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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Forming Limits of Thin Ferritic Stainless Steel for Fuel Cell Application

To lower the cost of fuel cell bipolar plate (BPP), less expensive ferritic stainless steel (FSS) BPP substrate materials are investigated. A series of tensile tests and multistage microchannel-forming tests were conducted on 85-µm-thick ferritic stainless steel foils, 439L, 444, and Chromeshield® 22, to understand the effect of the forming temperatures, tooling geometry, and processes on their formability. Three microchannel-forming processes were conducted, which are 1-Hit (single-stage forming), 2-Hit (two-stage forming) with 50% preform, and 2-Hit with 80% preform. FLC o s at various microchannel-forming conditions were obtained to address the formability of the ferritic stainless steel foils under plane strain conditions. It has been found that the larger the microchannel radius, the better the formability, two-stage forming is superior to the single-stage process, and a larger draw percentage in preform (stage I) leads to a higher FLC o or better formability. It has also been found from tensile tests that the thermal effect (higher temperature) has a negative impact on the failure strains. A similar phenomenon was also observed through channel-forming tests conducted at room temperature, 100 °C, and 200 °C.

08 HYDROGEN↗

DOE OSTI2026

Site specific porosity-thermal performance correlations in neutron irradiated U-10Zr fuel

In this work, we present a site-specific three-dimensional analysis of porosity evolution in neutron-irradiated U–10Zr metallic fuel using high-resolution synchrotron X-ray tomography. Focused ion beam cubic lift-outs from four radial positions—fuel center, middle, edge, and fuel-cladding interaction (FCCI) zones—were imaged, reconstructed, and segmented to quantify pore volume, density, morphology, and pore connectivity. Porosity increased modestly from 5.5% at the center to 10.5% at the edge, yet pore number density increased by over two orders of magnitude in the fuel portion near the FCCI interface (from 4.8 x 10 4 to 6.0 x 10 6 pores/mm 3 ). Morphological classification revealed a progression from small spherical pores at the center to equiaxed and tortuous networks at the periphery, with enhanced orientation along the radial direction. Connectivity and permeability analysis reveal that the FCCI region maintains dense, highly interconnected pores despite a moderate volume fraction, enabling rapid fission gas transport and lanthanide migration. Effective thermal conductivity models incorporating sodium logging confirm that these site-specific pore features critically influenced heat transport during reactor irradiation. These findings demonstrate that pore topology—not just porosity fraction—controls thermal performance and thermal pathways in U–10Zr fuels, impacting fuel thermal performance in a reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2013

Silicon Heat Pipe Array

Improved methods of heat dissipation are required for modern, high-power density electronic systems. As increased functionality is progressively compacted into decreasing volumes, this need will be exacerbated. High-performance chip power is predicted to increase monotonically and rapidly with time. Systems utilizing these chips are currently reliant upon decades of old cooling technology. Heat pipes offer a solution to this problem. Heat pipes are passive, self-contained, two-phase heat dissipation devices. Heat conducted into the device through a wick structure converts the working fluid into a vapor, which then releases the heat via condensation after being transported away from the heat source. Heat pipes have high thermal conductivities, are inexpensive, and have been utilized in previous space missions. However, the cylindrical geometry of commercial heat pipes is a poor fit to the planar geometries of microelectronic assemblies, the copper that commercial heat pipes are typically constructed of is a poor CTE (coefficient of thermal expansion) match to the semiconductor die utilized in these assemblies, and the functionality and reliability of heat pipes in general is strongly dependent on the orientation of the assembly with respect to the gravity vector. What is needed is a planar, semiconductor-based heat pipe array that can be used for cooling of generic MCM (multichip module) assemblies that can also function in all orientations. Such a structure would not only have applications in the cooling of space electronics, but would have commercial applications as well (e.g. cooling of microprocessors and high-power laser diodes). This technology is an improvement over existing heat pipe designs due to the finer porosity of the wick, which enhances capillary pumping pressure, resulting in greater effective thermal conductivity and performance in any orientation with respect to the gravity vector. In addition, it is constructed of silicon, and thus is better suited for the cooling of semiconductor devices.

