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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 739 records · Page 41

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DOE OSTI2020

Recovery of Cs-137 from Electric Arc Furnace Dust - 20562

The present work proposes the Cs-137 recovery from Electric Arc Furnace Dusts (EAFD) by leaching, in order to reduce the volume of radioactive waste to be managed. Leaching tests were performed on different samples of EAFD contaminated with Cs-137. Two leaching methodologies were tested: dynamic and static using as medium distilled water and in some cases NaOH. The results indicate the possibility of recovering Cs-137 from EAFD using the dynamic method; however, the recovery efficiencies of Cs-137 depend on EAFD's chemical composition. The leachates of Cs-137 were quantitatively adsorbed on exchange resins, showing its great potential to isolate or contain the Cs-137 recovery from EAFD. This study shows the feasible to apply the dynamic leaching methodology to recover Cs-137 from EAFD and the use of ion exchange resins for the isolation of removed Cs-137. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Maximizing Efficiency and Quality: Leveraging Automated Testing for Laboratory Commissioning

The traditional commissioning process uses sampling to select equipment for functional acceptance testing when large quantities of equipment are present. Although this approach is generally effective in identifying wide-spread issues, it has several shortcomings: it fails to evaluate equipment not included in the sample, provides only a one-time validation of equipment operation, and the standard documentation is a simple checklist of pass/fail questions. During the construction and commissioning process of the new Research and Innovation Laboratory (RAIL) in Golden, CO, the National Renewable Energy Laboratory team engaged Group14 Engineering to implement a Connected Commissioning process using fault detection and diagnostic software for automated functional acceptance testing. This presentation highlights the advantages offered by automated functional testing in this critical laboratory setting: (1) sampling 100% of BAS-connected equipment during functional testing, (2) testing results backed by data beyond the traditional pass/fail checklist, and (3) an automated test process that can be regularly executed by the building management team for ongoing commissioning throughout the life of the building. The presentation will also cover technical challenges associated with Connected Commissioning and the important conversations with key stakeholders that need to occur well before functional acceptance testing in order to successfully implement the automated testing processes.

automated testing↗

DOE OSTI2025

Powder Metallurgy – Hot Isostatic Pressing of 316H Stainless Steel for Nuclear Components

Overview of the PM-HIP work performed on stainless steel 316H as part of the microreactor program. High temperature mechanical testing was performed, with concerns identified with the creep-fatigue performance. Variations in feedstock and processing parameters did not conclusively identify the primary factor in the reduced creep-fatigue performance.

36 - MATERIALS SCIENCE↗

DOE OSTI2022

Scale-Up and Modeling Efforts Using an Omniphobic Surface Treatment for Mitigating Solids Deposition

Abstract Gas hydrates, waxes and asphaltenes represent some of the most significant flow assurance challenges, especially in subsea lines, where treatment options can be limited. Currently, complete avoidance is the primary strategy for hydrate management, while chemical or mechanical flushing/pigging may be utilized for other solids. Each system must also be treated with individualized solutions, as there have been no proved one-size-fits-all technologies demonstrated to date. As an alternative to constant chemical injection or thermodynamic controls such as insulation or heating, a robust omniphobic surface treatment material has been developed which has been shown in previous studies to significantly reduce the adhesion of flow assurance solids, resulting in lower risk for deposition and plugging of gas hydrates, waxes, and asphaltenes. As part of a Department of Energy study, laboratory scale tests were performed on a variety of apparatuses ranging from micromechanical force (micron scale) to laboratory flow loop testing (meter scale). While the results from these tests have been promising, there can be some disconnects between lab-scale observations and field-scale testing. Several factors can result in discrepancies between small-scale bench-top studies and deployment-scale efforts. These include flow conditions (Reynolds number, flow regime), chemistry (synthetic vs. crude oils, gas composition, and additives), physical differences (pipeline material, size, and geometry), etc. This work will describe the actions taken to better understand the deployment and performance of a material such as this omniphobic surface treatment in field scenarios, and to build confidence for deployment in a production scenario. These efforts include modeling field production scenarios using models developed from lab observations, application of the material to field-scale equipment to better understand application challenges, and expanded survivability and longevity testing. Understanding the bridge between laboratory testing and full-scale deployment allows for better technique and risk mitigation for field scale testing.

