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

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Total hemispherical emittance measured at high temperatures by the calorimetric method

A calorimetric vacuum emissometer (CVE) capable of measuring total hemispherical emittance of surfaces at elevated temperatures was designed, built, and tested. Several materials with a wide range of emittances were measured in the CVE between 773 to 923 K. These results were compared to values calculated from spectral emittance curves measured in a room temperature Hohlraum reflectometer and in an open-air elevated temperature emissometer. The results differed by as much as 0.2 for some materials but were in closer agreement for the more highly-emitting, diffuse-reflecting samples. The differences were attributed to temperature, atmospheric, and directional effects, and errors in the Hohlraum and emissometer measurements (plus or minus 5 percent). The probable error of the CVE measurements was typically less than 1 percent.

Difilippo, Frank↗
DOE OSTI2025

Effect of stress on Laves phase precipitation in creep ruptured Grade 92 ferritic martensitic steel characterized by a novel accessible method

At high temperature conditions relevant to fossil and nuclear energy plants, Laves phase (Fe 2 X, X=Mo, W) precipitation is observed in common ferritic martensitic (FM) structural steels, with various reported effects on creep behavior. Despite being valuable metrics to correlate with mechanical properties and other precipitate phases, the volume fraction and number density of Laves phase precipitates has been difficult to quantify accurately using common techniques such as transmission electron microscopy (TEM) due to the relatively large size (∼0.25 μm) and low number density (∼10 11 cm −3 ) of Laves precipitates. Here, to address this characterization challenge, we developed and demonstrated a high-throughput and widely accessible method to quantify the volume fraction and number density of the Laves phase based on scanning electron microscope (SEM) images with a backscattered electron signal and the information depth (ID) of backscattered electrons. We applied this new technique in creep ruptured Grade 92 FM steel to study the effect of Laves phase on creep properties and determine the influence of stress on Laves phase precipitation. The quantitative accuracy of the SEM-based volume fraction and number density values was verified using synchrotron high energy X-ray diffraction and serial sectioning tomography. Stress did not significantly affect the Laves phase size or volume fraction during creep testing at 550 – 650°C and stress levels of 90 – 260 MPa (vs. unstressed conditions). Conversely, a moderate but statistically significant stress-enhanced increase in Laves phase number density, corresponding to an increase in nucleation rate, occurred during creep exposure above 110 MPa.

Creep↗
NASA NTRS1987

Exposure time considerations in high temperature low cycle fatigue

The Conventional Strainrange Partitioning (CSRP) method for High-Temperature, Low-Cycle Fatigue (HTLCF) life prediction has its origins in the modeling of first-order, creep-fatigue waveform effects while treating as second-order effects, the influence of metallurgical or environmental time dependencies. Procedures are proposed to include the latter explicitly in the inelastic strainrange--life relations. For brevity, only the CP life relation will be presented in detail. The exposure-time effect within the CP inelastic strainrange (tensile creep reversed by compressive plasticity) was determined by tensile stresshold-time experiments for 316 SS at 816 C. Reductions in CP cyclic life of a factor of about two were observed with an increase in exposure time or a corresponding decrease in creep rate by a factor of about 100. The CP life relation has been modified to be expressed in terms of either Steady State Creep Rate (SSCR) or Exposure Time (ET). The applicability and accuracy of the time-dependent CP life relations is demonstrated by conducting verification experiments involving complex hysteresis loops. Metallographic examination revealed time-dependent degradation attributable to oxide formation and precipitation of carbides along grain boundaries.

Kalluri, S.↗
NASA NTRS1988

Exposure time considerations in high temperature low cycle fatigue

The Conventional Strainrange Partitioning (CSRP) method for High-Temperature, Low-Cycle Fatigue (HTLCF) life prediction has its origins in the modeling of first-order, creep-fatigue waveform effects while treating as second-order effects, the influence of metallurgical or environmental time dependencies. Procedures are proposed to include the latter explicitly in the inelastic strainrange-life relations. For brevity, only the CP life relation will be presented in detail. The exposure-time effect within the CP inelastic strainrange (tensile creep reversed by compressive plasticity) was determined by tensile stresshold-time experiments for 316 SS at 816 C. Reductions in CP cyclic life of a factor of about two were observed with an increase in exposure time or a corresponding decrease in creep rate by a factor of about 100. The CP life relation has been modified to be expressed in terms of either Steady State Creep Rate (SSCR) or Exposure Time (ET). The applicability and accuracy of the time-dependent CP life relations is demonstrated by conducting verification experiments involving complex hysteresis loops. Metallographic examination revealed time-dependent degradation attributable to oxide formation and precipitation of carbides along grain boundaries.

