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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Dynamics and Clearance Analysis of NASA's Space Launch System Block-1 and Block 1B Solid Rocket Booster Separation Event

NASA’s Space Launch System (SLS) solid rocket booster separation event is an essential area of study requiring high fidelity modelling to capture the complexity of an intra-atmospheric stage separation event. The setup and analysis for this event leveraged the NASA-developed CLVTOPS multi-body dynamics toolchain to model aerodynamics at the separation event, booster thrust tailoff, and Core Stage engine throttling in addition to the separation system itself (booster separation motors (BSMs), pyrotechnic bolts and struts). The approach documented here will give a brief background on the CLVTOPS toolchain, how key input models are integrated and verified, and how results are quantified using an ordered-statistics approach. Specific areas discussed herein address the performance-to-orbit realized by adjusting the delay time between the separation cue and the actual separation event, and how the orientation of the aft BSMs was tuned to address small clearances between the aft diagonal attach struts and the Core Stage. Post-flight results from the inaugural Artemis I flight are also shown, and validation is performed between predicted vs. actual separation dynamics and clearances. Challenging night launch conditions necessitated comparisons that were more qualitative in nature, but still showed very good agreement to pre-flight predictions.

Carole J Addona↗
DOE OSTI2021

Inkjet-Based 3D Printing: From Quantum Dots to Steel Tools

Inkjet-based additive manufacturing (AM) technologies are highly versatile among manufacturing processes due to their ability to shape any material in powder or ink form. The two inkjet-based AM technologies are binder jetting and material jetting, and as each of their names suggest, the former uses inkjet to deposit binder into the actual build material and the latter uses inkjet to deposit the actual build material. With each of these technologies comes unique opportunities in the form of embedding functional components within the build, creating material gradients within parts by selectively layering feedstocks, shaping non-weldable materials, and creating low-cost tooling with conformal cooling channels. Dr. Amy Elliott at Oak Ridge National Laboratory has explored a variety of materials and approaches with inkjet-based manufacturing technologies, focusing on industry-relevant applications such as injection molding tooling and mining drills.

Elliott, Amy↗
DOE OSTI2021

Design Guidelines for Predicting Stress in Cemented Doublets Undergoing Temperature Change, Part 2

This work builds on prior work that developed a methodology for evaluating thermal stress in cemented doublets. The prior studies were limited by a paucity of actual test data, particularly from thermally tested cemented doublets. This follow-on study uses the existing methodology to estimate stresses in cemented doublets that have been tested for a temperature range from –40°C to 85°C and establishes safe stress levels using actual data. We also discuss limitations and concerns that we need to address to improve our understanding of cemented doublet failure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Incorporation of Thermal Hydraulic Models for Thermal Power Dispatch into a PWR Power Plant Simulator

This report describes the development, modeling, and results of a generic pressurized water reactor power plant simulator that incorporates coupled electrical and thermal power dispatch to an industrial process located approximately one kilometer from the nuclear power plant. The simulator is a commercial PWR simulator that has been modified to include thermal power dispatch as described in past milestone reports [ , ]. The commercial PWR simulator is a generic simulator available from GSE SYSTEMS® (Sykesville, MD, USA) that is built using RELAP5-HDTM Real-Time Solution and in-house software developed by GSE Systems. This generic PWR (GPWR) simulator performs real-time simulation of the complete power plant from the reactor neutronics to the electricity generation and distribution. All primary, secondary, and auxiliary systems are modeled including all control logic in order to provide the most accurate representation of actual nuclear power plant (NPP) operation, and the simulator results have been rigorously verified by an actual NPP operating at approximately 1 GWe. This report is a continuation of worked performed in previous years, and supplemental information from previous reports is included in the appendix for reference.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Modeling Validation of Mechanical and Thermal Borehole Breakouts From Polyaxial Laboratory Tests to Determine Maximum Horizontal in Situ Stress