Yee, Karl Y.↗

DOE OSTI2020

Quantum Monte Carlo determination of the principal Hugoniot of deuterium

Here, we present coupled electron-ion Monte Carlo results for the principal Hugoniot of deuterium together with an accurate study of the initial reference state of shock-wave experiments. We discuss the influence of nuclear quantum effects, thermal electronic excitations, and the convergence of the potential energy surface by wave-function optimization within variational Monte Carlo and projection quantum Monte Carlo methods. Compared to a previous study, our calculations also include low pressure-temperature (P,T) conditions resulting in close agreement with experimental data, while our revised results at higher (P,T) conditions still predict a more compressible Hugoniot than experimentally observed.

36 MATERIALS SCIENCE↗

DOE OSTI2020

27 AlNMR chemical shift of Al(OH)$^{-}_{4}$ calculated from first principles: Assessment of error cancellation in chemically distinct reference and target systems

Predicting accurate nuclear magnetic resonance chemical shieldings relies upon cancellation of different types of errors between the theoretically calculated shielding constant of the analyte of interest and the reference. Often, the intrinsic error in computed shieldings due to basis sets, approximations in the Hamiltonian, description of the wave function, and dynamic effects is nearly identical between the analyte and reference, yet if the electronic structure or sensitivity to local environment differs dramatically, this cannot be taken for granted. Detailed prior work has examined the octahedral trivalent cation Al(H 2 O)$^{3+}_{6}$, accounting for ab initio intrinsic errors. However, the use of this species as a reference for the chemically distinct tetrahedral anion Al(OH)$^{-}_{4}$ requires an understanding of how these errors cancel, in order to define the limits of accurately predicting 27 Al chemical shielding in Al(OH)$^{-}_{4}$. In this work, we estimate the absolute shielding of the 27 Al nucleus in Al(OH)$^{-}_{4}$ at the coupled cluster level (515.1± 5.3 ppm). Shielding sensitivity to the choice of method approximation and atomic basis sets used has been evaluated. Solvent and thermal effects are assessed through ensemble averaging techniques using ab-initio molecular dynamics. The contribution of each type of intrinsic error is assessed for the Al(H 2 O)$^{3+}_{6}$ and Al(OH)$^{-}_{4}$ ions, revealing significant differences that fundamentally hamper the ability to accurately calculate the 27 Al chemical shift of Al(OH)$^{-}_{4}$ from first principles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2004

Redesign of the Human Metabolic Simulator

The National Aeronautics and Space Administration (NASA) is currently building a Human Metabolic Simulator (HMS) at the Johnson Space Center as part of the Advanced Life Support Air Revitalization Technology Evaluation Facility (ARTEF). The purpose of ARTEF is to evaluate Environmental Control and Life Support System Technologies for Advanced Missions. The HMS is needed to reproduce the primary metabolic effects of human respiration on an enclosed atmosphere when humans cannot be present and the impact of human presence on the system is required. A HMS was designed, built and successfully operated in 2000 but larger crew size requirements and the expense of upgrade of the current system necessitate redesign. This paper addresses the redesign. Several concepts were considered, ranging from chemical oxidation of a hydrocarbon like ethanol or ethyl acetate to carbon dioxide and water, oxidation of an iron-containing compound, or by using a fuel cell. For reasons of cost, simplicity, safety and other factors, the concept chosen includes: a molecular sieve packaged as an industrial oxygen concentrator to remove oxygen from the atmosphere, with direct carbon dioxide, water and heat injection. The water injection is done via heating water to steam with a heat exchanger and thermal effects are handled by directly adding heat to the air stream with a second heat exchanger. Both heat exchangers are supplied by a hot oil loop. The amount of oxygen removal, carbon dioxide addition, water addition and heat addition were calculated using metabolic profiles for respiration and heat, calculated using a series of empirical equations developed for International Space Station (ISS). Sketches of the Human Metabolic Simulator and the hot oil bath loop used to supply heat to the heat exchangers are included

