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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Time-Resolved Optical Measurements of Fuel-Air Mixedness in Windowless High Speed Research Combustors

Fuel distribution measurements in gas turbine combustors are needed from both pollution and fuel-efficiency standpoints. In addition to providing valuable data for performance testing and engine development, measurements of fuel distributions uniquely complement predictive numerical simulations. Although equally important as spatial distribution, the temporal distribution of the fuel is an often overlooked aspect of combustor design and development. This is due partly to the difficulties in applying time-resolved diagnostic techniques to the high-pressure, high-temperature environments inside gas turbine engines. Time-resolved measurements of the fuel-to-air ratio (F/A) can give researchers critical insights into combustor dynamics and acoustics. Beginning in early 1998, a windowless technique that uses fiber-optic, line-of-sight, infrared laser light absorption to measure the time-resolved fluctuations of the F/A (refs. 1 and 2) will be used within the premixer section of a lean-premixed, prevaporized (LPP) combustor in NASA Lewis Research Center's CE-5 facility. The fiber-optic F/A sensor will permit optical access while eliminating the need for film-cooled windows, which perturb the flow. More importantly, the real-time data from the fiber-optic F/A sensor will provide unique information for the active feedback control of combustor dynamics. This will be a prototype for an airborne sensor control system.

Nguyen, Quang-Viet↗
NASA NTRS1997

Oxygen Compatibility Screening Tests in Oxygen-Rich Combustion Environment

The identification and characterization of oxygen-rich compatible materials enables full-flow, staged combustion designs. Although these oxygen-rich designs offer significant cost, performance, and reliability benefits over existing systems, they have never been used operationally by the United States. If these systems are to be realized, it is critical to understand the long-term oxidative stability in high-temperature, high-pressure, oxygen-rich combustion environments. A unique facility has been constructed at the NASA Lewis Research Center to conduct tests of small-scale rocket engine materials and subcomponents in an oxygen-rich combustion environment that closely approximates a full-scale rocket engine. Thus, a broad range of advanced materials and concepts can be screened in a timely manner and at a relatively low cost.

Eckel, Anerew J.↗
NASA NTRS1999

Effects Investigated of Ambient High-Temperature Exposure on Alumina-Titania High-Emittance Surfaces for Solar Dynamic Systems

Solar-dynamic space power systems require durable, high-emittance surfaces on a number of critical components, such as heat receiver interior surfaces and parasitic load radiator (PLR) elements. An alumina-titania coating, which has been evaluated for solar-dynamic heat receiver canister applications, has been chosen for a PLR application (an electrical sink for excess power from the turboalternator/compressor) because of its demonstrated high emittance and high-temperature durability in vacuum. Under high vacuum conditions (+/- 10(exp -6) torr), the alumina-titania coating was found to be durable at temperatures of 1520 F (827 C) for approx. 2700 hours with no degradation in optical properties. This coating has been successfully applied to the 2-kW solar-dynamic ground test demonstrator at the NASA Lewis Research Center, to the 500 thermal-energy-storage containment canisters inside the heat receiver and to the PLR radiator. The solar-dynamic demonstrator has successfully operated for over 800 hours in Lewis large thermal/vacuum space environment facility, demonstrating the feasibility of solar-dynamic power generation for space applications.

deGroh, Kim K.↗
NASA NTRS1999

Coarsening in Solid-Liquid Mixtures Studied on the Space Shuttle

Ostwald ripening, or coarsening, is a process in which large particles in a two-phase mixture grow at the expense of small particles. It is a ubiquitous natural phenomena occurring in the late stages of virtually all phase separation processes. In addition, a large number of commercially important alloys undergo coarsening because they are composed of particles embedded in a matrix. Many of them, such as high-temperature superalloys used for turbine blade materials and low-temperature aluminum alloys, coarsen in the solid state. In addition, many alloys, such as the tungsten-heavy metal systems, coarsen in the solid-liquid state during liquid phase sintering. Numerous theories have been proposed that predict the rate at which the coarsening process occurs and the shape of the particle size distribution. Unfortunately, these theories have never been tested using a system that satisfies all the assumptions of the theory. In an effort to test these theories, NASA studied the coarsening process in a solid-liquid mixture composed of solid tin particles in a liquid lead-tin matrix. On Earth, the solid tin particles float to the surface of the sample, like ice in water. In contrast, in a microgravity environment this does not occur. The microstructures in the ground- and space-processed samples (see the photos) show clearly the effects of gravity on the coarsening process. The STS-83-processed sample (right image) shows nearly spherical uniformly dispersed solid tin particles. In contrast, the identically processed, ground-based sample (left image) shows significant density-driven, nonspherical particles, and because of the higher effective solid volume fraction, a larger particle size after the same coarsening time. The "Coarsening in Solid-Liquid Mixtures" (CSLM) experiment was conducted in the Middeck Glovebox facility (MGBX) flown aboard the shuttle in the Microgravity Science Laboratory (MSL-1/1R) on STS-83/94. The primary objective of CSLM is to measure the temporal evolution of the solid particles during coarsening.