To accurately assess rock behavior in the deep subsurface, it is necessary to measure the in situ stress directions and magnitudes. The current methods for measuring the in situ stress state in the deep subsurface primarily include hydraulic fracturing tests (i.e., the minimum horizontal stress) or occasionally observing existing compressive borehole breakouts (i.e., the maximum horizontal stress) that have occurred naturally from drilling. If there are no existing compressive breakouts in a borehole, the maximum horizontal in situ stress cannot be estimated with much confidence. In response to this data gap, a new thermal breakout technology is being developed that will provide a method for thermally inducing borehole breakouts and obtaining consistent measurements of the maximum horizontal stress magnitude. This thermal breakout technology involves heating the borehole and increasing the thermoelastic compressive stress in the rock until a breakout develops, which is directly correlated to the maximum horizontal stress magnitude. In support of developing the thermal breakout technology, polyaxial laboratory tests have been performed on small-scale boreholes within rock blocks where mechanically- and thermally-induced borehole breakouts have been created. Numerical models along with the principal of superposition were created and used to analyze the polyaxial laboratory tests to predict the maximum horizontal stress, given the same data that would be obtained in an actual subsurface borehole thermal breakout test. Multiple failure criteria were used to evaluate the best prediction of the breakout onset and maximum horizontal stress. The maximum horizontal stress predictions were compared to the actual maximum horizontal stress applied at breakout using acoustic events recorded from emission sensors in the polyaxial tests. The results showed consistent results that could be used to refine the modeling approach and failure criterion that are used to make the maximum horizontal stress predictions. This study provided insight and validation for the thermal breakout stress measurement concept.

Jones, Matt↗
DOE OSTI2021

Method and apparatus for controlling a vehicle including an adaptive cruise control system

Operating a subject vehicle equipped with an adaptive cruise control system includes setting initial states for control parameters, including setting a desired vehicle speed and determining a desired following gap range, wherein the desired following gap range is associated with a lead vehicle. Operation is controlled via the adaptive cruise control system based upon the initial states for the control parameters. Operation also includes monitoring for presence of the lead vehicle. Upon detecting presence of the lead vehicle, an actual following gap is determined between the subject vehicle and the lead vehicle, and the initial states of the control parameters associated with the adaptive cruise control system are adjusted based upon the actual following gap between the subject vehicle and the lead vehicle, and the desired following gap range. Operation is controlled via the adaptive cruise control system based upon the adjusted initial states of the control parameters.

Zhao, Junfeng↗
DOE OSTI2022

Crucible Melter Simulation in Nek5000

Nuclear tank waste at the Hanford site is slated for vitrification in large scale refractory-lined melters to transform it into a stable borosilicate waste form suitable for long-term storage or disposal. Molten glass corrodes the refractory lining over time at a rate correlated to the velocity of molten glass against the refractory-lined wall. To properly design a melter and plan for maintenance, it is necessary to accurately model the glass flow and find the correlation between flow velocity and corrosion rate. This modeling was started in STAR-CCM+ CFD software and is being continued in Nek5000 for its fast-running and quick turnaround code. This poster explains the basic process of reconstructing the geometry, fluid properties, and heating of test melters in Nek5000. The geometry is imported from a mesh file and boundary conditions assigned based on surface IDs. The fluid properties are set in the .par and .usr case files. The heating of the actual crucibles in joule heating with electrodes but simulated in Nek5000 with a volumetric heat source term. This volumetric heat source is fit to the actual heating profile with piecewise polynomials and exponentials. Basic results and verification methods are explained in the poster, as well as further work that must be done to complete modeling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

1.2.4.404 - Data-Driven Approach for Hydropower Plant Controller Prototyping Using Remote Hardware in the Loop (DR-HIL)

Real-time prototyping of hydropower plant controls is important for reducing the cost and the risk of field deployment. This project will 1) collect design and operational data from actual hydro plants and 2) use a physics-informed machine learning approach for real-time emulation of hydropower plants, including hydro turbine and hydrodynamics. The data-driven models will be interfaced with digital real-time simulation at NREL’s Flatirons campus for hardware-in-the-loop (HIL) testing of the governor hardware device or controller-HIL (CHIL). The proposed approach will also establish the connectivity based remote CHIL testing capability using real-time data streams from an actual hydro plant. This integrated hydro-plant emulation with CHIL will be used to prototype hydro-governor controls and eventually provide an opportunity to test hydropower integrated with various technologies (e.g. conventional and renewable generation, energy conversion, etc.) as HIL.