Duffield, Bruce↗

DOE OSTI2022

Uncertainty in Thermal Modeling of Spent Nuclear Fuel Casks

Uncertainty is a key metric in computational modeling that must be evaluated for results to have wide ranging applicability. A well characterized uncertainty range is ideal with clear error bars on results that can be presented to stakeholders. In the field of spent fuel cask modeling, this ideal has been historically difficult to achieve in practice because of the computationally intensive nature of the models used and the difficulty assigning reasonable uncertainties to quantities in as-built systems. The work in this report has been conducted to evaluate the overall state of uncertainty and sensitivity in spent fuel cask models and develop methodologies for evaluating these uncertainties. These methodologies must be practical for engineering applications. They should not require excessive computational resources or calendar time to achieve results. In engineering, the model must be on a scale such that it can be changed and adapted throughout a project as new information is discovered and project goals evolve. This report covers three major modeling task areas that provide an overview of the types of sensitivity and uncertainty present in a spent fuel storage and transportation system. Section 3 discusses sensitivity and uncertainty analysis in the effective thermal conductivity model for the fuel region and applies these results to a single assembly model. Section 4 shows sensitivity analysis of a full cask model in the TN-32B and Section 5 demonstrates the overall uncertainty workflow using Coolant Boiling in Rod Arrays – Spent Fuel Storage and STAR-CCM+ developed from the sensitivity work in the preceding sections.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2001

Further Investigations of Control Surface Seals for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a potential crew return vehicle (CRV) for the International Space Station. This vehicle would serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. Control surfaces on the X-38 (body flaps and rudder/fin assemblies) require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. NASAs Johnson Space Center (JSC) and Glenn Research Center (GRC) are working together to develop and evaluate seals for these control surfaces. This paper presents results for compression. flow, scrub, and arc jet tests conducted on the baseline X-38 rudder/fin seal design. Room temperature seal compression tests were performed at low compression levels to determine load versus linear compression, preload. contact area, stiffness. and resiliency characteristics under low load conditions. For all compression levels that were tested, unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits required to limit the loads on the adjoining Shuttle thermal tiles that the seals will contact. Flow rates through an unloaded (i.e. 0% compression) double arrangement were twice those of a double seal compressed to the 20% design compression level. The seals survived an ambient temperature 1000 cycle scrub test over relatively rough Shuttle tile surfaces. The seals were able to disengage and re-engage the edges of the rub surface tiles while being scrubbed over them. Arc jet tests were performed to experimentally determine anticipated seal temperatures for representative flow boundary conditions (pressures and temperatures) under simulated vehicle re-entry conditions. Installation of a single seat in the gap of the test fixture caused a large temperature drop (1710 F) across the seal location as compared to an open gap condition (140 F) confirming the need for seals in the rudder/fin gap location. The seal acted as an effective thermal barrier limiting heat convection through the seal gap and minimizing temperature increases downstream of the seal during maximum heating conditions.

Dunlap, Patrick H., Jr.↗

DOE OSTI2022

Numerical investigation of the effect of ultrasound on paper drying

The paper drying process is very energy inefficient. More than two-thirds of the total energy used in a paper machine is for drying paper. Novel drying technologies, such as ultrasound (US) drying, can be assessed numerically for developing next-generation drying technologies for the paper industry.This work numerically illustrates the impact on drying process energy efficiency of US transducers installed on a two-tiered dryer section of a paper machine. Piezoelectric transducers generate ultrasound waves, and liquid water mist can be ejected from the porous media. The drying rate of handsheet paper in the presence of direct-contact USis measured experimentally, and the resultant correlation is included in the theoretical model.The drying section of a paper machine is simulated by a theoretical drying model. In the model, three scenarios are considered. In the first scenario, the US modules are positioned in the dryer pockets, while in the second scenario, they are placed upstream of the drying section right after the press section. The third case is the combination ofthe first and second scenarios. The average moisture content and temperature during drying, enhancement of total mass flux leaving the paper by the US mechanism, total energy consumption, and thermal effect of heated US transducers are analyzed for all cases. Results show that the application of the US can decrease the total number of dryer drums for drying paper. This numerical study is based on the US correlation obtained with the US transducer in direct contact with the paper sample. Thus, future work should include US correlation based on a non-contact US transducer.