03 NATURAL GAS↗

DOE OSTI2024

High Temperature Mechanical Behavior of Refractory Alloys with Digital Image Correlation

Gas turbine efficiency is typically limited by the maximum allowable temperature for components at the inlet side and in the hot gas flow. Refractory alloys and SiC/SiC ceramic-matrix composites (CMCs) are promising candidates for advancing operating temperatures beyond those of Ni-based alloys (>1200 °C). Refractory alloys are more suitable than SiC/SiC CMCs for dynamic components, due to the latter's low toughness and ductility. However, it is well known that refractory alloys suffer from poor oxidation behavior under service lifetimes and conditions, leading to embrittlement concerns. The ARPA-E ULTIMATE program has set out to combine new alloys with advanced coatings to mitigate oxidation/embrittlement effects, while increasing the mechanical performance benefits of refractory materials. Low oxygen (inert gas) or vacuum systems are needed to assess high temperature mechanical performance of developed alloys. To investigate the environmental sensitivity of candidate alloys and develop high temperature testing capabilities, four argon tensile frames were upgraded as well as a single vacuum system at Oak Ridge National Laboratory. Digital image correlation was incorporated into the vacuum frame allowing for surface strain determination and refined insight into thermomechanical response. Creep testing was performed at 1300 °C on two alloys, C-103 and MHC in vacuum and high purity argon environments. The Mo-based alloy showed less sensitivity to oxygen, indicating that testing in well-controlled argon environments may be suitable. The C-103 alloy demonstrated a stronger sensitivity to oxygen in the well-controlled argon environment, illustrating the need for the developed vacuum testing capabilities. “Small” 25 mm and “large” 76 mm MHC specimens showed comparable results in terms of strain rate during creep testing and ultimate tensile strength during tensile testing, suggesting the viability of smaller geometries that use less material of advanced developmental alloys.

Bell, Sam↗

DOE OSTI2020

Probabilistic Look-ahead Contingency Analysis Integration with Commercial Tool and Practical Data

This paper presents an initial effort of integrating a smart sampling-based probabilistic look-ahead contingency analysis algorithm with General Electric (GE) Grid Solutions’ commercial energy management system (EMS) tool as a proof-of-concept for a seamless research tool integration using real world large-scale grid data. With the increasing impact of random forces such as variable generation and load, their stochastic behaviors cannot be ignored. However, the current practices are still dominated by deterministic tools. They are becoming increasingly inadequate for the future grid. The developed look-ahead contingency analysis algorithm incorporates forecast errors of variable energy and load to address the challenges brought by the increasing uncertainty of power system. The algorithm can reveal the potential violations caused by the variance of variable energy and load that are not normally detected by traditional deterministic approaches. To test its performance under practical environments ( real data with real commercial tool), significant efforts have been made to prepare test cases, modify GE EMS tool, and adapt an extreme value distribution algorithm to analyze the GE EMS’s violation-only outputs. The test results clearly demonstrate the effectiveness of the developed algorithm as new transformer violations that were not previously detected have been identified. This performance provides better situational awareness to engineers for their decision-making process under uncertainty. Moreover, with the discussion of computational performance and future work, this paper has shown a clear path for integrating the probabilistic algorithm with commercial tools to make us better equipped for the changing power system.

