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At least 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

Improved Creep-­Fatigue Models on Advanced Materials for SFR Applications (Final Report)

This report provides an update on the materials performance criteria and methodology relevant to sodium-cooled fast reactors (SFRs). The report is the second deliverable (Level 2) in FY11 (M2A11AN040303) under the work package A-11AN040303 “Materials Performance Criteria and Methodology” as part of the Advanced Structural Materials Program for the Advanced Reactor Concepts. The overall objective of the Materials Performance Criteria and Methodology work project is to evaluate the key requirements for the ASME Code qualification and the Nuclear Regulatory Commission (NRC) approval of advanced structural materials in support of the design and performance of sodium-cooled fast reactors. Advanced materials are a critical element in the development of fast reactor technologies. Enhanced materials performance not only improves safety margins and provides design flexibility, but also is essential for the economics of future advanced fast reactors. Qualification and licensing of advanced materials are prominent needs for the development and implementation of advanced fast reactor technologies. Nuclear structural component designs in the U.S. comply with the ASME Boiler and Pressure Vessel (B&PV) Code Section III (Rules for Construction of Nuclear Facility Components), and the NRC grants licensing. As the SFRs will operate at higher temperatures than the current light water reactors (LWRs), the design of elevated-temperature components must comply with ASME Section III Subsection NH (Class 1 Components in Elevated Temperature Service). A number of technical issues relevant to materials performance criteria and high temperature design methodology in the SFR were identified and presented in earlier reports. A viable approach to resolve these issues and the R&D priority were also recommended. The development of mechanistically based creep-fatigue interaction models for life prediction and reliable data extrapolation was chosen to be the central focus in near-term efforts. Our current focus is on the creep-fatigue damage issue in high-strength ferritic/martensitic steels such as mod.9Cr-1Mo (G91) and NF616 (G92) steels. The current ASME creep-fatigue design rule puts severe limits of fatigue and creep loads for G91 steel, the lead structural material for fast reactors. High-strength ferritic/martensitic steels behave fundamentally differently from austenitic stainless steels, for which the current ASME creep-fatigue design rules were developed. The unique deformation and damage characteristics in G91 steel, e.g. cyclic softening, degradation of creep and rupture strength during cyclic service, demands a new creep-fatigue design procedure that explicitly accounts for the material’s unique creep-fatigue behavior. G92 steel, a variant of G91 steel, is the lead candidate in the Advanced Alloy Development program. There is currently no creep-fatigue design rule available for this advanced alloy. To support the predictive model development and resolve the over-conservative issue with the ASME design rule for G91 steel, we recovered stress relaxation data from thirteen creep-fatigue tests conducted in the late 1980s and early 1990s at Oak Ridge National Laboratory, and conducted extensive data analysis in FY10. Based on this database and available literature data, we have developed a Cyclic Softening Model and a Stress Relaxation Model specifically applied to G91 steel. The Cyclic Softening Model describes the cyclic stress variation as a function of cycle number during creep-fatigue loading, and well captures the cyclic softening effect in G91 steel. The Stress Relaxation Model predicts the stress relaxation curve during the hold time of cyclic loading, and its dependence on the cyclic softening effect of G91 steel. Two creep-fatigue test systems have been set up to conduct model-oriented creep-fatigue experiments. Results from three creep-fatigue experiments on Heat 30176 of G91 steel are presented in the report: (1) a test performed at 550°C with total strain amplitude of 0.25% and a hold time of 60 s applied at peak strains in both tension and compression, (2) a test performed at 400°C with total strain amplitude of 0.5% and a tension and compression hold time of 60 s, and (3) a test performed at 20°C with total strain amplitude of 0.5% and a tension and compression hold time of 60 s. Three different test temperatures were chosen for two primary reasons: to determine the transition temperature of creep-fatigue interaction from a plasticity-dominated process to a creep-dominated process; to develop unified creep-fatigue models applicable for a wide range of temperatures. With the detailed information obtained in the creep-fatigue experiments, we have further refined the Cyclic Softening Model and Stress Relaxation Model. The Cyclic Softening Model and Stress Relaxation Model were incorporated into the Bilinear Creep-Fatigue Damage Model, forming a powerful framework for the life prediction by an improved creep-fatigue evaluation methodology. The cyclic softening and consecutive stress relaxation responses in G91 steel can be considered for each cycle of the entire cyclic process in the model calculation. The creep-fatigue damage in G91 steel was evaluated using the improved Bilinear Creep-Fatigue Damage Model without any safety margins. It was found that due to the significant cyclic softening in G91 steel, the unit creep damage in each cycle decreased continuously with increasing number of cycles. This continuous change in creep damage with cycling has significant implication in the evaluation of the total creep-fatigue damage. The total creep damage can be one order of magnitude lower when the unit creep damage at half-life was used in the evaluation in comparison with the calculations using the unit creep damage at cycle 10. An important conclusion was that the accurate assessment of the creep-fatigue damage in G91 steel must consider the history of cycling. This analysis provides a more realistic assessment of creep-fatigue damage and identifies critical factors that must be considered in the development of future advanced models for high-strength ferritic/martensitic alloys. An accelerated creep-fatigue testing methodology is proposed for the design of model-oriented experiments to guide and validate model developments. Future work will focus on creep-fatigue experiments of both G91 and G92 steels, and development of creep-fatigue models applicable to advanced ferritic/martensitic alloys. The Cyclic Softening Model and Stress Relaxation Model will be improved by incorporating microstructural parameters of dislocation density, subgrain structure, and second-phase particles. Collaborative modeling of combined Cyclic Softening Model, Stress Relaxation Model, and Interactive Damage Rate Model will be pursued for life prediction under creep-fatigue loading with extended hold time. Accelerated, well-controlled creep-fatigue tests will be conducted to provide high-quality experimental data to refine key material parameters and validate models.

