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NASA NTRSDate not supplied

Mars Ascent Vehicle Hybrid PropulsionEffort

A technology development program was undertaken to determine if the benefits of hybrid rocket propulsion could be realized for a Mars Ascent Vehicle (MAV) application. Specifically, the goal of this program was to increase the Technology Readiness Level (TRL) of a hybrid propulsion system such that it could be considered for a potential Mars Sample Return Campaign. Over the course of approximately five years, a new, wax-based fuel was developed, characterized and tested with Mixed Oxides of Nitrogen (from MON-3 to MON-25). Various ignition mechanisms were tested and solid hypergolic additives were evaluated for their potential to ignite the hybrid motor. Several hot-fire test campaigns were completed at both sub- and full-scale. The technology development program was born out of a JPL study documented by Shotwell and Karp that identified the Single Stage to Orbit (SSTO) hybrid propulsion system for a potential Mars Ascent Vehicle to be the lowest Gross Lift Off Mass option from the ten configurations evaluated. Benefits of the hybrid option included its predicted favorable low temperature storage and operation behavior, high performance and ability to restart (enabling the SSTO). The main disadvantage of the hybrid option was its low TRL,as it essentially started as a blank sheet design with a new fuel development. Near the end of the technology development program, a Preliminary Architecture Assessment (PAA) was completed to evaluate a single-stage hybrid propulsion system and a two-stage solid propulsion system for a potential MAV. The solid propulsion system was selected for further study in 2019, primarily because of its flight heritage. While the hybrid technology development program made many strides, there was still a list of challenges to overcome. This paper will discuss the substantial progress and remaining challenges from the technology development effort from 2015 through 2019. This includes fuel development and reformulation, sub- and full-scale testing at Space Propulsion Group, full scale testing at Parabilis, full scale testing at Whittinghill Aerospace, hypergolic additive testing at Purdue and Penn State and the evaluation of adding hypergolic additives to a full-scale grain. It also includes a discussion of the design that resulted from the Preliminary Architecture Assessment.

hybrid rocket↗
NASA NTRS2007

Design of a Resistively Heated Thermal Hydraulic Simulator for Nuclear Rocket Reactor Cores

A preliminary design study is presented for a non-nuclear test facility which uses ohmic heating to replicate the thermal hydraulic characteristics of solid core nuclear reactor fuel element passages. The basis for this testing capability is a recently commissioned nuclear thermal rocket environments simulator, which uses a high-power, multi-gas, wall-stabilized constricted arc-heater to produce high-temperature pressurized hydrogen flows representative of reactor core environments, excepting radiation effects. Initially, the baseline test fixture for this non-nuclear environments simulator was configured for long duration hot hydrogen exposure of small cylindrical material specimens as a low cost means of evaluating material compatibility. It became evident, however, that additional functionality enhancements were needed to permit a critical examination of thermal hydraulic effects in fuel element passages. Thus, a design configuration was conceived whereby a short tubular material specimen, representing a fuel element passage segment, is surrounded by a backside resistive tungsten heater element and mounted within a self-contained module that inserts directly into the baseline test fixture assembly. With this configuration, it becomes possible to create an inward directed radial thermal gradient within the tubular material specimen such that the wall-to-gas heat flux characteristics of a typical fuel element passage are effectively simulated. The results of a preliminary engineering study for this innovative concept are fully summarized, including high-fidelity multi-physics thermal hydraulic simulations and detailed design features.

Litchford, Ron J.↗
DOE OSTI2020

Drop Analysis of the Advanced Test Reactor Fresh Fuel Shipping Container with Heavier Low-Enriched Uranium Fuel Contents