Modeling and simulation of power systems, constrai↗

DOE OSTI2023

Testing Instrument Extremes in the TREAT Facility

TREAT is a transient power-shaping reactor whose primary mission is to enhance safety performance by testing nuclear fuels and materials under thermodynamic and neutronic conditions ranging from off-normal to extreme. Transient testing of nuclear fuels is analogous to car crash testing, in that the dramatic changes commonly seen when comparing the test specimens' initial and final state points necessitate in-situ measuring in order to interpret and understand the evolution of the experiment. TREAT’s experiment design strategy utilizes a highly reconfigurable and accessible reactor core that affords flexibility when installing experiment devices, thanks to the lack of a primary coolant boundary and the inclusion of multiple access points in the reactor bioshield. Within the experiment devices, the test specimens (which are integrated with their test environments), desired instrumentation diagnostics, and safety considerations are all contained in a single engineered package. The experiments encompass various types of environments (e.g., water, sodium, and gas at temperature and pressure), as well as a range of control options (e.g., static or flowing coolants). The experimental conditions are uniquely representative of advanced reactors, providing challenges to sensor performance but also affording a unique opportunity for development and qualification of sensors suited to these environments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Design and Initial Verification Testing of an In Situ Load Retention Aging Fixture

Load retention is a key metric used to evaluate long-term mechanical functionality of polymeric materials. Its measurement currently requires periodically removing the aging fixtures from the ovens, removing the specimens from the fixtures, and performing load testing on the specimens. The ability to perform load measurement in situ (i.e., without having to remove the specimens from the fixtures, and possibly even the ovens) would facilitate data acquisition/analysis, improve data quality, and enable uninterrupted compression of specimens which is more representative of the actual application.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Performance of Windows in Walls With Continuous Insulation

Window openings in walls are a significant contributor to poor thermal performance because of thermal bridging through the framing members (e.g., studs, joists, plates, bracing) and because windows lack the thermal properties of insulation. Window installation guidance for walls with continuous insulation (CI) is critical for continued market growth of this energy efficiency technology. This research project offers window manufacturers a starting point and a potential path toward developing installation instructions for windows over CI. The objectives of the research include evaluating the common method for installing windows in walls with CI, as well as establishing acceptance criteria for evaluating the performance of windows installed in walls with and without CI. The research measures: 1. The performance characteristics (e.g., water management, structural integrity) of windows in walls without CI. 2. The performance of different thicknesses and types of CI used in walls. 3. The performance of different types of window assemblies (e.g., double-hung windows, mulled double-hung windows, mulled casement windows, and slider windows) installed over CI. 4. The performance of window flange types (e.g., rigid mounting and less robust flanges) installed over CI. 5. Installing windows over CI using baseline installation instructions versus window manufacturer installation instructions. The project’s sequential testing protocol consists of the following: • A water penetration resistance testing adapted from two ASTM standards: E331 (uniform static air pressure in four steps) and E547 (cyclic static air pressure) • A temperature cycling adapted from ASTM E2264 Method B (convective hot air) • A service condition wind loading test adapted from ASTM E330 • A six-month vertical displacement observation phase prior to the structural performance testing • A final water penetration resistance test after vertical displacement observation • A structural performance test adapted from ASTM E330. Key research findings include: • The criterion for passing a water penetration resistance test is that there is no water overflowing at the interior face of the studs. If there is any bubbling or slight pooling of water at the sill, then it must recede after the pressure is removed. Excessive leakage and/or water leaking to the interior face of the framing around the window constitutes a failure. • All single double-hung windows installed directly to lumber or over oriented strand board passed all test protocols. • For most wall specimens, the test results showed that the use of foam sheathing did not affect the performance of the window for water leakage. • All wall specimens underwent temperature cycling. The results indicated that temperature cycling had little to no effect on windows installed over foam sheathing. • For wall specimens that underwent six-month vertical displacement monitoring, the results showed that windows installed over foam sheathing do not sag over time. • The single-hung and double-hung windows installed using window manufacturer installation instructions passed the structural performance test, compared to failures observed in windows that were installed using generic installation instructions. The generic and manufacturer installation methods differed on the following construction details: type of fasteners, fastening patterns on the flanges, and window shimming details. • Additional testing is required to determine methods to improve structural pressure performance of slider windows. Potential solutions that would require additional testing may include fastener spacing, different types of fasteners, masonry window clips, construction adhesive, foam sealant, stronger window flange material, and/or straps.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

A study on texture stability and the biaxial creep behavior of as-hydrided CWSR Zircaloy-4 cladding at the effective stresses from 55 MPa to 65 MPa and temperatures from 300°C to 400°C