Li, Meimei↗
DOE OSTI2018

Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three-dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

Huang, Hui↗
DOE OSTI2015

CD36 is indispensable for thermogenesis under conditions of fasting and cold stress

Hypothermia can occur during fasting when thermoregulatory mechanisms, involving fatty acid (FA) utilization, are disturbed. CD36/FA translocase is a membrane protein which facilitates membrane transport of long-chain FA in the FA consuming heart, skeletal muscle (SkM) and adipose tissues. It also accelerates uptake of triglyceride-rich lipoprotein by brown adipose tissue (BAT) in a cold environment. In mice deficient for CD36 (CD36{sup −/−} mice), FA uptake is markedly reduced with a compensatory increase in glucose uptake in the heart and SkM, resulting in lower levels of blood glucose especially during fasting. However, the role of CD36 in thermogenic activity during fasting remains to be determined. In fasted CD36{sup −/−} mice, body temperature drastically decreased shortly after cold exposure. The hypothermia was accompanied by a marked reduction in blood glucose and in stores of triacylglycerols in BAT and of glycogen in glycolytic SkM. Biodistribution analysis using the FA analogue {sup 125}I-BMIPP and the glucose analogue {sup 18}F-FDG revealed that uptake of FA and glucose was severely impaired in BAT and glycolytic SkM in cold-exposed CD36{sup −/−} mice. Further, induction of the genes of thermogenesis in BAT was blunted in fasted CD36{sup −/−} mice after cold exposure. These findings strongly suggest that CD36{sup −/−} mice exhibit pronounced hypothermia after fasting due to depletion of energy storage in BAT and glycolytic SkM and to reduced supply of energy substrates to these tissues. Our study underscores the importance of CD36 for nutrient homeostasis to survive potentially life-threatening challenges, such as cold and starvation. - Highlights: • We examined the role of CD36 in thermogenesis during cold exposure. • CD36{sup −/−} mice exhibit rapid hypothermia after cold exposure during fasting. • Uptake of fatty acid and glucose is impaired in thermogenic tissues during fasting. • Storage of energy substrates is reduced in thermogenic tissues during fasting. • CD36 is important for nutrient homeostasis to survive life-threatening challenges.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Computer-controlled finishing via dynamically constraint position-velocity-time scheduler

