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DOE OSTI2021

Investigating Wireless Quantum Key Distribution for Advanced Reactor Communications

Remote operation of small modular reactor (SMR) facilities is an appealing prospect for streamlined operation costs, safety concerns, and user convenience. The ability to guarantee security of communication channels between offsite users and nuclear reactor facilities is critical to enabling remote operations, given the sensitive nature of reactor state data. This report proposes a configuration implementing quantum key distribution (QKD) and advanced encryption standard (AES) protocols to establish secure reactor data feeds. The model outlined, which utilizes the Argonne-developed SeQUeNCe software package and custom MATLAB code, determines free-space channel losses for microwave-band communications in a variety of weather conditions and simulates QKD via ground-satellite links. This report demonstrates the feasibility of repeatable, real-time key generation and distribution for this configuration towards enabling secure wireless reactor communications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Final Report for Tech-X Corporations’s contribution to Enhancing Understanding of High Energy Density Plasmas from Wire Array and Solid Liner Implosions Using Fluid Modeling with Kinetic Closures

Recent results from experiments and simulation of magnetically driven pulsed power liners have explored the role of the early-time electrothermal instability in the evolution of the magneto-Rayleigh-Taylor instability. Our focus will be on understanding the development of such instabilities and the potential stabilization mechanisms via electron thermal conduction, viscosity, and large magnetic fields which we expect could play a significant role in supporting the success of the MagLIF program. Experiments have shown that studies of high-energy density plasmas from wire-array implosions require physics modeling that goes well beyond simple models such as ideal magnetohydrodynamics. The goal of this work is to provide increased understanding of these experiments by employing simulations with a multi-fluid extended-MHD model which uses kinetic closures for thermal conduction, resistivity and viscosity. We will use codes easily available to the wider research community, including university students, with a secondary goal of providing the community with well-benchmarked tools capable of advanced modeling of high-energy-density plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

FORCE Integration with DRAFT and IDAES

Integrated energy systems (IES) combine, in mutually beneficial ways, power from variable renewable energy sources and nuclear power plants (NPP) to produce multiple commodities and improve economic viability under uncertain market conditions. Technical and economic analysis of IES requires modeling of complex processes with software models having enough fidelity to capture real-world dynamics while still being capable of running using reasonable computing resources. The open-source Framework for Optimization of Resources and Economics (FORCE) tool suite, developed at Idaho National Laboratory (INL), has enabled comprehensive modeling and simulation of IES. The capabilities within FORCE include grid portfolio optimization through the Holistic Energy Resource Optimization Network (HERON) and the transient process model analysis library HYBRID, among others. Recent developments for the FORCE toolset have centered on strengthening the flexibility and modularity to link with external models and other available software to enhance IES simulations. Adding versatility to the FORCE toolset improves capability resulting in better techno-economic simulation of nuclear and IES components (both in potential higher fidelity and accuracy to expected performance after deployment). It also helps leverage existing work in the IES field and improve efficiency in national code development. This report focuses on two such endeavors: integration of the Dynamic Reliability Analysis Framework Tool (DRAFT) and the Design Integration and Synthesis Platform to Advance Tightly Coupled Hybrid Energy Systems (DISPATCHES) software packages into FORCE.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Deployment of BISON models of fuel restructuring at high burnup and related fission gas behavior in UO 2

This milestone report details the advancements made in fiscal year 2024 under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to improve the modeling of fission gas behavior in high burnup UO 2 nuclear fuel in the BISON fuel performance code. As nuclear fuel is pushed to higher burnups, significant microstructural changes occur within the fuel, including the formation of a high burnup structure (HBS) on the pellet rim and a dark zone deeper within the pellet. These regions, characterized by subgrain formation and increased pore densities, have critical implications for fission gas behavior and release, which are not well understood. The modeling capabilities in BISON did not adequately predict these phenomena, leading to an underestimation of fuel restructuring and - potentially - of fission gas release. To address these gaps, this milestone focused on three key objectives: (1) reviewing and assessing Sifgrs's capabilities for low burnup fuel, on which high burnup capabilities rely, (2) validating and expanding HBS fission gas modeling capabilities, including investigating mechanisms for fission gas release from HBS, and (3) expanding Sifgrs to enable modeling of dark zone formation and its effects on fission gas behavior. These objectives were achieved and are described herein. The achievements of this NEAMS milestone are significant for the industry's goal of burnup extension. The improved predictive modeling capabilities for both low- and high-burnup conditions enhance our understanding of fuel performance under both normal operations and transient scenarios. Although goals were reached, future work is necessary to validate these models against experimental data and quantify their accuracy in different conditions. In parallel, mechanistic modeling efforts should continue to extend and refine these capabilities to increase accuracy while reducing reliance on empirical models. This will ensure robust performance across a broader range of conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Conjugate Heat Transfer Modeling of Salt-Filled Fuel Pins for Stable Salt Reactor Safety Analysis