Caruso, John J.↗
NASA NTRS2001

Tensile Strength and Microstructure of Al2O3-ZrO2 Hypo-Eutectic Fibers Studied

Oxide eutectics offer high-temperature strength retention and creep resistance in oxidizing environments. Al2O3-ZrO2 eutectic strengths have been studied since the 1970's. Directionally solidified oxide eutectics exhibit improved resistance to slow crack growth and excellent strength retention at high temperatures up to 1400 C. Materials studied typically contain Y2O3 to metastably retain the high-temperature cubic and tetragonal polymorphs at room temperature. Al2O3-ZrO2 is of fundamental interest for creep studies because it combines a creep-resistant material, Al2O3, with a very low creep resistance material, ZrO2. Results on mechanical properties and microstructures of these materials will be used to define compositions for creep testing in future work. Substantial variations from the eutectic alumina to zirconia ratio can be tolerated without a loss in room-temperature strength. The effect of increasing Y2O3 addition on the room-temperature tensile strength of an Al2O3-ZrO2 material containing excess Al2O3 was examined at the NASA Glenn Research Center, where the materials were grown using Glenn's world-class laser growth facilities.

Farmer, Serene C.↗
NASA NTRS2002

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

Krause, David L.↗
NASA NTRS2002

One-Dimensional Spontaneous Raman Measurements of Temperature Made in a Gas Turbine Combustor

The NASA Glenn Research Center is working with the aeronautics industry to develop highly fuel-efficient and environmentally friendly gas turbine combustor technology. This effort includes testing new hardware designs at conditions that simulate the high-temperature, high-pressure environment expected in the next-generation of high-performance engines. Glenn has the only facilities in which such tests can be performed. One aspect of these tests is the use of nonintrusive optical and laser diagnostics to measure combustion species concentration, fuel/air ratio, fuel drop size, and velocity, and to visualize the fuel injector spray pattern and some combustion species distributions. These data not only help designers to determine the efficacy of specific designs, but provide a database for computer modelers and enhance our understanding of the many processes that take place within a combustor. Until recently, we lacked one critical capability, the ability to measure temperature. This article summarizes our latest developments in that area. Recently, we demonstrated the first-ever use of spontaneous Raman scattering to measure combustion temperatures within the Advanced Subsonics Combustion Rig (ASCR) sector rig. We also established the highest rig pressure ever achieved for a continuous-flow combustor facility, 54.4 bar. The ASCR facility can provide operating pressures from 1 to 60 bar (60 atm). This photograph shows the Raman system setup next to the ASCR rig. The test was performed using a NASA-concept fuel injector and Jet-A fuel over a range of air inlet temperatures, pressures, and fuel/air ratios.

Hicks, Yolanda R.↗
NASA NTRS2005

Non-contact Creep Resistance Measurement for Ultra-high temperature Materials

Continuing pressures for higher performance and efficiency in propulsion are driving ever more demanding needs for high-temperature materials. Some immediate applications in spaceflight include combustion chambers for advanced chemical rockets and turbomachinery for jet engines and power conversion in nuclear-electric propulsion. In the case of rockets, the combination of high stresses and high temperatures make the characterization of creep properties very important. Creep is even more important in the turbomachinery, where a long service life is an additional constraint. Some very high-temperature materials are being developed, including platinum group metals, carbides, borides, and silicides. But the measurement of creep properties at very high temperatures is itself problematic, because the testing instrument must operate at such high temperatures. Conventional techniques are limited to about 1700 C. A new, containerless technique for measuring creep deformation has been developed. This technique is based on electrostatic levitation (ESL) of a spherical sample, which is heated to the measurement temperature and rotated at a rate such that the centrifugal acceleration causes creep deformation. Creep of samples has been demonstrated at up to 2300 C in the ESL facility at NASA MSFC, while ESL itself has been applied at over 3000 C, and has no theoretical maximum temperature. The preliminary results and future directions of this NASA-funded research collaboration will be presented.