controls prototyping↗
DOE OSTI2023

Wind Turbine Drivetrain Reliability Research - Gearbox Bearing Axial Cracking Failure Mode Example

The U.S. Department of Energy's National Renewable Energy Laboratory and Argonne National Laboratory have been conducting wind turbine drivetrain (formerly gearbox) reliability research for many years. Although the drivetrain focus has not changed, detailed projects are adjusted every few years based on dynamic needs seen in the field across the wind industry. This webinar will walk through the research methodology by using wind turbine gearbox bearing axial cracking failure mode as an example. The detailed steps include: 1) top failure mode identification based on actual failure data collected from project partners, 2) bench-top testing to identify possible contributing factors and formulate a damage metric, 3) physics domain modeling and validation through testing, 4) reliability assessment and prognosis based on the physics domain model and data domain inputs, and further enhancement through machine learning algorithms, using actual wind plant operational and failure event data. Hopefully, the presented work is of interest to the IISE community, and some members can apply their expertise to wind turbine and plant applications, helping enhance wind power generation technology advancement and its broader deployment.

axial cracking↗
DOE OSTI2021

A Comparison of Human Error Probabilities Collected from HuREX and SHEEP Frameworks

This paper discusses how different are the HEPs collected from HuREX and SHEEP frameworks. This study is a preceding research to infer full-scope HRA data based on the data collected from the SHEEP framework. For the comparison, we used HEPs in the HuREX database published in KAERI-TR-6649 [6]. The HEPs have been collected from actual licensed operators when manipulating MCR simulators of Westinghouse type and Optimized Power Reactor (OPR1000) type in South Korea. For the HEPs based on the SHEEP framework, these have been collected from actual licensed operators and students when using a simplified simulator, i.e., Rancor Microworld.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Human Performance Analysis Depending on Operator Expertise (Student vs. Operator) and Simulator Complexity (Rancor Microworld vs. Compact Nuclear Simulator)

Human reliability analysis (HRA) evaluates human errors and provides human error probabilities (HEPs) for application in probabilistic safety assessment (PSA), which is a comprehensive safety assessment method for nuclear power plants (NPPs). Generally, HRA methods estimate HEPs based on human reliability data collected from actual historical measurement, simulator experiments, or expert judgement. Most recent HRA data collection studies focus on collecting data via full-scope main control room (MCR) simulators with actual licensed reactor operators. Contrary to this, Idaho National Laboratory (INL) has adopted a different approach, which attempts to collect HRA data based on experiment using simplified simulators and student participants by following the Simplified Human Error Experimental Program (SHEEP). This approach has a couple of advantages compared to full-scope data collection. Representatively, it has relatively low entry point for collecting HRA data, and secures large sample sizes with reasonable cost and labor. In the previous studies, we developed the SHEEP framework, then verified whether the data collected through the framework could support a representative full-scope data collection study, i.e., the Human Reliability Data Extraction (HuREX) study. Also, we analyzed human performance measurements depending on participant type (i.e., student vs. operator). In this paper, we analyze human performance data collected from an experiment comparing operator expertise and simulator complexity when using the more simplified simulator developed by INL, i.e., Rancor Microworld and the less simplified simulator, i.e., Compact Nuclear Simulator (CNS) developed by Korea Atomic Energy Research Institute (KAERI). Analysis of variance (ANOVA) tests and correlation analysis are used for analyzing the experimental data.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Optimizing Rate of Penetration and Tripping Decision-Making using Real-Time Bit Wear Monitoring While Drilling Geothermal Wells