The creep rupture of high burnup used nuclear fuel (> 45 GWD/MTU) cladding is regarded as one of the failure mechanisms during long-term dry storage. A high amount of zirconium hydride in the cladding matrix would degrade the mechanical properties of the cladding especially leading to delayed hydride cracking. To better understand the influence of zirconium hydride on the biaxial thermal creep performance and the crystalline texture stability of Zircaloy-4 cladding, the pressurized tube technique is applied to test the durability of the as-hydrided material. Tests were performed on as-received Zircaloy-4 tubular specimens as well as-hydrided ones with targeted 300 wt parts per million (wppm) or 750 wppm hydrogen. The biaxial creep experiments were conducted at temperatures from 300 degrees C to 400 degrees C and at equivalent stresses at mid-wall from 55 MPa to 65 MPa. The hydridation process prior to creep tests induces the formation of FCC delta-hydride platelets along the circumferential direction of the tube. This alignment and phase structure of hydride show no significant change after biaxial creep tests. The creep strain-rate negatively depends on the hydrogen content. The synchrotron wide-angle X-ray diffraction (WAXD) technique and electron backscatter diffraction (EBSD) analysis were applied for the study of the crystallographic orientation relationship. zirconium-to-hydride grain orientation follows Shoji-Nishiyama crystallographic relationship. This relationship is stable before and after creep deformation. These results of creep performance and texture stability of Zircaloy-4 claddings can help support the design basis of interim and long-term dry storage facilities.

creep↗

DOE OSTI2024

Length scale effects of micro- and meso-scale tensile tests of unirradiated and irradiated Zircaloy-4 cladding

Zircaloy-4 is an essential material for cladding structures within fission-based reactors. To explore the changes in properties measured on differing length scales, FIB-machined micro-scale tensile tests were performed on both irradiated and control groups of Zircaloy-4. This was correlated with tensile testing on femtosecond laser-machined meso-scale specimens. Pronounced size effects were found when varying specimen geometry. Increases in tensile geometry size were associated with a reduction in measured yield stress for both irradiated and unirradiated samples. Here, meso-scale testing found strength and strain values similar to that of bulk-scale testing.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Mechanical response of shape-recovering metamaterial structures fabricated by additive manufacturing

Abstract Three different metamaterial structures were fabricated using stereolithography 3D printing and a shape recovering material. Mechanical properties and recovery efficiency were assessed after compression testing. All three structures exhibited similar initial specific compressive moduli, while the highest specific toughness was observed for the stretch-dominated structure. The three metamaterial structures were re-tested after shape recovery. Significant strengthening was observed for all structures, with the bend-stretch-dominated structure strengthening to the highest degree. This strengthening phenomenon was characterized as strain hardening. It was found that the strengthening is highly geometry dependent. The geometry with stretch-dominated behavior exhibited the highest mechanical properties after a second test was performed. Improvements in specific toughness of up to 67% were observed after the second compressive test.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Development of 3-cell Traveling Wave SRF Cavity

Traveling wave SRF cavity is a new technology and requires a multi-stage process for development. Conceptual designs have been proposed to adopt TW resonance in an SRF cavity The early stages of developments have been funded by several SBIR grants to Euclid Techlabs which were completed in collaboration with Fermilab. A 3-cell proof-of-principle TW cavity was fabricated as part of that and demonstrated the TW resonance excitation at room temperature. A TW resonance control tuner for the 3-cell was also fabricated and the preliminary tests were performed. Now, the 3-cell cavity is being processed and prepared for the first cryogenic testing.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Testing of a Whole Home Energy Management System (Cooperative Research and Development Final Report)

NREL and B&B Technology Solutions Inc. will perform verification testing to demonstrate the effectiveness of our whole home energy management system. This energy management system will allow the electrification of various styles of homes reducing the emissions of CO2 by replacing existing fossil fuel-based home systems. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope, and/or uses the laboratory's core competencies, and/or enhances U.S. competitiveness by utilizing DOE developed intellectual property and/or capabilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

