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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
DOE OSTI2022

Mechanisms of Mitigating Chloride-Induced Stress Corrosion Cracking of Austenitic Steels by Laser Shock Peening

This study investigates the effect of laser shock peening (LSP) on the chloride-induced stress corrosion cracking (SCC) of 304 austenitic steels. LSP can induce a high compressive residual stress to a depth of 700 µm and plastic deformation structures of dislocations, deformation twins, and stacking faults. Constant-load SCC tests in MgCl2 solution suggested that LSP can retard the crack initiation and slow the crack growth. LSP-treated subsurface layers experience ductile fracture while the central regions exhibit intergranular SCC. The LSP-induced deformation structures may impede dislocation slips, while the LSP-induced compressive residual stress can lessen the stress intensity factor of crack tips and decrease the local stress for film rupture.

Materials Science↗
DOE OSTI2021

Science Federation Emulation Testbed: Demonstration of VFSIE Functionalities

The Virtual Federated Science Instrument Environment (VFSIE) is a digital twin of a federated infrastructure of multiple sites with science instruments and computing systems that are geographically dispersed. It emulates the federation using containers and virtual hosts (vhosts) connected over local and wide-area networks for the main purpose of supporting the development and testing of science workflows and software stacks, which will subsequently transition to the physical infrastructure. In this demo, we present VFSIE of a four sites scenario and illustrate the following use cases: (i) execution of federation stack components that expose resources to enable a science user to execute workflows, (ii) execution of remote control commands of beam-line instruments to collect measurements and position the sensor, and (iii) remote execution and access of Jupyter Notebook for tomographic image computations

Al Najjar, Anees↗
DOE OSTI2016

Progressive mechanical indentation of large-format Li-ion cells

We used large format Li-ion cells to study the mechanical responses of single cells of thickness 6.5 mm and stacks of three cells under compressive loading. We carried out various sequences of increasing depth indentations using a 1.0 inch (25.4 mm) diameter steel ball with steel plate as a rigid support surface. The indentation depths were between 0.025 and 0.250 with main indentation increments tests of 0.025 steps. Increment steps of 0.100 and 0.005 were used to pinpoint the onset of internal-short that occurred between 0.245 and 0.250 . The indented cells were disassembled and inspected for internal damage. Load vs. time curves were compared with the developed computer models. Separator thinning leading to the short circuit was simulated using both isotropic and anisotropic mechanical properties. This study show that separators behave differently when tested as a single layer vs. a stack in a typical pouch cell. The collective responses of the multiple layers must be taken into account in failure analysis. A model that resolves the details of the individual internal cell components was able to simulate the internal deformation of the large format cells and the onset of failure assumed to coincide with the onset of internal short circuit.

25 ENERGY STORAGE↗
DOE OSTI2017

Phenomena-based Uncertainty Quantification in Predictive Coupled- Physics Reactor Simulations

This project has sought to develop methodologies, tailored to phenomena that govern nuclearreactor behavior, to produce predictions (including uncertainties) for quantities of interest (QOIs) in the simulation of steady-state and transient reactor behavior. Examples of such predictions include, for each QOI, an expected value as well as a distribution around this value and an assessment of how much of the distribution stems from each major source of uncertainty. The project has sought to test its methodologies by comparing against measured experimental outcomes. The main experimental platform has been a 1-MW TRIGA reactor. This is a flexible platform for a wide range of experiments, including steady state with and without temperature feedback, slow transients with and without feedback, and rapid transients with strong feedback. The original plan was for the primary experimental data to come from in-core neutron detectors. We made considerable progress toward this goal but did not get as far along as we had planned. We have designed, developed, installed, and tested vertical guide tubes, each able to accept a detector or stack of detectors that can be moved axially inside the tube, and we have tested several new detector designs. One of these shows considerable promise.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

