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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Development of an Open-source Alloy Selection and Lifetime Assessment Tool for Structural Components in CSP

Lack of sufficient data on high temperature mechanical and corrosion behavior of structural materials is a huge barrier in the technological maturity of current and future Concentrating Solar Power (CSP) technologies. Rapid development and selection of materials cannot be achieved by expensive and time-consuming acquisition of experimental data. The goal of the proposed work is development of an open-source alloy selection and lifetime prediction tool that will integrate validated physics-based models to describe influence of temperature, alloy composition, environment and component geometry (thickness) on mechanical and corrosion behavior of Ni and Fe-based alloys employed in molten salts/sCO 2 heat exchangers. This one-year project leveraged the extensive dataset on the creep\corrosion behavior of candidate materials generated at ORNL through past projects and input from current collaborations with industrial partners. Based on previous experience and the feedback provided by industry (Brayton Energy and Echogen), three candidate materials of interest, Ni-based alloys 740H, 282 and 625 and application-specific operating conditions (max. temperature of 730 °C and stress of 150 MPa) were identified for the heat exchanger. An extensive corrosion and creep dataset was assimilated for the relevant operating conditions and was supported by detailed characterization of about 100 metallographic cross-sections. The corrosion dataset consisted of scanning electron microscopy images (secondary electron and backscatter electron), measured concentration profiles of alloying elements using energy dispersive X-ray spectroscopy (EDS), widths of denuded zones (dissolution of strengthening phases) and depths of attack in molten KCl-MgCl 2 mixtures using image analyses. The creep dataset comprised of creep rupture data and creep strain curves (for 740H and 282). Coupled thermodynamic-kinetic microstructure-based models were employed to predict the stress-corrosion induced compositional and phase evolutions in the alloy during operation under the identified operating conditions. Reduced order models were developed from advanced physics-based models and were integrated in a user-friendly alloy selection tool. The corrosion model was able to predict the time to a critical Cr concentration at the oxide/alloy interface (chemical lifetime) within ±10% (1 standard deviation) of typical statistical variation in corrosion tests and EDS measurement errors (±0.5 wt%). The initial scope of the project was limited to predict creep rupture times (Larson-Miller parameter). Based on the input provided by industry, the mechanical lifetime of the heat exchanger is governed by accumulated creep strains (2%) rather than creep rupture. To be able to predict the times to specific creep strains, a more extensive creep model development was undertaken largely beyond the initial scope of the project. The continuum damage mechanics creep model was able to predict times to 2% creep strain, t 2% with an accuracy of ±500h. Ultimately, a screening protocol for SiC was generated to demonstrate the pathway for integration of one of the currently immature materials from a commercial adoption standpoint in the current material evaluation tool. The modeling tool developed here is accessible to the science community and stakeholders and lays the foundation for methods that will enable a rapid evaluation of optimum materials for CSP applications and reliable prediction of material degradation thereby considerably reducing operational costs, improving reliability and increasing overhaul intervals. However, the complete potential of such a tool to include a wider range of materials and test conditions can only be realized with a more concentrated combined experimental-characterization-computation effort.

14 SOLAR ENERGY↗
NASA NTRS1998

A Modified NASA Team Sea Ice Algorithm for the Antarctic

A recent comparative study of the NASA Team and Bootstrap passive microwave sea ice algorithms revealed significantly different sea ice concentration retrievals in some parts of the Antarctic. The study identified potential reasons for the discrepancies including the influence of sea ice temperature variability on the Bootstrap retrievals and the influence of ice surface reflectivity on the horizontally polarized emissivity in the NASA Team retrievals. In this study, we present a modified version of the NASA Team algorithm which reduces the error associated with the use of horizontally polarized radiance data, while retaining the relative insensitivity to ice temperature variations provided by radiance ratios. By retaining the 19 GHz polarization as an independent variable, we also maintain a relatively large dynamic range in sea ice concentration. The modified algorithm utilizes the 19 GHz polarization (PR19) and both gradient ratios, GRV and GRH defined by (37V-19V)/(37V+19V) and (37H-19H)/(37H+19H), respectively, rather than just GRV used in the current NASA Team algorithm. A plot of GRV versus GRH shows that the preponderance of points lie along a quadratic curve, whereas those points affected by surface reflectivity anomalies deviate from this curve. This serves as a method of identifying the problems points. The 19H brightness temperature of these problem points is increased so they too fall along quadratic curve. Sea ice concentrations derived from AVHRR imagery illustrate the extent to which this method reduces the error associated with surface layering.