MULTI-MISSION THERMOELECTRIC GENERATOR ASSEMBLY TESTING AND LAUNCH OPERATIONS FOR MARS 2020

The Space Nuclear Power and Isotope Technologies (SNPIT) division at Idaho National Laboratory (INL) fuels, performs acceptance testing, and provides spacecraft integration support of Radioisotope Power Systems (RPS) in support of National Aeronautics and Space Administration (NASA) missions. Recently the SNPIT team completed assembly, testing and launch support of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) for the Mars 2020 Perseverance Rover mission.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2021

MULTI-MISSION THERMOELECTRIC GENERATOR ASSEMBLY TESTING AND LAUNCH OPERATIONS FOR MARS 2020

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2026

Oxidation of Materials and Coatings at 1000°C and 250 bar for use in Oxy-Combustion Turbine

Combinations of materials and coatings were tested in supercritical CO2 (sCO2) to evaluate their reliability in an oxy-fuel turbine being designed to operate in the 150-300 MWe size range at inlet temperatures of 1,150 °C at 300 bar and exhaust temperatures in the 725-775 °C range. Nickel alloys and stainless steels were exposed to supercritical CO2 at 1,000 °C and 250 bar for a total of over 1,500 hours. The materials were tested bare, with a nanocrystalline MCrAlY bond coat only, or with one of two types of bond coat and a thermal barrier coating. A novel test facility using a localized heat zone generated by an induction heater inside an externally cooled autoclave was developed to perform those tests. The specimens were weighed before and after exposure to determine the oxidation rate. All specimens were inspected visually, and a smaller group of coated specimens were studied using secondary electron microscopy (SEM). The integrity of the coating, and the morphology and composition of the thermally grown oxide were especially of interest for the SEM investigation. This paper presents the up-to-date results of the testing coated and uncoated superalloys in sCO2 at up to 1150 °C and up to 300 bar performed at Southwest Research Institute.

Bocher, Florent [Southwest Research Institute, San↗

DOE OSTI2020

Wireless Instrumented RB Experiment Preliminary Design and Analysis

The ability to deploy new nuclear fuels for current or future reactor concepts requires carefully designed experiments to generate data to support fuel qualification. Ideally these experiments would include state of-the-art sensing to maximize the amount of in situ data that can be collected during operation. Furthermore, advanced reactor systems can take advantage of integrated in-core sensing technologies to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator’s understanding of limiting peaking factors. Before any novel sensing technologies can be readily adopted for nuclear applications, they must first demonstrate acceptable performance in test reactors. This report summarizes the preliminary design and analysis of the most highly instrumented irradiation experiment ever performed in the removable beryllium (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL). The Wireless Instrumented RB Experiment 2021 (WIRE-21) will test a wide range of sensors including wireless sensors being developed by Westinghouse Electric Company (WEC) that could provide in situ measurements of peak fuel temperatures and fuel rod pressurization due to fission gas release. The ability to wirelessly transmit a signal through the fuel rod’s cladding is critical to improving fuel monitoring capabilities without requiring signal penetrations through the cladding pressure boundary, which would significantly impact fuel fabrication, handling, and operation. Other sensors that will be tested in WIRE-21 include an array of thermocouples, self-powered neutron detectors (SPNDs), and spatially distributed fiber-optic temperature sensors. More generally, WIRE-21 will establish a flexible irradiation vehicle design to allow accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. This report summarizes the mechanical design for WIRE-21, the experimental test matrix, initial neutronic and thermal design analyses, and the active monitoring and control system enhancements necessary to support testing of advanced sensor technologies. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) relevant to light water reactors (LWRs), but the flexible design of the experiment vehicle allows much higher operating temperatures (>1,100°C). Neutronic calculations determine the neutron flux conditions as well as the nuclear heating within the experiments. These results are used as inputs to detailed thermal finite element calculations, which are required to evaluate the complex, three-dimensional heat transfer that occurs within WEC’s wireless sensor enclosures. Initial results show that the temperatures of the sensors’ enclosures and the metal bellows can be operated near the temperature range of LWR coolants and cladding while simultaneously increasing the temperature of a surrogate fuel material to values in the range of 800–1200°C to simulate centerline fuel temperatures during LWR operation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