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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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Arc welding technique uses opposed electrodes on either side of the workpiece, operated in right angles, out-of-phase, pulsating direct current. complete penetration has been obtained with this technique in metals ranging from 0.062 to 1.0 inch thickness.
Improved apparatus distributes inert gas to protect against oxidation on root side of weld during welding and after welding while joint remains hot. Simple and lightweight; readily moved along weld path in synchronism with torch. Because it concentrates inert gas where needed, consumes gas at relatively low rate, and not necessary to monitor oxygen content of protective atmosphere. Apparatus does not obscure view of root side of weld. Used for full-penetration plasma-arc welding of such reactive metals as aluminum/lithium alloys and titanium.
The search for life on other worlds is among humanity’s greatest endeavors. Europa represents the most probable location to discover extraterrestrial life in our solar system, owing to its surface composition of ice covering a liquid water ocean, warmed by the tidal forces of its orbit around Jupiter. Unfortunately, the Jovian system hosts the most intense planetary radiation environment in the solar system due to the charged particles, namely electrons and protons, trapped by Jupiter’s immense magnetic field. Any mission that attempts to approach or land on Europa must survive this radiation environment [Hand et al, 2017]. Radiation effects were identified as a priority risk to the successful development of a de-orbit stage and solid rocket motor (SRM) early in the Europa Lander De-orbit Stage project concept. The effects of primary concern tend to occur very near the outer surface of the SRM. The charged particles deposit their energy quickly and are mostly stopped in the outer metallic case, but a significant portion of radiation penetrates through the bondline and outer propellant regions. High doses of ionizing radiation are known to cause significant changes to mechanical properties of many materials, especially polymers. For polymers such as the rubber-like materials (elastomers) in a solid rocket motor, the primary damage mechanism is known as cross-linking, in which ionization causes the restructuring of the matrix of long polymer chains. Ionization energy breaks the long polymer chains and allows formation of new cross-linked bonding sites. This hardens and often strengthens the polymer, but at the cost of decreased flexibility (or modulus). Propellant, insulation, liner, and pyrotechnic materials were identified as higher risk items, and so were irradiated at Marshall Space Flight Center (MSFC) for investigation of changes in mechanical and ballistic properties. This process required significant levels of analysis to evaluate how the radiation environment evolves within the spacecraft during the mission, and also to evaluate how dose is delivered into test articles within the irradiating facilities.
The search for life on other worlds is among humanity’s greatest endeavors. Europa represents the most probable location to discover extraterrestrial life in our solar system, owing to its surface composition of ice covering a liquid water ocean, warmed by the tidal forces of its orbit around Jupiter. Unfortunately, the Jovian system hosts the most intense planetary radiation environment in the solar system due to the charged particles, namely electrons and protons, trapped by Jupiter’s immense magnetic field. Any mission that attempts to approach or land on Europa must survive this radiation environment [Hand et al, 2017]. Radiation effects were identified as a priority risk to the successful development of a de-orbit stage and solid rocket motor (SRM) early in the Europa Lander De-orbit Stage project concept. The effects of primary concern tend to occur very near the outer surface of the SRM. The charged particles deposit their energy quickly and are mostly stopped in the outer metallic case, but a significant portion of radiation penetrates through the bondline and outer propellant regions. High doses of ionizing radiation are known to cause significant changes to mechanical properties of many materials, especially polymers. For polymers such as the rubber-like materials (elastomers) in a solid rocket motor, the primary damage mechanism is known as cross-linking, in which ionization causes the restructuring of the matrix of long polymer chains. Ionization energy breaks the long polymer chains and allows formation of new cross-linked bonding sites. This hardens and often strengthens the polymer, but at the cost of decreased flexibility (or modulus). Propellant, insulation, liner, and pyrotechnic materials were identified as higher risk items, and so were irradiated at Marshall Space Flight Center (MSFC) for investigation of changes in mechanical and ballistic properties. This process required significant levels of analysis to evaluate how the radiation environment evolves within the spacecraft during the mission, and also to evaluate how dose is delivered into test articles within the irradiating facilities.
