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Presentation as part of the Commissariat à l'énergie atomique et aux énergies alternatives (CEA), Idaho National Laboratory, and Advanced Fuels Campaign meeting. This meeting is in support of a bilateral between the United States and France.
Microbial biomanufacturing is important to accelerate lunar construction because it can leverage lunar material and waste streams as feedstocks to create a circular production system. In-space bio-mining and biomanufacturing using moon and asteroidal source material will enable the creation of infrastructure, produce industrial fuels and lubricants, and enable recovery of actinides and rare-earth elements (REEs) present in trace concentrations. Moreover, biomanufacturing in closed-loop systems (recycling and reuse of resources toward the establishment of a circular economy) will enable long-term lunar activities by recycling waste (CO 2 , gray water) and producing oxygen and biomaterials. Our response focuses on the use of lunar regolith and waste streams as feedstocks for protein and microbial-enabled biomining and bioprocessing to extract actinides and REEs, and to create biocomposites for lunar infrastructure. We envision an enclosed process that initiates with (1a) extracting actinides and REEs from lunar regolith using immobilized proteins, followed by (1b) creating biocomposites from the post-extracted lunar regolith for infrastructure, and (1c) cultivating diatoms and other microalgae on waste streams to harvest silica shells for incorporating into biocomposites and to generate O 2 for human respiration and/or producing refinable feedstocks. LLNL has significant expertise in all three processes and provides facilities, personnel, and expertise at the intersection of metal (lanthanide, actinide, transition) separations, purifications, biohydrometallurgy, radiobiochemistry, synthetic and systems biology, and materials science and engineering. Importantly, all three processes are relatively well-studied for Earth-based workflows and can be derisked for demonstration on the lunar surface by 2029.
A high-fidelity component-type model and real-time digital simulation of the General Electric T700-GE-700 turboshaft engine were developed for use with current generation real-time blade-element rotor helicopter simulations. A control system model based on the specification fuel control system used in the UH-60A Black Hawk helicopter is also presented. The modeling assumptions and real-time digital implementation methods particular to the simulation of small turboshaft engines are described. The validity of the simulation is demonstrated by comparison with analysis-oriented simulations developed by the manufacturer, available test data, and flight-test time histories.
Efforts to improve the characteristics of fuel-oxidizer mixing in liquid rocket combustors have lead to a swirl element design for a liquid oxygen injector which is being considered for use on the STME. For the design which is the subject of this investigation, the oxygen enters the injector element perpendicular to the injector axis and nearly tangent to the circular injector wall. This swirl element is at one end of a tube and the injector exit is at the other. This geometric configuration creates a plume in the shape of a conical sheet. This sheet is either primarily contiguous liquid or droplets depending on the pressure drop in the injector and the distance from the injector exit. Probe-based devices such as two-dimensional grid patternators have been used to investigate simulated LOX injector flow fields (Hulka). The primary work described herein is an effort to use optical techniques to investigate the plume of a swirl injector element. For this investigation, a high pressure (500 psig) cold flow test facility was constructed. Water was used as the LOX simulate and air pressure was used to drive the injector flow field. Laser-induced fluorescence (LIF) from dye seeded into the water was used to obtain quantitative measurements of the time-averaged water concentration distribution in the plume. Scattered laser light and LIF were used for time averaged plume visualization and scattered light from a strobe with a 1 microsecond pulse was used for time-resolved plume visualization. During the Summer Faculty Fellowship for which this report was developed, an additional effort, unrelated to the swirl injector investigation, was made to resolve fluctuations in the combustion product composition in the exhaust of a hybrid rocket motor. A brief description of this effort is included herein.
Nonlinear finite-element structural analyses were performed on the first stage high-pressure fuel turbopump blade of the Space Shuttle Main Engine. The analyses examined the structural response and the dynamic characteristics at typical operating conditions. Single crystal material PWA-1480 was considered for the analyses. Structural response and the blade natural frequencies with respect to the crystal orientation were investigated. The analyses were conducted based on typical test stand engine cycle. Influence of combined thermal, aerodynamic, and centrifugal loadings was considered. Results obtained showed that the single crystal secondary orientation effects on the maximum principal stresses are not highly significant.
