Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “High Temperature Materials Development”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,009 records · Page 56

SHARP-B2: Flight Test Objectives, Project Implementation and Initial Results

On September 28, 2000 the SHARP-B2 flight experiment was launched from Vandenberg Air Force Base, California. SHARP-B2 is the 2nd Ballistic flight test in the SHARP (Slender Hypervelocity Aerothermodynamic Research Probes) program which develops and tests new thermal protection materials and sharp body concepts. The flight tested Ultra-High Temperature Ceramics (UHTCs), which may radically change the design and performance of future aerospace vehicles. The new designs may overturn an age-old tenet of aerodynamics: that blunt-body aerospace vehicles, but not those with sharp leading edges, can survive the searing temperatures created as the vehicles tear through the atmosphere. Sharp leading edges offer numerous advantages over the blunt-body design currently in use. They could allow a space shuttle or crew return vehicle to maneuver in space more like an airplane and potentially allow astronauts to return to Earth from anywhere on orbit. They may allow improved astronaut safety by decreasing the risk of aborting into the ocean. They may reduce the electromagnetic interference that causes the communications blackouts that plague reentering blunt-body space vehicles. Reducing the amount of drag could lead to a reduction in propulsion requirements. Planetary probes could make use of sharp-body technology for aerobraking and to maximize their maneuvering capability. SHARP-B2 was a joint effort among NASA Ames, Sandia National Laboratories, the U.S. Air Force and the U.S. Army. It was funded by the Pathfinder Program at NASA's Marshall Space Flight Center. The SHARP-B2 payload was carried aboard a U.S. Air Force Minuteman III missile carrying a modified Mk 12A reentry vehicle (RV), which blasted off from Vandenberg Air Force Base near Lompoc, CA, at 3:01 a.m. PDT on Sept. 28. The RV was equipped with four 5. 1 inch-long strakes, or sharp leading edges. Each strake contained three UHTCs: ZrB2/SiC/C; ZrB2/SiC; and HfB2/SiC. Once it reached an altitude of about 400 nautical miles, the RV was released, returning through Earth's atmosphere at speeds exceeding Mach 22. One pair of strakes was designed to retract just before reaching temperatures high enough to cause the material to begin ablating. The other pair was designed to retract shortly after ablation began, at an expected temperature of nearly 5,100 degrees Fahrenheit. Sensors in the strakes measured how closely performance matched pre-flight calculations, and data was successfully collected throughout the 23-minute flight. A parachute was deployed (but not fully inflated) and the RV splashed down in a lagoon at the Kwajalein missile range in the Pacific Ocean. Within 3 hours radar track analysis showed ocean entry to be precisely at the latitude/longitude coordinates estimated during pre-flight simulation. An hour later a ship was deployed by the Army to recover the reentry vehicle, which was recovered in 165 feet of water, just 500 feet from its planned splash-down point. This is the first RV recovery in over a decade.

Salute, Joan↗

NASA GRC Stirling Technology Development Overview

The Department of Energy, Lockheed Martin (LM), Stirling Technology Company, and NASA Glenn Research Center (GRC) are developing a high-efficiency Stirling Radioisotope Generator (SRG) for potential NASA Space Science missions. The SRG is being developed for multimission use, including providing spacecraft onboard electric power for NASA deep space missions and power for unmanned Mars rovers. NASA GRC is conducting an in- house supporting technology project to assist in developing the Stirling convertor for space qualification and mission implementation. Preparations are underway for a thermalhacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. Heater head life assessment efforts continue, including verification of the heater head brazing and heat treatment schedules and evaluation of any potential regenerator oxidation. Long-term magnet aging tests are continuing to characterize any possible aging in the strength or demagnetization resistance of the permanent magnets used in the linear alternator. Testing of the magnet/lamination epoxy bond for performance and lifetime characteristics is now underway. These efforts are expected to provide key inputs as the system integrator, LM, begins system development of the SRG. GRC is also developing advanced technology for Stirling convertors. Cleveland State University (CSU) is progressing toward a multi-dimensional Stirling computational fluid dynamics code, capable of modeling complete convertors. Validation efforts at both CSU and the University of Minnesota are complementing the code development. New efforts have been started this year on a lightweight convertor, advanced controllers, high-temperature materials, and an end-to-end system dynamics model. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems.