Materials Science↗

NASA NTRS1992

Venus tectonic styles and crustal differentiation

Two of the most important constraints are known from Pioneer Venus data: the lack of a system of spreading rises, indicating distributed deformation rather than plate tectonics; and the high gravity/topography ratio, indicating the absence of an asthenosphere. In addition, the high depth/diameter ratios of craters on Venus indicate that Venus probably has no more crust than Earth. The problems of the character of tectonics and crustal formation and recycling are closely coupled. Venus appears to lack a recycling mechanism as effective as subduction, but may also have a low rate of crustal differentiation because of a mantle convection pattern that is more distributed, less concentrated, than Earth's. Distributed convection, coupled with the nonlinear dependence of volcanism on heat flow, would lead to much less magmatism, despite only moderately less heat flow, compared to Earth. The plausible reason for this difference in convective style is the absence of water in the upper mantle of Venus. We have applied finite element modeling to problems of the interaction of mantle convection and crust on Venus. The main emphasis has been on the tectonic evolution of Ishtar Terra, as the consequence of convergent mantle flow. The early stage evolution is primarily mechanical, with crust being piled up on the down-stream side. Then the downflow migrates away from the center. In the later stages, after more than 100 m.y., thermal effects develop due to the insulating influence of the thickened crust. An important feature of this modeling is the entrainment of some crustal material in downflows. An important general theme in both convergent and divergent flows is that of mixing vs. stratification. Models of multicomponent solid-state flow obtain that lower-density crustal material can be entrained and recycled, provided that the ration of low-density to high-density material is small enough (as in subducted slabs on Earth). The same considerations should apply in upflows; a small percent of partial melt may be carried along with its matrix and never escape to the surface. Models that assume melt automatically rising to the crust and no entrainment or other mechanism of recycling lower-density material obtain oscillatory behavior, because it takes a long time for heat to build up enough to overcome a Mg-rich low-density residuum. However, these models develop much thicker crust than consistent with estimates from crater depth/diameter ratios.

Kaula, W. M.↗

DOE OSTI2023

A high-performance lung-inspired ceramic 3D-printed heat exchanger for high-temperature energy-efficient systems

The thermal-to-electric conversion efficiency of next-generation supercritical carbon dioxide and concentrated solar power plants is significantly augmented by operating at temperatures exceeding 1000 °C if durable, compact, high-temperature heat exchangers (HXs) are developed. Whereas metal 3D-printed HXs fail to operate under extreme temperature conditions, ceramic 3D-printed HXs are deemed promising candidates for high-temperature, highly oxidizing environments. Ceramic 3D-printed HXs, however, exhibit a high gas permeability issue through hot and cold separating walls due to an excessive non-volatile photopolymer content utilized. Here, in this work, a novel leak-free lung-inspired ceramic 3D-printed HX employing a highly complex heat transfer topology is introduced for high-temperature energy-efficient systems. The high permeability issue of ceramic 3D-printed HXs is fully eliminated through a uniform zinc-based coating. It was determined that the effective thermal conductivity of the sintered ceramic heat exchangers is affected by the coated layer. The high-temperature thermal and hydraulic characteristics of the lung-inspired ceramic 3D-printed HX are comprehensively examined and compared against a millichannel 3D-printed HX module. Experimental results indicated that the lung-inspired 3D-printed ceramic HX significantly outperforms its millichannel counterpart. The lung-inspired HX shows a volume-based power density of 8.2 MW/m3 at a hot-side inlet air temperature of 700°C, a 71 % improvement compared with that of the millichannel HX. More importantly, the higher thermal duty of the lung-inspired 3D-printed HX is realized at a lower normalized pressure drop penalty of 510 Pa/W, 22 % lower than that of the millichannel ceramic HX. This study accelerates the advancement of high-performance ceramic 3D-printed HXs with complex topologies for high-temperature energy-efficient systems and/or corrosive environments.