Cavalieri, Donald J.↗
NASA NTRS2004

Efficiency Analysis of a High-Specific Impulse Hall Thruster

Performance and plasma measurements of the high-specific impulse NASA-173Mv2 Hall thruster were analyzed using a phenomenological performance model that accounts for a partially-ionized plasma containing multiply-charged ions. Between discharge voltages of 300 to 900 V, the results showed that although the net decrease of efficiency due to multiply-charged ions was only 1.5 to 3.0 percent, the effects of multiply-charged ions on the ion and electron currents could not be neglected. Between 300 to 900 V, the increase of the discharge current was attributed to the increasing fraction of multiply-charged ions, while the maximum deviation of the electron current from its average value was only +5/-14 percent. These findings revealed how efficient operation at high-specific impulse was enabled through the regulation of the electron current with the applied magnetic field. Between 300 to 900 V, the voltage utilization ranged from 89 to 97 percent, the mass utilization from 86 to 90 percent, and the current utilization from 77 to 81 percent. Therefore, the anode efficiency was largely determined by the current utilization. The electron Hall parameter was nearly constant with voltage, decreasing from an average of 210 at 300 V to an average of 160 between 400 to 900 V. These results confirmed our claim that efficient operation can be achieved only over a limited range of Hall parameters.

Jacobson, David↗
DOE OSTI2022

Efficient Loads Surrogates for Waked Turbines in an Array

Accurately and efficiently predicting wind turbine structural loading is a crucial step in wind farm design. Without considering structural loading, wind farm optimization could negatively impact turbine fatigue and ultimate loads, especially for waked and partially waked turbines, which could result in higher maintenance costs and reduced turbine lifetime. However, predicting turbine loads throughout an array is a costly step, as these quantities require time-accurate results across long time histories, which is often intractable for large array optimization. Therefore, surrogate models that link array spacing to load outputs are often used, but the surrogates are then unique to the inflow conditions and array configurations in the training library. This work develops surrogate models for many wind turbine load outputs based solely on rotor plane velocity measurements, with no required input about array configuration or freestream inflow parameters. Surrogate models were constructed for many turbine quantities of interest (QoI), considering mean, standard deviation, ultimate, and fatigue loads. In general, most QoI statistics were accurately captured, as measured by predicted vs. actual correlation coefficient, confirming the suitability of the approach. Temporal mean values of the QoI required only temporal mean measurements of the rotor plane inflow velocity. However, accurate prediction of temporal standard deviation, ultimate, and fatigue values of QoI also required temporal standard deviations of the rotor plane velocity field. Poor surrogate performance was observed when too many correlated inputs were used, such as multiple velocity components. If the fewest inflow parameters are used to construct the surrogates, the average correlation coefficient value for all output QoI statistics is 0.89. Surrogates for standard deviations and damage equivalent loads (DELs) of turbine QoIs generally had lower accuracy and tower-base and shaft load channels posed the most difficult to capture accurately. The results suggest that these surrogates could be easily paired with analytic wake models, which are frequently used for pre-construction wind farm array optimization, to account for turbine loading in addition to power production. By including the optimal inflow conditions, the surrogate accuracy can improve to an average correlation coefficient value for all output QoI statistics of 0.92. This work has established the ability to build accurate surrogates for mean, standard deviation, ultimate load, and DEL turbine QoI values based on the rotor plane inflow velocity, and identified which inflow conditions lead to greater surrogate accuracy.

17 WIND ENERGY↗
DOE OSTI2020

Stress-Drop and Source Scaling of the 2019 Ridgecrest, California, Earthquake Sequence

Stress drop, while difficult to measure reliably and at scale, is a key source parameter for understanding the earthquake rupture process and its relationship to strong ground motion. Here, we use a P-wave spectral decomposition approach, designed for large and densely sampled datasets, to measure earthquake stress drop in the region surrounding the 2019 Ridgecrest, California, earthquake sequence. With more than 11,000 measurements of earthquake stress drop in the 20-yr time period from 2000 through 2019, this dataset provides an opportunity to understand how coseismic stress changes and how other geophysical factors relate to the distribution of stress drop and its evolution in space and time. We observe a mild but persistent deviation from self-similar scaling, with larger events having systematically higher stress drops, though this trend depends on the assumption of an omega-square source spectral model. Earthquake stress drop increases with hypocentral depth in this study region, and the Ridgecrest aftershocks tend to have higher stress drops than the pre-event seismicity. This is in part due to their deeper hypocenters. Coherent spatial patterns of stress drop in the aftershock sequence correlate with the slip distribution of the M 7.1 mainshock, whose northwest rupture tip terminated in a long-lived zone of enervated stress drop. Although physical interpretation of these results is complicated by the trade-offs between the timing, depth, and location of these earthquakes, the observations provide new insight into the physics of the earthquake source in an area of renewed seismic activity in southern California.