Thieme, Lanny G.↗

Integrated Liquid Bismuth Propellant Feed System

A prototype bismuth propellant feed and control system was constructed and tested. An electromagnetic pump was used in this system to provide fine control of the hydrostatic pressure, and a new type of in-line flow sensor was developed to provide an accurate, real-time measurement of the mass flow rate. High-temperature material compatibility was a driving design requirement for the pump and flow sensor, leading to the selection of macor for the main body of both components. Post-test inspections of both components revealed no cracks or leaking in either. In separate proof-of-concept experiments, the pump produced a linear pressure rise as a function of current that compared favorably with theoretical pump pressure predictions, with a pressure of 10 kPa at 30 A. Flow sensing was successfully demonstrated in a bench-top test using gallium as a substitute liquid metal. A real-time controller was successfully used to control the entire system, simultaneously monitoring all power supplies and performing data acquisition duties.

Polzin, Kurt A.↗

Quench Crucibles Reinforced with Metal

Improved crucibles consisting mainly of metal-reinforced ceramic ampules have been developed for use in experiments in which material specimens are heated in the crucibles to various high temperatures, then quenched by, for example, plunging the crucibles into water at room temperature. In a traditional quench crucible, the gap between the ampule and the metal cartridge impedes the transfer of heat to such a degree that the quench rate (the rate of cooling of the specimen) can be too low to produce the desired effect in the specimen. One can increase the quench rate by eliminating the metal cartridge to enable direct quenching of the ampule, but then the thermal shock of direct quenching causes cracking of the ampule. In a quench crucible of the present improved type, there is no gap and no metal cartridge in the traditional sense. Instead, there is an overlay of metal in direct contact with the ampule, as shown on the right side of the figure. Because there is no gap between the metal overlay and the ampule, the heat-transfer rate can be much greater than it is in a traditional quench crucible. The metal overlay also reinforces the ampule against cracking.

Holmes, Richard R.↗

Performance scaling with an applied magnetic field in indirect-drive inertial confinement fusion implosions

Magnetizing a cryogenic deuterium–tritium (DT)-layered inertial confinement fusion (ICF) implosion can improve performance by reducing thermal conduction and improving DT-alpha confinement in the hot spot. A room-temperature, magnetized indirect-drive ICF platform at the National Ignition Facility has been developed, using a high-Z, high-resistivity AuTa 4 alloy as the hohlraum wall material. Experiments show a 2.5× increase in deuterium–deuterium (DD) neutron yield and a 0.8-keV increase in hot-spot temperature with the application of a 12-T B-field. Further, for an initial 26-T B-field, we observed a 2.9× yield increase and a 1.1-keV temperature increase, with the inferred burn-averaged B-field in the compressed hot spot estimated to be 7.1 ± 1.8 kT using measured primary DD-n and secondary DT-n neutron yields.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Evaluation of microstructure anisotropy on room and medium temperature ECAP deformed F138 steel

The microstructure developed during severe plastic deformation results in improved mechanical properties because of the decrease in domain sizes and accumulation of defects, mainly dislocation arrays. The characteristic deformation stages observed in low stacking fault energy (SFE) face centered cubic (FCC) materials are highly influenced by the development of the primary and secondary twinning that compete with dislocation glide. In this paper, a low SFE F138 stainless steel is deformed by equal channel angular pressing (ECAP) up to 4 passes at room temperature (RT) and at 300 °C to compare the grain refinement and twin boundary development with increasing deformation. Tensile tests were performed to determine the deformation stages reached by the material before and after ECAP deformation, and the resulting microstructure was observed by TEM. X-ray diffraction and EBSD, average technique the first and local the second one, were used to quantify the microstructural changes, allowing the determination of diffraction domain sizes, dislocation and stacking fault densities and misorientation indices, which lead to a complete analysis of the deformation introduced in the material, with comparative correlations between various microstructural parameters. - Highlights: • The microstructure of ECAP pressed F138 steel was studied using TEM, EBSD and XRD. • Increasing deformation reduced domain sizes and increased dislocation densities. • Dislocation array compactness and misorientation increased with higher deformation. • Largest dislocation densities, mostly screw, match with simultaneous activation of twins. • Several correlations among microstructural features and parameters have been disclosed.