In a Computer Numerical Controlled (CNC) finishing process, the target material removal from an optical surface is guided by the convolution between the influence function of a machine tool and its dwell time at certain points over the surface. To reduce dynamics stressing and increase machining efficiency, the dwell time must be converted to varying velocities, which are the actual inputs to the machine tool controller. Conventionally, the conversion assumed constant acceleration and relied on linear motion interpolation, which caused discontinuities in velocities. This unsmooth motion affects the material removal distribution, and, thus, the accuracy of the finished surface shape. Many modern CNC machines support the smoother, cubic-polynomial interpolated Position-Velocity-Time (PVT) motion mode; however, the conventional scheduler may fail to provide suitable velocities for the PVT. Here in this study answers this challenge by proposing a novel PVT-based velocity scheduler that achieves smooth motion while considering CNC dynamic limits. Firstly, the principle of the PVT is explained, and the PVT-based velocity scheduler is formulated. Secondly, a quadratic programming is used to optimize the velocities by imposing the CNC dynamic constraints and the C 1 continuities (zeroth and first derivatives are continuous) simultaneously. Thirdly, the smoothness and accuracy of the scheduled velocities are studied on different kinds of tool paths via simulation. Finally, a sub-0.3 nm level surface finishing experiment using ion beam figuring is demonstrated to verify the feasibility of the proposed method. The PVT-based scheduler and simulator code is open-sourced.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Assessment of irradiation embrittlement effect on fatigue life of a pressurized-water reactor pressure vessel using the fracture toughness master curve approach

The reactor pressure vessel (RPV) is a critical structural component in pressurized-water reactors, and it is designed to withstand extreme conditions, such as high pressures, elevated temperatures, and prolonged radiation exposure. Ensuring RPV integrity is essential for the safe and reliable long-term operation of nuclear power plants, especially as aging mechanisms such as fatigue and irradiation embrittlement pose increased risks. Fatigue, caused by cyclic thermal and mechanical loading, can lead to crack initiation in localized high-stress regions. Simultaneously, neutron irradiation, particularly in the beltline region, progressively reduces fracture toughness, increasing susceptibility to brittle fracture. These combined effects of fatigue and irradiation embrittlement potentially impact the RPV structural integrity, necessitating fitness-for-service assessments. This study applies the fracture toughness master curve approach to evaluate the impact of irradiation embrittlement on RPV fatigue life. A coupled thermo-mechanical stress analysis identifies critical stress locations under normal service transients, pinpointing regions most vulnerable to fatigue crack initiation and growth. Stress intensity factors for postulated flaws at these locations are calculated, enabling an assessment of fatigue life under irradiated and unirradiated conditions. The results indicate that neutron irradiation embrittlement accelerates the conditions in which a critical crack can form and lead to failure, particularly at lower temperatures. The failure occurs where reduced fracture toughness limits the material’s resistance to crack growth. Axial cracks at nozzle corners are the most life limiting without irradiation, while circumferential cracks demonstrate longer fatigue lives. The findings highlight the importance of incorporating irradiation effects into fatigue life predictions to ensure the long-term structural integrity of RPVs.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Effects of Electron Irradiation on Candidate Materials for Target Window in Accelerator-Driven Molybdenum-99 Production

NorthStar Medical technologies is planning to produce Mo-99 through the photo-nuclear reaction Mo-100 (γ,n) Mo-99 utilizing multiple high-power electron accelerators. In this approach, the production target consists of multiple thin disks of metal Mo-100 cooled by helium gas at high (300–400 psi) pressure [4]. The cost of enriched Mo-100 is on the order of $500 - 1,000 per gram, which makes a smaller target desirable and requires achieving the highest possible electron flux on the target. The heat deposition in the entrance window limits the maximum flux because the window separates the vacuum in the accelerator beam line from the high-pressure helium in the target and is only cooled on one side by the helium flow. Because the window is continuously under stress from the helium pressure and the heat from the electron beam, it is desirable to estimate a lifetime for the window and develop a replacement schedule for the target holder. Such an estimate requires the ability to predict changes in the window material properties under electron irradiation. Candidate materials for the Mo-99 production target window are Inconel 718, 250 maraging steel, and beryllium. These materials encompass a wide range of thermal conductivity, thermal expansion coefficients, Young’s modulus, tensile strength and tensile ductility. The Mo-99 target window is subjected to internal pressure from the helium coolant and thermal stresses. The operating conditions and relative advantages of each material have been described previously [1]. The current work investigates the effects of electron irradiation on the tensile properties of these materials. Axial tensile tests were conducted with electron-irradiated samples and results were compared to baseline results generated for as-fabricated materials.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Effect of moisture on the fatigue behavior of graphite/epoxy composite laminates

