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DOE OSTI2022

Subcomponent Validation of Composite Joints for Marine Energy Structures

The Marine Energy Advanced Materials project addresses the barriers and uncertainties facing marine renewable energy developers in using composite materials for load-bearing structures. Sponsored by the U.S. Department of Energy's Water Power Technologies Office, the multiyear project comprises of collaborators from the National Renewable Energy Laboratory (NREL), Sandia National Laboratories, Pacific Northwest National Laboratory (PNNL), Montana State University (MSU), Florida Atlantic University (FAU), and industry stakeholders. As part of the Marine Energy Advanced Materials project, marine renewable energy industry surveys and assessments were conducted to identify key materials and knowledge gaps that hinder the adoption of composite materials in marine renewable energy structures. Specific knowledge gaps highlighted for composite materials were environmental effects, fatigue strengths, and bonded and bolted interconnects (composite/composite and composite/metal). It was concluded that many of these gaps could be addressed through subcomponent validation; consequently, a program was developed at NREL with the goals of developing subcomponent validation methods for appropriate marine energy materials, which would improve the understanding of design allowables for full-scale structural components and joints. Ultimately, the aim is to reduce timelines and costs associated with full-scale structural validation efforts while also providing near-net-scale static and fatigue data of composite/metal subcomponents for marine renewable energy systems. To approach these goals, a testing program was developed at NREL to investigate a variety of materials and structural design details at the subcomponent scale to understand (a) the effects of harsh and corrosive marine energy environments and (b) the static and fatigue strengths of the complex geometries. The recent study from this testing program is perhaps the largest that has ever been conducted with respect to specimen scale and geographic diversity of underwater environmental conditions that the specimens were subjected to. A variety of specimen geometries were designed by NREL to highlight key features of multimaterial (composite/composite or metal/composite) interconnects that may be used in marine renewable energy structural designs. The designs used several different composite matrices, adhesives, and marine-grade steels, which were highlighted in the surveys as being the most appropriate for harsh marine environments. Composite panels were then manufactured at MSU, and were subsequently manufactured into test specimens by NREL. The specimens were shipped to FAU and PNNL for conditioning in ocean water tanks at various temperatures for an extended period. The specimens were then returned to NREL for structural validation. This presentation will provide an overview of recent advances within the testing program in terms of specimen design and test methods, and will discuss results and key findings of the subcomponent testing program to date at NREL.

adhesives↗

DOE OSTI2024

Visualization of post-detonation fireball flowfields and comparison to CFD modeling

Visualization of flow structures within post-detonation fireballs has been performed for benchmark validation of numerical simulations. Custom pressed PETN explosives with a 12-mm diameter hemispherical form factor were used to produce a spherically symmetric post-detonation flow with low soot yield. Hydroxyl-radical planar laser induce fluorescence (OH-PLIF) was employed to visualize the structure ranging from approximately 10 μs to 35 μs after shock breakout from the explosive pellet. Fireball simulations were performed using the HyBurn Computational Fluid Dynamics (CFD) package. Experimental OH-PLIF results were compared to synthetic OH-PLIF from post-processing of CFD simulations. From the comparison of experimental and synthetic OH-PLIF images, CFD is shown to replicate much of the flow structure observed in the experiments, revealing potential differences in turbulent length scales and OH kinetics. Furthermore, results provide significant advancement in experimental resolution of these harsh turbulent combustion environments and validate physical models thereof.

Detonator↗

DOE OSTI2026

Photoinduced Electron Transfer Informs on Pathway Coupling in Flavin-Based Electron Bifurcation