36 MATERIALS SCIENCE↗

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.↗

Sub-picowatt resolution calorimetry with niobium nitride thin-film thermometer

High-resolution calorimetry has many important applications such as probing nanoscale thermal transport and studying the thermodynamics of biological and chemical systems. In this work, we demonstrated a calorimeter with an unprecedentedly high resolution at room temperature using a high-performance resistive thermometry material, niobium nitride (NbN{sub x}). Based on a theoretical analysis, we first showed that the heat flux resolution of a resistive-thermometry based calorimeter depends on the parasitic thermal conductance of the device and the temperature coefficient of resistance (TCR) of the thermometer, when the noise is limited by the Johnson noise. Based on this analysis, we then developed a calorimeter using NbN{sub x} as the thermometry material because it possesses both high TCR (∼0.67%/K) and a low thermal conductivity (k ∼ 1.1 W/m K). This calorimeter, when used with the modulated heating scheme, demonstrated an unprecedentedly high power resolution of 0.26 pW at room temperature. In addition, NbN{sub x} based resistive thermometry can also be extended to cryogenic temperature, where the TCR is shown to be significantly higher.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Weld Development of FeCrAl Thin-Wall Cladding for LWR Accident Tolerant Fuel

The development of new cladding materials to replace Zr-based cladding for light water reactors (LWRs) has been actively pursued with improved high-temperature oxidation resistance to significantly suppress hydrogen production from an accident such as a loss of coolant event. FeCrAl alloy with a typical composition of approximately Fe-15Cr-5Al has been selected as a candidate material because of its improved high-temperature oxidation resistance over the present LWR zircaloy cladding. As a result of higher thermal neutron absorption for FeCrAl alloy, the cladding wall thickness needs to be reduced by approximately half compared to that of Zircaloy cladding to be comparable to the current LWR fuel performance under the normal operating condition. New weld techniques for joining the endplug to thin-walled cladding need to be developed. Both laser beam weld and pressure resistance weld were employed. This paper summarizes the recent progress on the laser weld development for FeCrAl cladding with 350 µm wall thickness. The results of microstructural characterization and mechanical property testing of the weld for the cladding-endplug set are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Multiscale study of helium diffusion in Ni-Cr alloys: Short-range trapping versus long-range channeling

Ni-Cr alloys are widely employed as structural materials in fast nuclear reactors but are vulnerable to high-temperature helium (He) embrittlement (HTHE) under fast neutron irradiation. A comprehensive understanding of He diffusion in Ni-Cr alloys, which governs the kinetics of HTHE, is therefore essential for developing resilient materials and preventing failure. In this work, we reveal the underlying mechanisms of He diffusion in pure Ni and Ni-Cr alloys by integrating density functional theory (DFT) with atomic kinetic Monte Carlo (AKMC) simulations. Our findings uncover a non-monotonic dependence of He diffusivity on Cr concentration, contradicting the monotonic trends predicted by DFT-parameterized theories. At low Cr concentrations, He diffusion is dominated by short-range trapping, characterized by multiple trapping sites and a distinct mechanism within the first nearest neighbor of Cr, differing from that in pure Ni. At high Cr concentrations, these local traps become interconnected, forming long-range fast diffusion channels that enhance He mobility. The competition between localized trapping and extended channeling results in a diffusivity that first decreases, then increases with rising Cr content. These atomic-scale insights offer critical guidance for the design of radiation-tolerant Ni-based alloys. Moreover, the combined DFT-AKMC methodology and the concept of random walker diffusion through interconnected energy basins present a broadly applicable framework for studying transport phenomena in disordered systems.

36 - MATERIALS SCIENCE↗

Technique development for modulus, microcracking, hermeticity, and coating evaluation capability characterization of SiC/SiC tubes

Driven by the need to enlarge the safety margins of nuclear fission reactors in accident scenarios, research and development of accident-tolerant fuel has become an important topic in the nuclear engineering and materials community. A continuous-fiber SiC/SiC composite is under consideration as a replacement for traditional zirconium alloy cladding owing to its high-temperature stability, chemical inertness, and exceptional irradiation resistance. An important task is the development of characterization techniques for SiC/SiC cladding, since traditional work using rectangular bars or disks cannot directly provide useful information on the properties of SiC/SiC composite tubes for fuel cladding applications. At Oak Ridge National Laboratory, experimental capabilities are under development to characterize the modulus, microcracking, and hermeticity of as-fabricated, as-irradiated SiC/SiC composite tubes. Resonant ultrasound spectroscopy has been validated as a promising technique to evaluate the elastic properties of SiC/SiC composite tubes and microcracking within the material. A similar technique, impulse excitation, is efficient in determining the basic mechanical properties of SiC bars prepared by chemical vapor deposition; it also has potential for application in studying the mechanical properties of SiC/SiC composite tubes. Complete evaluation of the quality of the developed coatings, a major mitigation strategy against gas permeation and hydrothermal corrosion, requires the deployment of various experimental techniques, such as scratch indentation, tensile pulling-off tests, and scanning electron microscopy. In addition, a comprehensive permeation test station is being established to assess the hermeticity of SiC/SiC composite tubes and to determine the H/D/He permeability of SiC/SiC composites. This report summarizes the current status of the development of these experimental capabilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Metal Hydride Thermal Storage: Reversible Metal Hydride Thermal Storage for High-Temperature Power Generation Systems