Experimental results are presented for a series of experiments that addressed the effect of small pinhole defects on the potential lifetime of a Venus superpressure balloon. The experiments were performed on samples of a candidate balloon envelope material through which a single small hole of 80 to 300 microns in diameter was deliberately made in each one by puncturing with a metal pin. The material was mounted horizontally in a test apparatus and then a 2-3 mm thick layer of sulfuric acid was placed on top to mimic balloon wetting at Venus. Acid penetration and damage manifested itself as a darkening of the aluminum metal and adhesive layers around the hole in the balloon material. There were no test conditions under which the acid simply fell through the pinhole due to gravity because the surface tension forces always compensated at this size. Very little acid-damaged material was observed for the smallest 80 micron pinholes while gas flowed through the hole due to balloon-like pressurization: the black spot size was approximately 0.2 mm in diameter after 6 days with 86% sulfuric acid. The damage area grew more quickly in the absence of gas flowing out of an 80 micron hole, namely at a rate of 2 mm/day. It was concluded that the flow of escaping gas out of the hole provides a substantial reduction of the rate of acid penetration and damage. Larger diameter pinholes of approximately 300 micron diameter showed larger growth rates of 0.7 mm/day with gas flow and 1.7 mm/day without. The pinhole size did not change over the duration of these experiments because the material has an outer layer of fluoropolymer film that remained intact during the process and thereby held the hole size constant. None of the damage rates measured in these experiments pose a threat to the lifetime of the balloon over the projected course of a 30 day mission because the affected area is too small to cause a structural failure either through direct damage or increased solar heating and attendant balloon pressurization leading to burst.
Cladosporium cladosporioides and C. hebarum colonized painted metal surfaces of covering panels and register vents of heating, air conditioning and ventilation systems. Hyphae penetrated the paint film and developed characteristic conidiophores and conidia. The colonies were tightly appressed to the metal surface and conidia were not readily detectable via standard air sampling procedures.
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The surface of rare-earth silicides (Er, Tb, etc.), formed by the reaction of thin-film metal layers with a silicon substrate, is typically dominated by deep penetrating, regularly shaped pits. These pits may have a detrimental effect on the electronic performance of low Schottky barrier height diodes utilizing such silicides on n-type Si. This study suggests that contamination at the metal-Si or silicide-Si interface is the primary cause of surface pitting. Surface pits may be reduced in density or eliminated entirely through either the use of Si substrate surfaces prepared under ultrahigh vacuum conditions prior to metal deposition and silicide formation or by means of ion irradiation techniques. Silicide layers formed by these techniques possess an almost planar morphology.
Thin-film composite mixed-matrix membranes (TFC-MMMs) have potential applications in practical gas separation processes because of their high permeance (gas flux) and gas selectivity. In this study, we fabricated a high-performance TFC-MMM based on a rubbery comb copolymer, i.e., poly(2-[3-(2H-benzotriazol-2-yl)-4-hydroxyphenyl] ethyl methacrylate)-co-poly(oxyethylene methacrylate) (PBE), and metal–organic framework MOF-808 nanoparticles. The rubbery copolymer penetrates through the pores of MOF-808, thereby tuning the pore size. In addition, the rubbery copolymer forms a defect-free interfacial morphology with polymer-infiltrated MOF-808 nanoparticles. Consequently, TFC-MMMs (thickness = 350 nm) can be successfully prepared even with a high loading of MOF-808. As polymer-infiltrated MOF is incorporated into the polymer matrix, the PBE/MOF-808 membrane exhibits a significantly higher CO 2 permeance (1069 GPU) and CO 2 /N 2 selectivity (52.7) than that of the pristine PBE membrane (CO 2 permeance = 431 GPU and CO 2 /N 2 selectivity = 36.2). Therefore, the approach considered in this study is suitable for fabricating high-performance thin-film composite membranes via polymer infiltration into MOF pores.