58 GEOSCIENCES↗
NASA NTRS1982

Kinetics of the reaction O + HO2 yields OH + O2 from 229 to 372 K

The discharge-flow resonance fluorescence technique has been used to obtain absolute rate data for the O + HO2 reaction from 229 to 372 K at a total pressure of 1 torr. Pseudo-first-order conditions were used with HO2 concentrations in large excess over initial atomic oxygen in order to minimize interference from secondary reactions. The results are independent of the method used to generate HO2 and atomic oxygen. At 299 K, the result is (6.1 + or - 0.4) x 10 to the -11th cu cm/molecule s. The temperature dependence expressed in Arrhenius form is (3.1 + or - 0.3) x 10 to the -11th exp/(+200 + or - 28)/T/. The error limits given are twice the standard deviation; overall experimental error is estimated to be + or - 25%.

Keyser, L. F.↗
NASA NTRS1990

Effects of structural offset, axial shortening, and gravitational torque on the slewing of a flexible spacecraft

The large-angle maneuvering of a Shuttle-beam-reflector spacecraft in the plane of a circular earth orbit is examined by considering the effects of the structural offset connection, the axial shortening, and the gravitational torque on the slewing motion. The offset effect is analyzed by changing the attachment point of the reflector to the beam. As the attachment point is moved away from the mass center of the reflector, the responses of the nonlinear system deviate from those of the linearized system. The axial geometric shortening effect induced by the deformation of the beam contributes to the system equations through second order terms in the modal amplitudes and rates. The gravitational torque effect is relatively small.

Li, Feiyue↗
NASA NTRS1996

Static test induced loads verification beyond elastic limit

Increasing demands for reliable and least-cost high performance aerostructures are pressing design analyses, materials, and manufacturing processes to new and narrowly experienced performance and verification technologies. This study assessed the adequacy of current experimental verification of the traditional binding ultimate safety factor which covers rare events in which no statistical design data exist. Because large, high-performance structures are inherently very flexible, boundary rotations and deflections under externally applied loads approaching fracture may distort their transmission and unknowingly accept submarginal structures or prematurely fracturing reliable ones. A technique was developed, using measured strains from back-to-back surface mounted gauges, to analyze, define, and monitor induced moments and plane forces through progressive material changes from total-elastic to total inelastic zones within the structural element cross section. Deviations from specified test loads are identified by the consecutively changing ratios of moment-to-axial load.

Verderaime, V.↗
NASA NTRS1998

Numerical Study of Rotating Turbulence with External Forcing

Direct numerical simulation at 256(exp 3) resolution have been carried out to study the response of isotropic turbulence to the concurrent effects of solid-body rotation and numerical forcing at the large scales. Because energy transfer to the smaller scales is weakened by rotation, energy input from forcing gradually builds up at the large scales, causing the overall kinetic energy to increase. At intermediate wavenumbers the energy spectrum undergoes a transition from a limited k(exp -5/3) inertial range to k(exp -2) scaling recently predicted in the literature. Although the Reynolds stress tensor remains approximately isotropic and three-components, evidence for anisotropy and quasi- two-dimensionality in length scales and spectra in different velocity components and directions is strong. The small scales are found to deviate from local isotropy, primarily as a result of anisotropic transfer to the high wavenumbers. To understand the spectral dynamics of this flow we study the detailed behavior of nonlinear triadic interactions in wavenumber space. Spectral transfer in the velocity component parallel to the axis of rotation is qualitatively similar to that in non-rotating turbulence; however the perpendicular component is characterized by a greatly suppressed energy cascade at high wavenumber and a local reverse transfer at the largest scales. The broader implications of this work are briefly addressed.