Hyers, Robert W.↗
NASA NTRS2004

PS300 Tribomaterials Evaluated at 6500C by Bushing Test Rig

A new facility has been developed to test the tribological behavior (friction and wear) of PS300 solid lubricant bushings at high temperatures. PS300 is a commercially available solid lubricant invented at the NASA Glenn Research Center. It can be prepared as a plasma spray coating or as a free-standing powder metallurgy component, designated PM300. PS300 and PM300 composites are designed to lubricate sliding components at temperatures above the capability of today's best oils, greases, and solid lubricants. One of the primary applications being pursued for PM300 is the development of bushings for use in high-temperature machinery. Examples include inlet guide vane bushings for gas turbines and conveyors, and bearings for industrial furnaces and ovens. Encouraging preliminary field trials indicate that PS300 and PM300 lubricant materials have been commercialized successfully in several industrial applications. However, the lack of laboratory performance data has hindered further commercialization especially for new applications that differ significantly from the established experience base. The purpose of the newly developed bushing test rig will be to determine the performance characteristics of PM300, and other materials, under conditions closely matching intended applications. The data will be used to determine engineering friction and wear rates and to estimate the life expectancy of bushings for new applications. In the new rig, the bushing is loaded against a rotating shaft inside a furnace enclosure (see the preceding photograph). Loads can vary from 5 to 200 N, speeds from 1 to 400 rpm, and temperatures from 25 to 800 C. Furnace temperature, bushing temperature, shaft speed, and torque are monitored during the test, and wear of both the bushing and the shaft is measured after testing is completed. Initially, PM300 bushings will be evaluated and compared with lower temperature, traditional bushing materials like graphite and porous bronze. The baseline PM304 composition is 60 wt% NiCr (a binder), 20 wt% Cr2O3 (a hardener), 10 wt% BaF2/CaF2 (a high-temperature lubricant), and 10 wt% Ag (a low-temperature lubricant). Future research efforts will include determining the effects of load, sliding speed, and temperature on tribological performance and, possibly, tailoring composition for specific applications. We expect that the availability of measured performance data will enhance the market penetration of PM300 technology.

Striebing, Donald R.↗
NASA NTRS2005

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗
NASA NTRS2008

Future NTP Development Synergy Leveraged from Current J-2X Engine Development

This paper is a discussion of how the many long-lead development elements required for the realization of a future nuclear thermal propulsion (NTP) system can be effectively leveraged from the ongoing work being conducted on the J-2X engine program for the Constellation Program. Development studies conducted to date for NTP forward planning have identified a number of technical areas that will require advancement to acceptable technology readiness levels (TRLs) before they can be utilized in NTP system development. These include high-temperature, high-area ratio nozzle extension; long-life, low-NPSP. turbomachinery; and low-boiloff propellant management; and a qualified nuclear fuel element. The current J-2X program is working many of these areas that can be leveraged to support NTP development in a highly compatible and synergistic fashion. In addition to supporting technical development, there are other programmatic issues being worked in the J-2X program that can be leveraged by a future NTP development program. These include compliance with recently-evolved space system requirements such as human-rating, fault tolerance and fracture control. These and other similar mandatory system requirements have been adopted by NASA and can result in a significant technical impact beyond elevation of the root technologies required by NTP. Finally, the exploitation of experience, methodologies, and procedures developed by the J-2X program in the areas of verification, qualification, certification, altitude simulation testing, and facility definition will be especially applicable to a future NTP system. The similarities in system mission (in-space propulsion) and operational environment (vacuum, zero-gee) between J-2X and NTP make this highly synergistic. Thus, it can be $hown that the collective benefit of leveraging experience and technologies developed during the J-2X program can result in significant savings in development cost and schedule for NTP.