AGC-4 Experiment Irradiation Monitoring Data Qualification Interim Report

The Graphite Technology Development Program is running a series of six experiments to quantify the effects of irradiation on nuclear grade graphite. The fourth experiment, Advanced Graphite Creep 4 (AGC 4), began with Advanced Test Reactor (ATR) cycle 157D on May 30, 2015, and has been irradiated for two cycles. The capsule was removed from the reactor after ATR cycle 158A, which ended on January 2, 2016, due to interference with another experiment. Irradiation will resume when the interfering experiment is removed from the reactor. This report documents qualification of AGC 4 experiment irradiation monitoring data for use by the Advanced Reactor Technologies (ART) Technology Development Office (TDO) Program for research and development activities required to design and license the first HTR nuclear plant. Qualified data meet the requirements for use as described in the experiment planning and quality assurance documents. Failed data do not meet the requirements and provide no useable information. Trend data may not meet all requirements, but still provide some useable information. Use of Trend data requires assessment of how any deficiencies affect a particular use of the data. All thermocouples (TCs) have functioned throughout the AGC-4 experiment. All temperature data are Qualified for use by the ART TDO Program. Argon, helium, and total gas flow data were within expected ranges and are Qualified for use by the ART TDO Program. Discharge gas line moisture values were consistently low during cycle 157D. At the start of cycle 158A, gas moisture briefly spiked to over 600 ppmv and then declined throughout the cycle. Moisture values are within the measurement range of the instrument and are Qualified for use by the ART TDO Program. Graphite creep specimens were subjected to one of three loads, 393, 491, or 589 lbf. For a brief period during cycle 157D between 12:19 on June 2, 2015 and 08:23 on June 11, 2015 the load cells were wired incorrectly resulting in missing stack load data. Missing stack loads were estimated from measured ram pressures using regression equations developed from the existing data from cycle 157D. Estimated stack loads during this period are considered to be an accurate representation of actual load applied to the stacks. These loads deviate slightly from the planned loads. This deviation does not prevent the data from being Qualified for use, but must be taken into account when analyzing the effect of load on creep. Stack displacement increased consistently throughout the first two cycles with total displacement ranging from 0.4 to 0.8 in. During ATR outages, a set of pneumatic rams raised the stacks of graphite creep specimens to ensure the specimens were not stuck within the test train. This stack raising was performed twice. All stacks were raised successfully each time. The load and displacement data are Qualified for use by the ART TDO Program.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Technology Development for Modular, Low-Cost, High-Temperature Recuperators for Supercritical CO 2 Power Cycles (Final Report)

The program’s focus was to evaluate, advance, and demonstrate recuperator design concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low-cost recuperators. Emphasis was placed on recompression closed Brayton cycles having a turbine inlet temperature exceeding 700°C and differential pressures on the order of 200 bar and were scalable to accommodate plant sizes from 10 to 1,000 MWe. The primary objectives of the first budget period, which included conceptual design, preliminary development, and prototype fabrication and testing, were accomplished. A new recuperator design concept, stacked-sheet heat exchanger (SSHX), was realized during the project. The design was taken from paper to hardware and successfully tested. The SSHX prototype recuperator met or exceeded program thermal, hydraulic and performance/cost metrics goals. The first budget period was extended to retire risk in scaling the recuperator from the kWt to MWt thermal capacity scale. The fabrication and design requirements for the budget period one extension were met. Delays associated with the Covid-19 pandemic prevented the fabrication and testing of the industrial scale prototype.