Flavin-based electron bifurcation (FBEB) is an enzymatic mechanism that generates extremely high-energy electrons to drive unfavorable chemical reactions. It is utilized by the NADHdependent ferredoxin:NADP + -oxidoreductase (Nfn) enzyme in hyperthermophile Pyrococcus furiosus to bifurcate electrons from NADPH into the coupled low-potential (endergonic) and highpotential (exergonic) pathways. This process enables P. furiosus to live in harsh and uninviting environments. Despite its biological importance, the mechanisms used by Nfn to facilitate exceptional directional control over short-lived, high-energy electrons and to prevent undesired transfer, particularly along the low-potential pathway, are still not well understood. To elucidate how the protein environment contributes to electronic control in the lowpotential pathway, new techniques must be utilized to probe these unstable intermediates. In this study, we have adapted lowtemperature photoexcitation combined with electron paramagnetic resonance (EPR) to accumulate the short-lived intermediate and place it in the context of the other cofactors involved in the low-potential pathway of Nfn. We observed coincident growth of both the radical intermediate and its nearby [4Fe-4S] cluster over 4.5 h of illumination with NADPH at cryogenic temperatures. The photogenerated paramagnetic species were stable in LN 2 storage indefinitely and recombined when warmed to higher temperatures. The results provide insights into the electron transfer steps and cofactor interactions along the low potential pathway, facilitating a more robust mechanistic understanding of the high-energy events of electron bifurcation. Furthermore, through comparison of cryogenic and room temperature experiments, a potential gating step involving the movement of key residues important for the reversibility of electron flow along this pathway is suggested.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Sustainable Functional Epoxies through Boric Acid Templating

Thermoset polymers (e.g. epoxies, vulcanizable rubbers, polyurethanes, etc.) are crosslinked materials with excellent thermal, chemical, and mechanical stability; these properties make thermoset materials attractive for use in harsh applications and environments. Unfortunately, material robustness means that these materials persist in the environment with very slow degradation over long periods of time. Balancing the benefits of material performance with sustainability is a challenge in need of novel solutions. Here, we aimed to address this challenge by incorporating boronic acid-amine complexes into epoxy thermoset chemistries, facilitating degradation of the material under pH neutral to alkaline conditions; in this scenario, water acts as an initiator to remove boron species, creating a porous structure with an enhanced surface area that makes the material more amenable to environmental degradation. Furthermore, the expulsion of the boron leaves the residual pores rich in amines which can be exploited for CO 2 absorption or other functionalization. We demonstrated the formation of novel boron species from neat mixing of amine compounds with boric acid, including one complex that appears highly stable under nitrogen atmosphere up to 600 °C. While degradation of the materials under static, alkaline conditions (our “trigger”) was inconclusive at the time of this writing, dynamic conditions appeared more promising. Additionally, we showed that increasing boronic acid content created materials more resistant to thermal degradation, thus improving performance under typical high temperature use conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Fusion Materials Research at Oak Ridge National Laboratory in FY22

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Machine Learning Enhanced Development of Functionally Graded Materials Enabled by Directed Energy Deposition

The ability to functionally grade materials provides designers with a new dimension of design flexibility that can be leveraged to improve functionality, reduce cost, or improve efficiency in a wide range of applications. This program was specifically focused on FGMs for hot and harsh gas path environments. These environments are common for the hot sections of jet engines and gas turbines, where parts undergo high temperature and mechanical loads in a corrosive environment. Expensive high γ' strengthened Ni superalloys such as René 41 (R41) and René 80 (R80) are generally used exclusively for a whole part, although only a section of the part demands such superalloys. To minimize cost, low/no γ' strengthened Ni superalloys such as Inconel 718 (INC718) could be used at less-demanding sections of the part could be welded to the high γ' strengthened Ni superalloys. However, the welding typically is a failure site due to the low durability at the welding interface. Functionally grading provides a welding alternative that can allow cost reduction without sacrificing mechanical performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion environment. The overarching goal of the ORNL Fusion Materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science—Fusion Energy Sciences program, in parallel with developing the materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Feasibility Assessment of Using Electrical Impedance Tomography for Damage Localization in Graphite Microreactor Components

