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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Analytical and Numerical Analysis of Lithium Plating Onset in Single and Bilayer Graphite Electrodes during Fast Charging

Lithium plating is commonly observed in anodes charged at fast rates, and can lead to capacity loss and battery safety issues. The increased risk of plating has been attributed to transport limitations, and architectured electrodes may reduce plating risk. However, while theoretical studies have shown that reaction non-uniformity arises due to interplay of transport limitations, anode open circuit voltage behavior and reaction kinetics, its effect on lithium plating has not been studied. We use analytic and numerical simulations to predict onset of plating in graphite anode half-cells at high C-rates and demonstrate how anodes with layered porosities can delay plating. Simplified analytical models identify trends for plating onset and predictions are calibrated against numerical models. A calibrated numerical model of graphite demonstrates qualitative agreement with analytical model predictions. This reaction inhomogeneity mechanism occurs in the absence of lithium ion depletion, indicating that these mechanisms may contribute to capacity loss independently or simultaneously. A bilayer model of graphite exhibits delayed plating onset, and an optimization procedure is presented. This theoretical work presents quantitative and mechanistic insight on how reaction inhomogenity affects lithium metal plating onset and can be used as a guide to engineer anodes resistant to lithium plating.

Mijailovic, Aleksandar S.↗

DOE OSTI2019

Effect of Prolonged Ultraviolet Radiation Exposure on the Blast Response of Fiber Reinforced Composite Plates

An experimental study with corresponding numerical simulations was conducted to evaluate the blast response of composite plates after prolonged exposure to ultraviolet radiation. Two composite materials were used in this study, namely carbon fiber/epoxy and glass fiber/vinyl ester. The composite materials consisted of four unidirectional fiber plies oriented in a [± 45°]s layup. The plates were placed in a QUV Accelerated Weathering Tester for 500 h of exposure on each face, totaling 1000 h of ultraviolet radiation exposure, equivalent to 2.5 MJ/m{sup 2} of energy. The QUV Accelerated Weathering Tester was equipped with eight UVA-340 lamps to provide real service life exposure conditions. Material characterization experiments were performed on virgin specimens, as well as specimens exposed to ultraviolet radiation for 1000 h to determine its effect on the mechanical properties of the composites. Blast experiments were conducted on the composite plates to investigate the dynamic response before and after exposure to ultraviolet radiation. The plates were clamped on all edges and subjected to an air blast using a shock tube apparatus. Three-dimensional digital image correlation was coupled with high-speed photography to obtain full-field displacements of the specimens during blast loading. Furthermore, three piezoelectric pressure transducers were mounted on the shock tube apparatus and utilized to measure the pressure history of the shock wave loading. The quasi-static material characterization showed that the tensile modulus E{sub 1} had minimal change after exposure to ultraviolet radiation for 1000 h. However, matrix-dominated properties such as the in-plane shear modulus G{sub 12} increased after exposure to ultraviolet light for both the carbon and glass fiber composites, which resulted in lower out-of-plane displacements during blast loading. For the carbon fiber plates, the forced vibration frequency induced by the transverse blast load was higher in plates exposed to ultraviolet radiation when compared to virgin specimens. However, for the glass fiber plates exposed to ultraviolet radiation, the forced vibration frequency decreased when compared to virgin specimens. Finally, the finite element simulations were in good agreement with the experimental results. The simulations revealed that the glass fiber plates exposed to ultraviolet radiation had higher failure strains at the boundary than virgin specimens, despite having higher stiffness. A parametric study in which higher loading was simulated also showed that the glass fiber plates experienced more damage after 1000 h of ultraviolet radiation exposure.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Flow maldistribution in plate heat exchangers – Impact, analysis, and solutions