Yeung, P. K.↗
NASA NTRS1949

Performance of Axial-Flow Supersonic Compressor of XJ55-FF-1 Turbojet Engine: Over-All Performance of Compressor - III

An investigation was conducted to determine the performance characteristics of the rotor and inlet guide vanes used in the axial-flow supersonic compressor of the XJ55-FF-1 turbojet engine. Outlet stators used in the engine were omitted to facilitate study of the supersonic rotor. The extent of the deviation from design performance indicates that the design-shock configuration was not obtained. A maximum pressure ratio of 2.26 was obtained at an equivalent tip speed of 1614 feet per second and an adiabatic efficiency of 0.61. The maximum efficiency obtained was 0.79 at an equivalent tip speed of 801 feet per second and a pressure ratio of 1.29. The performance obtained was considerably below design performance. The effective aerodynamic forces encountered appeared to be large enough to cause considerable damage to the thin aluminum leading edges of the rotor blades.

Hartmann, Melvin J.↗
NASA NTRS1982

Vacuum deposition of iridium on large astronomical mirrors for use in the far UV

An iridium coating has been deposited by electron-beam evaporation on a 0.91-m mirror which serves as the telescope primary of a sounding rocket instrument for far-UV spectrometry. The evaporation was carried out by applying 8 kV at 400 mA to the electron gun. Zone refined Ir of 99.99% purity was used, and the electron beam was electromagnetically swept over the surface of the evaporant. Under these conditions, deposition rates of 0.55 A/sec were achieved. The reflectance distribution achieved at a wavelength of 584 A was extremely uniform; the mean reflectance was 21.2% with a standard deviation of only 0.3%. This represents a substantial improvement over Al + MgF2 and Al + LiF coatings for applications involving multiple reflections and weak signals, as might be expected in a high-resolution spectrograph studying distant celestial objects.

Herzig, H.↗
DOE OSTI2023

Absolute light yield of the EJ-204 plastic scintillator

The absolute light yield of a scintillator, defined as the number of scintillation photons produced per unit energy deposited, is a useful quantity for scintillator development, research, and applications. Yet, literature data on the absolute light yield of organic scintillators are limited. The goal of this work is to assess the suitability of the EJ-204 plastic scintillator from Eljen Technology to serve as a reference standard for measurements of the absolute light yield of organic scintillators. Four EJ-204 samples were examined: two manufactured approximately four months prior and stored in high-purity nitrogen, and two aged approximately eleven years and stored in ambient air. The scintillator response was measured using a large-area avalanche photodiode calibrated using low energy $γ$-ray and X-ray sources. The product of the quantum efficiency of the photodetector and light collection efficiency of the housing was characterized using an experimentally-benchmarked optical photon simulation. The average absolute light yield of the fresh samples, 9100 ± 400 photons per MeV, is lower than the manufacturer-reported value of 10400 photons per MeV. Moreover, the aged samples demonstrated significantly lower light yields, deviating from the manufacturer specification by as much as 26%. These results are consistent with recent work showcasing environmental aging in plastic scintillators and suggest that experimenters should use caution when deploying plastic scintillators in photon counting applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Signature of Many-Body Localization of Phonons in Strongly Disordered Superlattices

Many-body localization (MBL) has attracted significant research attention due to its immunity to thermalization, role in logarithmic entanglement entropy growth, and opportunities to reach exotic quantum orders. However, experimental realization of MBL in solid-state systems has remained challenging. Here we report evidence of a possible phonon MBL phase in disordered GaAs/AlAs superlattices. Through grazing-incidence inelastic X-ray scattering, we observe a strong deviation of the phonon population from equilibrium in disordered samples doped with ErAs nanodots at low temperature, signaling a departure from thermalization. This behavior occurs within finite phonon energy and wavevector windows, suggesting a localization-thermalization crossover. We support our observation by proposing a theoretical model for the effective phonon Hamiltonian in disordered superlattices, and showing that it can be mapped exactly to a disordered 1D Bose-Hubbard model with a known MBL phase. The large on-site repulsion qualitatively explains the experimental findings. Furthermore, our work provides mode-resolved experimental evidence of phonon localization, potentially extending the scope of MBL to disordered solid-state systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Quantum bath augmented stochastic nonequilibrium atomistic simulations for molecular heat conduction

