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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 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Swelling In Light Water Reactor Internal Components: Insights from Computational Modeling

A modern cluster dynamics model has been used to investigate the materials and irradiation parameters that control microstructural evolution under the relatively low-temperature exposure conditions that are representative of the operating environment for in-core light water reactor components. The focus is on components fabricated from austenitic stainless steel. The model accounts for the synergistic interaction between radiation-produced vacancies and the helium that is produced by nuclear transmutation reactions. Cavity nucleation rates are shown to be relatively high in this temperature regime (275 to 325°C), but are sensitive to assumptions about the fine scale microstructure produced under low-temperature irradiation. The cavity nucleation rates observed run counter to the expectation that void swelling would not occur under these conditions. This expectation was based on previous research on void swelling in austenitic steels in fast reactors. This misleading impression arose primarily from an absence of relevant data. The results of the computational modeling are generally consistent with recent data obtained by examining ex-service components. However, it has been shown that the sensitivity of the model s predictions of low-temperature swelling behavior to assumptions about the primary damage source term and specification of the mean-field sink strengths is somewhat greater that that observed at higher temperatures. Further assessment of the mathematical model is underway to meet the long-term objective of this research, which is to provide a predictive model of void swelling at relevant lifetime exposures to support extended reactor operations.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Analytical Formulation for Sizing and Estimating the Dimensions and Weight of Wind Turbine Hub and Drivetrain Components

This report summarizes the theory, verification, and validation of a new sizing tool for wind turbine drivetrain components, the Drivetrain Systems Engineering (DriveSE) tool. DriveSE calculates the dimensions and mass properties of the hub, main shaft, main bearing(s), gearbox, bedplate, transformer if up-tower, and yaw system. The level of fi¬ delity for each component varies depending on whether semiempirical parametric or physics-based models are used. The physics-based models have internal iteration schemes based on system constraints and design criteria. Every model is validated against available industry data or finite-element analysis. The verification and validation results show that the models reasonably capture primary drivers for the sizing and design of major drivetrain components.

17 WIND ENERGY↗
DOE OSTI2014

Improving Energy Efficiency by Developing Components for Distributed Cooling and Heating Based on Thermal Comfort Modeling (General Motors LLC Final Project Report)

On November 3, 2009, General Motors (GM) accepted U.S. Department of Energy (DOE) Cooperative Agreement award number DE-EE0000014 from the National Energy Technology Laboratory (NETL). GM was selected to execute a three-year cost shared research and development project on Solid State Energy Conversion for Vehicular Heating, Ventilation & Air Conditioning (HVAC) and for Waste Heat Recovery. The primary objective of this project was to develop a distributed automotive HVAC system that provides thermal comfort equivalent to current state-of-the-art centralized systems while using significantly less energy. To satisfy this objective, the team identified the following goals: • Reduce by at least 30% of the “billions of gallons” the fuel used in cooling mode to maintain occupant comfort through the localized use of thermoelectric (TE) technology while maintaining occupant comfort and safety. • Develop TE HVAC components with a coefficient of performance (COP) greater than 1.3 for cooling and greater than 2.3 for heating, then integrate and test these components as part of a reliable distributed HVAC system in a conventional vehicle (an eAssist Buick Lacrosse) and an extended range electric vehicle (a Chevrolet Volt). • Update the UCB Thermal Comfort model to predict the response of vehicle occupants to localized heating and cooling based on human subject testing, and develop associated computer-aided engineering (CAE) tools to support the integration of distributed HVAC components into future vehicle designs. A secondary objective of the project was to improve the efficiency of thermoelectric generators for converting engine waste heat into electricity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Nonlinear Ultrasonic Techniques to Monitor Radiation Damage in RPV and Internal Components