Plate heat exchangers are commonly used in various industrial applications, such as refrigeration, air conditioning, heat pumps, powerplants, and chemical industries. Plate heat exchangers are well known for their superior heat transfer performance, compactness, and low refrigerant charge. Despite offering several advantages, they suffer from flow maldistribution issues. The flow maldistribution can deteriorate both the heat transfer and pressure drop performance, ultimately resulting in a lower system efficiency where plate heat exchangers are deployed. The flow maldistribution issues become more pronounced when the heat exchanger size is relatively large and the number of plates is higher, limiting the deployment of plate heat exchangers in larger industrial systems. Consequently, analyzing and understanding the flow maldistribution behavior in plate heat exchangers and finding ways to mitigate flow maldistribution related issues become essential topics of interest. Further, this review aims to address the effect of flow maldistribution on plate heat exchanger characteristics. First, the experimental and numerical works on flow maldistribution under single-phase and two-phase conditions are detailed. Subsequently, the end-channel and end-plate effects are discussed. Then, the methods to mitigate flow maldistribution in plate heat exchangers are outlined. Finally, based on a thorough literature survey and industrial requirements, future research directions are recommended.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Energy transfer between a passing vortex ring and a flexible plate in an ideal quiescent fluid

Recent advancements in highly deformable smart materials have lead to increasing interest in small-scale energy harvesting research for powering low consumption electronic devices. One such recent experimental study by Goushcha et al. explored energy harvesting from a passing vortex ring by a cantilevered smart material plate oriented parallel to and offset from the path of the ring in an otherwise quiescent fluid. The present study focuses on modeling this experimental study using potential flow to facilitate optimization of the energy extraction from the passing ring to raise the energy harvesting potential of the device. The problem is modeled in two-dimensions with the vortex ring represented as a pair of counter-rotating free vortices. Vortex pair parameters are determined to match the convection speed of the ring in the experiments, as well as the imposed pressure loading on the plate. The plate is approximated as a Kirchhoff-Love plate and represented as a finite length vortex sheet in the fluid domain. The analytical model matches experimental measurements, including the tip displacement, the integrated force along the entire plate length as a function of vortex ring position, and the pressure along the plate. The potential flow solution is employed in a parametric study of the governing dimensionless parameters in an effort to guide the selection of plate properties for optimal energy harvesting performance. Results of the study indicate an optimal set of plate properties for a given vortex ring configuration, in which the time-scale of vortex advection matches that of the plate vibration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Delayed Critical and Subcritical Experiments with Polyethylene Moderated Unreflected Thin 15 in. Diameter HEU Metal Plates

The thin ~15 in. diameter highly enriched uranium (HEU) metal plates were assembled to delayed criticality at the Oak Ridge Critical Experiments Facility (ORCEF) in 1969 with various thicknesses of polyethylene (varying from 1/16 to 2$\frac{3}{8}$ inches) between uranium metal plates. The average 235 U enrichment was 93.27 wt. %. These unreflected critical configurations contained 4$\frac{2}{3}$ to 20$\frac{5}{6}$ thin 15 in. diameter HEU metal plates (on loan from Los Alamos National Laboratory [LANL] and shipped to Oak Ridge National Laboratory [ORNL] on June 3, 1969). Depending on the thickness of polyethylene, the enriched uranium masses varying from 28,053 to 135,148 grams. Fractional plate sections consisted of the appropriate number of 60° pie sections. In addition to the measurement at delayed criticality, subcritical measurements were also performed by the inverse kinetic rod drop method. Prompt neutron decay constant measurements were also performed by the Rossi alpha and randomly pulsed neutron method using a time-tagged spontaneous fission californium neutron source; these are briefly reported here. At the time of these measurements in 1969, the thin HEU metal plates were in near-pristine condition with extremely little oxidation, allowing better descriptions of the uranium plates than the use of these plates in a heavily oxidized and deteriorated condition in recent reflected benchmark experiments at the LANL facility at the Nevada Test Site with these same thin highly enriched uranium metal plates. This report documents the experimental information for the measurements performed so that later researchers can perform the required uncertainty and calculational analyses and documentation to use these data for an International Nuclear Criticality Safety Benchmark Evaluation Program (ICSBEP) or a Nuclear Energy Agency (NEA) benchmark. Data from the experiments described should be acceptable for use as criticality safety benchmark experiments for the ICSBEP and the NEA nuclear criticality safety benchmark program once the uncertainty analysis on the measured neutron multiplication factors is completed. Additional data—such as the dimensional inspection reports, uranium isotopic information, and other relevant particulars—should be retrieved from the Y-12 Plant or LANL and incorporated in the final ICSBEP benchmark. Based on previous ICSBEP benchmarks with this enriched uranium metal at ORCEF, the uncertainties in $k_{eff}$ could be as low as ± 0.0002 for some configurations. Other experiments with smaller-diameter than 15 in. diameter HEU metal plates have been benchmarked in HEU-METFAST-001. The prompt neutron time decay measurements could be the basis for an International Reactor Physics Benchmark Program. Preparation of the present report is part of an effort at ORNL to document more than 15 undocumented critical and subcritical experiments enumerated in ORNL/TM-2019/18 and performed by ORNL at ORCEF and other US Department of Energy critical experiments facilities using more than 500 operational days of critical facility time. This work for this report publication was supported by the Nuclear Criticality, Radiation Transport and Safety NCSP Program at ORNL.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Evaluation of flow-induced plate deflection for University of Missouri research reactor low-enriched uranium fuel element