Sandia National Laboratories is developing a new method for detecting penetration of tamper - indicating enclosures (TIEs). This method incorporates the use of "bleeding" materials (analogous to visually obvious, colorful bruised skin that doesn't heal) into the design of TIEs. As designed, it will allow inspectors to use simple visual observation to detect attempts to penetrate the external surfaces of a TIE, without providing adversaries the ability to repair damage. A material of this type can enhance tamper indication of current TIEs used to support treaty verification regimes. Current TIE inspections are time - consuming and rely on subjective visual assessment by an inspector, equipment such as eddy current or camera devices, or involve approaches that may be limited due to application environment. The complexities and requirements that volumetric sealing methods (or TIEs) must address are: (1) enclosures that are non - standard in size/shape; (2) enclosures that may be inspectorate - or facility - owned; (3) finding tamper attempts that are difficult and time consuming for an inspector to locate; (4) enclosures that are reliable and durable enough to survive the conditions that exist in the operating environment (including facility handling); and (5) methods that prevent adversaries from repairing penetrations. Early project R&D [1] focused on encapsulated transition metals. Due to the challenges associated with the transition metal - based approach, a mitigation approach was investigated resulting in two separate research paths — one that involves fabricating custom TIE molds that meet the specific (size and shape) needs of safeguards equipment a nd one that can be deployed as a sprayed on or painted coating to an existing TIE or surface. The "custom mold" approach is based on creating thin layers of materials that , when penetrated, expose an inner material to O 2 which causes an irreversible color change. The "in-situ coating" approach is based on applying a sensor solution containing color changing microcapsules that bleed when the microcapsule is ruptured. The anticipated benefits of this work are passive, flexible, scalable, robust , cost-effective TIEs with visually obvious responses to tamper attempts. This provides more efficient and effective monitoring , as inspectors will require little or no additional equipment and will be able to detect tamper without extensive time - consuming visual examination. Applications include custom TIEs (cabinets , equipment enclosures or seal bodies ), or spray-coating/painting onto facility-owned items, walls or structures, or circuit boards. The paper describes research and testing completed to-date on the method and integration of select system components.
Electronic systems contained within sealed metallic enclosures, such as nuclear waste containers where wire penetration is not an option, require a through-wall data transfer technology to communicate. One such technology utilizes piezoelectric ultrasonic transducers to communicate through the barrier using elastic waves. Currently demonstrated ultrasonic through-wall data communication techniques have relied on having a direct interface with the ultrasonic transducers on either side. Here, this work studies the coupling of an antenna to such an ultrasonic communication system. A computationally efficient model of a piezobarrier ultrasonic communication system and antenna using a simplified antenna model and a transfer matrix piezobarrier model is utilized to perform a representative parameter space search. The system efficiency and bandwidth trends are shown for the system parameters as well as operating frequency. The tradeoff between efficiency and bandwidth is also presented. A system configuration within the parameter space is fabricated and demonstrated to achieve a data rate of up to 100 kb/s.
The US Department of Energy’s Oak Ridge National Laboratory and Soteria Battery Innovation Group collaborated to develop a metallized polymer film as a current collector for lithium-ion batteries and design slit patterns for electrodes to improve battery safety. The metallized polymer film serves as a fuse that will break under high temperature resulting from a short circuit. Consequently, the short circuit will be broken and the heat generated from the short circuit will be alleviated to avoid thermal runaway. The electrodes with slit patterns are expected to be broken into small segments upon mechanical impact, which can isolate the damaged electrodes from the rest. Thus, the heat generation associated with the mechanical impact will be reduced, along with the likelihood of thermal runaway. This effort aimed to improve lithium-ion battery safety by replacing traditional metal foils with metallized polymer films as current collector and introducing slit patterns to battery electrodes. The metallized polymer films were polyethylene terephthalate with a thin metal (aluminum for cathodes and copper for anodes) coating on both sides. Slit patterns with various geometries and dimensions were designed via simulation. Temperature distribution on cells with electrodes with and without slit patterns was also simulated via nemerical modeling. Electrodes on traditional metal foils and metallized polymer films were coated via a pilot-scale slot-die coater at the US Department of Energy Battery Manufacturing Facility at Oak Ridge National Laboratory. The electrodes were calendered to 35% porosity and punched out with and without slit patterns. Pouch cells were assembed with the electrodes inside a dry room for electrochemical and safety testing. Electrodes coated on metallized polymer films exhibited comparable electrochemical performance to their counterparts coated on traditional metal foils. They also showed improved safety in nail penetration and indentation tests.