The Stable Salt Reactor (SSR) combines the proven structural design of light water reactor fuel assemblies with the inherent safety and fuel-cycle advantages of molten salt technology. In its fast reactor configuration, the SSR utilizes recycled nuclear waste as fuel, sealed within narrow salt-filled fuel pins and cooled by a surrounding liquid salt coolant. Reliable transfer of heat from the molten fuel salt through the cladding to the external coolant is essential for both reactor safety and performance. This work investigates conjugate heat transfer (CHT) in the SSR’s salt-filled fuel pins using NekRS, a high-fidelity spectral element computational fluid dynamics (CFD) solver. The analyses capture internal natural convection within the molten fuel salt and external forced convection in the coolant, under steady-state and transient operating conditions. Parametric studies evaluate how variations in reactor power and coolant flow rate influence heat transfer distributions and system response. The high-fidelity CFD results are time-averaged and post-processed for direct comparison with moderate-fidelity Reynolds-averaged Navier–Stokes (RANS) models, and for the development of reduced-order models within the SAM system code. These validated models support fast-running safety analyses of normal and off-normal transients, improving predictive capability for key safety margins. By integrating advanced CFD with system-level safety tools, this study strengthens the modeling framework for SSR design, reduces uncertainty in molten salt CHT simulations, and accelerates the engineering and licensing of next-generation nuclear reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Microstructure & Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1)expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L.Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY2025activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging-induced degradation of tensile and fracture behavior in LPBF316H.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Microstructure and Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1) expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5 of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L. Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY 2025 activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging induced degradation of tensile and fracture behavior in LPBF 316H.

36 MATERIALS SCIENCE↗

NASA NTRS1984

The prediction of transonic flows on advancing rotors

The object of this investigation was to find and demonstrate a means of performing efficient finite-difference computations of rotor loading for a trimmed rotor in high-speed, advancing flight. The essence of the scheme that was developed is a loose-coupled iteration procedure between a finite difference and a comprehensive integral rotor code. The coupling involves a transfer of appropriate load and inflow data between the two codes such that consistency is maintained. Sample computations, including a limited comparison with model rotor data, are presented. The scheme converges rapidly. The finite-difference computation of one rotor revolution with this scheme may provide sufficient accuracy for many purposes.

Tung, C.↗

NASA NTRS1986

Computation of transonic flow about helicopter rotor blades

An inviscid, nonconservative, three-dimensional full-potential flow code, ROT22, has been developed for computing the quasi-steady flow about a lifting rotor blade. The code is valid throughout the subsonic and transonic regime. Calculations from the code are compared with detailed laser velocimeter measurements made in the tip region of a nonlifting rotor at a tip Mach number of 0.95 and zero advance ratio. In addition, comparisons are made with chordwise surface pressure measurements obtained in a wind tunnel for a nonlifting rotor blade at transonic tip speeds at advance ratios from 0.40 to 0.50. The overall agreement between theoretical calculations and experiment is very good. A typical run on a CRAY X-MP computer requires about 30 CPU seconds for one rotor position at transonic tip speed.

Arieli, R.↗

NASA NTRS1990

Probabilistic analysis of bladed turbine disks and the effect of mistuning

Probabilistic assessment of the maximum blade response on a mistuned rotor disk is performed using the computer code NESSUS. The uncertainties in natural frequency, excitation frequency, amplitude of excitation and damping are included to obtain the cumulative distribution function (CDF) of blade responses. Advanced mean value first order analysis is used to compute CDF. The sensitivities of different random variables are identified. Effect of the number of blades on a rotor on mistuning is evaluated. It is shown that the uncertainties associated with the forcing function parameters have significant effect on the response distribution of the bladed rotor.

Shah, A. R.↗

NASA NTRS1990

Corrosion fatigue crack propagation in metals

This review assesses fracture mechanics data and mechanistic models for corrosion fatigue crack propagation in structural alloys exposed to ambient temperature gases and electrolytes. Extensive stress intensity-crack growth rate data exist for ferrous, aluminum and nickel based alloys in a variety of environments. Interactive variables (viz., stress intensity range, mean stress, alloy composition and microstructure, loading frequency, temperature, gas pressure and electrode potential) strongly affect crack growth kinetics and complicate fatigue control. Mechanistic models to predict crack growth rates were formulated by coupling crack tip mechanics with occluded crack chemistry, and from both the hydrogen embrittlement and anodic dissolution/film rupture perspectives. Research is required to better define: (1) environmental effects near threshold and on crack closure; (2) damage tolerant life prediction codes and the validity of similitude; (3) the behavior of microcrack; (4) probes and improved models of crack tip damage; and (5) the cracking performance of advanced alloys and composites.