The University of Missouri Research Reactor (MURR), located on the campus of the University of Missouri in Columbia, Missouri, is one of the six United States (U.S.) High Performance Research Reactors (USHPRR), including one critical facility, that are actively collaborating with the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Office of Material Management and Minimization (M3) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥20 wt% U-235) fuel to low-enriched uranium (LEU, <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow conversion of some USHPRR, including MURR. In the design of its fuel elements, MURR is using thin parallel curved fuel plates separated by coolant channels. In this work, fluid-structure interaction (FSI) analysis of the MURR LEU fuel element is performed at the element level (as compared to the plate level analysis), which models all components of the LEU fuel element, including fuel plates and the supporting structures. Therefore, the effect of supporting structures on the flow distribution within the element and the fuel plate deflection are evaluated. In addition to the element nominal flow rate and dimensions, the tolerances in the geometry of the coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are evaluated. For the LEU fuel plates, which are thinner than the current HEU plates, the predicted plate deflection is found to be small compared to the fabrication and assembly tolerances. Thus, the FSI-induced deflections are not expected to noticeably reduce the coolant flow rate or predicted safety margins in the limiting channels for the MURR LEU fuel element. In addition to the simulation work, a hydraulic performance test of the MURR LEU fuel element is currently being planned to support conversion to the use of LEU fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Lithium Plating Characteristics in High Areal Capacity Li-Ion Battery Electrodes

Li-ion battery degradation and safety events are often attributed to undesirable metallic lithium plating. Since their release, Li-ion battery electrodes have been made progressively thicker to provide a higher energy density. However, the propensity for plating in these thicker pairings is not well understood. Herein, we combine an experimental plating-prone condition with robust mesoscale modeling to examine electrode pairings with capacities ranging from 2.5 to 6 mAh/cm 2 and negative to positive (N/P) electrode areal capacity ratio from 0.9 to 1.8 without the need for extensive aging tests. Using both experimentation and a mesoscale model, we identify a shift from conventional high state-of-charge (SOC) type plating to high overpotential (OP) type plating as electrode thickness increases. Further, these two plating modes have distinct morphologies, identified by optical microscopy and electrochemical signatures. We demonstrate that under operating conditions where these plating modes converge, a high propensity of plating exists, revealing the importance of predicting and avoiding this overlap for a given electrode pairing. Further, we identify that thicker electrodes, beyond a capacity of 3 mAh/cm 2 or thickness >75 μm, are prone to high OP, limiting negative electrode (NE) utilization and preventing cross-sectional oversizing the NE from mitigating plating. Here, it simply contributes to added mass and volume. The experimental thermal gradient and mesoscale model either combined or independently provide techniques capable of probing performance and safety implications of mild changes to electrode design features.