A simple, fast, and economical alcohol penetration method for assessing the solid oxide cell to metal window frame seal in a typical planar design is presented. An alcohol such as ethanol or isopropanol is placed into the cavity of a cell sealed to the window frame. Within 3–5 min, one can determine if the glass seal is hermetic by visual observation along the seal edges on the side of the sealed frame. Cross bubbling and open circuit voltage methods for determining whether the seal failed or cracked at high temperature after final stack firing are also discussed.
Split-half cover eliminates the surface marring and dirt penetration problems previously encountered during handling and cable assembly. Metal retaining ring slips over the two plastic halves to hold them in place.
A first order study of the interfacial (keyhole) shape between a penetrating argon plasma arc jet and a stationary liquid metal weld pool is presented. The interface is determined using the Young-Laplace equation by assuming that the plasma jet behaves as a one-dimensional ideal gas flow and by neglecting flow within the weld pool. The solution for the keyhole shape allows an approximate determination of the liquid-solid metal phase boundary location based on the assumption that the liquid melt is a stagnant thermal boundary layer. Parametric studies examine the effect of plasma mass flow rate, initial plasma enthalpy, liquid metal surface tension, and jet shear on weldment shape under both normal and zero gravity. Among the more important findings of this study is that keyhole and weld geometries are minimally affected by gravity, suggesting that data gathered under gravity can be used in planning in-space welding.
My goal is to develop and implement efficient, accurate, and robust Implicit-Explicit Runge-Kutta (IMEX RK) methods [9] for overcoming geometry-induced stiffness with applications to computational electromagnetics (CEM), computational fluid dynamics (CFD) and computational aeroacoustics (CAA). IMEX algorithms solve the non-stiff portions of the domain using explicit methods, and isolate and solve the more expensive stiff portions using implicit methods. Current algorithms in CEM can only simulate purely harmonic (up to lOGHz plane wave) EM scattering by fighter aircraft, which are assumed to be pure metallic shells, and cannot handle the inclusion of coatings, penetration into and radiation out of the aircraft. Efficient MEX RK methods could potentially increase current CEM capabilities by 1-2 orders of magnitude, allowing scientists and engineers to attack more challenging and realistic problems.
The United States Department of Energy is seeking to evaluate the feasibility of extended dry storage of aluminum-clad spent nuclear fuel (ASNF) in helium-backfilled cannisters. A significant research effort has been devoted to determining the amount of radiation-induced molecular hydrogen generation from corrosion layers that would be present on the fuel assembly surfaces. However, to date, no evidence of radiation-induced changes in the microstructure of the corroded aluminum surfaces have been reported. This report provides surface characterization, in terms of corrosion layer composition and morphology, for aluminum alloy 6061-T6 “plume” samples subjected to one of three potential ASNF drying techniques—“vacuum only”, “vacuum + 4 hours at 100 oC”, and “vacuum + 4 hours at 220 oC”—and gamma irradiated (= 53 MGy) in the presence of helium gas with ~0% added relative humidity. At these high absorbed gamma doses, for the first time ever, radiation-induced circular defects were found on the sample surface, regardless of the drying regime employed. Additionally, large cracks that penetrated through the corrosion layer to expose bare aluminum metal were observed in irradiated “plume” specimens subjected to drying conditions of “vacuum + 4 hours at 220 oC”. The nature and implications of these defects on the extended dry storage of ASNF is unclear, requiring further study.
The US continues to prioritize commercial deployment of advanced reactors—particularly those utilizing U-Zr metallic and TRISO particle fuels. Fission product-induced failure mechanisms for these systems include fuel–cladding chemical interaction in metallic fuel rods, which threatens cladding integrity, and Pd penetration in TRISO particles, which degrades SiC layer properties. Empirical models can be applied within the bounds of existing irradiation databases, but their utility is limited when considering new designs or investigating fundamental material behaviors. The Nuclear Energy Advanced Modeling and Simulation Program is therefore developing mechanistic models for these behaviors, which are expected to aid in fuel design, assist in development of failure mitigation strategies, and provide support for qualification and licensing. These efforts leverage multiscale capabilities to capture the microstructural features and processes that govern these behaviors. This talk summarizes past and ongoing efforts to develop and validate these models for the BISON fuel performance code.