Aluminum combined with oxygen has been proposed as a potential lunar in situ propellant for ascent/descent and return missions for future lunar exploration. Engine concepts proposed to use this propellant have not previously been demonstrated, and the impact on performance from combustion and two-phase flow losses could only be estimated. Therefore, combustion tests were performed for aluminum and aluminum/magnesium alloy powders with oxygen in subscale heat-sink rocket engine hardware. The metal powder was pneumatically injected, with a small amount of nitrogen, through the center orifice of a single element O-F-O triplet injector. Gaseous oxygen impinged on the fuel stream. Hot-fire tests of aluminum/oxygen were performed over a mixture ratio range of 0.5 to 3.0, and at a chamber pressure of approximately 480 kPa (70 psia). The theoretical performance of the propellants was analyzed over a mixture ratio range of 0.5 to 5.0. In the theoretical predictions the ideal one-dimensional equilibrium rocket performance was reduced by loss mechanisms including finite rate kinetics, two-dimensional divergence losses, and boundary layer losses. Lower than predicted characteristic velocity and specific impulse performance efficiencies were achieved in the hot-fire tests, and this was attributed to poor mixing of the propellants and two-phase flow effects. Several tests with aluminum/9.8 percent magnesium alloy powder did not indicate any advantage over the pure aluminum fuel.
A thermal evaluation of a composite tank wall design for a liquid hydrogen tank was performed in the present study. The primary focus of the current effort was to perform one-dimensional, temperature nonlinear, transient thermal analyses to determine the through-the-thickness temperature profiles. These profiles were used to identify critical points within the flight envelope that could have detrimental effects on the adhesive bondlines used in the construction of the tank wall. Additionally, this paper presents the finite element models, analysis strategies, and thermal analysis results that were determined for several vehicle flight conditions. The basic tank wall configuration used to perform the thermal analyses consisted of carbon-epoxy facesheets and a Korex honeycomb core sandwich that was insulated with an Airex cryogenic foam and an Alumina Enhanced Thermal Barrier (AETB-12). Nonlinear, transient thermal analyses were conducted using the ABAQUS finite element code. Tank wall models at a windward side location on the fuel tank were analyzed for three basic flight conditions: cold-soak (ground-hold), ascent, and re-entry. Additionally, three ambient temperature boundary conditions were applied to the tank wall for the cold-soak condition, which simulated the launch pad cooldown process. Time-dependent heating rates were used in the analyses of the ascent and reentry segments of the flight history along with temperature dependent material properties. The steady-state through-the-thickness temperature profile from the cold-soak condition was used as the initial condition for the ascent analyses. Results from the nonlinear thermal analyses demonstrated very good correlation with results from similar models evaluated by Northrop- Grumman using a different analysis tool. Wall through-the-thickness temperature gradients as a function of flight time were obtained for future incorporation into a full-scale thermostructural analysis to evaluate the adhesive bondlines. As a result of the thermal analyses conducted, a sufficient level of confidence was demonstrated in the thermal modeling and analysis capabilities of ABAQUS to warrant future use as a thermo-structural analysis tool to evaluate cryogenic tank wall designs.
NASA's Pulsed Plasma Thruster Program consists of flight demonstration experiments, base research, and development efforts being conducted through a combination of in-house work, contracts, and collaborative programs. The program receives sponsorship from Energetics Project, the New Millennium Program, and the Small Business Innovative Research Program. The Energetics Project sponsors basic and fundamental research to increase thruster life, improve thruster performance, and reduce system mass. The New Millennium Program sponsors the in-orbit operation of the Pulsed Plasma Thruster experiment on the Earth Observing 1 spacecraft. The Small Business Innovative Research Program sponsors the development of innovative diamond-film capacitors, piezoelectric ignitors, and advanced fuels. Programmatic background, recent technical accomplishments, and future activities for each programmatic element are provided.
Sprays occur in a wide variety of industrial and power applications and in the processing of materials. A liquid spray is a phase flow with a gas as the continuous phase and a liquid as the dispersed phase (in the form of droplets or ligaments). Interactions between the two phases, which are coupled through exchanges of mass, momentum, and energy, can occur in different ways at different times and locations involving various thermal, mass, and fluid dynamic factors. An understanding of the flow, combustion, and thermal properties of a rapidly vaporizing spray requires careful modeling of the rate-controlling processes associated with the spray's turbulent transport, mixing, chemical kinetics, evaporation, and spreading rates, as well as other phenomena. In an attempt to advance the state-of-the-art in multidimensional numerical methods, we at the NASA Lewis Research Center extended our previous work on sprays to unstructured grids and parallel computing. LSPRAY, which was developed by M.S. Raju of Nyma, Inc., is designed to be massively parallel and could easily be coupled with any existing gas-phase flow and/or Monte Carlo probability density function (PDF) solver. The LSPRAY solver accommodates the use of an unstructured mesh with mixed triangular, quadrilateral, and/or tetrahedral elements in the gas-phase solvers. It is used specifically for fuel sprays within gas turbine combustors, but it has many other uses. The spray model used in LSPRAY provided favorable results when applied to stratified-charge rotary combustion (Wankel) engines and several other confined and unconfined spray flames. The source code will be available with the National Combustion Code (NCC) as a complete package.