The Advanced Test Reactor Fresh Fuel Shipping Container (ATR FFSC) is a rectangular stainless steel container used for shipping radioactive material. The container is described in the ATR FFSC Safety Analysis Report (SAR). Per the ATR FFSC SAR, the ATR FFSC is designated a Type AF-96 packaging per the definition of 10 CFR §71.4, and was originally designed to transport high enriched uranium (HEU) reactor fuel elements for the Advanced Test Reactor (ATR), the Advanced Test Reactor Critical (ATRC) facility, the Massachusetts Institute of Technology Reactor (MITR), and the University of Missouri Research Reactor (MURR). The Department of Energy, National Nuclear Security Administration’s (NNSA), Office of Material Management and Minimization (M3) is working with the Idaho National Laboratory (INL) to develop and qualify new low enriched uranium (LEU) fuels and technologies for use in the ATR, ATRC, MITR, and MURR reactors. The LEU fuel elements will weigh significantly more than the current HEU designs and, combined with their associated Fuel Handling Enclosures for packaging, some configurations will exceed the 50 lbf used in the ATR FFSC qualifying drop tests. There are LEU versions of MITR, MURR, and ATR fuel elements. However, for this evaluation, drop analysis of the ATR FFSC with only the heavier ATR Low Enrichment (LOWE) fuel element is considered in this evaluation because the LOWE fuel element is the heaviest of the considered LEU fuel elements. The ATR HEU fuel element and the ATR LOWE fuel element are identical in every design aspect except for the fuel meat inside the 19 fuel plates. The LEU fuel meats are made using a U-10Mo high-density foil rather than uranium dispersed in aluminum in the HEU fuel elements. The high density of the uranium in the LEU fuel meat increases the LOWE fuel element weight to just under 44 lbf (versus the 22.1 lbf weight of the tested ATR HEU fuel element). ATR fuel elements are placed in a thin-gauge aluminum weldment called a "Fuel Handling Enclosure" during packaging. The Fuel Handling Enclosure is used to cover and protect the element during loading and unloading operations. The ATR Fuel Handling Enclosure weighs about 15 lbf per the drawings in the ATR FFSC SAR and the weight is accounted for in this evaluation. Transporting the heavier LEU fuel elements require evaluation of two issues. The first is the effect of the increased mass of the LEU fuel elements on the survivability of the ATR FFSC package following the requisite drop qualifications. The second is the effect of the increased mass of the fuel plates on the fuel element during the same drops. The ATR FFSC containing an ATR HEU fuel element in an ATR Fuel Handling Enclosure was physically dropped multiple times to qualify the container as a Type AF-96 package. The ATR FFSC SAR describes the drop tests performed with an actual ATR HEU fuel element weighing 22.1 lbf contained in a 14.3 lbf Fuel Handling Enclosure for a total payload of 36.4 lbf. Those drop tests showed that the ATR FFSC maintained containment of the ATR HEU fuel element and the fuel element was not significantly damaged. (Containment herein is not defined as a leak tight but is retention of the radioactive contents.) The purpose of the evaluation is to analytically show that, for a similar set of tests, the ATR FFSC maintains containment of the heavier ATR LOWE fuel element and to assess the damage to the fuel element during the drops. The approach was to create finite element analysis (FEA) models that produce the same results as the physical drops. Those models were then used as the benchmarks for the follow-on analyses using the heavier contents. FEA models of the drops of ATR FFSC using up to a 115 lbf fuel element were run and evaluated. Likewise, drops of a LOWE fuel element weighing 44 lbf in the ATR FFSC were run and evaluated. It is important to note that this report was done at the quality level necessary to be included in a nuclear facility safety basis. However, it is not the intent of this report to conclude the suitability of the ATR FFSC for transporting the heavier payloads. This report only describes the results of the FEA as related to the required drop scenarios. Incorporation of the FEA into the safety basis will be evaluated by the ATR FFSC design authority. The physical drop tests of the HEU fuel element and FEA drop analysis for the LOWE fuel element showed noteworthy damage to the fuel plates. An aluminum protective block was conceived to mitigate the damage. The concept requires the blocks to be placed in the fuel element between the end boxes and fuel plates. Additional FEA drop analyses were performed using the protective block. The addition of the blocks is primarily intended to mitigate the damage to the LOWE fuel element fuel plates. However, FEA drop analyses of the ATR HEU fuel element with the blocks were also performed and included for information.

