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NASA NTRS2023

NASA Strategy for Technology Development

At the National Aeronautics and Space Administration (NASA), foresight is a coordinated, iterative, and continual process for making informed decisions. NASA faces diverse and relatively unique challenges and opportunities as the leading U.S. agency for aeronautics development, cutting-edge scientific discovery, and human space exploration. To address these challenges and leverage opportunities, NASA uses foresight to strategically plan technology development across four mission directorates: Aeronautics Research Mission Directorate, Space Technology Mission Directorate, Science Mission Directorate, and Human Exploration and Operations Mission Directorate (recently separated into the new Exploration Systems Development Mission Directorate and Space Operations Mission Directorate). The mission directorates leverage a broad community of experts and partners to incorporate technology foresight into mission and program planning. Through this process NASA realizes tangible benefits to the agency’s science, technology, and exploration programs. As an independent office, NASA’s Office of Technology, Policy, and Strategy (OTPS) provides strategic advice, supported by independent assessments and rigorous analysis, to inform NASA senior leadership on key areas to align mission and agency-level activities. OTPS serves as a trusted authority to inform technology strategy at the agency to enable future missions. Specifically, OTPS coordinates and uses inputs from a broad community of experts, both internal and external to NASA, to inform decision making for technology plans, investments, and partnerships. OTPS develops and maintains the NASA Technology Taxonomy to standardize communication across the agency’s diverse technology portfolio and the related Strategic Technology Investment Plan that integrates priorities and informs technology investment. Through these efforts, OTPS has refined elements of foresight-informed strategic planning that may be applicable to other technology-driven industries where foresight is essential for resilience. This chapter describes the processes of foresight for technology development at NASA and provides insight into the value the agency derives from these processes. The chapter further describes the role of OTPS as an independent advisory office that supports NASA’s efforts to capitalize on foresight and strategic technology planning. We present these examples with consideration for how organizations in defense, security, and other technology-driven industries can operationalize foresight in their own strategic technology development.

Erica Rodgers↗

NASA NTRSDate not supplied

LANDO: Developing Autonomous Payload Offloading Capabilities for Lunar Surface Operations

Introduction: The Lightweight Surface Manipulation System (LSMS) AutoNomy capabilities Development for surface Operations and construction (LANDO) project is an Early Career Initiative selected for funding by NASA Space Technology Mission Directorate. LANDO is developing a general-purpose autonomy framework applicable to serial and tension-actuated manipulation agents, that will be validated using an existing prototype of the LSMS-L35 (35-kg wrist lift capacity on the lunar surface [Fig. 1], sized for a Commercial Lunar Pay-load Services (CLPS) mission). The autonomous LSMS-L35 will be used to demonstrate autonomous payload handling capabilities for Lunar and other planetary surfaces, directly addressing STMD capability gaps in autonomous excavation and construction operations, advanced robotics and spacecraft autonomy technologies, and technologies supporting emerging space industries including the In-Space Servicing, Assembly and Manufacturing national strategy. LSMS: The LSMS is a tension actuated robotic agent that is scalable (reach and lifting capacity in different gravity environments), versatile (types of surface operations), and reusable. Compared to serial arms, the LSMS provides significantly higher structural efficiency and mechanical advantage, enabling a greater payload lift capacity at a lower system mass. The LSMS is envisioned to be a crucial part of the excavation and construction portfolio, capable of supporting a variety of activities on the lunar surface. Autonomous payload handling is one of the first activities the LSMS can support that develops capabilities that are extensible to other surface operations. Payload handling is required to: remove payloads from a lander; place payloads on mobile agents for transport from a lander to construction site/assembly point; emplace payloads in their operational configuration, and aggregate components to create an asset. As an example of this critical gap, manifested CLPS missions do not currently have a ubiquitous payload offloading capability; payloads (excluding rovers) are designed to remain on the lander. Why Autonomy? Autonomous robotic systems capable of carrying out excavation and construction operations are a fundamental and critical capability required for realizing the NASA Artemis program vision to “emplace and build the infrastructure, systems, and robotic missions that can enable a sustained lunar surface presence.” While teleoperation is still feasible for lunar surface operations, increased latency at Mars will require validated supervised autonomous technologies capable of operating with minimal human involvement (human-on-the-loop) unless an unexpected event occurs requiring human intervention. Autonomy reduces operator burden, allows operations to continue during uncrewed periods, in-creases the safety of operations by automatically detecting and handling faults, and allows operating in high latency environments. Development Activities: LANDO is extending critical autonomous operations to the manipulation domain and creating an integrated system, based on reusable software modules, that is capable of planning and executing payload handling and autonomous surface operations without requiring hu-man intervention beyond a supervisory role. The priority features under development are 1) autonomously offload payloads from a tilted lander deck without buckling the LSMS; 2) sensing whether a payload is safe to lift and handle; and 3) integrate with Astrobotic’s CLPS lander. The poster presentation will highlight current development activities over the past year on LSMS-L35 prototype hard-ware design, and autonomy software.