Ballard, Richard O.↗
NASA NTRS2008

High-precision Non-Contact Measurement of Creep of Ultra-High Temperature Materials for Aerospace

For high-temperature applications (greater than 2,000 C) such as solid rocket motors, hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines, creep becomes one of the most important design factors to be considered. Conventional creep-testing methods, where the specimen and test apparatus are in contact with each other, are limited to temperatures approximately 1,700 C. Development of alloys for higher-temperature applications is limited by the availability of testing methods at temperatures above 2000 C. Development of alloys for applications requiring a long service life at temperatures as low as 1500 C, such as the next generation of jet turbine superalloys, is limited by the difficulty of accelerated testing at temperatures above 1700 C. For these reasons, a new, non-contact creep-measurement technique is needed for higher temperature applications. A new non-contact method for creep measurements of ultra-high-temperature metals and ceramics has been developed and validated. Using the electrostatic levitation (ESL) facility at NASA Marshall Space Flight Center, a spherical sample is rotated quickly enough to cause creep deformation due to centrifugal acceleration. Very accurate measurement of the deformed shape through digital image analysis allows the stress exponent n to be determined very precisely from a single test, rather than from numerous conventional tests. Validation tests on single-crystal niobium spheres showed excellent agreement with conventional tests at 1985 C; however the non-contact method provides much greater precision while using only about 40 milligrams of material. This method is being applied to materials including metals and ceramics for non-eroding throats in solid rockets and next-generation superalloys for turbine engines. Recent advances in the method and the current state of these new measurements will be presented.

Rogers, Jan R.↗
NASA NTRS2008

Analysis of International Space Station Materials on MISSE-3 and MISSE-4

For high-temperature applications (> 2,000 C) such as solid rocket motors, hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines, creep becomes one of the most important design factors to be considered. Conventional creep-testing methods, where the specimen and test apparatus are in contact with each other, are limited to temperatures ~1,700 deg. C. Development of alloys for higher-temperature applications is limited by the availability of testing methods at temperatures above 2000 C. Development of alloys for applications requiring a long service life at temperatures as low as 1500 C, such as the next generation of jet turbine superalloys, is limited by the difficulty of accelerated testing at temperatures above 1700 0c. For these reasons, a new, non-contact creep-measurement technique is needed for higher temperature applications. A new non-contact method for creep measurements of ultra-high-temperature metals and ceramics has been developed and validated. Using the electrostatic levitation (ESL) facility at NASA Marshall Space Flight Center, a spherical sample is rotated quickly enough to cause creep deformation due to centrifugal acceleration. Very accurate measurement of the deformed shape through digital image analysis allows the stress exponent n to be determined very precisely from a single test, rather than from numerous conventional tests. Validation tests on single-crystal niobium spheres showed excellent agreement with conventional tests at 1985 C; however the non-contact method provides much greater precision while using only about 40 milligrams of material. This method is being applied to materials including metals and ceramics for noneroding throats in solid rockets and next-generation superalloys for turbine engines. Recent advances in the method and the current state of these new measurements will be presented.

Finckenor, Miria M.↗
NASA NTRS2008

Water-Based Coating Simplifies Circuit Board Manufacturing

The Structures and Materials Division at Glenn Research Center is devoted to developing advanced, high-temperature materials and processes for future aerospace propulsion and power generation systems. The Polymers Branch falls under this division, and it is involved in the development of high-performance materials, including polymers for high-temperature polymer matrix composites; nanocomposites for both high- and low-temperature applications; durable aerogels; purification and functionalization of carbon nanotubes and their use in composites; computational modeling of materials and biological systems and processes; and developing polymer-derived molecular sensors. Essentially, this branch creates high-performance materials to reduce the weight and boost performance of components for space missions and aircraft engine components. Under the leadership of chemical engineer, Dr. Michael Meador, the Polymers Branch boasts world-class laboratories, composite manufacturing facilities, testing stations, and some of the best scientists in the field.

Source record↗
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.↗
NASA NTRSDate not supplied

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO↗
DOE OSTI2025

Computational Fluid Dynamics Simulations of Glass Vitrification Refractory Coupon Tests