42 ENGINEERING↗
DOE OSTI2022

U.S. High Temperature Materials Highlights

U.S. GIF VHTR work is continuing on graphite qualification, Alloy 617 regulatory issues beyond the Code space, Alloy 800H weldments, and ASME Codes and Standards R&D is still considering both pebble bed and prismatic and steam generator and heat exchanger U.S. DOE Advanced Reactor Demonstration Program (ARDP) Two U.S.-based teams were selected to demonstrate advanced nuclear reactors in the United States that can be operational by 2027 One of the teams is X-energy (Rockville, MD) which will demonstrate a modular gas-cooled reactor design (Xe-100) with four 80 MWe, TRISO fuel, pebble bed reactors A number of U.S.-based teams were selected to design and develop safe and affordable reactor technologies that can be licensed and deployed over the next 10 to 14 years (Risk Reduction) One of the teams is BWXT Advanced Technologies, LLC which will develop a commercially viable transportable microreactor with the design focused on using TRISO fuel particles and silicon carbide (SiC) matrix A number of U.S.-based teams were selected to assist the progression of advanced reactor designs in their earliest phases (Advanced Reactor Concepts-20) One of the teams is Massachusetts Institute of Technology which will mature the Modular Integrated Gas-Cooled High Temperature Reactor (MIGHTR) concept with a horizontal compact design from a pre-conceptual stage to a conceptual stage to support commercialization

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Operando X-ray absorption spectroscopic investigation of electrocatalysts state in anion exchange membrane fuel cells

Capturing the active state of (electro)catalysts under operating conditions, namely operando, is the ultimate objective of (electro)catalyst characterization, enabling the unraveling of reaction mechanisms and advancing (electro)catalyst development. Operando insights advance our understanding of the correlations between electrochemical tests and device-level performances. However, operando characterization of electrocatalysts is challenging due to the complexity of electrochemical devices and instrumental limitations. As a result, the majority of electrocatalyst characterizations have been limited to half-cell in situ studies. Here, we present an operando X-ray absorption spectroscopic study of Mn spinel oxide electrocatalysts in an operating fuel cell employing a custom-designed cell. Our results reveal that in anion exchange membrane fuel cells, the Mn valence state, within spinel Mn 3 O 4 /C, increases to above 3+, adopting an octahedral coordination devoid of Jahn-Teller distortions. This structural change results in an AEMFC performance equivalent to that of Co 1.5 Mn 1.5 O 4 /C, a composition that outperforms Mn 3 O 4 /C in rotating disk electrode tests. Our results underscore the importance of operando characterizations in elucidating the active state of electrocatalysts and understanding the correlation(s) between electrochemical tests and device performance.

Electrocatalysis↗
DOE OSTI2023

Benchmark Specifications for TREAT Tests M5, M6, and M7

Detailed information describing three TREAT tests performed on metallic fuels has been collected and organized for use as a benchmark in evaluating the performance of metallic fuel models and codes. The tests, designated M5, M6, and M7, subjected EBR-II-irradiated fuel pins to a single type of overpower transient (at prototypical conditions with full coolant flow and an exponential power rise on an 8 second period) in flowing sodium loops. Six fuel pins were tested; five were ternary (U-19Pu-10Zr) alloy fuel clad in D9 with burnup ranging from 0.8 to 9.8 at. %, and one was binary alloy fuel (U-10Zr) clad in HT9 with 2.9 at. % burnup. The information gathered from the test records is expected to be useful for pre-transient characterization of the irradiated fuel pins as well as the transient analysis of the metallic fuel when subjected to severe accident conditions. This report presents benchmark specifications for the M5, M6, and M7 TREAT tests, identifies where primary sources of benchmark-related information can be found, and includes background information to help a user of the data understand their applicability and limitations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Multi-scale fission product release model with comparison to AGR data