42 ENGINEERING↗

NASA NTRS1994

Associated with aerospace vehicles development of methodologies for the estimation of thermal properties

Thermal stress analyses are an important aspect in the development of aerospace vehicles at NASA-LaRC. These analyses require knowledge of the temperature distributions within the vehicle structures which consequently necessitates the need for accurate thermal property data. The overall goal of this ongoing research effort is to develop methodologies for the estimation of the thermal property data needed to describe the temperature responses of these complex structures. The research strategy undertaken utilizes a building block approach. The idea here is to first focus on the development of property estimation methodologies for relatively simple conditions, such as isotropic materials at constant temperatures, and then systematically modify the technique for the analysis of more and more complex systems, such as anisotropic multi-component systems. The estimation methodology utilized is a statistically based method which incorporates experimental data and a mathematical model of the system. Several aspects of this overall research effort were investigated during the time of the ASEE summer program. One important aspect involved the calibration of the estimation procedure for the estimation of the thermal properties through the thickness of a standard material. Transient experiments were conducted using a Pyrex standard at various temperatures, and then the thermal properties (thermal conductivity and volumetric heat capacity) were estimated at each temperature. Confidence regions for the estimated values were also determined. These results were then compared to documented values. Another set of experimental tests were conducted on carbon composite samples at different temperatures. Again, the thermal properties were estimated for each temperature, and the results were compared with values obtained using another technique. In both sets of experiments, a 10-15 percent off-set between the estimated values and the previously determined values was found. Another effort was related to the development of the experimental techniques. Initial experiments required a resistance heater placed between two samples. The design was modified such that the heater was placed on the surface of only one sample, as would be necessary in the analysis of built up structures. Experiments using the modified technique were conducted on the composite sample used previously at different temperatures. The results were within 5 percent of those found using two samples. Finally, an initial heat transfer analysis, including conduction, convection and radiation components, was completed on a titanium sandwich structural sample. Experiments utilizing this sample are currently being designed and will be used to first estimate the material's effective thermal conductivity and later to determine the properties associated with each individual heat transfer component.

Scott, Elaine P.↗

DOE OSTI2025

Nanoscale and Element-Specific Lattice Temperature Measurements Using Core-Loss Electron Energy-Loss Spectroscopy

Measuring nanoscale local temperatures, particularly in vertically integrated and multicomponent systems, remains challenging. Spectroscopic techniques like X-ray absorption and core-loss electron energy-loss spectroscopy (EELS) are sensitive to lattice temperature, but understanding thermal effects is nontrivial. This work explores the potential for nanoscale and element-specific core-loss thermometry by comparing the Si L2,3 edge’s temperature- dependent redshift against plasmon energy expansion thermometry (PEET) in a scanning TEM. Using density functional theory (DFT), time-dependent DFT, and the Bethe−Salpeter equation, we ab initio model both the Si L 2,3 and plasmon redshift. We find that the core-loss redshift occurs due to bandgap reduction from electron−phonon renormalization. Our results indicate that despite lower core-loss signal intensity compared to plasmon features, core-loss thermometry has key advantages and can be more accurate through standard spectral denoising. Specifically, we show that the Varshni equation easily interprets the core-loss redshift for semiconductors, which avoids plasmon spectral convolution for PEET in complex junctions and interfaces. We also find that core-loss thermometry is more accurate than PEET at modeling thermal lattice expansion in semiconductors, unless the specimen’s temperature-dependent dielectric properties are fully characterized. Furthermore, core-loss thermometry has the potential to measure nanoscale heating in multicomponent materials and stacked interfaces with elemental specificity at length scales smaller than the plasmon’s wave function.

Bethe–Salpeter equation↗

DOE OSTI2020

Foam Degradation Model during Thermal Hypothetical Accident Conditions

Current practice in Safety Analysis Report for Packaging (SARP) thermal analysis for hypothetical accident conditions (HAC) of packages is to not explicitly model the consequence to the foam impact limiting material, but instead to make conservative estimates of those consequences and begin calculations from that point. This approach is typically used for the foam regression distance, which is the thickness of the degraded foam layer after the 30-minute fire event. Estimates for regression distance can come directly from package burn test results or from correlations based on one-dimensional testing by the foam manufacturer. In either case, this is a subjective process, and although it can be used to produce a conservative result, it is a significant approximation in the analysis. This paper describes testing and refinement of a simplified foam regression model. Comparisons are made against available data from laboratory experiments. Model refinements were tested until satisfactory agreement was achieved. The final modeling approach was then compared with post-test inspection results from HAC burn test data. A new model with an effective thermal conductivity based on foam to char density variation was shown successful in representing laboratory-scale foam thermal degradation experiments and full-scale burn tests of a current package. This model offers a technically defensible and predictive approach for modeling thermal degradation of rigid polyurethane insulation in transport packages.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Investigation of N 2 /O 2 plasma interaction with Pt-catalyst: effect of metastable adsorbates on product hysteresis