Understanding bit wear while drilling is critical to minimizing non-productive time (NPT) and optimizing rate of penetration (ROP). Lengthening drilling runs with damaged bits does not only lower the ROP, but also elevates the risk of inducing severe bit damage, which could potentially lead to time-consuming fishing operations. When drillers believe the bit has worn off substantially, the bit is tripped out to be replaced. On geothermal wells, tripping can take up to 20% of the overall well construction time, and this is generally acknowledged as an opportunity for improvement. Ideally, a bit run should be terminated before the bit is damaged beyond repair. At the same time, premature bit pulls are to be avoided as well. This study aims to leverage bit and tooth wear metrics that can be obtained in real time to characterize bit condition in order to optimize ROP and determine the optimal time to pull the bit. Two metrics were explored in this study: a bit wear metric that incorporated depth-of-cut, and a tooth wear metric developed by Bourgoyne & Young characterizing the state of bit teeth dull. Both metrics were computed using recorded data from 12¼ inches roller cone insert bit runs in five geothermal wells targeting a granodiorite formation in the western United States. Together with the actual dull grades, determined after the bits were pulled to surface, the metric trends were interpreted to characterize the downhole bit condition and identify the point at which the bit should have optimally been tripped out. The insights from studying the actual dull grades and how they relate to the two metrics were used to establish a reliable bit pull criterion. The bit wear metric trend correctly showed a noticeable departure from baseline for bits experiencing major dulling behavior. Additionally, the tooth wear model predicted the cutter dull within two dull grades for most runs, with better performance in predicting the inner teeth dull. Moreover, the combination of the bit wear and tooth wear metrics was effective in revealing the cause of the bit performance impairment. Proactive tracking of these two metrics in real-time can facilitate geothermal drilling ROP optimization and better-informed tripping decision-making, thereby avoiding wasted time and cost.

Ashari, Rahmat↗
DOE OSTI2022

Stable Element Doping of Sol-gel Toward Simulating Environmental Matrix in Surrogate Explosive Nuclear Debris

Training nuclear forensic analysis personnel in post-detonation scenarios is of critical importance to nuclear threat response capabilities. Thus, realistic nuclear debris simulants which resemble the size, color, elemental composition, and radionuclide content of actual nuclear fallout from a recent detonation would be valuable for training nuclear first responders in realistic scenarios. As nuclear fallout types vary significantly in each of these parameters based on detonation environment (rural, urban, maritime etc.) and collection location, the ability to tailor each of these parameters accurately in simulated debris would be of immense benefit to the post-detonation analysis community for training both in-field collections and triage and the validation of laboratory level nuclear forensic techniques. Sol-gel synthesis techniques can provide the tunability of size, shape and composition required for producing surrogate nuclear debris of a wide variety. The sol-gel process consists of forming a metal oxide material, often silica, through polymerization of a metal-alkoxy precursor. In this work, we characterize the ability to load the sol-gel particles with secondary elemental components such as iron, aluminum, and calcium toward approximating the elemental composition of debris from various detonation environments and demonstrate the ability to produce particles with controllable size, shape, and color. We also demonstrate quantitative radionuclide encapsulation toward reproducing the radionuclide content of actual fallout from a recent detonation. Finally, we then employ these techniques in producing simulated aerodynamic debris samples with realistic elemental matrix composition and radionuclide content simulating a recent uranium-fueled detonation taking place in a rural desert environment and compare it to historic fallout from the Nevada Nuclear Security Site.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Methodology and Tool for the Physical Security Analysis of Micro and Advanced Reactors

This work proposes a dynamic evaluation methodology to relax the conservatism in physical security evaluation, by leveraging an ongoing work in the Light Water Reactor Sustainability pathway. This methodology is implemented in a dynamic risk assessment tool named Event Modeling Risk Assessment using Linked Diagrams (EMRALD). The work extends EMRALD’s capability to support a sandbox feature where analysts can easily create attack scenarios and modify advanced/small modular reactor (A/SMR) security and safety features using templates. This approach saves time and cost since the analysis does not require creating detailed computer-aided design models, as is commonly required in commercial force-on-force software tools. EMRALD is completely free to use at https://emraldapp.inl.gov. We have developed basic templates including physical barriers, intrusion sensors, physical areas, and safety actions, that can be downloaded from EMRALD’s GitHub site: https://github.com/idaholab/EMRALD. These templates use generic data commonly used for training purposes, which do not reflect any actual operating nuclear reactor. Users may adjust the data in the templates with their own dataset and/or create new templates in EMRALD. The proposed methodology combines security and safety by assessing sabotage effects up to the radiological consequence to the public instead of merely the core damage state. This practice follows the industry standard for advanced non-light-water reactors currently proposed for endorsement by the Nuclear Regulatory Commission. The combination of security and safety is expressed in an achievability-consequence chart. EMRALD can be used to generate data for this chart. A hypothetical case study using a representative sodium-cooled fast reactor (SFR) facility is presented in this report to demonstrate this methodology. This case study does not contain any actual nuclear plant information. This work will benefit A/SMR vendors and utilities to implement security by design during the reactor design iteration phase, such that they do not have to perform upgrades and retrofits to the reactor after it is installed to improve its physical protection system. The tool may also be used to analyze domestic or foreign reactor designs to support the International Nuclear Security Techniques for Advanced Reactors (INSTAR) bilateral missions. Future works are planned to implement the methodology on a reference SFR reactor and a reference high-temperature gas-cooled reactor to obtain insights and lessons-learned for the A/SMR community.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Event analysis in an electric power system