Kalluri, S.↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
DOE OSTI2020

Method for conducting in situ high-temperature digital image correlation with simultaneous synchrotron measurements under thermomechanical conditions

This work presents a novel method of obtaining in situ strain measurements at high temperature by simultaneous digital image correlation (DIC), which provides the total strain on the specimen surface, and synchrotron x-ray diffraction (XRD), which provides lattice strains of crystalline materials. DIC at high temperature requires specialized techniques to overcome the effects of increased blackbody radiation that would otherwise overexpose the images. The technique presented herein is unique in that it can be used with a sample enclosed in an infrared heater, remotely and simultaneously with synchrotron XRD measurements. The heater included a window for camera access, and the light of the heater lamps is used as illumination. High-temperature paint is used to apply a random speckle pattern to the sample to allow the tracking of displacements and the calculation of the DIC strains. An inexpensive blue theatrical gel filter is used to block interfering visible and infrared light at high temperatures. This technique successfully produces properly exposed images at 870 °C and is expected to perform similarly at higher temperatures. The average strains measured by DIC were validated by an analytical calculation of the theoretical strain. Simultaneous DIC and XRD strain measurements of Inconel 718 (IN718) tensile test specimens were performed under thermal and mechanical loads and evaluated. Finally, this approach uses the fact that with DIC, the total strain is measured, including plastic strain, while with XRD, only elastic strain is captured. The observed differences were discussed with respect to the effective deformation mechanisms.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Creep resistant Ni-based superalloy casting and method of manufacture for advanced high-temperature applications

One or more embodiments relates to a method of casting a creep-resistant Ni-based superalloy and a homogenization heat treatment for the alloy. The method includes forming a feed stock having Nickel (Ni) and at least one of Chromium (Cr), Cobalt (Co), Aluminum (Al), Titanium (Ti), Niobium (Nb), Iron (Fe), Carbon (C), Manganese (Mn), Molybdenum (Mo), Silicon (Si), Copper (Cu), Phosphorus (P), Sulfur (S) and Boron (B). The method further includes fabricating the creep-resistant Ni-based superalloy in a predetermined shape using the feed stock and at least one process such as vacuum induction melting (VIM), electroslag remelting (ESR) and/or vacuum arc remelting (VAR).

Jablonski, Paul D.↗
NASA NTRS1950

Fundamental Effects of Aging on Creep Properties of Solution-Treated Low-Carbon N-155 Alloy

A method is developed whereby the fundamental mechanisms are investigated by which processing, heat treatment, and chemical composition control the properties of alloys at high temperatures. The method used metallographic examination -- both optical and electronic --studies of x-ray diffraction-line widths, intensities, and lattice parameters, and hardness surveys to evaluate fundamental structural conditions. Mechanical properties at high temperatures are then measured and correlated with these measured structural conditions. In accordance with this method, a study was made of the fundamental mechanism by which aging controlled the short-time creep and rupture properties of solution-treated low-carbon n-155 alloy at 1200 degrees F.

Frey, D N↗
DOE OSTI2020

Direct observation of the formation and stabilization of metallic nanoparticles on carbon supports

Direct formation of ultra-small nanoparticles on carbon supports by rapid high temperature synthesis method offers new opportunities for scalable nanomanufacturing and the synthesis of stable multi-elemental nanoparticles. However, the underlying mechanisms affecting the dispersion and stability of nanoparticles on the supports during high temperature processing remain enigmatic. In this work, we report the observation of metallic nanoparticles formation and stabilization on carbon supports through in situ Joule heating method. We find that the formation of metallic nanoparticles is associated with the simultaneous phase transition of amorphous carbon to a highly defective turbostratic graphite (T-graphite). Molecular dynamic (MD) simulations suggest that the defective T-graphite provide numerous nucleation sites for the nanoparticles to form. Furthermore, the nanoparticles partially intercalate and take root on edge planes, leading to high binding energy on support. This interaction between nanoparticles and T-graphite substrate strengthens the anchoring and provides excellent thermal stability to the nanoparticles. These findings provide mechanistic understanding of rapid high temperature synthesis of metal nanoparticles on carbon supports and the origin of their stability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Preliminary description of a new creep-fatigue design method that reduces over conservatism and simplifies the high temperature design process

The report provides the initial description of a new creep-fatigue design method for structural components in high temperature nuclear service. The new method is based on an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that reduces over conservatism, improves the treatment of elastic follow up, and simplifies the design procedure, when compared with the current creep-fatigue design methods in ASME Boiler and Pressure Vessel Code. Developing the design charts for the EPP-SMT design method requires extrapolating SMT test data as a function of hold time and follow up factor. The report develops the preliminary design charts for Alloy 617 at temperatures between 800°C and 950°C by combining two extrapolation approaches developed in a previous work. The report also presents a comparative analysis between the EPP-SMT design method and the current ASME creep-fatigue design methods by evaluating design life of two sample geometries under different loading conditions. Results from the comparative analysis verify the EPP-SMT design charts but suggest the requirement of additional test data in the low strain range regime for improving the extrapolation procedure that will further reduce the over conservatism in the creep-fatigue damage evaluation. The report also concludes that the EPP-SMT design procedure can account for effect of primary load on creep-fatigue life by using a fixed, bounding value of follow up in constructing the design charts. The conclusions to this report describe the future work required to complete this new design method so it can be codified through a nuclear Code Case.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2001