TRistructural ISOtropic (TRISO) particle fuel is central to several advanced, high-temperature reactor designs. Each particle consists of a fuel kernel encapsulated by three layers of carbon and ceramics that prevent the release of fission products and ensure physical integrity. Despite outstanding retention properties, fission product release has been observed from intact particles. To better understand and quantify fission product release from TRISO particles, a multiscale, mechanistic model of fission product transport is being developed by the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. Previous work focused on silver (Ag) transport and improved Ag release predictions. The work described in this report builds on this experience to better understand cesium (Cs) transport in silicon carbide (SiC), the main barrier to the release of fission products. Atomistic simulations provide bulk and grain boundary (GB) Cs diffusivities in SiC, which are used by phase field simulations in the mesoscale code Marmot to determine the temperature, microstructure, and irradiation-dependent Cs diffusivity at the mesoscale in SiC. This approach attributes the different temperature regimes experimentally observed for Cs diffusivities in SiC to a transition from bulk-dominated diffusivity at high temperatures to a GB-dominated regime at low temperatures, providing new insight. The multiscale, mechanistic effective diffusivity is then implemented in the fuel performance code BISON and further validated by comparing Cs release predictions from Advanced Gas Reactor (AGR)-1 and AGR-2 post-irradiation measurements. The new model improves BISON’s predictability. This document also reports improvements made on Ag transport modeling by accounting for different GB types having different diffusivities. Moreover, this report details preliminary efforts to model palladium (Pd) attack of the SiC at the mesoscale using a phase field approach. Pd attack and its impact on accelerated Ag transport remains a misunderstood phenomenon, and we use the model to demonstrate that the formation of lamellae that has been observed in experiments can be explained by the reaction of Pd with SiC to form alternating layers of graphite and Pd 2 Si. This effort aims to improve our understanding of the reaction and eventually provide a model for BISON to account for Pd penetration and its effects on fission product release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1989

Hypersonic airbreathing vehicle conceptual design (focus on aero-space plane)

The airbreathing single stage to orbit (SSTO) vehicle design environment is variable-rich, intricately networked and sensitivity intensive. As such, it represents a tremondous technology challenge. Creating a viable design will require sophisticated configuration/synthesis and the synergistic integration of advanced technologies across the discipline spectrum. In design exercises, reductions in the fuel weight-fraction requirements projected for an orbital vehicle concept can result from improvements in aerodynamics/controls, propulsion efficiencies and trajectory optimization; also, gains in the fuel weight-fraction achievable for such a concept can result from improvements in structural design, heat management techniques, and material properties. As these technology advances take place, closure on a viable vehicle design will be realizable.

Hunt, James L.↗
NASA NTRS1993

Aircraft wing structural detail design (wing, aileron, flaps, and subsystems)

The goal of this project was to design, in detail, the wing, flaps, and ailerons for a primary flight trainer. Integrated in this design are provisions for the fuel system, the electrical system, and the fuselage/cabin carry-through interface structure. This conceptual design displays the general arrangement of all major components in the wing structure, taking into consideration the requirements set forth by the appropriate sections of Federal Aviation Regulation Part 23 (FAR23) as well as those established in the statement of work.

Downs, Robert↗
NASA NTRS1985

Evaluation of fuel preparation systems for lean premixing-prevaporizing combustors

A series of experiments was carried out in order to produce design data for a premixing prevaporizing fuel-air mixture preparation system for aircraft gas turbine engine combustors. The fuel-air mixture uniformity of four different system design concepts was evaluated over a range of conditions representing the cruise operation of a modern commercial turbofan engine. Operating conditions including pressure, temperature, fuel-to-air ratio, and velocity, exhibited no clear effect on mixture uniformity of systems using pressure-atomizing fuel nozzles and large-scale mixing devices. However, the performance of systems using atomizing fuel nozzles and large-scale mixing devices was found to be sensitive to operating conditions. Variations in system design variables were also evaluated and correlated. Mixing uniformity was found to improve with system length, pressure drop, and the number of fuel injection points per unit area. A premixing system capable of providing mixing uniformity to within 15 percent over a typical range of cruise operating conditions is demonstrated.