According to some embodiments, system and methods are provided including receiving, via a communication interface of an event detection and classification module comprising a processor, data from one or more sensors in a system; determining an event occurred based on the received data; applying a coherency similarity process to the received data via a classification module; determining whether the event is an actual event or a mal-doer event based on an output of the classification module; transmitting the determination of the event as the actual or the mal-doer event; and modifying operation of the system based on the transmitted output. Numerous other aspects are provided.

Hart, Philip Joseph↗
DOE OSTI2022

Stable Element Doping of Sol-gel Toward Simulating Environmental Matrix in Surrogate Explosive Nuclear Debris

Training nuclear forensic analysis personnel in post-detonation scenarios is of critical importance to nuclear threat response capabilities. Thus, realistic nuclear debris simulants which resemble the size, color, elemental composition, and radionuclide content of actual nuclear fallout from a recent detonation would be valuable for training nuclear first responders in realistic scenarios. As nuclear fallout types vary significantly in each of these parameters based on detonation environment (rural, urban, maritime etc.) and collection location, the ability to tailor each of these parameters accurately in simulated debris would be of immense benefit to the post-detonation analysis community for training both in-field collections and triage and the validation of laboratory level nuclear forensic techniques. Sol-gel synthesis techniques can provide the tunability of size, shape and composition required for producing surrogate nuclear debris of a wide variety. The sol-gel process consists of forming a metal oxide material, often silica, through polymerization of a metal-alkoxy precursor. In this work, we characterize the ability to load the sol-gel particles with secondary elemental components such as iron, aluminum, and calcium toward approximating the elemental composition of debris from various detonation environments and demonstrate the ability to produce particles with controllable size, shape, and color. We also demonstrate quantitative radionuclide encapsulation toward reproducing the radionuclide content of actual fallout from a recent detonation. Finally, we then employ these techniques in producing simulated aerodynamic debris samples with realistic elemental matrix composition and radionuclide content simulating a recent uranium-fueled detonation taking place in a rural desert environment and compare it to historic fallout from the Nevada Nuclear Security Site.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Diagnostic methods for a high efficiency exhaust aftertreatment system

A method includes acquiring nitrogen oxide (NOx) data indicative of a first amount of NOx in an exhaust flow exiting an engine and a second amount of NOx in the exhaust flow exiting an exhaust aftertreatment system coupled to the engine where the exhaust aftertreatment system including a selective catalytic reduction (SCR) system including a SCR catalyst; determining a NOx conversion efficiency fault is present within the exhaust aftertreatment system based on the first amount of NOx and the second amount of NOx; monitoring an actual amount of NOx in the exhaust flow downstream of the SCR catalyst; determining an expected amount of NOx downstream of the SCR catalyst; and determining the SCR catalyst is responsible for the NOx conversion efficiency fault in response to the actual amount of NOx differing from the expected amount of NOx by more than a threshold amount.