An explicit material model that uses predicted pressure in the pores of a carbon-cloth phenolic (CCP) composite has been developed. This model is intended to be used within a finite-element model to predict phenomena specific to CCP components of solid-fuel-rocket nozzles subjected to high operating temperatures and to mechanical stresses that can be great enough to cause structural failures. Phenomena that can be predicted with the help of this model include failures of specimens in restrained-thermal-growth (RTG) tests, pocketing erosion, and ply lifting
The Aviation Safety Reporting System (ASRS) in a partnership between the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), participating carriers, and labor organizations. It is designed to improve the National Airspace System by collecting and studying reports detailing unsafe conditions and events in the aviation industry. Employees are able to report safety issues or concerns with confidentiality and without fear of discipline. Safety reports highlighting fuel policies and alternate requirements for the aviation community highlight the human element in the complex aviation system.
Molten salt reactors (MSRs) are among the most promising Generation IV nuclear reactors. The salts used in these reactors exhibit a high affinity for moisture and oxygen, and heating does not eliminate the oxides that are formed. Additionally, due to the high operating temperatures, reactor parts experience pronounced corrosion, and the resulting corrosion products integrate into the fuel salt system. It is hypothesized that the speciation of f-elements in molten salts would change in the presence of oxides and corrosion products. These changes in local structure can alter the rheological properties, which are critical to the operational and safety parameters of the reactors. Therefore, an in-depth understanding of how corrosion products influence lanthanide/actinide speciation is crucial. To test this hypothesis, lanthanides (as surrogates for actinides) and actinide chlorides were mixed with oxides (such as nickel oxide and lithium oxide) and/or corrosion products (e.g., nickel chloride) and reacted in molten salts. The resulting phases were analyzed using techniques such as powder X-ray diffraction, Raman spectroscopy, UV-Visible spectroscopy, and nuclear magnetic resonance spectroscopy. In the presence of oxides, due to the high oxophilicity of f-elements, these elements capture oxygen from the oxides, forming lanthanide/actinide oxide or oxychloride phases. Specifically, with cerium chloride, the introduction of lithium oxide to the formation of various final products depending on the oxide concentration. At lower oxide concentrations, cerium oxychloride (CeOCl) in the +3 oxidation state was observed, while an increase in the oxide concentration led to the formation of cerium dioxide (CeO2), where cerium is in the +4 oxidation state. In contrast, with nickel oxide, CeOCl formation was consistently observed, regardless of the oxide concentration. This project successfully determined that the speciation of f-elements change in the presence of oxides and different oxides in molten salts result in different final products. When the influence of nickel chloride was examined, changes in f-element speciation were not observed. However, it reacted with lithium chloride to generate a lithium-nickel-chloride (Li6NiCl8) phase, which was also observed when nickel oxide was reacted. Computational models were developed to simulate the phases anticipated under experimental conditions.
As the nuclear energy sector advances toward next-generation reactors, the need for high-performance fuel cladding materials has become increasingly urgent. Traditional alloys like zirconium and stainless steel are reaching their performance limits under higher temperatures, more corrosive coolants, and extended irradiation. This report presents the development of a new class of fuel cladding materials based on Non-Concentrated Alloys (NCAs) ? multi-element systems designed to deliver enhanced mechanical strength, corrosion resistance, and radiation tolerance. Through a combination of computational modeling (Computer Coupling of Phase Diagrams and Thermochemistry: CALPHAD), simulation-guided alloy selection, and experimental fabrication via arc melting and spark plasma sintering (SPS), three strategic alloy design paths were explored: (1) FeCrAl-based NCAs, (2) refractory-lean neutron-efficient alloys, and (3) equimolar high-entropy compositions. Microstructural analysis confirmed the formation of stable body-centered cubic BCC_A2 phases, while mechanical testing demonstrated hardness values significantly exceeding those of conventional cladding materials. The results highlight the tunability of NCA systems and their potential for balancing strength and ductility ? a critical consideration for in-reactor performance. Looking forward, future work will focus on thermomechanical optimization, CALPHAD refinement, and benchmarking against industry standards to enable scalable deployment. This work not only advances the science of nuclear materials but also supports broader goals in nuclear safety, performance, and nuclear energy innovation.
The purpose of the project was to: Develop a finite element thermal model of the General Purpose Heat Source (GPHS) Module loaded with four fueled clads; Perform steady state analysis to validate the thermal model via energy balance; Perform transient thermal analysis to predict clad temperatures at various times; and, Transient model results will be used to inform module soak time needed to reach a desired clad temperature prior to impact.