Dodds, W. J.↗
DOE OSTI2021

Sustainable Lactic Acid Production from Lignocellulosic Biomass

Lignocellulosic biomass is a promising feedstock for sustainable biofuels and bioproducts. Among emerging bioproducts, lactic acid has attracted significant interest because of its growing application in many industries (e.g., packaging, medical, and pharmaceutical). In this study, BioSTEAM—an open-source platform—was leveraged for the design, simulation, and evaluation (via techno-economic analysis, TEA, and life cycle assessment, LCA) of lignocellulosic lactic acid biorefineries. With a minimum product selling price (MPSP) between 1.38 and 1.91 kg –1 (5th–95th percentiles, baseline at 1.57 kg –1 ), the biorefinery was capable of producing market-competitive lactic acid (market price between 1.7 and 2.1 kg –1 ), and its performance could be further enhanced (e.g., MPSP down to 1.09 kg –1 , global warming potential of 2.79 kg CO 2 -eq·kg –1 , and fossil energy consumption of 31.7 MJ·kg –1 ) with advancements in key technological parameters (fermentation yield and separation process conversions) and optimization in process operation. Sensitivity analyses focused on the fermentation unit (across titer, yield, and productivity; neutral vs low-pH fermentation) and feedstock characteristics (carbohydrate content and price) were also included to quantify their impact on the sustainability of the biorefinery. Overall, this research highlights the ability of agile TEA/LCA to screen promising biorefinery designs, prioritize research needs, and establish a road map for the continued development of bioproducts and biofuels.

09 BIOMASS FUELS↗
DOE OSTI2025

Evaluation of AGR-3/4 In-pile Silver Release Predictions Against Post-Irradiation Examination Measurements

Fuel performance modeling codes that accurately predict the transport of radionuclides in high-temperature gas-cooled reactors that utilize tristructural isotopic (TRISO) fuel particles are an important aspect of reactor safety analyses. One objective of the Advanced Gas Reactor (AGR)-3/4 experiment was to assess the transport of fission products through fuel particles and their subsequent release into the compact matrix and structural graphite materials. This was accomplished by irradiating uranium oxycarbide (UCO) driver fuel particles and designed-to-fail (DTF) particles to serve as known sources of fission products. The fission product of particular interest when it comes to such transport is silver (Ag-110 m), as it has a 250-day half-life and has relatively high mobility in the TRISO coating layers. Furthermore, to assess the current modeling capabilities and diffusion parameters employed in the fuel performance codes PARFUME and BISON, the fractional release of silver release predicted by the two codes were compared against post-irradiation examination measurements from the AGR-3/4 experiment.

AGR-3/4 Experiment↗
DOE OSTI2023

AN INITIAL LOOK AT THE HEAT PIPE RESILIENCY TO REACTOR OPERATION

Several special purpose reactor designs are aiming to utilize heat pipes due to its inherently passive features allowing safe heat removal to the power conversion systems. There is insufficient data on heat pipe survivability in reactor environments, although heat-pipe failures are predicted to have low failure rates. In this paper, we perform a coupled neutronics and thermo-mechanics analyses for a 45 kWth HALEU fueled, hydride moderated homogenous design to evaluate the transient effects during both startup and a heatpipe-failure scenario. The heatpipe-failure study includes both a single failure case and a failure-propagation (cascading) case. While the model only evaluates a homogenous core, the approach could be applied to more complex models for any heat pipe cooled small reactor.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS1981

The design and development of a mixer compound exhaust system for a quiet clean general aviation turbofan

Lower engine fuel consumption has become a dominant factor in turbofan engine design due to rapidly increasing fuel costs. One engine component with a large impact on engine performance is the exhaust system. Previous exhaust system studies have demonstrated the significant exhaust system efficiency gains available through mixing of the core and bypass flows. Typically, a large, costly rig and engine program are required to develop and optimize these gains. The purpose of this paper is to present the results of the low-cost design system used for the quiet, clean general aviation turbofan mixer nozzle design and development. The scale model and full-scale engine test results confirm the predicted 3 to 5% reduction in cruise fuel consumption. This unique design system, which is based on integrating advanced three-dimensional viscous numerical methods with empirical optimization techniques, is summarized and detailed comparisons with test data are presented. The ability to accurately predict relative performance of mixer systems with substantially reduced development time and cost savings is demonstrated.