Microreactors have great potential to decrease capital costs and construction timelines, reducing the barriers to implementing advanced nuclear reactor technologies. However, the lower power output of these microreactors introduces economic challenges if the operation and maintenance costs cannot be reduced sufficiently. Many microreactor concepts use graphite materials for in-core moderator and structural purposes, which will require periodic inspection or, ideally, in situ structural health monitoring. This work describes an initial evaluation of the feasibility of leveraging graphite’s semiconducting properties to perform electrical impedance tomography (EIT) for defect localization. First, a study was performed to identify the best methods for bonding electrical contacts to minimize the effects of contact resistance that interfere with impedance measurements of the graphite. After determining the best bonding approach, electrodes were attached to multiple graphite components with varying geometries (e.g., simple block and more representative microreactor hexagonal block). In parallel, finite element analysis approaches were developed and implemented to analyze the impact of defects and contact resistances and to inform an iterative inverse model for reconstructing the conductivity distribution. The results of this study show that defect localization in graphite components is possible using EIT if a sufficient number of electrodes (to improve spatial resolution) can be bonded using a technique with very low contact resistance and those contact resistances remain stable during reactor operation. If the reactor core and vessel design do not allow electrodes to be bonded during reactor operation, then it may be possible to detach/reattach electrodes between reactor operation and outages if a suitable mechanical connection that offers repeatable contact resistance can be identified. Alternatively, future work could focus on identifying contacts that can survive the harsh reactor operating environment so that contacts do not need to be removed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1985

Ribbon burner simulation of T-700 turbine shroud for ceramic lined seals research

Experimental and analytical studies were conducted to determine the acceptability of a ribbon-burner simulation of engine conditions for testing ceramic-lined turbine tip shrouds. The calculated values reveal that the ribbon burner establishes at least as harsh a thermal environment as is present at any time within the turbine shroud. Comparisons were made with ceramic components in a turboshaft engine.

Little, J. K.↗

NASA NTRS1985

Ribbon-burner simulation of T-700 turbine shroud for ceramic-lined seals research

Little, J. K.↗

NASA NTRS1999

A New Frontier Beckons: Space Exploration in the 21st Century

Throughout recorded history, small groups of explorers have Pushed back the edge of the frontier and opened up new territories for others to follow. As the 20th Century closes, history will record that in the 1960's humankind opened the vast frontier beyond Earth's atmosphere. Although the Apollo program blazed a trail of exploration to the Moon, the development of space has only reached into low Earth orbit. The Space Shuttle and International Space Station programs, and the communication and scientific satellite networks established in orbit around the Earth, are all stepping stones that will enable explorers to venture once again beyond our home planet. Exploration is difficult. It is difficult for the people and machines that travel in extreme environments and endure harsh conditions, and it is difficult for the national leaders who must champion and fund the programs that lead to discovery and reward. Christopher Columbus spent many years meeting with the Kings of Portugal, England, and France only to see his dream of sailing west into the vast Atlantic with ships and crew. discredited. Queen Isabella of Spain was willing to look beyond the many problems plaguing her own shores and see the potential reward for her investment in the future. The voyages of Columbus set the stage for more Spanish explorers, who turned Spain into a great world power. The Apollo program and the unpiloted Lunar Orbiter, Surveyor, Mariner and Viking spacecraft that NASA launched in the 1966's &1970's were our country's first investment, in the exploration of the solar system. These human and robotic missions rewarded us with the first close views of the lunar and martian surfaces, and laid before our eyes territories as vast as all the continents of Earth combined. The Lunar Prospector, Near Earth Asteroid Rendezvous, and Mars Pathfinder and Global Surveyor missions are continuing our scientific conquest of the inner solar system, leading the way for humans to follow.

Mendell, Wendell W.↗

NASA NTRS2001

Development of Electronics for Low-Temperature Space Missions

Electronic systems that are capable of operating at cryogenic temperatures will be needed for many future NASA space missions, including deep space probes and spacecraft for planetary surface exploration. In addition to being able to survive the harsh deep space environment, low-temperature electronics would help improve circuit performance, increase system efficiency, and reduce payload development and launch costs. Terrestrial applications where components and systems must operate in low-temperature environments include cryogenic instrumentation, superconducting magnetic energy storage, magnetic levitation transportation systems, and arctic exploration. An ongoing research and development project for the design, fabrication, and characterization of low-temperature electronics and supporting technologies at NASA Glenn Research Center focuses on efficient power systems capable of surviving in and exploiting the advantages of low-temperature environments. Supporting technologies include dielectric and insulating materials, semiconductor devices, passive power components, optoelectronic devices, and packaging and integration of the developed components into prototype flight hardware. An overview of the project is presented, including a description of the test facilities, a discussion of selected data from component testing, and a presentation of ongoing research activities being performed in collaboration with various organizations.