HEATS Project: PNNL is developing a thermal energy storage system based on a Reversible Metal Hydride Thermochemical (RMHT) system, which uses metal hydride as a heat storage material. Heat storage materials are critical to the energy storage process. In solar thermal storage systems, heat can be stored in these materials during the day and released at night—when the sun is not out—to drive a turbine and produce electricity. In nuclear storage systems, heat can be stored in these materials at night and released to produce electricity during daytime peak-demand hours. PNNL’s metal hydride material can reversibly store heat as hydrogen cycles in and out of the material. In a RHMT system, metal hydrides remain stable in high temperatures (600- 800°C). A high-temperature tank in PNNL’s storage system releases heat as hydrogen is absorbed, and a low-temperature tank stores the heat until it is needed. The low-cost material and simplicity of PNNL’s thermal energy storage system is expected to keep costs down. The system has the potential to significantly increase energy density.

ARPA-E↗

Evaluation of Engineered Barrier Systems (FY19 Report)

This report describes research and development (R&D) activities conducted during fiscal year 2019 (FY19) specifically related to the Engineered Barrier System (EBS) R&D Work Package in the Spent Fuel and Waste Science and Technology (SFWST) Campaign supported by the United States (U.S.) Department of Eneregy (DOE). The R&D activities focus on understanding EBS component evolution and interactions within the EBS, as well as interactions between the host media and the EBS. A primary goal is to advance the development of process models that can be implemented directly within the Genreric Disposal System Analysis (GDSA) platform or that can contribute to the safety case in some manner such as building confidence, providing further insight into the processes being modeled, establishing better constraints on barrier performance, etc.The FY19 EBS activities involved not only modeling and analysis work, but experimental work as well. The report documents the FY19 progress made in seven different research areas as follows: (1) thermal analysis for the disposal of dual purpose canisters (DPCs) in sedimentary host rock using the semianalytical method, (2) tetravalent uranium solubility and speciation, (3) modeling of high temperature, thermal-hydrologic-mechanical-chemical (THMC) coupled processes, (4) integration of coupled thermalhydrologic- chemical (THC) model with GDSA using a Reduced-Order Model, (5) studying chemical controls on montmorillonite structure and swelling pressure, (6) transmission x-ray microscope for in-situ nanotomography of bentonite and shale, and (7) in-situ electrochemical testing of uranium dioxide under anoxic conditions. The R&D team consisted of subject matter experts from Sandia National Laboratories, Lawrence Berkeley National Laboratory (LBNL), Los Alamos National Laboratory (LANL), Pacific Northwest National Laboratory (PNNL), the Bureau de Recherches Géologiques et Minières (BRGM), the University of California Berkeley, and Mississippi State University. In addition, the EBS R&D work leverages international collaborations to ensure that the DOE program is active and abreast of the latest advances in nuclear waste disposal. For example, the FY19 work on modeling coupled THMC processes at high temperatures relied on the bentonite properties from the Full-scale Engineered Barrier EXperiment (FEBEX) Field Test conducted at the Grimsel Test Site in Switzerland. Overall, significant progress has been made in FY19 towards developing the modeling tools and experimental capabilities needed to investigate the performance of EBS materials and the associated interactions in the drift and the surrounding near-field environment under a variety of conditions including high temperature regimes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of High Temperature Out-of-Pile Experiments for Testing Nuclear Thermal Propulsion Fuel Surrogates

Nuclear thermal propulsion (NTP) technology is designed to provide “in-space” vehicle propulsion by deriving thrust from a hydrogen working fluid that is heated from a nuclear reaction. Initial NTP fuel structures (primarily carbon/carbide based materials) developed by the Rover/NERVA program were designed to withstand temperatures exceeding 2400 K and remain intact after tens of firing cycles. Current programs responsible for development of this technology expect the fuels to withstand temperatures in excess of 2550K under a similar duty cycle. Experiments that subject fuels to these conditions are being developed to provide data and performance information for optimization and potential down-selection of the candidate materials. Initial tests will be designed for laboratory benchtop operation and will not expose surrogate specimens to the hydrogen working fluid or irradiation fields. The primary focus of these out-of-pile experiments will be to study thermal performance and thermal failure limits of the candidate specimen materials.