25 ENERGY STORAGE↗

DOE OSTI2014

Evaluation of the feasibility for detecting hidden corrosion damage in multi-layer gusset plates using multiple inspection techniques

Gusset plates are used to connect the members in truss bridges and they are usually inspected using calipers or conventional thickness measurement ultrasonic testing (UT) devices. The damage mechanism of particular concern in gusset plates is corrosion and the regions most susceptible to corrosion damage are on the gusset interior surface where it intersects the chord, diagonal, and vertical members from water collecting at the interfaces. For heavily loaded gusset plates, one or more shingle plates are used to reinforce the gusset plate, creating a multi-layer structure. While the areas with corrosion damage remain near the members on the gusset plate, the shingle plates cover the gusset plate and greatly limit the surface access to the gusset plate, making UT thickness measurement impractical. Because of the critical nature of the gussets, a viable inspection strategy for multi-layer gusset assemblies must be developed. The premise of this research and development effort was to develop viable, field-deployable inspection approaches for this problem area. This paper presents three separate inspection approaches: two ultrasonic-based techniques and one radiographic approach. Each of these techniques was evaluated on a mock-up specimen provided by the Federal Highway Administration (FHWA) that is representative of gusseted connection from a truss bridge.

42 ENGINEERING↗

DOE OSTI2014

SU-E-T-235: Monte Carlo Analysis of the Dose Enhancement in the Scalp of Patients Due to Titanium Plate Backscatter During Post-Operative Radiotherapy

Purpose: To quantify the clinically observed dose enhancement adjacent to cranial titanium fixation plates during post-operative radiotherapy. Methods: Irradiation of a titanium burr hole cover was simulated using Monte Carlo code MCNPX for a 6 MV photon spectrum to investigate backscatter dose enhancement due to increased production of secondary electrons within the titanium plate. The simulated plate was placed 3 mm deep in a water phantom, and dose deposition was tallied for 0.2 mm thick cells adjacent to the entrance and exit sides of the plate. These results were compared to a simulation excluding the presence of the titanium to calculate relative dose enhancement on the entrance and exit sides of the plate. To verify simulated results, two titanium burr hole covers (Synthes, Inc. and Biomet, Inc.) were irradiated with 6 MV photons in a solid water phantom containing GafChromic MD-55 film. The phantom was irradiated on a Varian 21EX linear accelerator at multiple gantry angles (0–180 degrees) to analyze the angular dependence of the backscattered radiation. Relative dose enhancement was quantified using computer software. Results: Monte Carlo simulations indicate a relative difference of 26.4% and 7.1% on the entrance and exit sides of the plate respectively. Film dosimetry results using a similar geometry indicate a relative difference of 13% and -10% on the entrance and exit sides of the plate respectively. Relative dose enhancement on the entrance side of the plate decreased with increasing gantry angle from 0 to 180 degrees. Conclusion: Film and simulation results demonstrate an increase in dose to structures immediately adjacent to cranial titanium fixation plates. Increased beam obliquity has shown to alleviate dose enhancement to some extent. These results are consistent with clinically observed effects.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

A “Master Curve” Describing Reaction Inhomogeneity and Plating Onset during Fast-Charging of Graphite Electrodes