High Temperature Fatigue Crack Growth Behavior of Alloy 10

Methods to improve the high temperature, dwell crack growth resistance of Alloy 10, a high strength, nickel-base disk alloy, were studied. Two approaches, heat treat variations and composition modifications, were investigated. Under the heat treat approach, solution temperature, cooling rates, and stabilization, were studied. It was found that higher solution temperatures, which promote coarser grain sizes, coupled with a 1550 F stabilization treatment were found to significantly reduce dwell crack growth rates at 1300 F Changes in the niobium and tantalum content were found to have a much smaller impact on crack growth behavior. Lowering the niobium:tantalum ratio did improve crack growth resistance and this effect was most pronounced for coarse grain microstructures. Based on these findings, a coarse grain microstructure for Alloy 10 appears to be the best option for improving dwell crack growth resistance, especially in the rim of a disk where temperatures can reach or exceed 1300 T. Further, the use of advanced processing technologies, which can produce a coarse grain rim and fine grain bore, would be the preferred option for Alloy 10 to obtain the optimal balance between tensile, creep, and crack growth requirements for small gas turbine engines.

Gayda, John↗
NASA NTRS2014

Experimental and Theoretical Study of Thermodynamics of the Reaction of Titania and Water at High Temperatures

The transpiration method was used to determine the volatility of titanium dioxide (TiO2) in water vapor-containing environments at temperatures between 1473 and 1673 K. Water contents ranged from 0 to 76 mole % in oxygen or argon carrier gases for 20 to 250 hr exposure times. Results indicate that oxygen is not a key contributor to volatilization and the primary reaction for volatilization in this temperature range is: TiO2(s) + H2O(g) = TiO(OH)2(g). Data were analyzed with both the second and third law methods to extract an enthalpy and entropy of formation. The geometry and vibrational frequencies of TiO(OH)2(g) were computed using B3LYP density functional theory, and the enthalpy of formation was computed using the coupled-cluster singles and doubles method with a perturbative correction for connected triple substitutions [CCSD(T)]. Thermal functions are calculated using both a structure with bent and linear hydroxyl groups. Calculated second and third heats show closer agreement with the linear hydroxyl group, suggesting more experimental and computational spectroscopic and structural work is needed on this system.

equilibrium↗
NASA NTRS1991

Structural characterization of high temperature composites

Glass, ceramic, and carbon matrix composite materials have emerged in recent years with potential properties and temperature resistance which make them attractive for high temperature applications such as gas turbine engines. At the outset of this study, only flexural tests were available to evaluate brittle matrix composites at temperatures in the 600 to 1000 C range. The results are described of an ongoing effort to develop appropriate tensile, compression, and shear test methods for high temperature use. A tensile test for unidirectional composites was developed and used to evaluate the properties and behavior of ceramic fiber reinforced glass and glass-ceramic matrix composites in air at temperatures up to 1000 C. The results indicate generally efficient fiber reinforcement and tolerance to matrix cracking similar to polymer matrix composites. Limiting properties in these materials may be an inherently very low transverse strain to failure, and high temperature embrittlement due to fiber/matrix interface oxidation.

Mandell, J. F.↗
DOE OSTI2020

An Initial Assessment of the Design Margins of Different ASME Section III, Division 5 Design Rules

This report develops a method for assessing the design margin of the ASME Section III, Division 5 Class A design rules, focusing on a definition of margin as the ratio between the actual, expected component life and the ASME design life. Full inelastic finite element simulations with a complete damage model capturing the available creep, creep-fatigue, fatigue, and tension test failure data produce the expected component lives, which can then be compared to corresponding ASME design calculations. The focus of this particular work is on Alloy 617 and the ASME creep-fatigue design rules, but the approach is general and could be applied to other design limits and to other materials. A margin assessment of a representative Alloy 617 component shows the ASME creep-fatigue design rules applied to this component have a margin of 10 on design life. The report describes several challenges in completing a more comprehensive margin assessment of the ASME rules, in particular challenges in developing probabilistic assessment methods for high temperature structural components. The report details these challenge and discusses the immediate possibilities of the deterministic margin assessment method developed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1970

Ultrasonic propagation in gases at high temperatures

Ultrasonic pulse method /1 to 3 MHz/ measures both sound speed and absorption in monatomic and polyatomic gases in a temperature range of 300 to 20000 degrees K at atmospheric pressure. Helium, nitrogen, oxygen, and argon are investigated.

Carey, C.↗
NASA NTRS1982

HOST high temperature crack propagation

Methods for characterizing and predicting crack growth at elevated temperatures are discussed. Nonlinear behavior, thermal gradients, and thermomechanical cycling are discussed.

Orange, T. W.↗