Classical molecular dynamics (MD) has been shown to be effective in simulating heat conduction in certain molecular junctions since it inherently takes into account some essential methodological components which are lacking in the quantum Landauer-type transport model, such as many-body full force-field interactions, anharmonicity effects and nonlinear responses for large temperature biases. However, the classical MD reaches its limit in the environments where the quantum effects are significant (e.g. with low-temperatures substrates, presence of extremely high frequency molecular modes). Here, we present an atomistic simulation methodology for molecular heat conduction that incorporates the quantum Bose–Einstein statistics into an “effective temperature” in the form of a modified Langevin equation. We show that the results from such a quasi-classical effective temperature MD method deviates drastically when the baths temperature approaches zero from classical MD simulations and the results converge to the classical ones when the bath approaches the high-temperature limit, which makes the method suitable for full temperature range. In addition, we show that our quasi-classical thermal transport method can be used to model the conducting substrate layout and molecular composition (e.g. anharmonicities, high-frequency modes). Anharmonic models are explicitly simulated via the Morse potential and compared to pure harmonic interactions to show the effects of anharmonicities under quantum colored bath setups. Finally, the chain length dependence of heat conduction is examined for one-dimensional polymer chains placed in between quantum augmented baths.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1972

Wind shear near the ground and aircraft operations.

The variance of wind shear in the first 150-200 m of the atmosphere is a function of the direction of the mean wind relative to the flight path, the zenith angle of the flight path, the standard deviation of the three components of the turbulence velocity vector, the surface friction velocity, the stability properties of the atmospheric boundary layer, and the heights above natural grade of the beginning and end points of the portion of the flight path over which the shear is to be calculated. The results are applied by calculating wind shear for various risks of occurrence assuming wind shear is a Gaussian process, and it is shown that turbulence produces significantly large dispersions in wind shear about the mean wind shear. The results are interpreted in terms of the ICAO interim shear criteria for reporting wind shear in qualitative terms.

Fichtl, G. H.↗
NASA NTRS1982

Spacecraft thermal balance testing using infrared sources

A thermal balance test (controlled flux intensity) on a simple black dummy spacecraft using IR lamps was performed and evaluated, the latter being aimed specifically at thermal mathematical model (TMM) verification. For reference purposes the model was also subjected to a solar simulation test (SST). The results show that the temperature distributions measured during IR testing for two different model attitudes under steady state conditions are reproducible with a TMM. The TMM test data correlation is not as accurate for IRT as for SST. Using the standard deviation of the temperature difference distribution (analysis minus test) the SST data correlation is better by a factor of 1.8 to 2.5. The lower figure applies to the measured and the higher to the computer-generated IR flux intensity distribution. Techniques of lamp power control are presented. A continuing work program is described which is aimed at quantifying the differences between solar simulation and infrared techniques for a model representing the thermal radiating surfaces of a large communications spacecraft.

Tan, G. B. T.↗
NASA NTRS1996

Static test induced loads verification beyond elastic limit

Increasing demands for reliable and least-cost high-performance aerostructures are pressing design analyses, materials, and manufacturing processes to new and narrowly experienced performance and verification technologies. This study assessed the adequacy of current experimental verification of the traditional binding ultimate safety factor which covers rare events in which no statistical design data exist. Because large high-performance structures are inherently very flexible, boundary rotations and deflections under externally applied loads approaching fracture may distort their transmission and unknowingly accept submarginal structures or prematurely fracturing reliable ones. A technique was developed, using measured strains from back-to-back surface mounted gauges, to analyze, define, and monitor induced moments and plane forces through progressive material changes from total-elastic to total-inelastic zones within the structural element cross section. Deviations from specified test loads are identified by the consecutively changing ratios of moment-to-axial load.

Verderaime, V.↗
DOE OSTI2023

A novel additive manufacturing compression overmolding process for hybrid metal polymer composite structures

Metal polymer composites combining low density, high strength composites with highly ductile and tough metals have gained traction over the last few decades as lightweight and high-performance materials for industrial applications. However, the mechanical properties are limited by the interfacial bonding strength between metals and polymers achieved through adhesives, welding, and surface treatment processes. In this paper, a novel manufacturing process combining additive manufacturing and compression molding to obtain hybrid metal polymer composites with enhanced mechanical properties is presented. Additive manufacturing enabled deposition of polymeric material with fibers in a predetermined pattern to form tailored charge or preform for compression molding. Here, a grade 300 maraging steel triangular lattice is first fabricated using AddUp FormUp350 laser powder bed system and compression overmolded with additively manufactured long carbon fiber-reinforced polyamide-6,6 (40% wt. CF/PA66) preform. The fabricated hybrid metal polymer composites showed high stiffness and tensile strength. The stiffness and failure characteristics determined from the uniaxial tensile tests were correlated to a finite element model within 20% deviation. Fractographic analyses was performed using microscopy to investigate failure mechanisms of the hybrid structures.

36 MATERIALS SCIENCE↗