14 SOLAR ENERGY↗
DOE OSTI2020

AGC-4 Experiment Irradiation Monitoring Data Qualification Final Report

The Graphite Technology Development Program ran a series of six experiments to quantify the effects of irradiation on nuclear grade graphite. This report focuses on the fourth experiment, Advanced Graphite Creep 4 (AGC 4). The Advanced Reactor Development (ARD) Technology Development Office (TDO) Program for research and development activities require documentation of qualified monitoring data to design and license the first high-temperature reactor nuclear plant. Qualified data meets the requirements for use as described in the experiment planning and quality assurance documents. Failed data do not meet the requirements and provide no useable information. Trend data may not meet all requirements but still provide some useable information. Use of Trend data requires assessment of how any deficiencies affect a particular use of the data. AGC-4 began with Advanced Test Reactor (ATR) Cycle 157D on May 30, 2015. After irradiating the graphite for two cycles, the capsule was removed from the reactor after ATR Cycle 158A, which ended on January 2, 2016, due to interference with another experiment. Irradiation was resumed with Cycle 162A on October 7, 2017 after the interfering experiment was removed from the reactor. AGC-4 irradiation completed by the end of Cycle 166B on January 10, 2020. Between Cycles 162A and 166B, AGC-4 capsule was removed from the reactor core during two Powered Axial Locator Mechanism (PALM) Cycles 163A and 165A to avoid overheating. All thermocouples (TCs) have functioned throughout the AGC-4 experiment. A total of 9,256,184 out of all 11,167,213 temperature records (or 82.9%) are Qualified for use by the ARD Program and 1,911,029 missing values are Failed. Argon, helium, and total gas flow data were within expected ranges, except only eight out-of-range values occurred during outages. A total of 21,240,627 out of all 22,288,5103 gas flow rates (or 92.8%) are Qualified for use by the ARD Program and 1,644,476 are Failed records mostly due to missing values. Discharge gas line moisture values were consistently low during full ATR power, except for 162B, when moisture content was increasing to more than 200 ppmv by the end of this cycle. During outages, moisture content reached as high as 700 ppmv. 1,089,941 out of a total of 1,107,331 moisture values (or 98.4%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 17,390 missing moisture values are Failed. Graphite creep specimens were subjected to one of three loads: 393, 491, or 589 lbf. For a brief period during Cycle 157D between 12:19 on June 2, 2015, and 08:23 on June 11, 2015, the load cells were wired incorrectly, resulting in missing stack load data. Missing stack loads were estimated from measured ram pressures using regression equations developed from the existing data from Cycle 157D. Estimated stack loads during this period are considered to be an accurate representation of actual load applied to the stacks. These loads deviate slightly from the planned loads. This deviation does not prevent the data from being Qualified for use but must be taken into account when analyzing the effect of load on creep. 6,095,728 out of a total of 6,403,985 moisture values (or 95.2%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 308,257 missing load values are Failed. Stack displacement increased consistently throughout the eight cycles, with total displacement reached highest value of 2.4 in by the end of irradiation. During ATR outages, a set of pneumatic rams raised the stacks of graphite creep specimens to ensure the specimens were not stuck within the test train. This stack raising was performed seven times throughout irradiation. All stacks were raised successfully each time. 4,744,974 out of a total of 6,094,513 displacement values (or 77.9%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 1,349,539 displacement values are Failed mostly due to missing values. Analyses were conducted on correlations between TCs to look for trends and step changes that might indicate instrument degradation or failure. Correlation analysis was used to identify instances when TCs form short circuits, referred to as virtual junctions, which result in TCs reporting temperatures from some location in the capsule other than the location where they were intended to read. No evidence of virtual junctions was found. Analyses were also conducted on control charts of temperature differences of between two TCs, which are expected to behave consistently throughout the entire irradiation period. Upward or downward trend over time indicates at least one TC in the pair was drifted. Examining control charts for all 66 possible pairs out of twelve TCs installed in the AGC-4 capsules reveal no clear drift failures occurred, except unstable behavior of two TCs in Zone 3, TC-7 and TC-8, over irradiation time. In conclus

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

29 mm Diameter Test Target Design Report

The Northstar target for Mo99 production is made up of Mo100 disks in a stack separated by coolant gaps for helium flow. A number of targets have been tested at ANL for both production of Mo99 and for thermal-hydraulic performance. These have all been with a 12 mm diameter target, even while the production goals have increased the diameter to now 29 mm. A 29 mm diameter target has been designed that is consistent with the ANL beam capabilities and the capabilities of the helium circulation system currently in use at ANL. This target is designed for 500 μA at 35 MeV electrons. While the plant design calls for 42 MeV, the chosen design point is more favorable and higher power given the limits of the ANL accelerator. The intended beam spot size is 12 mm FWHM, but the thermal analysis presented herein conservatively assumed a 10 mm FWHM beam, which results in a 44% higher beam current density at beam center.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Strength distributions of laminated FeNi-based metal amorphous nanocomposite ribbons

Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Facility Activity Inference Using Radiation Networks

We consider the problem of inferring the operational status of a reactor facility using measurements from a radiation sensor network deployed around the facility’s ventilation off-gas stack. The intensity of stack emissions decays with distance, and the sensor counts or measurements are inherently random with parameters determined by the intensity at the sensor’s location. We utilize the measurements to estimate the intensity at the stack, and use it in a one-sided Sequential Probability Ratio Test (SPRT) to infer on/off status of the reactor. We demonstrate the superior performance of this method over conventional majority fusers and individual sensors using (i) test measurements from a network of 21 NaI detectors, and (ii) effluence measurements collected at the stack of a reactor facility. We also analytically establish the superior detection performance of the network over individual sensors with fixed and adaptive thresholds by utilizing the Poisson distribution of the counts. We quantify the performance improvements of the network detection over individual sensors using the packing number of the intensity space.