The form of the moisture distribution in the specimen (gradient and flat profile) was considered to establish the influence of accelerated moisture conditioning on fatigue behavior. For the gradient specimens having an average moisture content of 1.4 percent, fatigue life was reduced by a factor of 8 at all stress levels investigated. Corresponding reduction in fatigue life for the flat moisture profile specimens at the same average moisture content was comparatively smaller, being about a factor of 5 from the value in dry specimens. X-ray radiographic analysis of damage accumulation in compression-compression fatigue revealed interlaminar cracking to be the dominant mode of failure responsible for the observed enhanced cyclic degradation of moisture-conditioned specimens. This finding was corroborated by the observed systematic reduction in interlaminar shear strength as a function of moisture content, which, in turn, increased the propensity for delamination under cyclic compressive loads. Residual strength measurements on cycled specimens indicated significant strength reductions at long lives, particularly in moisture conditioned specimens.

Ramani, S. V.↗
NASA NTRS1986

Biomedical support of man in space

The effects of G and/or exercise on cardiopulmonary adjustments to stresses are studied. The control of the cardiopulmonary system is examined using simulated microgravity (recumbency, immersion, lower body positive pressure, and 6-deg head-down tilt) and increased acceleration. It is observed that at rest and during exercise in simulated zero-6 environments, the stroke volume and cardiac output are initially increased and then (after prolonged exposure) return to prezero-G levels. Cardiovascular responses to increased gravity (1, 2, and 3 G) at rest and during exercise are analyzed; a decrease in plasma volume resulting in decreases in stroke volume and cardiac output, and an increase in heart rate are detected.

Pendergast, D. R.↗
NASA NTRS2002

Cyclic Failure Mechanisms of Thermal and Environmental Barrier Coating Systems Under Thermal Gradient Test Conditions

Plasma-sprayed ZrO2-8wt%Y2O3 and mullite+BSAS/Si multilayer thermal and environmental barrier coating (TBC-EBC) systems on SiC/SiC ceramic matrix composite (CMC) substrates were thermally cyclic tested under high thermal gradients using a laser high-heat-flux rig in conjunction with furnace exposure in water-vapor environments. Coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after exposure. Sintering kinetics of the coating systems were also independently characterized using a dilatometer. It was found that the coating failure involved both the time-temperature dependent sintering and the cycle frequency dependent cyclic fatigue processes. The water vapor environments not only facilitated the initial coating conductivity increases due to enhanced sintering and interface reaction, but also promoted later conductivity reductions due to the accelerated coating cracking and delamination. The failure mechanisms of the coating systems are also discussed based on the cyclic test results and are correlated to the sintering and thermal stress behavior under the thermal gradient test conditions.

Zhu, Dongming↗
DOE OSTI2013

Atomistic Studies of Cation Transport in Tetragonal ZrO2 During Zirconium Corrosion

Zirconium alloys are the major fuel cladding materials in current reactors. The water-side corrosion is one of the major degradation mechanisms of these alloys. During corrosion the transport of oxidizing species in zirconium dioxide (ZrO2) determines the corrosion kinetics. Previously it has been argued that the outward diffusion of cation ions is important for forming protective oxides. In this work, the migration of Zr defects in tetragonal ZrO2 is studied with temperature accelerated dynamics and molecular dynamics simulations. The results show that Zr interstitials have anisotropic diffusion and migrate preferentially along the [001] or c direction in tetragonal ZrO2. The compressive stresses can increase the Zr interstitial migration barrier significantly. The migration barriers of some defect clusters can be much lower than those of point defects. The migration of Zr interstitials at some special grain boundaries is much slower than in a bulk oxide. The implications of these atomistic simulation results in the Zr corrosion are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Summary of Test Results of MQXFS1 - The First Short Model 150 mm Aperture $Nb_3Sn$ Quadrupole for the High-Luminosity

The development of $Nb_3Sn$ quadrupole magnets for the High-Luminosity LHC upgrade is a joint venture between the US LHC Accelerator Research Program (LARP)* and CERN with the goal of fabricating large aperture quadrupoles for the LHC in-teraction regions (IR). The inner triplet (low-β) NbTi quadrupoles in the IR will be replaced by the stronger Nb3Sn magnets boosting the LHC program of having 10-fold increase in integrated luminos-ity after the foreseen upgrades. Previously LARP conducted suc-cessful tests of short and long models with up to 120 mm aperture. The first short 150 mm aperture quadrupole model MQXFS1 was assembled with coils fabricated by both CERN and LARP. The magnet demonstrated strong performance at the Fermilab’s verti-cal magnet test facility reaching the LHC operating limits. This paper reports the latest results from MQXFS1 tests with changed pre-stress levels. The overall magnet performance, including quench training and memory, ramp rate and temperature depend-ence, is also summarized.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Quantum stresses in the hydrogen atom