Gangloff, Richard P.↗

NASA NTRS1994

Particle kinetic simulation of high altitude hypervelocity flight

Rarefied flows about hypersonic vehicles entering the upper atmosphere or through nozzles expanding into a near vacuum may only be simulated accurately with a direct simulation Monte Carlo (DSMC) method. Under this grant, researchers enhanced the models employed in the DSMC method and performed simulations in support of existing NASA projects or missions. DSMC models were developed and validated for simulating rotational, vibrational, and chemical relaxation in high-temperature flows, including effects of quantized anharmonic oscillators and temperature-dependent relaxation rates. State-of-the-art advancements were made in simulating coupled vibration - dissociation - recombination for post-shock flows. Models were also developed to compute vehicle surface temperatures directly in the code rather than requiring isothermal estimates. These codes were instrumental in simulating aerobraking of NASA's Magellan spacecraft during orbital maneuvers to assess heat transfer and aerodynamic properties of the delicate satellite. NASA also depended upon simulations of entry of the Galileo probe into the atmosphere of Jupiter to provide drag and flow field information essential for accurate interpretation of an onboard experiment. Finally, the codes have been used extensively to simulate expanding nozzle flows in low-power thrusters in support of propulsion activities at NASA-Lewis. Detailed comparisons between continuum calculations and DSMC results helped to quantify the limitations of continuum CFD codes in rarefied applications.

Boyd, Iain↗

NASA NTRS2000

Parametric Weight Comparison of Advanced Metallic, Ceramic Tile, and Ceramic Blanket Thermal Protection Systems

A parametric weight assessment of advanced metallic panel, ceramic blanket, and ceramic tile thermal protection systems (TPS) was conducted using an implicit, one-dimensional (I-D) finite element sizing code. This sizing code contained models to account for coatings fasteners, adhesives, and strain isolation pads. Atmospheric entry heating profiles for two vehicles, the Access to Space (ATS) vehicle and a proposed Reusable Launch Vehicle (RLV), were used to ensure that the trends were not unique to a certain trajectory. Ten TPS concepts were compared for a range of applied heat loads and substructural heat capacities to identify general trends. This study found the blanket TPS concepts have the lightest weights over the majority of their applicable ranges, and current technology ceramic tiles and metallic TPS concepts have similar weights. A proposed, state-of-the-art metallic system which uses a higher temperature alloy and efficient multilayer insulation was predicted to be significantly lighter than the ceramic tile stems and approaches blanket TPS weights for higher integrated heat loads.

Myers, David E.↗

NASA NTRS2003

Research in Computational Astrobiology

We report on several projects in the field of computational astrobiology, which is devoted to advancing our understanding of the origin, evolution and distribution of life in the Universe using theoretical and computational tools. Research projects included modifying existing computer simulation codes to use efficient, multiple time step algorithms, statistical methods for analysis of astrophysical data via optimal partitioning methods, electronic structure calculations on water-nuclei acid complexes, incorporation of structural information into genomic sequence analysis methods and calculations of shock-induced formation of polycylic aromatic hydrocarbon compounds.

Chaban, Galina↗

NASA NTRS1999

Parametric Weight Comparison of Current and Proposed Thermal Protection System (TPS) Concepts

A parametric weight assessment of advanced metallic panel, ceramic blanket, and ceramic tile thermal protection systems (TPS) was conducted using an implicit, one-dimensional (1 -D) thermal finite element sizing code. This sizing code contained models to ac- count for coatings, fasteners, adhesives, and strain isolation pads. Atmospheric entry heating profiles for two vehicles, the Access to Space (ATS) rocket-powered single-stage-to-orbit (SSTO) vehicle and a proposed Reusable Launch Vehicle (RLV), were used to ensure that the trends were not unique to a particular trajectory. Eight TPS concepts were compared for a range of applied heat loads and substructural heat capacities to identify general trends. This study found the blanket TPS concepts have the lightest weights over the majority of their applicable ranges, and current technology ceramic tiles and metallic TPS concepts have similar weights. A proposed, state-of-the-art metallic system which uses a higher temperature alloy and efficient multilayer insulation was predicted to be significantly lighter than the ceramic tile systems and approaches blanket TPS weights for higher integrated heat loads.