Howard, Richard↗

Manufacturability of U{sub 3}Si{sub 2} and its high temperature oxidation behaviour

High density fuels, such as uranium silicide (U{sub 3}Si{sub 2}), are being considered alongside improved cladding materials to develop new fuels which are both economic to manufacture and demonstrate enhanced accident tolerance. Through a collaborative programme led by Westinghouse and involving national laboratories in the US and UK, efforts are being made to establish a viable route by which U{sub 3}Si{sub 2} can be manufactured and to test its suitability as a fuel. In the UK work has focused on routes to convert UF{sub 6} and UF{sub 4} to U{sub 3}Si{sub 2} directly, without needing to reduce the uranium to its metallic state. Experimental observations of reactions between UF{sub 4} and Si indicate the formation of a USi{sub 2-x} phase at a temperature of 1000 C. degrees, consistent with thermodynamic assessments. Work on the construction of a rig which will pass UF{sub 6} heated to 1000 C. degrees through a bed of finely divided Si powder, is also reported. At Westinghouse, U{sub 3}Si{sub 2} fabricated by the arc-melting process has been subjected to high temperature steam and synthetic air tests and the reaction rate measured as a function of temperature using differential scanning calorimetry. The rates are compared to UO{sub 2} and UN (Uranium mononitride). At Idaho National Laboratory irradiation testing of U{sub 3}Si{sub 2} fuel is in progress. Fuel specimens were prepared by conventional arc melting process to formulate the U{sub 3}Si{sub 2} followed by conventional powder metallurgy processes to create pellets. These irradiation tests are intended to help resolve questions concerning the swelling of U{sub 3}Si{sub 2} under conditions representative of LWR fuel. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Temperature and dose effects on dislocation loops in self-ion irradiated high-purity iron

Body-centered cubic (BCC) Fe-based alloys are promising candidate materials for advanced nuclear reactors. However, a detailed understanding of irradiation induced dislocation loop microstructure development remains unresolved. It is a widespread belief that 〈001〉 loops become increasingly favorable over ½〈111〉 loops as irradiation temperature rises above ∼300 C. Unfortunately, the temperature effects on 〈001〉 loop have been primarily examined in in-situ irradiation on TEM thin foils but poorly explored on bulk Fe due to exceedingly limited experimental studies on bulk specimens, raising concerns about the potential influence of TEM thin foil artifacts on observed results. Here, in this study, we conducted experiments on ultra-high purity BCC Fe specimens irradiated with 6.7–8 MeV Fe ions over a wide temperature range on bulk samples. We investigated the effects of temperature (T irr = 250–500 °C), dose rate (10⁻⁵ to 10⁻³ dpa/s), and dose (0.35 to 3.5 dpa) on the formation and evolution of 〈001〉 and ½〈111〉 loops as well as cavity (void) formation. Post-irradiation Burgers vector analysis via g•b method on dislocation segments and loops revealed that 〈001〉 loop fraction does not show a monotonic positive correlation with irradiation temperature. Combined with previous and current theoretical as well as experimental findings, we explore the temperature effects on all existing models of 〈001〉 loop formation. We conclude that the prevailing reports regarding the dominance of 〈001〉 loops in Fe at elevated temperatures are mainly attributable to the loss of glissile ½〈111〉 clusters in TEM thin foil experiments.

36 MATERIALS SCIENCE↗

Performance Modeling of Materials-Based Hydrogen Storage Systems for Automotive Applications

One of the challenges of fuel cell vehicles is storage of the hydrogen fuel. In an effort to reduce the temperature and pressure limitations of storing neat hydrogen either as a high pressure gas or cryogenic liquid, material-based hydrogen storage is being developed. Hydrogen stored either as an adsorbent or as a chemical compound not only provides more reasonable pressures and temperatures but also improves the storage density of the hydrogen. Modeling tools have been developed as part of the U.S. Department of Energy's Hydrogen Storage Engineering Center of Excellence to assess the performance of these materials in light duty vehicle applications. The purpose of these modeling tools is to evaluate newly developed hydrogen storage materials and ensure that they meet customer expectations for driving range and performance before further investment. Recent advances in these modeling tools have been made to allow direct material property inputs. Such material properties as hydrogen capacity, isotherms and other thermodynamic and kinetic properties can reasonably be measured by materials researchers. Using these properties as inputs, the models can then provide estimates of the mass and volume of the storage system and the driving range and fuel efficiency of the vehicle during transient operation with four different drive cycles. The system sizing estimator and the framework model used to perform this analysis will be described and results presented for adsorbents and chemical based storage materials.

25 ENERGY STORAGE↗