Blackmore, W. L.↗
DOE OSTI2020

Advanced Modular Sub-Atmospheric Hybrid Heat Engine (Phase 1 Final Report)

The Phase 1 Final Report describes the results of the work completed during the “Advanced Modular Sub-Atmospheric Hybrid Heat Engine” project. The objectives of Phase 1 work were to develop a conceptual design of the turbine-based modular hybrid heat engine (MHHE), including thermodynamic cycle analysis, define the nominal engine component boundary conditions, identify technology gaps, and develop a detailed test plan to address these gaps through bench scale testing in a potential subsequent Phase 2 project. To achieve the project objective, the following activities were performed in Phase 1 work: (1) Market analysis and primary fuel selection, (2) Conceptual design and integrated layout development, (3) Design support and key components characterization, (4) Planning to move technology to pre-commercial demonstration.

42 ENGINEERING↗
NASA NTRS1979

The aerial relay system - An energy-efficient solution to the airport congestion problem

The aerial relay system concept, which was developed as a means of exploiting inflight transfer, utilizing large 'cruise liner' aircraft that fly continuously along their routes and dock periodically with short-haul 'feeder' aircraft for payload exchanges, is discussed. The system employs two distinctly different kinds of aircraft, one for takeoff and landing and one for cruising, with provisions for the routine inflight transfer of passengers, baggage, fuel, etc. The liner design consists of a module of 320 ft span and 80 ft chord with an 800 seat capacity and capable of cruising at 0.75 M, while the feeder is a relatively conventional short-haul transport aircraft with a modified fuselage to accommodate special docking and transportation operations. It is concluded that this concept could alleviate present inadequacies in an extremely cost-effective and fuel-efficient way, and could be expanded indefinitely to become a high-quality, high-capacity national system.

Kyser, A. C.↗
DOE OSTI2024

Modeling diurnal and annual ethylene generation from solar-driven electrochemical CO 2 reduction devices

Integrated solar fuels devices for CO 2 reduction (CO 2 R) are a promising technology class towards reducing carbon emissions. Designing integrated CO 2 R solar fuels devices requires careful co-design of electrochemical and photovoltaic components as well as consideration of the diurnal and seasonal effects of solar irradiance, temperature, and other meteorological factors expected for ‘on-sun’ deployment. Using a photovoltaic-electrochemical (PV-EC) platform, we developed a temperature and potential-dependent diurnal and annual model using experimentally-determined CO 2 R performance of Cu-based electrocatalysts, local meteorological data from the National Solar Radiation Database (NSRD), and modeled performance of commercial c-Si PVs. Here we simulated gaseous diurnal product outputs with and without the effects of ambient temperature. From these outputs, we observed seasonal variation in gaseous product generation, with up to two-fold increases in ethylene productivity between the Winter and Summer, analyzed the consequences of dynamic cloud coverage, and identified periods where device cooling/heating mechanisms could be implemented to maximize ethylene generation. Finally, we modeled the annual ethylene generation for a scaled 1 MW solar farm at three different locations (Beijing, CN; Sydney, AUS; Barstow, CA) to determine the consequences of local meteorological climates on PV-EC CO 2 R product output, recording a maximum ethylene output of 18.5 tonne per year at Barstow. Overall, this model presents a critical tool for streamlining the translation of experimental solar-driven electrochemical research to real-world implementation.

14 SOLAR ENERGY↗
NASA NTRS1993

Nuclear concepts/propulsion

Nuclear thermal and nuclear electric propulsion systems will enable and/or enhance important space exploration missions to the moon and Mars. Current efforts are addressing certain research areas, although NASA and DOE still have much work yet to do. Relative to chemical systems, nuclear thermal propulsion offers the potential of reduced vehicle weight, wider launch windows. and shorter transit times, even without aerobrakes. This would improve crew safety by reducing their exposure to cosmic radiation. Advanced materials and structures will be an important resource in responding to the challenges posed by safety and test facility requirements, environmental concerns, high temperature fuels and the high radiation, hot hydrogen environment within nuclear thermal propulsion systems. Nuclear electric propulsion (NEP) has its own distinct set of advantages relative to chemical systems. These include low resupply mass, the availability of large amounts of onboard electric power for other uses besides propulsion, improved launch windows, and the ability to share technology with surface power systems. Development efforts for NEP reactors will emphasize long life operation of compact designs. This will require designs that provide high fuel burnup and high temperature operation along with personnel and environmental safety.

Miller, Thomas J.↗