology solution since it does not stipulate additional certification or integration requirements on UAS manufacturers. However, a standalone display configuration has the potential to result in pilot performance issues resulting from the cognitive costs of switching between the primary DAA display and the primary navigation and control display. This configuration is also particularly susceptible to errors if the displays are in different orientations (e.g., north-up versus track-up). Both the integrated and standalone display configurations were presented to 16 active UAS pilots in a medium-fidelity simulation, which included confederate air traffic controllers and pseudo pilots operating simulated manned traffic. Pilots were tasked with navigating two different mission routes while maintaining DAA well clear with scripted conflicts. Pilot response times (i.e., measured response) and ability to remain DAA well clear are reported. Primary results indicate that both display configurations resulted in favorable response times and well clear rates. While there were clear trends of pilots objectively performing better in the integrated display condition, with several measured response metrics reaching statistical significance, the differences between the two displays were typically moderate. While the primary variable of DAA display location did not have an especially large impact on pilot performance on its own, when examined alongside the type of DAA threat the pilot was facing (a caution-level versus a warning-level alert), the response time benefits associated with the integrated display were amplified. The implications of these American Institute of Aeronautics and Astronautics 2 results on the Phase 1 DAA MOPS and the connection of this data to previous studies is also discussed.

detect and avoid↗
DOE OSTI2024

Data and Scripts Associated with the Manuscript “Water Column Respiration in the Yakima River Basin is Explained by Temperature, Nutrients and Suspended Solids”

This data package is associated with the publication “Water Column Respiration in the Yakima River Basin is Explained by Temperature, Nutrients and Suspended Solids” published in EGU Biogeochemistry (Laan et al. 2025). In this research, water column respiration (ERwc) data, surface water chemistry data, organic matter (OM) chemistry data, and publicly available geospatial data were used in analysis to evaluate the variability in ERwc at 47 sites across the Yakima River basin in Washington, USA. In addition to this readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions. The data package includes the data inputs, and outputs, and R scripts to reproduce all the analyses performed in the manuscript and create manuscript figures. The data package is comprised of three main folders (Code, Data, and Figures). The Code folder is comprised of four scripts and three analysis-specific subfolders that contain the R scripts to perform the analyses described in the publication and create publication figures. The Data folder is comprised of two “.csv” files and four subfolders that contain data input and output files. The Published_Data folder contains a readme that directs the user to download the appropriate files and add to this folder when using scripts. The Figures folder includes figures from the manuscript in “.pdf” and “.png” formats and a folder with intermediate figure files. This data package is associated with a GitHub repository which can be found at https://github.com/river-corridors-sfa/rcsfa-RC2-SPS-ERwc. We acknowledge the Yakama Nation as owners and caretakers of the lands where we collected some of these data. We thank the Confederated Tribes and Bands of the Yakama Nation Tribal Council and Yakama Nation Fisheries for working with us to facilitate sample collection and optimization of data usage according to their values and worldview.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Solute effects upon dislocation motion and recovery in Mg alloys (Final Report)

The objective the research was to develop a firmer understanding of the interactions between substitutional solute atoms and dislocations within Mg alloys. These interactions govern the absolute and relative mobilities of various types of dislocations in Mg (e.g., basal < a>, non-basal < a>, and pyramidal < c+a>). Furthermore, they have an impact on dislocation recovery processes (e.g., cross-glide, climb, rearrangement, and annihilation). Ultimately, solute-dislocation interactions strongly impact a) strain hardening, b) strain rate sensitivity, c) plastic anisotropy of textured polycrystals, d) texture evolution, e) dislocation substructures evolution, and even f) recrystallization behavior. It is broadly known that Mg alloys exhibit poor low temperature formability. Since formability is largely governed by properties (a) – (c) in this list, it is critical to develop a better understanding of solute-dislocation interactions, if one hopes to improve the situation. While the theory of static solute strengthening is well developed, especially for alloys with face centered cubic (FCC) crystal structures, there are outstanding questions related to applications to hexagonal close packed (HCP) crystal structures and dynamic strain aging (DSA) in materials of various structures. DSA has far-reaching implications for metal formability and, in the case of Mg alloys, appears to correlate with the so-called rare-earth (RE) texture which has been shown to benefit formability. The Portevin-Le Chatelier (PLC) effect, and associated negative strain rate sensitivity, occur at higher temperatures (>100℃) in Mg alloys as compared with similar Al alloys, even though they have similar melting points and solute diffusivities. Our preliminary research has shown that modern, physics-based models of DSA can be tuned to describe the behavior of Mg alloys if a rather higher activation enthalpy is assumed for cross-core diffusivity. While this partially explains the delay in DSA to higher temperatures, it is also hypothesized that this delay is due in part to the intrinsically more thermally activated (rate sensitive) nature of non-basal < a> dislocation motion which is required for macroscopic flow of Mg alloys, whereas octahedral slip in many FCC metals like aluminum is essentially athermal at room temperature. It was originally proposed to employ a combination of in-situ diffraction-based experimental characterization to validate existing theory. It was envisioned to perform in-situ transmission electron microscopy (TEM) to assess individual dislocation behavior and in-situ high-energy X-ray diffraction (HEXRD) techniques which were showing great promise for elucidating collective dislocation behavior, 2 including recovery, especially if the contributions to various forms of diffraction peak broadening (𝜂𝜂,𝜔𝜔,and 2𝜃𝜃) can be effectively integrated. Finally, it was envisioned to perform discrete dislocation dynamics (DDD) modeling approaches to aide in the interpretation of both TEM and HEXRD experiments. In the end, mechanical tests were performed on more complex Mg alloys which exhibited evidence of dynamic strain aging, and this led to the establishment of another project. Mechanical test data obtained at McMaster University served as the basis of an assessment of the applicability of Bazinski’s “stress equivalence” theory of solute strengthening to polycrystalline alloys of Mg. Although we did not succeed in applying the approach to Mg alloys, we did develop expertise with the HEXRD approach using a BCC, β-Ti alloy and demonstrated numerous new capabilities that may be applied to any polycrystalline material in collaboration with researchers at CHESS and around the world: (1) assessment of details of the elastoplastic transition (yielding) using a combination of HEXRD and full-field polycrystal plasticity modeling, (2) the first-ever experimental observation of strong stress rotation within the individual grains of a polycrystalline material, and (3) a comprehensive analysis of the grain-level dislocation density evolution based upon diffraction peak broadening along 𝜂𝜂,𝜔𝜔,and 2𝜃𝜃 directions. This final aspect allowed us to confirm that dislocations were gliding on multiple plane types and not restricted to {110} type planes, and it also provided clues as to why some grains were unloading during straining, with surprising implications for our understanding of the effects of geometrically necessary dislocations (GNDs). Finally, graduate student, Mohammed Shabana, developed a MATLAB code which confirmed the conclusions of Prof. Catalin Picu (Rensallear Polytechnic Institute, RPI) regarding the effect of solute-trapped, forest dislocations on the breaking stress of Lomer lock junctions in FCC metal alloys. He applied the same anisotropic line-tension model to a variety of dislocation junction configurations and found an inconsistency in the widely cited results of Dupuy and Fivel regarding the Hirth Lock, and he outlined an approach to extend these finding to HCP Mg alloys that we are still pursuing with discretionary fundings at UVA.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Development of Corrosion Resistant Coatings for Structural Materials for Liquid Fueled Molten Salts Reactors Applications (Final Report)

