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At least 73 records · Page 4

Potentialities of TEC topping: A simplified view of parametric effects

An examination of the benefits of thermionic-energy-conversion (TEC)-topped power plants and methods of increasing conversion efficiency are discussed. Reductions in the cost of TEC modules yield direct decreases in the cost of electricity (COE) from TEC-topped central station power plants. Simplified COE, overall-efficiency charts presented illustrate this trend. Additional capital-cost diminution results from designing more compact furnaces with considerably increased heat transfer rates allowable and desirable for high temperature TEC and heat pipes. Such improvements can evolve of the protection from hot corrosion and slag as well as the thermal expansion compatibilities offered by silicon-carbide clads on TEC-heating surfaces. Greater efficiencies and far fewer modules are possible with high-temperature, high-power-density TEC: This decreases capital and fuel costs much more and substantially increases electric power outputs for fixed fuel inputs. In addition to more electricity, less pollution, and lower costs, TEC topping used directly in coal-combustion products contributes balance-of-payment gains.

Morris, J. F.↗

Space nuclear power systems; Proceedings of the 8th Symposium, Albuquerque, NM, Jan. 6-10, 1991. Pts. 1-3

The present conference discusses NASA mission planning for space nuclear power, lunar mission design based on nuclear thermal rockets, inertial-electrostatic confinement fusion for space power, nuclear risk analysis of the Ulysses mission, the role of the interface in refractory metal alloy composites, an advanced thermionic reactor systems design code, and space high power nuclear-pumped lasers. Also discussed are exploration mission enhancements with power-beaming, power requirement estimates for a nuclear-powered manned Mars rover, SP-100 reactor design, safety, and testing, materials compatibility issues for fabric composite radiators, application of the enabler to nuclear electric propulsion, orbit-transfer with TOPAZ-type power sources, the thermoelectric properties of alloys, ruthenium silicide as a promising thermoelectric material, and innovative space-saving device for high-temperature piping systems. The second volume of this conference discusses engine concepts for nuclear electric propulsion, nuclear technologies for human exploration of the solar system, dynamic energy conversion, direct nuclear propulsion, thermionic conversion technology, reactor and power system control, thermal management, thermionic research, effects of radiation on electronics, heat-pipe technology, radioisotope power systems, and nuclear fuels for power reactors. The third volume discusses space power electronics, space nuclear fuels for propulsion reactors, power systems concepts, space power electronics systems, the use of artificial intelligence in space, flight qualifications and testing, microgravity two-phase flow, reactor manufacturing and processing, and space and environmental effects.

El-Genk, Mohamed S.↗

Assessment of a Grade 91 Steel Forging and Seamless Pipe Section After 141,000-Hours of Operation in a Superheat Outlet Header

In this work, two unique heats of 9Cr creep strength enhanced ferritic (CSEF) steels extracted from a retired superheat outlet header after 141,000 hours of service were evaluated. These two CSEF steels were a forging manufactured to SA-182 F91 (F91) reducer and a seamless pipe produced to SA-335 P91 (P91) pipe. Their creep deformation and fracture behavior were assessed using a lever arm creep frame integrated with in-situ high-temperature digital image correlation (DIC) system. Critical metallurgical and microstructure factors, including composition, service damage, grain matrix degradation, precipitates, and inclusions were quantitatively characterized to link the performance of the two service aged F91 and P91 CSEF steels. The creep test results show the F91 and P91 steels exhibit a large variation in creep strength and creep ductility. The F91 steel fractured at 572 hours while P91 steel fractured at 1,901 hours when subjected to a test condition of 650 °C and 100 MPa. The nominal creep strains at fracture were 12.5% (F91) and 14.5% (P91), respectively. The high-resolution DIC strain measurements reveal the local creep strain in F91 was about 50% while the local creep strain in P91 was >80%. The characterization results show that the F91 steel possessed pre-existing creep damage from its time in service, a higher fraction of inclusions, and a faster matrix grain coarsening rate. These features contribute to the observed reduction in performance for the F91 steel. The context for these findings, and the importance of metallurgical risk in an integrated life management approach will be emphasized.