The Waste Treatment and Immobilization Plant (WTP) at the Hanford site is nearing the start of the Direct-Feed Low-Activity Waste (DFLAW) operations. DFLAW is destined to convert a pretreated low activity waste portion of the 56 million gallons of tank waste into a stable solid glass. In the subsequent decade completion of the high-level waste (HLW) facility is anticipated. Sustained operational missions of both LAW and HLW melter facilities are expected over multiple decades. In high-temperature glass melters, the refractory lining corrodes over time, which could potentially be an issue for longer term operations, this refractory corrosion is higher at the level of the glass-air interface due to surface tension driven flow. The glass viscosity, melt pool temperature, and glass chemical composition can impact the rate at which the refractory corrodes. This rate is important to quantify for the various waste glasses to be produced at the WTP since the integrity of the refractory should not be a limiting factor affecting the lifetime of the melter. To this end, a series of glasses representative of the first batches of waste glass produced by the WTP will be melted in small-scale crucibles with Monofrax® K-3 coupons inserted. The corrosion of the K-3 will be measured in the melt and at the meltline (or neckline). A model for the corrosion rate will be constructed and implemented into a previously developed framework for a computational fluid dynamics (CFD) model of the full-scale WTP. To assist with experimental design and validate the implementation of the model in the full-scale melter, CFD simulations of the small-scale crucible tests were performed. The bubbling that occurs in the small-scale crucible is initially validated here with a model that uses silicone oil at room temperature. The viscosity of the oil ranges from 1 to 100 Pa•s, which corresponds to operating glass pool temperatures near 1150 °C down to idling temperatures near 950 °C. The simulation results show good agreement with the bubble sizes that form during experiments. CFD modeling of the crucible setup was used to determine bubbling characteristics to match the range of near-wall velocities expected in the full-scale WTP. This study presents the initial CFD modeling results, corrosion testing plan, and some preliminary corrosion samples with an outline for the next steps for the development of the corrosion model.

Abboud, Alexander W. [Idaho National Lab]↗
DOE OSTI2026

MARVEL Reactor Fuel Performance Report

The Microreactor Applications Research Validation and EvaLuation (MARVEL) project is producing a high temperature liquid metal-cooled nuclear test bed at Idaho National Laboratory (INL) to ultimately improve the integration of microreactors to end-user applications. This ambitious effort seeks to design, authorize, construct, test, and operate the reactor within five years. In order to construct and operate the MARVEL reactor in a timely manner, the system will utilize materials and component designs which have already been used, qualified, or licensed from previous reactors. The MARVEL reactor will be located at the INL Transient Reactor Test (TREAT) facility in the north high-bay equipment pit and will use the existing 304 stainless steel-clad U-ZrH1.6 pin-type fuel system developed by General Atomics and purchased from TRIGA International. This fuel has been previously qualified under the United States Department of Energy’s (US DOE) Reduced Enrichment for Research and Test Reactors (RERTR) Program. Even though the regulator of the MARVEL reactor is the US DOE, the standards and overall approach recommended by the Nuclear Regulatory Commission is well-defined and utilized here. Following NUREG-1537 regulatory guidance, this report documents the authorization case for the MARVEL fuel system’s application to MARVEL and establishes stable and predictable fuel performance during the most thermophysically unfavorable conditions achievable in the MARVEL reactor. To that end, this report provides a comprehensive survey of the known thermophysical properties, performance, and quantitative relationships associated with the MARVEL reactor fuel element and uses this information to determine its mechanical integrity and risk of reaching unacceptable conditions during the most extreme accident scenarios predicted for the reactor using the most conservative assumptions available. The information contained herein is compiled from a combination of historical reports and peer reviewed scientific publication manuscripts. Known mechanisms under which the fuel is susceptible to failure are highlighted and compared to conditions that could exist in the MARVEL reactor during an unanticipated transient or accident scenario. The two scenarios considered for analysis in this report are (1) an unprotected loss of flow accident and (2) a hypothetical unprotected loss of coolant accident during the loss of flow accident. Preliminary 2D steady-state analyses herein indicate that both fuel-cladding chemical interactions and fuel-cladding mechanical interactions are negligible throughout the fuel’s operational cycle under both normal and high temperature accident scenario conditions. Although higher fidelity 3D time-dependent modeling and simulations are planned, the following may be concluded presently. The MARVEL fuel element maintains its geometric stability and structural integrity during the most extreme accident scenarios predicted for the MARVEL reactor. The hoop stress during the unprotected loss of flow accident reaches about -1.27 MPa; this negative stress indicates that it is compressive rather than tensile. The compressive stress is a result of the NaK pressure on the outside of the fuel element, caused by the restricted thermal expansion of the NaK coolant, exceeding the internal pressures generated inside of the fuel element. The hoop stress generated in the cladding during the unprotected loss of coolant accident reaches a maximum of about approximately 10 MPa, which is nearly an order of magnitude less than the predicted yield strength of the cladding under high-temperature accident scenario conditions. Calculations were compared with results from high performance computational simulations using BISON and are in very close agreement. A conservative MARVEL fuel meat peak temperature limit of 900 °C is recommended presently, which is about 180 °C higher than the peak fuel temperature predicted to occur during the most extreme accident. Based on the known properties and behavior of the MARVEL fuel element, the fuel successfully meets its design and safety requirements under normal and most extreme accident conditions with a large safety margin.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