Lithium plating in porous graphite electrodes is a major limitation for fast charging. Theoretical evidence suggests plating during fast charging is largely due to inhomogeneous intercalation through the electrode thickness (caused by ionic/mass transfer limitations and inherent thermodynamic properties of the graphite material). Numerical and analytical predictions of plating onset during fast charging have been proposed but not compared directly with experiments. This work validates these model predictions against plating onset measurements via the “dOCV” method in graphite half-cells, for various electrode thicknesses and C-rates. Remarkably, it is shown that experimental and theoretical trends in plating onset (vs C-rate and electrode thickness) collapse to a single “master curve” using a nondimensional “reaction inhomogeneity” parameter. This observation supports the hypothesized reaction inhomogeneity mechanism for accelerating plating onset and provides practical guidance for electrode design. Furthermore, this work develops theory to quantify reaction inhomogeneity in situ directly from voltage V vs capacity Q data, using dQ / dV analysis. Here again, experiments and numerical predictions show good agreement, where peaks that correspond to LiC 6 correlate with plating onset. This work provides experimental validation of theoretical tools that can predict plating onset, aid electrode design, and give insight for plating onset mechanisms during fast charging.

25 ENERGY STORAGE↗

DOE OSTI2023

Copper plating qualification process for the fundamental power coupler waveguides for CEBAF cryomodules

To provide sufficient energy for CEBAF operation, cryomodules and components are being refurbished yearly as necessary. Copper plated fundamental power coupler waveguides are important components of the cryomodules. The integrity and quality of copper plating is critical to reduce the heat load from the waveguides into the He bath at 2.07 K. A search of copper plating resources is underway for plating or re-plating CEBAF-style waveguides. This effort ensures a continuous capability of copper plating on cryomodule components, especially on waveguides. To qualify plating vendors, the waveguide copper plating specifications were revisited, and a thorough plating evaluation process is being developed. The evaluation process ranges from coupon testing to sample waveguide qualification. Recent results are summarized and future work is planned.

Zhao, Liang↗

DOE OSTI2017

Evaluation of Thin Plate Hydrodynamic Stability through a Combined Numerical Modeling and Experimental Effort

An experimental and computational effort was undertaken in order to evaluate the capability of the fluid-structure interaction (FSI) simulation tools to describe the deflection of a Missouri University Research Reactor (MURR) fuel element plate redesigned for conversion to lowenriched uranium (LEU) fuel due to hydrodynamic forces. Experiments involving both flat plates and curved plates were conducted in a water flow test loop located at the University of Missouri (MU), at conditions and geometries that can be related to the MURR LEU fuel element. A wider channel gap on one side of the test plate, and a narrower on the other represent the differences that could be encountered in a MURR element due to allowed fabrication variability. The difference in the channel gaps leads to a pressure differential across the plate, leading to plate deflection. The induced plate deflection the pressure difference induces in the plate was measured at specified locations using a laser measurement technique. High fidelity 3-D simulations of the experiments were performed at MU using the computational fluid dynamics code STAR-CCM+ coupled with the structural mechanics code ABAQUS. Independent simulations of the experiments were performed at Argonne National Laboratory (ANL) using the STAR-CCM+ code and its built-in structural mechanics solver. The simulation results obtained at MU and ANL were compared with the corresponding measured plate deflections.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Fuel Swelling and Creep Analysis for a MURR LEU U-10Mo Monolithic Plate

In this work, finite element analysis (FEA) is used to model and simulate the thermo-mechanical behavior of a selected LEU MURR fuel plate under typical irradiation conditions of the proposed LEU MURR core. The proposed LEU fuel element for MURR conversion has 23 curved fuel plates. The fuel element design and analysis are described in Reference [7]. The safety analysis for calculating the margin to flow instability that had elements with a mixture of burnups, which is typical for MURR operations. In addition to the application of engineering hot channel factors to account for variations in the fuel element manufacturing that could affect the coolant channel gaps, the analysis assumed a constriction of the coolant channel gaps due to an increase in the fuel plate thicknesses during the element lifetime. Estimates of the local plate thickness increase at end-of-life (EOL) due to fuel swelling and creep were developed from experimental data presented in References [8] and [9]. The maximum local plate thickness increase from that analysis was calculated for fuel plate 23 in an EOL element. Furthermore, the minimum margin to flow instability for the reference LEU cores was calculated to occur in coolant channel 23 of an EOL element, which is the coolant channel between plates 22 and 23. Therefore,the work performed here evaluated plate 23 only, as this was found to be the most limiting plate.