Wang, Yiyu↗

Root cause analysis of a molten salt pump in FLUSTFA

The primary salt pump installed in the high-temperature FLUoride Salt Test Facility (FLUSTFA) was successfully operated for some time, but later ceased operation. To understand what occurred, a Root Cause Analysis (RCA) was performed. Steps taken to try to get the pump operational include adjusting the shaft position, increasing the heating power of the tape heaters on the pump volute, and manually rotating the pump shaft. While removing the insulation, corrosion was noted on the outside of the pump volute, and decolorization of the insulation and tape heaters was observed. Significant corrosion products were also observed in the pump itself and the piping connected to the pump. The nitrogen cover gas was maintained from before salt was introduced into the loop until the pump was dismounted and continues to be maintained even after the pump was removed. After considering probable scenarios, causes were assigned and corrective actions were developed to prevent those causes. Then, the RCA was presented to an advisory committee for review, the “Review Committee,” consisting of experts in large molten salt systems: Brandon Haugh, David Holcomb, Kevin Robb, and Vicente Rojas. As a result, the advisory committee provided comprehensive feedback, which have been incorporated into a revised RCA. Findings have then been summarized and reported in this publication.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Experimental Operation of a Prototype 750C Advanced Chloride Molten Salt Bellows Valve

To achieve DOE 2030 SunShot targets that reduce the cost of liquid-based solar by an additional 40% to 70% beyond 2018 costs, a more reliable, highly manufacturable flow valve, capable of achieving operational temperatures of >700°C is required [1]. This paper investigates the development of an innovative high-temperature chloride molten salt valve, with operation up to 750°C. This valve is intended to be employed within Gen 3 CSP liquid-based thermal energy storage (TES) systems as well as Gen 4 modular salt reactor (MSR) technologies. This work details the general design and flow testing of a bellows-seal flow control valve (FCV). This design includes an integrated closed-loop thermal control system to ensure robust design for freeze-thaw cycles. The self-contained thermal management STM system, is unique in the salt valve industry since it is an integrated solution to provide a consistent, repeatable alternative to typical heat tracing. Additionally, the design includes the employment of a novel heat pipe valve stem to facilitate enhanced passive thermal management into the valve assembly. This valve stem heat pipe is designed to facilitate natural circulation within the bonnet to ensure robust operation, during both nominal and transient thermal operation. The valve body and trim will be designed using SS316H, consistent with Flowserve Corporation’s existing product base and is code qualified but will utilize clad material for materials corrosion, manufacturing cost reduction and compatibility to ensure design flexibility. A test campaign was performed in this investigation utilizing a novel 750°C ternary chloride (20%NaCl/40%MgCl2/40%KCl by mol. wt. %) molten salt flow loop. A discussion about the design and installation of the valves within this test bed is provided for this investigation. Valve test results from this study assessed Cv curves as well as multiple actuator cycles, under varying thermodynamic and operational mode conditions, which would be characteristic within a commercial molten salt facility. The results indicate nominal operation for the baseline design, though improved performance and reliability is expected with the full designed FCV.