Gravitational form factors are often interpreted as providing access to stresses inside hadrons, in particular through Fourier transforms of the form factors 𝐷 and $\bar{𝑐}$. Some researchers, however, have expressed skepticism of this interpretation. I revisit the question, and argue that it is indeed appropriate to interpret these quantities as stress distributions. I consider the hydrogen atom’s ground state as a familiar example, and use the pilot wave interpretation of quantum mechanics to give the distributions a clear meaning. A striking result is that $\bar{𝑐}$—rather than 𝐷—quantifies the force law binding the system, which can be understood through Cauchy’s first law of motion.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2024

PIP-II cryoplant non thermal cycling updates

The Proton Improvement Plan-II (PIP-II) is a crucial upgrade to the Fermilab accelerator complex, featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (LINAC) with 23 cryomodules operating at 2 K. The LINAC thermohydraulic conditions are satisfied by the cryogenic subsystems: Cryogenic Distribution System (CDS), a helium refrigerator cold box (CB), a warm compression station (WCS) and a helium recovery system (RSYS). The accelerator has a strict requirement of non-thermal cycling of the LINAC cryomodules during planned and unplanned subsystem outages. This paper presents an integrated reliability analysis of the PIPII cryoplant. The study evaluates both normal and abnormal operating modes, with a focus on identifying integrated scenarios that put subsystems components under stress. The conclusions of this study will help build redundancy to mitigate LINAC thermal cycling risks during planned and unplanned subsystem outages.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Activation of Nrf2 attenuates carbonyl stress induced by methylglyoxal in human neuroblastoma cells: Increase in GSH levels is a critical event for the detoxification mechanism

The present study focused on the methylglyoxal (MG) detoxification mechanism in neuroblastoma cells. The involvement of nuclear factor erythroid 2-related factor 2 (Nrf2)/Kelch-like ECH-associated protein 1 (Keap1) pathway as a defense response against the formation of MG-modified proteins, which is well-known evidence of carbonyl stress, was also examined. We found that MG treatment resulted in accumulation of modified proteins bearing the structure of advanced glycation end products (AGEs) derived from MG in SH-SY5Y cells. This accumulation was suppressed by activation of the Nrf2 pathway prior to MG exposure via pre-treatment with an Nrf2 activator, carnosic acid and CDDO-Im, confirming the involvement of the Nrf2 pathway in MG detoxification. Although pre-treatment with the Nrf2 activator did not affect mRNA levels of GLO1, AKR1B1, and AKR7A2, the expressions of GCL and xCT mRNA, involved in GSH synthesis, were induced prior to increase in GSH levels. Furthermore, we demonstrated that a GSH synthesis inhibitor eliminated the MG detoxification effect derived from pretreatment with the Nrf2 activator. These results indicated that increase in GSH levels, induced by pre-treatment with carnosic acid, promoted the formation of the GLO1 substrate, hemithioacetal, thereby accelerating MG metabolism via the glyoxalase system and suppressing its toxicity. It was, therefore, determined that promotion of GSH synthesis via the Nrf2/Keap1pathway is important in the MG detoxification mechanism against neuronal MG-induced carbonyl stress, and Nrf2 activators contribute to reduction in the accumulation and toxic expression of carbonyl proteins. - Highlights: • Nrf2 activator prevents methylglyoxal-induced cytotoxicity and protein modifications. • MG treatment resulted in accumulation of modified proteins bearing the structure of CEL and MG-H1. • The promotion of GSH synthesis by activation of Nrf2 is a key response to MG detoxification.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Ion-beam radiation-induced Eshelby transformations: The mean and variance in hydrostatic and shear residual stresses