The objective of this research is to demonstrate that nonlinear ultrasonics (NLU) can be used to directly and quantitatively measure the remaining life in radiation damaged reactor pressure vessel (RPV) and internal components. Specific damage types to be monitored are irradiation embrittlement and irradiation assisted stress corrosion cracking (IASCC). Our vision is to develop a technique that allows operators to assess damage by making a limited number of NLU measurements in strategically selected critical reactor components during regularly scheduled outages. This measured data can then be used to determine the current condition of these key components, from which remaining useful life can be predicted. Methods to unambiguously characterize radiation related damage in reactor internals and RPVs remain elusive. NLU technology has demonstrated great potential to be used as a material sensor – a sensor that can continuously monitor a material’s damage state. The physical effect being monitored by NLU is the generation of higher harmonic frequencies in an initially monochromatic ultrasonic wave. The degree of nonlinearity is quantified with the acoustic nonlinearity parameter, β, which is an absolute, measurable material constant. Recent research has demonstrated that nonlinear ultrasound can be used to characterize material state and changes in microscale characteristics such as internal stress states, precipitate formation and dislocation densities. Radiation damage reduces the fracture toughness of RPV steels and internals, and can leave them susceptible to IASCC, which may in turn limit the lifetimes of some operating reactors. The ability to characterize radiation damage in the RPV and internals will enable nuclear operators to set operation time thresholds for vessels and prescribe and schedule replacement activities for core internals. Such a capability will allow a more clear definition of reactor safety margins. The research consists of three tasks: (1) materials sensing and monitoring; (2) physics-based materials and damage evolution modeling; and (3) remaining life estimation by integrating sensing, modeling and uncertainty.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Moly99 Production Facility: Report on Beamline Components, Requirements, Costs

In FY14 we completed the design of the beam line for the linear accelerator production design concept. This design included a set of three bending magnets, quadrupole focusing magnets, and octopoles to flatten the beam on target. This design was generic and applicable to multiple different accelerators if necessary. In FY15 we built on that work to create specifications for the individual beam optic elements, including power supply requirements. This report captures the specification of beam line components with initial cost estimates for the NorthStar production facility.This report is organized as follows: The motivation of the beamline design is introduced briefly, along with renderings of the design. After that, a specific list is provided, which accounts for each beamline component, including part numbers and costs, to construct the beamline. After that, this report details the important sections of the beamline and individual components. A final summary and list of follow-on activities completes this report.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2016

Feasibility and Testing of Additive Manufactured Components

This project focused on demonstrating the ability to fabricate two parts with different geometry: an arc flash interrupter and a hydraulic manifold. Eaton Corporation provided ORNL solid models, information related to tolerances and sensitive parameters of the parts and provided testing and evaluation. ORNL successfully manufactured both components, provided cost models of the manufacturing (materials, labor, time and post processing) and delivered test components for Eaton evaluation. The arc flash suppressor was fabricated using the Renishaw laser powder bed technology in CoCrMo while the manifold was produced from Ti-6Al-4V using the Arcam electron beam melting technology. These manufacturing techniques were selected based on the design and geometrical tolerances required. A full-scale manifold was produced on the Arcam A2 system (nearly 12 inches tall). A portion of the manifold was also produced in the Arcam Q10 system. Although a full scale manifold could not be produced in the system, a full scale manifold is expected to have similar material properties, geometric accuracy, and surface finish as could be fabricated on an Arcam Q20 system that is capable of producing four full scale manifolds in a production environment. In addition to the manifold, mechanical test specimens, geometric tolerance artifacts, and microstructure samples were produced alongside the manifold. The development and demonstration of these two key components helped Eaton understand the impact additive manufacturing can have on many of their existing products. By working within the MDF and leveraging ORNL’s manufacturing and characterization capabilities, the work will ensure the rapid insertion and commercialization of this technology.

42 ENGINEERING↗
DOE OSTI2016

Transportation of Large Wind Components: A Permitting and Regulatory Review

This report summarizes permitting and regulatory issues associated with transporting wind turbine blades, towers, and nacelles as well as large transformers (wind components). These wind components are commonly categorized as oversized and overweight (OSOW) and require specific permit approvals from state and local jurisdictions. The report was developed based on a Quadrennial Energy Review (QER) recommendation on logistical requirements for the transportation of 'oversized or high-consequence energy materials, equipment, and components.'