Armijo, Kenneth (ORCID:0000000346832147)↗

Molten Salt Loop Operational Experience and Test Campaigns in FY24

The Facility to Alleviate Salt Technology Risks (FASTR) at the US Department of Energy (DOE) Oak Ridge National Laboratory (ORNL) was developed to demonstrate technology for high-temperature chloride salt systems (Figure 1). FASTR is primarily constructed using alloy C-276 and is designed to operate at temperatures of up to 725°C. The facility is loaded with 250 kg of NaCl-KCl-MgCl 2 salt. This salt provides a relevant test environment for de-risking technology while avoiding the costs and hazards associated with beryllium-based or uranium-bearing salts. The facility’s major components include a centrifugal pump for salt circulation, an air-based heat exchanger to reject heat, a suite of instrumentation, and trace heating to prevent salt freezing. The salt was purified in 2020 and 2022, and the pumped loop first operated in December 2022. FASTR is a unique US capability for high-temperature molten halide salt testing. FASTR’s scale, co located purification system, and relatively large power (465 kW) differentiates it from other testing systems. Furthermore, access to the DOE-supported facility and efficient communication of results— which are generally disseminated publicly—distinguish FASTR as being broadly significant throughout the molten salt reactor community. FASTR is similar to ORNL’s Liquid Salt Test Loop (LSTL), although FASTR contains chloride-based salt instead of the fluoride-based salt (LiF-NaF-KF) found in LSTL. Furthermore, FASTR is approximately 2× larger than LSTL in terms of pipe size and length, power, salt volume, flow rate, and number of thermocouples. The LSTL first operated in 2016. At the end of FY23, there was a suspected gas leak in the LSTL that halted operation. At the start of FY24, a leak in the LSTL pump’s tank gas space was confirmed. Because the gas-space leak prevented operation of LSTL, FY24 efforts were focused on operation of FASTR. This report summarizes the progress made during FY24 in support of the DOE Office of Nuclear Energy (DOE-NE) work package, AT-24OR070202 Salt Loop and Capability for Testing Sensors and Off Gas Components.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Heat load measurements for the PIP-II pHB650 cryomodule

This study presents a brief overview of the 1st and 2nd phases and an in-depth analysis of the 3rd phase heat load testing performed on the pHB650 (prototype High Beta 650 MHz) cryomodule at PIP2IT (PIP-II Injector Test Facility), with a focus on both the results and the methodological advancements that have improved testing efficiency and accuracy. A key challenge identified in the testing campaign is the higher-than-expected heat loads observed in the first PIP-II (Proton Improvement Plan II) prototype cryomodules (pSSR1 and pHB650) tested at PIP2IT. Elevated heat loads are concerning given the fixed capacity of the PIP-II cryoplant that is currently being installed at Fermilab. However, understanding the sources of these elevated heat loads offers a critical opportunity to implement effective heat load mitigations on upcoming PIP-II cryomodules to stay within the available capacity of the PIP-II cryoplant. The study includes a summary of test results, descriptions of measurement procedures, and key observations on parameters directly and indirectly related to heat load measurements. Direct observations include measured heat loads and the effectiveness of JT heat exchanger under varying conditions, while indirect observation analyze factors such as the temperature distribution on the two-phase pipe and relief piping under varying conditions. Thermal acoustic oscillations (TAO) were identified during testing, which was mitigated by replacing the original G10 stem with a stainless steel stem equipped with wipers for the cryomodule cooldown valve. A major innovation during pHB650 Phase 3 testing was the development of an automated Python script to streamline data acquisition, analysis, and reporting of heat load results. This script automatically retrieved data from ACNET (Accelerator Control Network), performed heat load calculations, and generated detailed reports featuring plots and tables. This advancement significantly reduced manual labor and enhanced the thoroughness of data analysis compared to earlier campaigns. The heat load test reports were promptly uploaded to the electronic logbook shortly after each test, enabling rapid feedback and collaboration between the SRF and cryogenic teams. The heat load measurements included various components: HTTS (high-temperature thermal shield), LTTS (low-temperature thermal shield), 2K isothermal and non-isothermal heat loads. Results were recorded both within the cryomodule and between the bayonet can supply and return. Measurements were conducted under different operating conditions such as "standard", "linac", and "simulated dynamic". Additionally, HTTS and LTTS heat loads were calculated in real time, allowing for the tracking of thermal stability and identification of changes during testing, both in steady-state and transient conditions. The results of this testing campaign not only provide valuable insights into the performance of the pHB650 cryomodule but also highlight best practices and lessons learned that will inform future cryomodule testing at PIP2IT. These include adopting automated tools for data analysis, refining real-time measurement capabilities, and emphasizing detailed pre-test planning. The framework established in this campaign aims to set an improved standard for cryomodule testing and heat load reporting in future cryomodule test campaigns.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗

On the Feasibility of Deep Geothermal Wells Using Numerical Reservoir Simulation

This study examines the geothermal energy extraction potential from the basement rock within the Denver–Julesburg Basin, focusing on the flow performance and heat extraction efficiency of different geothermal well configurations. It specifically compares U-shaped, V-shaped, inclined V-shaped, and pipe-in-pipe configurations against enhanced geothermal system setups. Through numerical modeling, we evaluated the thermal behavior of these systems under various operational scenarios and fracture conditions. The results suggest that while closed-loop systems offer moderate temperature increases, Enhanced geothermal system configurations show substantial potential for high-temperature extraction. This underscores the importance of evaluating well configurations in complex geological settings. The insights from this study aid in strategic geothermal energy planning and development, marking significant advancements in geothermal technology and setting a foundation for future explorations and optimizations.

15 GEOTHERMAL ENERGY↗

High-temperature, high-power-density thermionic energy conversion for space

Theoretic converter outputs and efficiencies indicate the need to consider thermionic energy conversion (TEC) with greater power densities and higher temperatures within reasonable limits for space missions. Converter-output power density, voltage, and efficiency as functions of current density were determined for 1400-to-2000 K emitters with 725-to-1000 K collectors. The results encourage utilization of TEC with hotter-than-1650 K emitters and greater-than-6W sq cm outputs to attain better efficiencies, greater voltages, and higher waste-heat-rejection temperatures for multihundred-kilowatt space-power applications. For example, 1800 K, 30 A sq cm TEC operation for NEP compared with the 1650 K, 5 A/sq cm case should allow much lower radiation weights, substantially fewer and/or smaller emitter heat pipes, significantly reduced reactor and shield-related weights, many fewer converters and associated current-collecting bus bars, less power conditioning, and lower transmission losses. Integration of these effects should yield considerably reduced NEP specific weights.

Morris, J. F.↗

High temperature thermal energy storage in moving sand

Several high-temperature (to 500 C) heat-storage systems using sand as the storage medium are described. The advantages of sand as a storage medium include low cost for sand, widespread availability, non-toxicity, non-degradation characteristics, easy containment, and safety. The systems considered include: stationary sand with closely spaced tubes throughout the volume, the use of a fluidized bed, use of conveyor belt transporter, and the use of a blower rapid transport system. For a stationary sand bed, very close spacing of heat transfer tubes throughout the volume is required, manifesting as high power related system cost. The suggestion of moving sand past or around pipes is intended to reduce the power related costs at the penalty of added system complexity. Preliminary system cost estimates are offered. These rough calculations indicate that mobile sand heat storage systems cost less than the stationary sand approach.

Turner, R. H.↗

Optimize out-of-core thermionic energy conversion for nuclear electric propulsion

Thermionic energy conversion (TEC) potentialities for nuclear electric propulsion (NEP) are examined. Considering current designs, their limitations, and risks raises critical questions about the use of TEC for NEP. Apparently a reactor cooled by hotter-than-1675 K heat pipes has good potentialities. TEC with higher temperatures and greater power densities than the currently proposed 1650 K, 5-to-6 W/sq cm version offers substantial gains. Other approaches to high-temperature electric isolation appear also promising. A high-power-density, high-temperature TEC for NEP appears, therefore, attainable. It is recommended to optimize out-of-core thermionic energy conversion for nuclear electric propulsion. Although current TEC designs for NEP seem unnecessary compared with Brayton versions, large gains are apparently possible with increased temperatures and greater power densities.

Morris, J. F.↗

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, J. R.↗

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, Joseph R.↗

High-Temperature, High-Flux Multifoil Shield Developed for Space Applications

Spacecraft employing solar dynamic power systems typically use parabolic, point focus concentrators to collect solar power and direct it to the aperture of a heat receiver. Solar fluxes several thousand times the intensity of one solar constant are typically produced in the focal plane of such concentrators. Under heat loading this severe, passively cooled surfaces constructed of most engineering materials would rapidly melt. Therefore, high-temperature shielding is required to protect heat receiver surfaces and other spacecraft surfaces that may be exposed to high flux. To meet this challenge for the joint U.S./Russian Solar Dynamic Flight Demonstration Program, AlliedSignal Aerospace and the NASA Lewis Research Center developed a high-temperature, high-flux multifoil shield tolerant of extreme heat loading conditions in a vacuum environment. The shield is passively cooled, obviating the need for pumped fluid loops and/or heat pipe cooling systems with their attendant cost, mass, complexity, and reliability issues.