Patterson, Richard L.↗

NASA NTRS2003

Simulation-Based Verification of Livingstone Applications

AI software is viewed as a means to give greater autonomy to automated systems, capable of coping with harsh and unpredictable environments in deep space missions. Autonomous systems pose a serious challenge to traditional test-based verification approaches, because of the enormous space of possible situations that they aim to address. Before these systems are put in control of critical applications, appropriate new verification approaches need to be developed. This article describes Livingstone PathFinder (LPF), a verification tool for autonomous diagnosis applications based on NASA's Livingstone model-based diagnosis system. LPF applies state space exploration algorithms to an instrumented testbed, consisting of the Livingstone diagnosis system embedded in a simulated operating environment. The article describes different facets of LPF and reports some experimental results from applying LPF to a Livingstone model of the main propulsion feed subsystem of the X-34 space vehicle. This paper describes Livingstone PathFinder (LPF), a verification tool for autonomous diagnosis applications based on NASA's Livingstone model-based diagnosis system. LPF applies state space exploration algorithms to an instrumented testbed, consisting of the Livingstone diagnosis system embedded in a simulated operating environment. Section 2 provides an overview of Livingstone; Section 3 describes the LPF architecture; Section 4 discusses its applicability; Section 5 reviews some experimental results; Section 6 compares LPF to related verification approaches; Section 7 draws conclusions and discusses some perspectives.

Lindsey, Anthony E.↗

NASA NTRS2004

Simulation-Based Verification of Autonomous Controllers via Livingstone PathFinder

AI software is often used as a means for providing greater autonomy to automated systems, capable of coping with harsh and unpredictable environments. Due in part to the enormous space of possible situations that they aim to addrs, autonomous systems pose a serious challenge to traditional test-based verification approaches. Efficient verification approaches need to be perfected before these systems can reliably control critical applications. This publication describes Livingstone PathFinder (LPF), a verification tool for autonomous control software. LPF applies state space exploration algorithms to an instrumented testbed, consisting of the controller embedded in a simulated operating environment. Although LPF has focused on NASA s Livingstone model-based diagnosis system applications, the architecture is modular and adaptable to other systems. This article presents different facets of LPF and experimental results from applying the software to a Livingstone model of the main propulsion feed subsystem for a prototype space vehicle.

Lindsey, A. E.↗

NASA NTRS2000

Electronics Demonstrated for Low- Temperature Operation

The operation of electronic systems at cryogenic temperatures is anticipated for many NASA spacecraft, such as planetary explorers and deep space probes. For example, an unheated interplanetary probe launched to explore the rings of Saturn would experience an average temperature near Saturn of about 183 C. Electronics capable of low-temperature operation in the harsh deep space environment also would help improve circuit performance, increase system efficiency, and reduce payload development and launch costs. An ongoing research and development program on low-temperature electronics at the NASA Glenn Research Center at Lewis Field is focusing on the design of efficient power systems that can survive and exploit the advantages of low-temperature environments. The targeted systems, which are mission driven, include converters, inverters, controls, digital circuits, and special-purpose circuits. Initial development efforts successfully demonstrated the low-temperature operation and cold-restart of several direct-current/direct-current (dc/dc) converters based on different types of circuit design, some with superconducting inductors. The table lists some of these dc/dc converters with their properties, and the photograph shows a high-voltage, high-power dc/dc converter designed for an ion propulsion system for low-temperature operation. The development efforts of advanced electronic systems and the supporting technologies for low-temperature operation are being carried out in-house and through collaboration with other Government agencies, industry, and academia. The Low Temperature Electronics Program supports missions and development programs at NASA s Jet Propulsion Laboratory and Goddard Space Flight Center. The developed technologies will be transferred to commercial end users for applications such as satellite infrared sensors and medical diagnostic equipment.