Rao, Nageswara S.↗
DOE OSTI2019

Performance of layer wound epoxy-impregnated coils made from a multifilamentary cable of exfoliated YBCO

The performance and reliability of magnets made from second generation (2G), exfoliated, YBCO conductors are highly improved by use of narrow, stacked, multifilamentary cable instead of a single wide tape. This work reports on tests of five mini-coils wound from 2.4 mm wide ExoCable™, which is comprised of eight, stacked, exfoliated, YBCO filaments. The filaments are coupled electrically through a re-flow process, which results in enhanced electrical connectivity between the adjacent layers. The coils were tested at 77 K (up to 500 A) in liquid nitrogen and at 22 K (up to 700 A) in a conduction-cooled mode. The cable carries 500 A critical current at 77 K. A six-layer coil wound from 10.5 m of the cable, the largest coil created in the study, demonstrates a critical current of 280 A at 77 K at 0.4 T magnetic field on the winding. The coils were fully impregnated with Stycast 1266 and Henkel W19 low-viscosity epoxies. Repeated thermal cycling, to 77 and 22 K, does not degrade the coil's performance. The cable AC loss and the coil winding magnetization are compared with the traditional 2G wide tape pancake geometry at 77 K. We observe a five times reduction of the winding magnetization when the 12 mm tape is replaced by a 2.4 mm cable, which is explained by the smaller magnetic moment of the cable winding. The field hysteresis profiles recorded at 22 and 77 K are presented to demonstrate the effect of the operation temperature on the winding magnetization. A finite element analysis of the winding magnetization shows a good agreement between the experimentally measured trapped field value, and the critical state model prediction. Finally, we discuss the stability of an ExoCable™ coil in a conduction-cooled operation.

2G cables↗
DOE OSTI2017

Simulation-based Testing of Control Software

It is impossible to adequately test complex software by examining its operation in a physical prototype of the system monitored. Adequate test coverage can require millions of test cases, and the cost of equipment prototypes combined with the real-time constraints of testing with them makes it infeasible to sample more than a small number of these tests. Model based testing seeks to avoid this problem by allowing for large numbers of relatively inexpensive virtual prototypes that operate in simulation time at a speed limited only by the available computing resources. In this report, we describe how a computer system emulator can be used as part of a model based testing environment; specifically, we show that a complete software stack including operating system and application software - can be deployed within a simulated environment, and that these simulations can proceed as fast as possible. To illustrate this approach to model based testing, we describe how it is being used to test several building control systems that act to coordinate air conditioning loads for the purpose of reducing peak demand. These tests involve the use of ADEVS (A Discrete Event System Simulator) and QEMU (Quick Emulator) to host the operational software within the simulation, and a building model developed with the MODELICA programming language using Buildings Library and packaged as an FMU (Functional Mock-up Unit) that serves as the virtual test environment.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Evaluation of SR/ TEVA/ TRU triple stack for separation of activation products

A rapid method to separate Ta, Po, Au, Pt, and W from a sample containing mixed fission and activation products was developed using three commercially available extraction chromatography resins stacked in series. When the separation was tested using all the target activation products, even those with short half-lives were measurable. Finally, combining multiple extraction chromatography resin cartridges in tandem allows for multiple short-lived activation products to be separated from one sample addition without the complication of multiple steps.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2019