Kerslake, Thomas W.↗

Improved Mo-Re VPS Alloys for High-Temperature Uses

Dispersion-strengthened molybdenum- rhenium alloys for vacuum plasma spraying (VPS) fabrication of high-temperature-resistant components are undergoing development. In comparison with otherwise equivalent non-dispersion-strengthened Mo-Re alloys, these alloys have improved high-temperature properties. Examples of VPS-fabricated high-temperature-resistant components for which these alloys are expected to be suitable include parts of aircraft and spacecraft engines, furnaces, and nuclear power plants; wear coatings; sputtering targets; x-ray targets; heat pipes in which liquid metals are used as working fluids; and heat exchangers in general. These alloys could also be useful as coating materials in some biomedical applications. The alloys consist of 60 weight percent Mo with 40 weight percent Re made from (1) blends of elemental Mo and Re powders or (2) Re-coated Mo particles that have been subjected to a proprietary powder-alloying-and-spheroidization process. For most of the dispersion- strengthening experiments performed thus far in this development effort, 0.4 volume percent of transition-metal ceramic dispersoids were mixed into the feedstock powders. For one experiment, the proportion of dispersoid was 1 volume percent. In each case, the dispersoid consisted of either ZrN particles having sizes <45 m, ZrO2 particles having sizes of about 1 m, HfO2 particles having sizes <45 m, or HfN particles having sizes <1 m. These materials were chosen for evaluation on the basis of previously published thermodynamic stability data. For comparison, Mo-Re feedstock powders without dispersoids were also prepared.

Hickman, Robert↗

In-Service Monitoring of Steam Pipe Systems at High Temperatures

An effective, in-service health monitoring system is needed to track water condensation in real time through the walls of steam pipes. The system is required to measure the height of the condensed water from outside the pipe, while operating at temperatures that are as high as 250 C. The system needs to account for the effects of water flow and cavitation. In addition, it is desired that the system does not require perforating the pipes and thereby reducing the structural integrity. Generally, steam pipes are used as part of the district heating system carrying steam from central power stations under the streets to heat, cool, or supply power to high-rise buildings and businesses. This system uses ultrasonic waves in pulse-echo and acquires reflected signal data. Via autocorrelation, it determines the water height while eliminating the effect of noise and multiple reflections from the wall of the pipe. The system performs nondestructive monitoring through the walls of steam pipes, and automatically measures the height of condensed water while operating at the high-temperature conditions of 250 C. For this purpose, the ultrasonic pulse-echo method is used where the time-of-flight of the wave reflections inside the water are measured, and it is multiplied by the wave velocity to determine the height. The pulse-echo test consists of emitting ultrasonic wave pulses from a piezoelectric transducer and receiving the reflections from the top and bottom of the condensed water. A single transducer is used as a transmitter as well as the receiver of the ultrasonic waves. To obtain high resolution, a broadband transducer is used and the frequency can be in the range of 2.25 to 10 MHz, providing sharp pulses in the time domain allowing for higher resolution in identifying the individual reflections.