17 WIND ENERGY↗
DOE OSTI2016

Transportation of Large Wind Components: A Review of Existing Geospatial Data

This report features the geospatial data component of a larger project evaluating logistical and infrastructure requirements for transporting oversized and overweight (OSOW) wind components. The goal of the larger project was to assess the status and opportunities for improving the infrastructure and regulatory practices necessary to transport wind turbine towers, blades, and nacelles from current and potential manufacturing facilities to end-use markets. The purpose of this report is to summarize existing geospatial data on wind component transportation infrastructure and to provide a data gap analysis, identifying areas for further analysis and data collection.

17 WIND ENERGY↗
DOE OSTI2016

Study the Cyclic Plasticity Behavior of 508 LAS under Constant, Variable and Grid-Load-Following Loading Cycles for Fatigue Evaluation of PWR Components

This report provides an update of an earlier assessment of environmentally assisted fatigue for components in light water reactors. This report is a deliverable in September 2016 under the work package for environmentally assisted fatigue under DOE’s Light Water Reactor Sustainability program. In an April 2016 report, we presented a detailed thermal-mechanical stress analysis model for simulating the stress-strain state of a reactor pressure vessel and its nozzles under grid-load-following conditions. In this report, we provide stress-controlled fatigue test data for 508 LAS base metal alloy under different loading amplitudes (constant, variable, and random grid-load-following) and environmental conditions (in air or pressurized water reactor coolant water at 300°C). Also presented is a cyclic plasticity-based analytical model that can simultaneously capture the amplitude and time dependency of the component behavior under fatigue loading. Results related to both amplitude-dependent and amplitude-independent parameters are presented. The validation results for the analytical/mechanistic model are discussed. This report provides guidance for estimating time-dependent, amplitude-independent parameters related to material behavior under different service conditions. The developed mechanistic models and the reported material parameters can be used to conduct more accurate fatigue and ratcheting evaluation of reactor components.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Statistical Framework for Planning a Component Shelf Life Program.

This document outlines a statistical framework for establishing a shelf-life program for components whose performance is measured by the value of a continuous variable such as voltage or function time. The approach applies to both single measurement devices and repeated measurement devices, although additional process control charts may be useful in the case of repeated measurements. The approach is to choose a sample size that protects the margin associated with a particular variable over the life of the component. Deviations from expected performance of the measured variable are detected prior to the complete loss of margin. This ensures the reliability of the component over its lifetime.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Integrated Predictive Tools for Customizing Microstructure and Material Properties of Additively Manufactured Aerospace Components

Additive Manufacturing (AM) refers to a process by which digital three-dimensional (3-D) design data is converted to build up a component by depositing material layer-by-layer. United Technologies Corporation (UTC) is currently involved in fabrication and certification of several AM aerospace structural components made from aerospace materials. This is accomplished by using optimized process parameters determined through numerous design-of-experiments (DOE)-based studies. Certification of these components is broadly recognized as a significant challenge, with long lead times, very expensive new product development cycles and very high energy consumption. Because of these challenges, United Technologies Research Center (UTRC), together with UTC business units have been developing and validating an advanced physics-based process model. The specific goal is to develop a physics-based framework of an AM process and reliably predict fatigue properties of built-up structures as based on detailed solidification microstructures. Microstructures are predicted using process control parameters including energy source power, scan velocity, deposition pattern, and powder properties. The multi-scale multi-physics model requires solution and coupling of governing physics that will allow prediction of the thermal field and enable solution at the microstructural scale. The state-of-the-art approach to solve these problems requires a huge computational framework and this kind of resource is only available within academia and national laboratories. The project utilized the parallel phase-fields codes at Oak Ridge National Laboratory (ORNL) and Lawrence Livermore National Laboratory (LLNL), along with the high-performance computing (HPC) capabilities existing at the two labs to demonstrate the simulation of multiple dendrite growth in threedimensions (3-D). The LLNL code AMPE was used to implement the UTRC phase field model that was previously developed for a model binary alloy, and the simulation results were compared against the UTRC simulation results, followed by extension of the UTRC model to simulate multiple dendrite growth in 3-D. The ORNL MEUMAPPS code was used to simulate dendritic growth in a model ternary alloy with the same equilibrium solidification range as the Ni-base alloy 718 using realistic model parameters, including thermodynamic integration with a Calphad based model for the ternary alloy. Implementation of the UTRC model in AMPE met with several numerical and parametric issues that were resolved and good comparison between the simulation results obtained by the two codes was demonstrated for two dimensional (2-D) dendrites. 3-D dendrite growth was then demonstrated with the AMPE code using nondimensional parameters obtained in 2-D simulations. Multiple dendrite growth in 2-D and 3-D were demonstrated using ORNL’s MEUMAPPS code using simple thermal boundary conditions. MEUMAPPS was then modified to incorporate the complex, time-dependent thermal boundary conditions obtained by UTRC’s thermal modeling of single track AM experiments to drive the phase field simulations. The results were in good agreement with UTRC’s experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components

Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this research pursued three new methods of manufacturing these advanced alloys: 1) Directly built AM parts; 2) AM cans for HIP/PM; and 3) AM cans produced in the final part material. The project utilized Carpenter atomized A-282 in varied mesh sizes customized for both AM and HIP, ExOne’s binderjet technology, the fastest metal 3D printing technique on the market at the current time, coupled with an alloy specific sintering profile to produce a sufficiently dense part for final HIP by Bodycote. Final parts were subjected to chemical and physical property tests and results were compared to published and gathered data. Chemistry results for all the parts were within the published criteria. Furthermore, the AM and HIP/PM parts showed measurable improvement over previous A282 HIP/PM results, in part due to an improved HT spec, and a marked improvement over results from A282 castings. These results indicate that combining AM and HIP/PM in the manner set forth in this project provides a credible manufacturing approach of these activities are set forth in this Final Technical Report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Nuclear Power Plant Component Flooding Fragility Research

This report describes progress on Nuclear Power Plant component flooding fragility research conducted at the Component Flooding Evaluation Laboratory (CFEL). The progress includes additional steering committee membership and invitations, performance improvements to the Portal Evaluation Tank (PET), PET based experiments using industrial steel doors, pipe rupture spray pattern characterization, coupling the smoothed particle hydrodynamics (SPH) code Neutrino and the Idaho National Laboratory (INL) developed Risk Analysis Virtual Environment (RAVEN), continued development of component fragility mathematical models, and wave impact simulation device development, testing, and analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Nuclear Power Plant Mechanical Component Flooding Fragility Experiments FY-2017 Report

This report describes FY17 progress on Nuclear Power Plant mechanical component flooding fragility experiments and supporting research. The progress includes execution of full scale component fragility experiments, design and implementation of improvements to the Portal Evaluation Tank, experiment design exploiting the improved Portal Evaluation Tank capabilities, fragility mathematical model development, Smoothed Particle Hydrodynamic simulations and RAVEN coupling, wave impact simulation device design, and pipe rupture mechanics research. Additionally, a component flooding experiments steering committee charter was developed and initial committee member invitations were issued. Various laboratory tours also occurred including a tour for the Idaho State Board of Education.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Updated Draft ASME Boiler and Pressure Vessel Code Case for Use of Alloy 617 for Construction of Nuclear Components for Section III Division 5