Two short turbojet combustors designed for use with vaporized hydrocarbon fuels were tested in a one-quarter annular duct. The experimental combustors consisted of many small "swirl-can" combustor elements manifolded together. This design approach allowed the secondary mixing zone to be considerably reduced over that of conventional combustors. The over-all combustion lengths, for the two configurations were 13.5 and 11.0 inches, approximately one-half the length of the shortest conventional combustors. These short combustors did not provide combustion efficiencies as high as those for conventional combustors at low pressures. However, over the range of combustor-inlet total-pressures expected in aircraft capable of flight at Mach numbers of 2.5 and above, these short combustors gave very high efficiencies. A combustion efficiency of 97 percent was obtained at a combustor-inlet total-pressure of 25.0 inches of mercury absolute, reference velocity of 120 feet per second, and inlet-air total temperature of 1160 deg R. By proportioning the fuel flow between the manifold rows of can combustor elements, control of the combustor-outlet radial total-temperature profile was demonstrated. Combustor totalpressure loss varied from 0.75 percent of the inlet total pressure at isothermal conditions and a reference velocity of 75 feet per second to 5.5 percent at a total-temperature ratio of 1.8 and a reference velocity of 180 feet per second.
Optical sensors and chemometric models were leveraged for the quantification of uranium(VI) (0–100 μg mL –1 ), europium (0–150 μg mL –1 ), samarium (0–250 μg mL –1 ), praseodymium (0–350 μg mL –1 ), neodymium (0–1000 μg mL –1 ), and HNO 3 (2–4 M) with varying corrosion product (iron, nickel, and chromium) levels using laser fluorescence, Raman scattering, and ultraviolet–visible–near-infrared absorption spectra. In this paper, an efficient approach to developing and evaluating tens of thousands of partial least-squares regression (PLSR) models, built from fused optical spectra or multimodal acquisitions, is discussed. Each PLSR model was optimized with unique preprocessing combinations, and features were selected using genetic algorithm filters. The 7-factor D-optimal design training set contained just 55 samples to minimize the number of samples. The performance of PLSR models was evaluated by using an automated latent variable selection script. PLS1 regression models tailored to each species outperformed a global PLS2 model. PLS1 models built using fused spectra data and a multimodal (i.e., analyzed separately) approach yielded similar information, resulting in percent root-mean-square error of prediction values of 0.9–5.7% for the seven factors. Further, the optical techniques and data processing strategies established in this study allow for the direct analysis of numerous species without measuring luminescence lifetimes or relying on a standard addition approach, making it optimal for near-real-time, in situ measurements. Nuclear reactor modeling helped bound training set conditions and identified elemental ratios of lanthanide fission products to characterize the burnup of irradiated nuclear fuel. Leveraging fluorescence, spectrophotometry, experimental design, and chemometrics can enable the remote quantification and characterization of complex systems with numerous species, monitor system performance, help identify the source of materials, and enable rapid high-throughput experiments in a variety of industrial processes and fundamental studies.
The separation of U from Tc and other problematic fission product elements like Mo and Ru, along with Sr, Zr, Cs, and Nd, has been achieved via the crystallization of uranyl nitrate hexahydrate (UNH). Rejection of technetium as pertechnetate anion ( 99 TcO 4 – ) is an especially important feature of this system, as it otherwise tends to follow U (VI) in extractive separations. It also raises the salient question regarding why this oxoanion cannot replace nitrate within the crystalline lattice of UNH. Results showed high-yield (>90 %), high-purity (>99 %) recovery of U as UNH from solutions containing 99 TcO 4 – by simple reduction of temperature from 60°C to 20°C. There was no observable interaction of 99 TcO 4 – with UO 2 2+ . The addition of other cations like, Sr 2+ , Zr 4+ , Cs + , and Nd 3+ , also did not form secondary, contaminant solid phases, leaving the > 99 % of the fission product elements in the mother liquor, while the U was recovered at > 90 %. Similarly, Mo and Ru, when added to the mixture, were shown to behave as the other fission-product elements, remaining in the mother liquor during crystallization. As a result, DFT calculations showed that, despite the higher binding strength of TcO 4 – , HMoO 4 – , and BiO 3 – with the UO 2 2+ cation compared to NO 3 – , the hydrogen-bonding network of the two coordinated ions and four waters of hydration in the UNH crystal structure is the driving force for the high specificity of this separation.
A computational study has been performed to better understand the mixing characteristics of liquid rocket injector elements. Variations in injector geometry as well as differences in injector element inlet flow conditions are among the areas examined in the study. Most results involve the nonreactive mixing of gaseous fuel with gaseous oxidizer but preliminary results are included that involve the spray combustion of oxidizer droplets. The purpose of the study is to numerically predict flowfield behavior in individual injector elements to a high degree of accuracy and in doing so to determine how various injector element properties affect the flow.