Bar-Cohen, Yoseph↗

A Warm Garage for a Lunar Rover

Approach: One approach to heating a rover during the lunar night is the so-called thermal wadis concept [1]. This involves heating the regolith with solar concentrators and placing the rover on the heated surface for the night. Since the regolith is heated by a relatively weak heat flux, a high thermal conductivity is required for heating a sufficiently large mass of regolith. However, lunar regolith has a low thermal conductivity. Therefore, the concept involves increasing the conductivity by sintering the regolith, which requires a significant energy input and complex procedures. Here we propose an alternative approach where the low thermal conductivity of regolith is an advantage. Specifically, we propose to use a highly exothermic combustible mixture for heat generation. The mixture pellets are placed in the surface layer of regolith and ignited. The combustion forms condensed products and releases heat, which then slowly spreads to the surrounding regolith. Heat can also be transferred, for example, by heat pipes, into radiant heating surfaces installed on the ground. A greenhouse that transmits sunlight during the day and decreases the radiative heat losses during the night can also be installed. Selection of the Heat-generating Mixture: The reactive mixture should have a high specific energy and generate only condensed products since gases could disturb the regolith layer, carry enthalpy out of the system, and lead to an explosion. There are mixtures, (sometimes called pyrolants) that possess very high specific energies. One example is magnesium-Teflon-Viton mixtures used in flares. However, they produce gases and may cause explosions. Other mixtures that include magnesium cannot be used either because of the high vapor pressure of Mg at temperatures well below the combustion temperature. Recently, mixtures that involve lithium peroxide (Li2O2) have been proposedfor using in space power systems [2]. However, they produce lithium oxide (Li2O), which boils at 2800 K at 1 atm and hence at a lower temperature in vacuum. Fortunately, there exist many mixtures that release a lot of heat and form only condensed products during the combustion. Many such mixtures have been used for self-propagating high-temperature synthesis (SHS) of various materials [3, 4]. For the application discussed here, t itanium/boron (1:2 mole ratio) mixture appears to be particularly promising. The specific energy is 4.0 MJ/kg (1.1 kWh/kg), the adiabatic flame temperature is about 3200 K, and the reaction forms solid titanium diboride (TiB2, melting point: 3500 K). The mixture can be ignited easily with a heated tungsten wire, and it has been used widely as a booster to ignite the main mixture in the SHS process.Estimates: Assuming that specific heat of regolith is 500 J/(kg∙K) [5] and all generated heat is transferred to regolith, 12.5 kg of the Ti/B mixture would increase the temperature of 1000 kg of regolith by 100 K. To evaluate the rate of heat transfer in the regolith, a spherical model was analyzed where the heat released by a 12.5 kg Ti/B core propagates by thermal conduction through a 1000 kg regolith shell with no heat loss from its outer surface. At a bulk density of 1500 kg/m3 [5], the radius of the shell was 54 cm, while the radius of the core was about 11 cm. The calculations were conducted using Thermal Desktop SINDA/FLUINT (Cullimore and Ring Technologies) software at two constant values of bulk thermal conductivityk of the regolith: 0.001 and 0.01 W/(m∙K). The results show that after 14.5 days the core lost 31% of the released heat at the lower k and 77% at the higher k. At a distance of 20 cm from the core surface, the temperature of the regolith increased by only 1 K at the lower k and by 132 K at the higher k. In reality, the regolith near the heat source will be melted, so its thermal conductivity will increase significantly. Nevertheless, the conducted estimates indicate that combustion-based heat generators, placed directly in the regolith, could provide heat during a rather long period such as the lunar night.Conclusion: Heat generators based on gasless combustion of highly energetic reactive mixtures could be installed directly in the surface layer of lunar regolith. Because of the low thermal conductivity of the regolith, such generators would keep thermal energy for days and gradually supply heat to a rover/lander.Acknowledgment: The material presented in this work is based upon the work supported by National Aeronautics and Space Administration (NASA) under Grant #80NSSC20K0293.References: [1] Balasubramaniam R. et al. (2011) J. Thermophys. Heat Trans., 25,130−139. [2] Blair R.G. and Vasu S.S. (2022) Conf. Advanced Power Systems for Deep Space Exploration. [3] Varma A. et al. (1998) Adv. Chem. Eng., 24,79−226. [4] Levashov E.A. et al. (2017) Int. Mater. Rev., 62,203−239. [5] Wood-Robinson R. et al. (2019) J. Geophys. Res. Planets, 124, 1989−2011.

lunar↗

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials↗