The coupling of catalysts and atmospheric-pressure plasma has the potential to improve the efficiency of certain catalytic reactions. Understanding the changes that the catalyst surface undergoes during exposure to plasma is key to improving plasma–catalytic performance. In this work, long term exposure of Pt–Al 2 O 3 powder catalyst to an Ar/N 2 /O 2 non-equilibrium atmospheric-pressure plasma-jet was investigated. Products produced by the interaction were analyzed downstream with Fourier-transform infrared spectroscopy while surface species were analyzed operandi with diffuse reflectance infrared Fourier transform spectroscopy. During exposure, the catalyst temperature was ramped cyclically between 100 °C and 350 °C to understand how substrate temperature affects the plasma–catalyst interaction. Long-lasting changes were revealed to take place on the catalyst surface during plasma exposure. At low temperatures, Pt–O and Pt–NO accumulate on the surface which react at elevated temperatures to form NO 2 . NO 2 initially appears to spill on to the Al 2 O 3 support as nitrites and nitrates instead of desorbing. Stable surface conditions are only achieved after prolonged plasma exposure, when nitrate sites on the Al 2 O 3 support are filled. By changing the catalyst temperature at various rates, the impact of total plasma species flux to the surface was analyzed. It was found that decreasing the heating rate increased the hysteresis in the pattern of NO 2 formation during thermal cycling. The variation with temperature demonstrates that plasma exposure results in a buildup of surface NO x and oxygen species which react or desorb at high temperatures. The observed changes are discussed from the generic viewpoint that a non-equilibrium plasma interacting with a catalyst at low temperature introduces metastable steady-state surface conditions. Upon heating above a threshold temperature, the introduced surface modifications can change either due to thermal effects, or, for a plasma environment, by additional interaction with the incident plasma species flux. The surface/material changes take place in a highly predictable fashion and after sufficient time above the threshold temperature reach a steady-state condition that is different from the transient behavior that is observed during initial heating. During cooling the plasma-surface interaction exhibits a different behavior than during heating, and this results in hysteresis of diverse observables. The metastability/hysteresis description appears quite generic and analogous to hysteresis behavior seen for different systems. Furthermore, it is expected to be useful for understanding the consequences of plasma–catalyst surface interactions for various systems.

36 MATERIALS SCIENCE↗

NASA NTRS2017

Non-Linear Analysis of the NASA Super Pressure Balloons: Whole Flight Simulations

Tensys have a long-established background in the shape generation and load analysis of architectural stressed membrane structures. Founded upon their inTENS finite element analysis suite, these activities have broadened to encompass 'lighter than air' structures such as aerostats, airships, hybrid air vehicles and stratospheric balloons. Tensys have acted as consultants to the NASA Super Pressure Balloon (SPB) Program since 2004. Previous papers have focussed upon the application of inTENS to the overall structural and stability analysis of pumpkin type balloons as used in the SPB Program. Particular emphasis has been placed upon the ability to study both stress and stability at all stages of a flight. As the program has developed, increasing modelling fidelity has been introduced as design refinement has moved emphasis from the overall shape to the performance of individual details. Examples include the introduction of a contact capability into inTENS to better represent the separate cap layer of film. Localised investigations have considered the consequence of local geometric anomalies introduced during fabrication and the effects of debonding of the PBO tendon within its sleeve. Analysis to date has used a material model for the polyethylene shell film developed by Dr Rand of Winzen Engineering, supported by a program of fine resolution material tests at the Balloon Research and Development Laboratory (BRDL) at the GSFC Wallops Island Facility. Based upon work first reported by Schapery, this model has been incorporated into so-called 'snapshot' analyses within inTENS. For a given elapsed time point and temperature distribution, non-linear material properties are iteratively updated for the current stress state in each individual element until changes in those material properties are insignificant. This process has to be iterative as the film stresses and material properties are interdependent. Attempts to derive a time-stepping incremental viscoelastic capability using the Schapery Rand model encountered problems when dealing with the varying temperatures associated with balloon deployment, pressurisation and diurnal behaviour. An alternative approach has been developed by Pellegrino et al at Caltech, again with support from the NASA Balloon Program Office. This is a large strain non-linear viscoelastic model that includes film out-of-plane mechanical and thermal effects. Working from a unified base, this model can be utilised for time-stepping analyses in both a modulus or compliance mode, or a combination of both. This new capability is intended to enhance the current NASA balloon design process. This paper presents the implementation of the Caltech model into a specialist finite element suite, inTENS and its application to whole flight simulations.