Patterson, Richard L.↗

NASA NTRS2005

Molecular Rayleigh Scattering Techniques Developed for Measuring Gas Flow Velocity, Density, Temperature, and Turbulence

Nonintrusive optical point-wise measurement techniques utilizing the principles of molecular Rayleigh scattering have been developed at the NASA Glenn Research Center to obtain time-averaged information about gas velocity, density, temperature, and turbulence, or dynamic information about gas velocity and density in unseeded flows. These techniques enable measurements that are necessary for validating computational fluid dynamics (CFD) and computational aeroacoustic (CAA) codes. Dynamic measurements allow the calculation of power spectra for the various flow properties. This type of information is currently being used in jet noise studies, correlating sound pressure fluctuations with velocity and density fluctuations to determine noise sources in jets. These nonintrusive techniques are particularly useful in supersonic flows, where seeding the flow with particles is not an option, and where the environment is too harsh for hot-wire measurements.

Mielke, Amy F.↗

NASA NTRS2008

Lunar Dust Simulant in Mechanical Component Testing - Paradigm and Practicality

Due to the uniquely harsh lunar surface environment, terrestrial test activities may not adequately represent abrasive wear by lunar dust likely to be experienced in mechanical systems used in lunar exploration. Testing to identify potential moving mechanism problems has recently begun within the NASA Engineering and Safety Center Mechanical Systems Lunar Dust Assessment activity in coordination with the Exploration Technology and Development Program Dust Management Project, and these complimentary efforts will be described. Specific concerns about differences between simulant and lunar dust, and procedures for mechanical component testing with lunar simulant will be considered. In preparing for long term operations within a dusty lunar environment, the three fundamental approaches to keeping mechanical equipment functioning are dust avoidance, dust removal, and dust tolerance, with some combination of the three likely to be found in most engineering designs. Methods to exclude dust from contact with mechanical components would constitute mitigation by dust avoidance, so testing seals for dust exclusion efficacy as a function of particle size provides useful information for mechanism design. Dust of particle size less than a micron is not well documented for impact on lunar mechanical components. Therefore, creating a standardized lunar dust simulant in the particulate size range of ca. 0.1 to 1.0 micrometer is useful for testing effects on mechanical components such as bearings, gears, seals, bushings, and other moving mechanical assemblies. Approaching actual wear testing of mechanical components, it is beneficial to first establish relative wear rates caused by dust on commonly used mechanical component materials. The wear mode due to dust within mechanical components, such as abrasion caused by dust in grease(s), needs to be considered, as well as the effects of vacuum, lunar thermal cycle, and electrostatics on wear rate.

Jett, T.↗

NASA NTRS2009

Lunar Lava Tubes - The Promise of New Orbital Data

The basaltic plains of the Moon contain lava channels on scales of tens of meters to hundreds of kilometers. Many of these channels are segmented, strongly suggesting that some portions include covered lava tubes. Lunar lava tubes are expected to provide unique environments below the harsh lunar surface, maintaining near-isothermal conditions and substantial shielding from solar and galactic radiation. A lava tube has often been suggested as natural shelter for a future human outpost. Previous searches for lunar lava tubes have been limited by a combination of image resolution and completeness of coverage. The five robotic Lunar Orbiter spacecraft combined to photograph essentially the entire lunar surface with a resolution of 60 m, and covered selected sites with resolutions as high as 2 m. The highest-resolution Apollo images, from the mapping and panoramic cameras, covered swaths totaling 16% of the lunar surface, at resolutions of approximately 5 m. The Lunar Reconnaissance Orbiter -- launched in June 2009 to a polar orbit -- carries a suite of instruments that will revolutionize lunar remote sensing, including the identification and characterization of lava tubes. The Lunar Reconnaissance Orbiter Camera (LROC) system includes a multi-spectral wide-angle camera with a resolution of 70 m, allowing a comprehensive survey of the entire lunar surface. The LROC narrow-angle camera is providing targeted images at resolutions of 0.5 - 2 m, including stereo coverage, which should allow detection of tube entrances and breakdown structures. The Lunar Orbiter Laser Altimeter is producing a global topographic map with a vertical resolution of 1 m and a horizontal resolution of 50 m. These data will be critical to understanding lava dynamics and tube emplacement.

Allen, Carlton C.↗