Ion beam plays a pivotal role in ion implantations and the fabrication of nanostructures. However, there lacks a quantitative model to describe the residual stresses associated with the ion-beam radiation. Radiation-induced residual stress/transformation strain have been mostly recognized in the hydrostatic sub strain space. Here, in this study, we use molecular dynamics (MD) simulations to show that the response of a material to irradiation is generally anisotropic that depends on the ion-beam direction, and should be described using tensorial quantities. We demonstrate that accelerator-based ion beam irradiation, combined with the intrinsic lattice anisotropy and externally induced anisotropy (such as anisotropic mechanical loadings), causes radiation-actuated shear transformation strains in addition to hydrostatic expansion. We map out these complex correlations for several materials. Radiation-induced defects are shown to be responsible for residual shear stresses in the manner of Eshelby inclusion transformation. We propose such tensorial response model should be considered for accurate nanoscale fabrication using ion-beam irradiation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2013

Contact detection acceleration in pebble flow simulation for pebble bed reactor systems

Pebble flow simulation plays an important role in the steady state and transient analysis of thermal-hydraulics and neutronics for Pebble Bed Reactors (PBR). The Discrete Element Method (DEM) and the modified Molecular Dynamics (MD) method are widely used to simulate the pebble motion to obtain the distribution of pebble concentration, velocity, and maximum contact stress. Although DEM and MD present high accuracy in the pebble flow simulation, they are quite computationally expensive due to the large quantity of pebbles to be simulated in a typical PBR and the ubiquitous contacts and collisions between neighboring pebbles that need to be detected frequently in the simulation, which greatly restricted their applicability for large scale PBR designs such as PBMR400. Since the contact detection accounts for more than 60% of the overall CPU time in the pebble flow simulation, the acceleration of the contact detection can greatly enhance the overall efficiency. In the present work, based on the design features of PBRs, two contact detection algorithms, the basic cell search algorithm and the bounding box search algorithm are investigated and applied to pebble contact detection. The influence from the PBR system size, core geometry and the searching cell size on the contact detection efficiency is presented. Our results suggest that for present PBR applications, the bounding box algorithm is less sensitive to the aforementioned effects and has superior performance in pebble contact detection compared with basic cell search algorithm. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Design and Analysis of a Double Wall, Water Cooled Window for Accelerator Based Mo-99 Production

The electron accelerator based Mo-99 production technique requires the use of Rhodotrons to generate 38 MeV, 6.32 mA pulsed electron beams. The introduction of the pulsed beam structure has introduced fatigue concerns in the vacuum-helium windows that did not exist previously for electron beam production via linear accelerators. Previous analysis has shown that temperature fluctuations of approximately 100°C above and below the steady state operating temperature of ~500°C will occur within the windows. A water cooled window will eliminate this concern by reducing the primary mechanical stress due to the 300-psig helium pressure load as well as the secondary thermally induced stress. Although a water cooled window was considered years ago, the complexities of adding an additional water line was unattractive until now. A double wall, water cooled window has been designed and analyzed for this reason. The water cooled window design is shown to decrease the helium-side window temperature to as low as 125°C, while the vacuum-side window is maintained at 161°C at a water flow rate of 3.2 GPM. These low steady state temperatures reduce the thermal stress of the helium-side window significantly. Also, the primary mechanical stress has been reduced by roughly 50% due to the reduced pressure gradient across the helium-side window (150-psig water and 300-psig helium). Considering a Mo-99 production loss of roughly 1%, the water cooled window is a drastic improvement over the previous helium cooled designs and should be greatly considered for future upgrades and redesign.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

High pressure effects on EBC systems in high temperature environments

Environmental barrier coatings (EBCs) are designed to protect SiCfiber/SiCmatrix ceramic matrix composites (CMCs) in turbine engines by mitigating wear in high-temperature water vapor environments. The failure of EBCs is frequently attributed to the accelerated oxidation of the silicon bond coating layer when exposed to high-temperature steam, leading to the formation of a thickened thermally grown oxide (TGO). TGO growth increases interfacial stress, weakens adhesion, and results in coating spallation. Understanding the impact of high-temperature oxidation of EBC systems is essential for developing accurate lifespan models for turbine components, although pressurized oxidation testing is extremely sparse in the open literature. In this work, oxidation tests were performed on rare earth silicate EBCs coated onto SiC substrates under increased pressure conditions. The coated specimens were tested at 1100°C, 1200°C, and 1300°C at both 1 atm and 10 atm total pressure in steam environments. Subsequent characterization focused on the microstructural evolution of the EBC/Si/SiC system. The experimental findings indicated that TGO behavior is dependent on high-pressure conditions, with elevated pressure leading to an increase in oxide scale thickness and modifications in its morphology.

Ardrey, Kristyn [ORNL] (ORCID:0000000184407796)↗