Wakefield, David↗

DOE OSTI2024

Heat transfer optimization of uo 2 -mo fuel using genetic algorithms

Two genetic algorithm (GA) methods were applied to thermal finite element models to optimize the heat transfer efficacy of a UO 2 -Mo composite fuel pellet with typical pressurized water reactor fuel geometry. Mo additions to UO 2 have been shown to increase the thermal conductivity, thus reducing centerline temperatures and temperature gradients. Previous studies evaluated uniformly dispersed Mo or continuous Mo internal geometries (e.g., fins, plates, discs) that were selected using engineering intuition. The current study uses two different implementations of the same GA to optimize Mo placement and minimize the fuel temperature with the only constraint being a maximum 10% Mo volume fraction. One approach superimposed Mo line elements onto the monolithic UO 2 pellet model, and the other converted entire UO 2 volume elements to Mo. The former method generated 1D heat transfer connections between nodes, whereas the latter method allowed for the formation of 3D structures. Features of the optimal fuel design produced by the GAs included dispersed Mo near the centerline that shifted the peak fuel temperature outward by 0.6 mm, Mo chains in the high-heat-flux region in the mid-to-outer radial zone, and a large continuous structure that spanned the full radius and height of the pellet and accounted for 87.7 % of the total Mo in the pellet. Analysis of this design indicates that the optimal Mo configuration is a balance between creating continuous heat transfer pathways and optimally dispersing Mo to minimize the heat transfer distance through UO 2 . This architecture ultimately produced an effective thermal conductivity of 11.3 W/m·K under the assumed boundary conditions. This result is higher than any previous values from the literature. In conclusion, potential fabrication methods and challenges are discussed in addition to the implications on fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2004

Effects of Subsurface Sampling & Processing on Martian Simulant Containing Varying Quantities of Water

The presence of water-ice in the Martian subsurface is a subject of much debate and excited speculation. Recent results from the gammaray spectrometer (GRS) on board NASA's Mars Odyssey spacecraft indicate the presence of large amounts of hydrogen in regions of predicted ice stability. The combination of chemistry, low gravitational field (3.71 m/s(exp 2)) and a surface pressure of about 6.36 mbar at the mean radius, place limits on the stability of H2O on the surface, however, results from the GRS indicate that the hydrogen rich phase may be present at a depth as shallow as one meter in some locations on Mars. The potential for water on Mars leads directly to the speculation that life may once have existed there, since liquid water is the unifying factor for environments known to support life on Earth. Lubricant-free drilling has been considered as a means of obtaining water-rich subsurface samples on Mars, and two recent white papers sponsored by the Mars Program have attempted to identify the problems associated with this goal. The two major issues identified were: the engineering challenges of drilling into a water-soil mixture where phase changes may occur; and the potential to compromise the integrity of in-situ scientific analysis due to contamination, volatilization, and mineralogical or chemical changes as a result of processing. This study is a first attempt to simulate lubricantfree drilling into JSC Mars-1 simulant containing up to 50% water by weight. The goal is to address the following: 1) Does sample processing cause reactions or changes in mineralogy which will compromise the interpretation of scientific measurements conducted on the surface? 2) Does the presence of water-ice in the sample complicate (1)? 3) Do lubricant-free drilling and processing leave trace contaminants which may compromise our understanding of sample composition? 4) How does the torque/power required for drilling change as a function of water content and does this lead to unexpected thermal effects?

Menard, J.↗