Gupta, Aniket↗
DOE OSTI2020

Accelerated Aging Humidity Chamber for Nuclear Grade HEPA Filter Media

A unique accelerated aging humidity chamber for simulating the natural aging process of nuclear grade high efficiency particulate air (HEPA) filter media is being designed, implemented, and tested. The nuclear industry currently lacks information regarding the shelf life and service life of HEPA filter media. The Department of Energy recommends disposing of HEPA filters 10 years after the manufacture date for filters operated under dry conditions. Studies have shown the tensile strength and water repellency of HEPA filter media diminish with age. The chamber's principal function is to sustain an elevated relative humidity condition for an extended duration specified by the Arrhenius aging model. To accomplish this, various design parameters were established: (1) consistently achieve uniform humidity conditions within the chamber to equally expose media sheets, (2) ensure the chamber is sufficiently sealed to mitigate the uncontrolled infiltration of air, (3) confidently secure the media sheets to avert the introduction of unnecessary stressing/creasing, (4) fabricate the chamber from clear polycarbonate material to allow inspection of the media sheets, (5) provide a safe and ergonomic design for personnel, (6) ensure the chamber design is replicable and relatively easy to fabricate/assemble. A humidity source, fan, PID controller, humidity and temperature transmitters, and data loggers are required for proper operation and control of the chamber. The humidity source must accommodate target values up to 95% relative humidity throughout the chamber. The three humidity and temperature transmitters are strategically spaced throughout the chamber to ensure uniform conditions. The 10 cubic feet per minute (CFM) fan selected intends to accomplish the desired air change rate inside the chamber of approximately 20 air changes per hour (ACH). The 2 plenums on the upper and lower portions of the chamber utilize a perforated design to uniformly distribute air, promote air mixing, and control the air velocity entering the chamber. Industrial blueprint hanging clamps are being retrofitted to be seated within the chamber drawers and firmly secure the nuclear grade filter media. The aged media will be evaluated using autopsy methodology, and the results obtained intend to help clarify the useful life of nuclear grade HEPA filters. Nuclear grade high efficiency particulate air (HEPA) filters are defined as disposable, extended-media, dry-type filters with a rigid casing enclosing the full depth of the pleats and have a minimum particle removal efficiency of 99.97%. [1] - HEPA filters are constantly exposed to stressors and subsequently have been shown to degrade as the filter ages. Properties such as tensile strength and water repellency, along with others, are negatively impacted. [2] - Due to the scarcity of naturally aged HEPA filters available, it is crucial to develop accelerated aging methods which effectively mimic the natural degradation effects. - After accelerated aging, the filters are subject to testing in the Axial Flow Large Scale Test Stand (ALSTS) and other analysis techniques such as the same qualification tests performed directly after being manufactured. - Quality data is necessary for future decisions regarding the lifetime of nuclear grade HEPA filters. - The objective is to develop a prototype accelerated aging humidity chamber for nuclear grade HEPA filter media. The chamber should expose the media to commonly occurring stressors to expedite the degradation process caused by aging. PID yields reliable and reproducible results: - CFD model correlates well with actual performance; - Further analysis is needed to complete characterization; - Future work for the chamber is still to be completed. The data shown in Figure 5 and Table 1 indicate the system is functioning as designed. As can be determined from the system response evaluation in Table 1, the PID controller is yielding reliable and reproducible results at each set point. As the set point increases, the time constant and 20% settling time increase accordingly. From the results in Table 1, it stands to reason that the CFD model correlates well with the actual performance of the system. Each system response parameter for the 90%RH* CFD model is slightly lower than the parameters collected from the physical model tested at an equivalent set point. This is to be expected considering the inlet in the CFD model is a constant supply of water vapor, whereas the physical model uses a PID controller to monitor the amount of water vapor needed and reacts accordingly. More analysis is still to be done on the prototype chamber. A pressure test will be conducted in order to determine the hourly leak rate of the chamber. This test will involve constant air flow into the chamber until the desired pressure is reached. A uniformity test will also be conducted in order to ensure each filter medium is being exposed to equivalent relative humidity levels. This test will involve an array of humidity meters strategically oriented inside the chamber to record any possible gradients. Future work for the chamber includes dehumidification abilities, tests while fully loaded with filters, and temperature control. Once completed, the autopsy team at Institute of Clean Energy Technology will conduct necessary accelerated aging studies as needed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