Mohamed, Walid↗

DOE OSTI2020

Multi-Axis Resonant Plate Shock Testing Evaluation and Test Specification Development

Resonant plate testing is a shock test method that is frequently used to simulate pyroshock events in the laboratory. Recently, it was discovered that if the unit under test is installed at an off-center location, a tri-axial accelerometer would record a shock response in three directions and the resulting shock response spectra implied that the test may have qualified the component in three directions simultaneously. The purpose of this research project was to evaluate this idea of multi-axis shock testing to determine if it was truly a multi-axis shock environment and if such a test could be used as an equivalent component qualification test. A study was conducted using generic, additively manufactured components tested on a resonant plate, along with an investigation of plate motion to evaluate the component response to off- center plate excitation. The data obtained here along with the analytical simulations performed indicate that off-center resonant plate tests are actually not three-axis shock tests, but rather single axis shocks at an arbitrary angle dictated by the location of the unit under test on the plate. This conclusion is supported by the fact that only one vectored shock input is provided to the component in a resonant plate test. Thus, the output response is a coupled response of the transverse plate vibration and the rotational motion of the component on the plate. Additionally, a multi-axis shock test defined by three single axis test environments always results in a significant component over-test in one direction.

42 ENGINEERING↗

DOE OSTI2023

Copper plating qualification process for the fundamental power coupler waveguides for CEBAF cryomodules

Zhao, Liang↗

DOE OSTI2014

Nuclear reactor alignment plate configuration

An alignment plate that is attached to a core barrel of a pressurized water reactor and fits within slots within a top plate of a lower core shroud and upper core plate to maintain lateral alignment of the reactor internals. The alignment plate is connected to the core barrel through two vertically-spaced dowel pins that extend from the outside surface of the core barrel through a reinforcement pad and into corresponding holes in the alignment plate. Additionally, threaded fasteners are inserted around the perimeter of the reinforcement pad and into the alignment plate to further secure the alignment plate to the core barrel. A fillet weld also is deposited around the perimeter of the reinforcement pad. To accomodate thermal growth between the alignment plate and the core barrel, a gap is left above, below and at both sides of one of the dowel pins in the alignment plate holes through with the dowel pins pass.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Actively controlling coolant-cooled cold plate configuration

Cooling apparatuses are provided to facilitate active control of thermal and fluid dynamic performance of a coolant-cooled cold plate. The cooling apparatus includes the cold plate and a controller. The cold plate couples to one or more electronic components to be cooled, and includes an adjustable physical configuration. The controller dynamically varies the adjustable physical configuration of the cold plate based on a monitored variable associated with the cold plate or the electronic component(s) being cooled by the cold plate. By dynamically varying the physical configuration, the thermal and fluid dynamic performance of the cold plate are adjusted to, for example, optimally cool the electronic component(s), and at the same time, reduce cooling power consumption used in cooling the electronic component(s). The physical configuration can be adjusted by providing one or more adjustable plates within the cold plate, the positioning of which may be adjusted based on the monitored variable.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Plate heat exchanger for heating or cooling bulk solids

A heat exchanger includes an inlet for receiving bulk solids, a plurality of heat transfer plate assemblies, a plurality of spacers disposed between adjacent heat transfer plate assemblies, and supports for supporting the heat transfer plate assemblies. The heat transfer plate assemblies include a first plate having a first pair of holes extending therethrough, the first plate having channels extending along a surface thereof, for the flow of fluid through the channels, and a second plate bonded to the first plate to enclose the channels, the second plate including a second pair of holes generally aligned with the first pair of holes to form through holes to facilitate flow of the fluid through the through holes and the channels.

Byman, Ashley D.↗