Current structural alloys, code certified for the MSRs temperature ranges, contain high levels of chromium, making them highly susceptible to molten halide salt corrosion. One potential solution to circumvent the need for code certification of novel alloys, which is expensive and time consuming, is to design claddings that will protect the underlying code certified materials from corrosion damage during operation. In this work, we examined the corrosion of Ni and Cu electroplated, Ni and CuNi weld overlay, Mo-laser clad, and carburized claddings on SS316H for use in molten salt reactor environments. After characterization of the cladded materials (Task 1), static corrosion tests were used to assess corrosion resistance of the claddings in typical molten fluoride salts (Task 2). The corrosion tests were performed in molten FLiNaK at 700°C up to 1000 hours. Pre- and post-corrosion Scanning Electron Microscopy (SEM), energy-dispersive-spectroscopy (EDS), Transmission Electron Microscopy (TEM), X-ray Diffraction (XRD) and glow-discharge-optical-emission-spectroscopy (GDOES) were performed on cladding cross-sections and surfaces to evaluate degradation. The Cu and Ni electroplated samples, as well as the carburized samples, showed excellent corrosion resistance relative to the bare SS316H. To assess high temperature cladding stability, ageing experiments were performed at temperatures up to 900 C in inert atmosphere for the electroplated and carburized samples and a diffusion model was developed to predict long term cladding behavior (Task 3). It was found that the Cu cladding was basically insensitive to the high temperature ageing, except for small secondary phases forming at the interface. On the other hand, the Ni electroplated cladding experienced significant interdiffusion. Nevertheless, the gain in corrosion resistance for a 100μm Ni electroplated cladding is phenomenal, with more than 50% reduction in chromium dissolution from the substrate material for the first 15 years of salt exposure at 700°C. To assess radiation resistance and phase stability, high-temperature 4MeV Ni heavy ion irradiation was performed across the cladding/substrate interface up to 50 displacement-per-atom (DPA) at 500°C and 700°C to assess the phase stability and irradiation behaviors of the electroplated systems (Task 4). The Ni and Cu electroplated systems did not experience void swelling at the contrary to the SS316H substrate due to their nanocrystalline nature. Some level of recrystallization was observed in the cladding, as well as radiation induced segregation and enhanced diffusion. The interface acted as a potent sink for point defects with the presence of a void denuded zone. The mechanical properties of the claddings were assessed using thermal shock, micro-indentation, nano-indentation, and four-point bend testing experiments (Task 5). These experiments were performed on the claddings in as-received, corroded, irradiated, and thermally aged states to determine the effects of typical molten salt reactor environments on cladding integrity. No significant mass loss was observed after repeated thermal shocks. While the electroplated samples softened after high-temperature ageing, irradiation hardening compensate this effect, such that there is little different with the as-received materials. The results of these experiments suggest that the electroplated (copper/nickel) show the greatest promise for application in molten salt reactor development. These claddings prevented any chromium dissolution from occurring during the static corrosion experiments. Additionally, they demonstrated favorable properties for high temperature diffusion, phase stability, interfacial mechanical properties, and irradiation resistance. Weld-overlay cladding are also of great interest and could reach properties similar to the electroplated samples upon optimization (especially with multiple weld passes). The carburized SS316H showed excellent behavior as well, but more work needs to be done to assess their long-term stability. Finally, the Mo-laser clad system was not pursued further due to the manufacturing challenges. It is also worth noting that the Ni cladding systems should behave relatively well in terms of weldability since the Ni-weld overlay microstructure and associated corrosion rate are sound. While the NiCu weld-overlay has even lower corrosion rates than the Ni-weld overlay, more studies on welding of Cu-electroplated systems are necessary since Cu clusters are known to embrittle steels.

36 MATERIALS SCIENCE↗