Myers, David E.↗

NASA NTRS2000

Propulsion Aeroelastic Analysis Developed for Flutter and Forced Response

The NASA Glenn Research Center at Lewis Field develops new technologies to increase the fuel efficiency of aircraft engines, improve the safety of engine operation, reduce emissions, and reduce engine noise. With the development of new designs for fans, compressors, and turbines to achieve these goals, the basic aeroelastic requirements are that there should be no flutter (self-excited vibrations) or high resonant blade stresses (due to forced response) in the operating regime. Therefore, an accurate prediction and analysis capability is required to verify the aeroelastic soundness of the designs. Such a three-dimensional viscous propulsion aeroelastic analysis capability has been developed at Glenn with support from the Advanced Subsonic Technology (AST) program. This newly developed aeroelastic analysis capability is based on TURBO, a threedimensional unsteady aerodynamic Reynolds-averaged Navier-Stokes turbomachinery code developed previously under a grant from Glenn. TURBO can model the viscous flow effects that play an important role in certain aeroelastic problems such as flutter with flow separation, flutter at high loading conditions near the stall line (stall flutter), flutter in the presence of shock and boundary-layer interaction, and forced response due to wakes and shock impingement. In aeroelastic analysis, the structural dynamics representation of the blades is based on normal modes. A finite-element analysis code is used to calculate these in-vacuum vibration modes and the associated natural frequencies. In an aeroelastic analysis using the TURBO code, flutter and forced response are modeled as being uncoupled. To calculate if a blade row will flutter, one prescribes the motion of the blade to be a harmonic vibration in a specified in-vacuum normal mode. An aeroelastic analysis preprocessor is used to generate the displacement field required for the analysis. The work done by aerodynamic forces on the vibrating blade during a cycle of vibration is calculated. If this work is positive, the blade is dynamically unstable, since it will extract energy from the flow, leading to an increase in the blade s oscillation amplitude. The forced-response excitations on a blade row are calculated by modeling the flow through two adjacent blade rows using the TURBO code. The blades are assumed to be rigid. As an option, a single blade row can be modeled with the upstream blade row influence represented by a time-varying disturbance (gust) at the inlet boundary. The unsteady forces on a blade row from such analyses are used in a structural analysis along with the blade structural dynamics characteristics and aerodynamic damping associated with blade vibration to calculate the resulting dynamic stresses on the blade.

Bakhle, Milind A.↗

NASA NTRS2010

A Computational Study of BVI Noise Reduction Using Active Twist Control

The results of a computational study examining the effects of active-twist control on blade-vortex interaction (BVI) noise using the Apache Active Twist Rotor are presented. The primary goal of this activity is to reduce BVI noise during a low-speed descent flight condition using active-twist control. Rotor aeroelastic behavior was modeled using the Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics code and the rotor noise was predicted using the acoustics code PSU-WOPWOP. The accuracy of the analysis was validated through comparisons with experimental acoustic data for the first generation Active Twist Rotor at an advance ratio of mu=0.14. The application of active-twist to the main rotor blade system consisted of harmonic actuation frequencies ranging from 2P to 5P, control phase angles from 0' to 360 , and tip-twist amplitudes ranging from 0.5 to 4.0 . The acoustic analysis was conducted for a single low-speed flight condition of advance ratio =0.14 and shaft angle-of-attack, c^=+6 , with BVI noise levels predicted on a flat plane of observers located 1.1 rotor diameters beneath the rotor. The results indicated reductions of up to 11dB in BVI noise using 1.25 tip-twist amplitude with negligible effects on 4P vertical hub shear.

Fogarty, David E.↗

NASA NTRS2006

Numerical Propulsion System Simulation

The NASA Glenn Research Center, in partnership with the aerospace industry, other government agencies, and academia, is leading the effort to develop an advanced multidisciplinary analysis environment for aerospace propulsion systems called the Numerical Propulsion System Simulation (NPSS). NPSS is a framework for performing analysis of complex systems. The initial development of NPSS focused on the analysis and design of airbreathing aircraft engines, but the resulting NPSS framework may be applied to any system, for example: aerospace, rockets, hypersonics, power and propulsion, fuel cells, ground based power, and even human system modeling. NPSS provides increased flexibility for the user, which reduces the total development time and cost. It is currently being extended to support the NASA Aeronautics Research Mission Directorate Fundamental Aeronautics Program and the Advanced Virtual Engine Test Cell (AVETeC). NPSS focuses on the integration of multiple disciplines such as aerodynamics, structure, and heat transfer with numerical zooming on component codes. Zooming is the coupling of analyses at various levels of detail. NPSS development includes capabilities to facilitate collaborative engineering. The NPSS will provide improved tools to develop custom components and to use capability for zooming to higher fidelity codes, coupling to multidiscipline codes, transmitting secure data, and distributing simulations across different platforms. These powerful capabilities extend NPSS from a zero-dimensional simulation tool to a multi-fidelity, multidiscipline system-level simulation tool for the full development life cycle.

Naiman, Cynthia↗