Early in the United States’ very high temperature reactor program, several candidate nickel alloys were considered for use in construction of the intermediate heat exchanger. Based primarily on technical maturity, a downselection was made to focus on Alloy 617. After this downselection, the primary goal of the research and development program was to develop sufficient information on the high temperature properties of the material to qualify it for construction of high temperature nuclear components in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (BPV) Code. Alloy 617 is a solid solution strengthened material with nominal Ni Cr Co Mo composition, originally developed for aerospace applications such as burner can liners for turbine engines by Huntington Alloys. (Huntington Alloys is now Special Metals Division of Precision Castparts, Inc.) The ASME BPV Code allows use of Alloy 617 for construction of non nuclear pressure vessels, and Alloy 617 is used in fossil fired power plants. Section III, Division 1, Subsection NB of the ASME BPV Code was developed for construction of nuclear components in light water reactors and allows use of ferritic materials up to 700°F and austenitic alloys up to 800°F. Subsection NH of Section III Division 1 was written to allow higher temperature construction with a primary focus on sodium cooled reactors. Recently, a new Division 5 of Section III was published specifically for high temperature reactors (regardless of the primary working fluid) and incorporates both Subsections NB and NH. There are only five alloys currently allowed for use in high temperature nuclear components: 2.25Cr 1 Mo and V modified 9Cr 1Mo steels, Types 304 and 316 stainless steels, and the high nickel austenitic Alloy 800H. This very sparse set of allowed materials is in contrast with the collection of more than 150 materials that are allowed for use in non nuclear pressure vessel construction. A draft Code Case to add Alloy 617 to the list of qualified alloys for use in high temperature nuclear design was submitted to ASME in the early 1990s, but it was withdrawn prior to formal Code action.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Process Development and Optimization of a Direct Cast U-6Nb 250 mm Hemispherical Component

Direct Casting is the process of casting a near-net shape part of U-6wt%Nb in a multi-zone VIM furnace for subsequent heat treatment and machining in to a final component. This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6Nb components with a hemispherical geometry. Specifically, process parameters and mold design are examined in detail for producing a 250 mm diameter hemisphere component. The goal is to efficiently produce a sound casting with a minimum of microporosity and uniform niobium composition. Prior work had tried unsuccessfully to cast this shape in a large single-coil vacuum induction melting (VIM) furnace. These castings had unacceptable levels microporosity and niobium segregation. In this work, this same part was cast in a multi-zone VIM and a sound casting was obtained. Beyond simply casting a sound part, this work aimed to optimize the hot-top design, metal pouring temperature, and mold pole temperature. Sound castings where produced using both a tapered and step hot-top designs. There were slightly lower porosity levels and about 5% better metal usage with the step hot-top so that design slightly better. With the current mold design, which uses a funnel and filter arrangement, there a large amount of superheat loss in the funnel/filter during mold filling. This temperature loss, and the apparent variability in the filling behavior, lead to casting defects in the pole region of several of the castings. The variability and defects were overcome by moving to a higher mold pole temperature (850°C) and a higher metal pour temperature (1500°C). For future work it is believed that a no-funnel design, with the filter integral to the crucible, will be a better and more robust strategy.

42 ENGINEERING↗
DOE OSTI2018

Additive Manufacturing of Sensors and Components for Non-Destructive Evaluation Applications

Additively manufactured machine components were designed for use in non-destructive evaluations. Additive manufacturing (3D printing) enables rapid production of simple or complex objects at a low cost for use in many fields of research and industry. 3D printed components were used to optimize an eddy current array probe to inspect various complex shaped objects, such as gears. Preliminary eddy current inspections were conducted to test the functionality and compatibility of the 3D printed components to the array probe and existing system. These were done by wrapping replica 3D printed gears with aluminum foil. The results were as expected, rough, uneven surface of the aluminum foil. Calibration scans were also executed to enable proper measurement of defect size in metal structures. For use in waveguide-based distributive sensing technologies, additively manufactured custom waveguides were designed for use in liquid environments to collect pressure and flow data. Waveguides were designed with membranes, thin sections of the walls, which would be pressed inward due to fluid pressure. Waveguide models continue to be developed and revised for most functional utility in liquid environments.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The NSLS-II Components Relative Alignment Deviation Estimate

The alignment of NSLS-II components will be conducted under the constraint of survey control network. The control network system is categorized as outside, primary and secondary control networks, and all of them have random errors due to measurement random errors. In the error propagation point of view, they all will contribute to the final positioning accuracy of each component in global sense. However, as the global positioning requirement is relative loose (i.e. ± 3mm for storage ring), relative positioning accuracy is what we really concern. In this situation, only secondary control network will contribute as only secondary monuments will be employed to direct the adjustment of components. Other error sources include instrument setup error, adjustment residuals and slab movement etc. This article will analyze the maximum relative deviation of 3 positions in one cell’s region, which is a simulation of 1 ID and 2 Vacuum chamber positions.

43 PARTICLE ACCELERATORS↗