Creep performance of transient liquid phase bonded haynes 230 alloy

In this study, creep performance of a potential heat exchanger alloy, Haynes 230 was investigated. To simulate mechanical performance of a heat exchanger, sheet material of Haynes 230 transient liquid phase (TLP) bonded together. Sheets were plated on both sides with a Ni–P compound, subsequently stacked and TLP bonded together. Duplicate creep tests show low scatter in creep results, meaning a good repeatable joint was formed by TLP bonding. Overall creep performance showed less ductility and shorter times to failure than specimens originating from plate material. Lastly, evolution of a phosphorous compound at the bond line was observed and thought to potentially reduce ductility of the TLP bonded alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Virtual machine provisioning, code management, and data movement design for the Fermilab HEPCloud Facility

The Fermilab HEPCloud Facility Project has as its goal to extend the current Fermilab facility interface to provide transparent access to disparate resources including commercial and community clouds, grid federations, and HPC centers. This facility enables experiments to perform the full spectrum of computing tasks, including data-intensive simulation and reconstruction. We have evaluated the use of the commercial cloud to provide elasticity to respond to peaks of demand without overprovisioning local resources. Full scale data-intensive workflows have been successfully completed on Amazon Web Services for two High Energy Physics Experiments, CMS and NOνA, at the scale of 58000 simultaneous cores. This paper describes the significant improvements that were made to the virtual machine provisioning system, code caching system, and data movement system to accomplish this work. The virtual image provisioning and contextualization service was extended to multiple AWS regions, and to support experiment-specific data configurations. A prototype Decision Engine was written to determine the optimal availability zone and instance type to run on, minimizing cost and job interruptions. We have deployed a scalable on-demand caching service to deliver code and database information to jobs running on the commercial cloud. It uses the frontiersquid server and CERN VM File System (CVMFS) clients on EC2 instances and utilizes various services provided by AWS to build the infrastructure (stack). We discuss the architecture and load testing benchmarks on the squid servers. We also describe various approaches that were evaluated to transport experimental data to and from the cloud, and the optimal solutions that were used for the bulk of the data transport. Finally, we summarize lessons learned from this scale test, and our future plans to expand and improve the Fermilab HEP Cloud Facility.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Modeling Framework to Analyze Performance and Structural Reliability of Solid Oxide Electrolysis Cells

Solid oxide electrolysis cells (SOEC) have been receiving significant attention recently because of their high energy efficiency and fast hydrogen production. In this study a multi-physics model to simulate the SOEC performance and structural reliability of a state-of-the-art planar SOEC design was developed. The electrochemical reactions, fluid dynamics, species transport, electron transfer, and heat transfer were modeled in the commercial computational fluid dynamics (CFD) software STAR-CCM+. The thermomechanical analysis and the associated structural reliability evaluations were conducted using the commercial finite element analysis software ANSYS. The electrochemistry model was validated by using the experimentally obtained current-voltage (I-V) characteristics of the electrode-supported SOECs. The reliability analysis using a risk-of-rupture approach showed low failure probabilities under standard operating conditions considered in this study. For cells operated at voltages well above a thermoneutral voltage, the reliability evaluations indicated a potential risk of cell failure, but the damage was concentrated locally in specific areas of the cell which typically do not lead to total loss of cell function. The presented approach provides insights for evaluating representative cell and stack performances and structural reliability without intensive testing and for developing optimally performing and structurally reliable SOECs for efficient hydrogen generation.

25 ENERGY STORAGE↗
DOE OSTI2016

A Sailor in the Los Alamos Navy

As part of the War Department’s Manhattan Engineer District (MED), Los Alamos was an Army installation during World War II, complete with a base commander and a brace of MPs. But it was a unique Army installation, having more civilian then military personnel. Even more unique was the work performed by the civilian population, work that required highly educated scientists and engineers. As the breadth, scope, and complexity of the Laboratory’s work increased, more and more technically educated and trained personnel were needed. But, the manpower needs of the nation’s war economy had created a shortage of such people. To meet its manpower needs, the MED scoured the ranks of the Army for anyone who had technical training and reassigned these men to its laboratories, including Los Alamos, as part of its Special Engineer Detachment (SED). Among the SEDs assigned to Los Alamos was Val Fitch, who was awarded the Nobel Prize in Physics in 1980. Another was Al Van Vessem, who helped stack the TNT for the 100 ton test, bolted together the Trinity device, and rode shotgun with the bomb has it was driven from Los Alamos to ground zero.

99 GENERAL AND MISCELLANEOUS↗