in-space assembly↗

NASA NTRSDate not supplied

Development and Future of the Ten Simple Rules for Credible Practice of Models and Simulations in HealthCare

In this session, we will review the development and implementation history of the Ten Simple Rules (TSR) for credible practice in models and simulations that support healthcare. Our focus will be initially on the need and background for the Committee on Credible Practice of Models and Simulations in Healthcare (CPMS) as well as the TSR development process and implementation. This will flow into a demonstration of how the TSR has evolved as means of communicating and understanding the model development process, likely successful application and where the model could fail. We will end this presentation with a discussion on future development avenue, the CPMS efforts to develop a comprehensive rubric supporting current TSR implementation, and efforts to support further adoption of the TSR. The audience will be encouraged to comment on the current state of the TSR, share their TSR application experiences, and provide their insights on future development.

model↗

NASA NTRSDate not supplied

Development of Urban Air Mobility (UAM) Vehicles for Ease of Operation

To date the air transportation system has been developed with the in-cremental introduction of new technology and with highly experienced air transport pilots and air traffic controllers overseeing flight operations. Thus, we currently have one of the safest commercial aviation systems in the world. General Aviation (GA) in the United States, however, has not always followed the same cautious and monitored approach to implementation; consequently, the GA safety record does not meet the high standards of commercial aviation. Recently, a new system known as Urban Air Mobility (UAM), is attracting considerable interest and investment from industry and government agencies. UAM refers to a system of passenger and small-cargo air transportation vehicles within an urban area with the goal of reducing the number of times we need to use our cars, thus improving urban traffic by moving people and cargo from crowded single pas-senger vehicles on our roads to personal and on-demand air vehicles. These UAM vehicles will be small and based on electric, Vertical-Take-Off-and-Landing (eV-TOL) systems. A significant component of UAM is offloading of flight-man-agement responsibilities from human pilots to newly-developed autonomy. Cur-rently, over 100 UAM vehicles are either in development or production. Most, if not all, have a goal of fully autonomous vehicle operations, but fully autonomous flying vehicles are not expected in the near future. Therefore, we are de-veloping concepts for UAM vehicles that will be easy to fly and/or manage by operators with minimal pilot training. In this paper we will discuss our human-automation teaming approach to develop an easy-to-operate VTOL aircraft, and some of the fly-by-wire technology needed to stabilize the vehicle so that a sim-ple ecological mental model of the flying task can be implemented. We will discuss the requirements for a stability augmentation system that must be developed to support our simple pilot input model, and also present design guidelines and requirements based on a pilot input and management model. Finally, our ap-proach to vehicle development will involve considerable operator testing and evaluation: improving pilot model, inceptors, displays and also work on a plan for how a UAM vehicle can be integrated with terminal area air traffic control airspace with minimal impact on controller workload.

UAM↗

NASA NTRS2023

Harnessing the Digital Transformation for Development of Electrified Aircraft Propulsion Control Systems

Hybrid electric aircraft propulsion is an emerging technology that presents a variety of potential benefits along with technical integration challenges. Developing these new propulsion architectures with their complex control systems, and ultimately proving their benefit, is a multistep process. This process includes concept development and analysis, dynamic simulation, hardware-in-the-loop testing, full-scale testing, and so on. This effort is being revolutionized and indeed enabled by new digital tools that support increasing the technology readiness level throughout the maturation process. As part of this Digital Transformation, NASA has developed a suite of publicly available digital tools that facilitate the path from concept to implementation. This paper describes the NASA-developed tools and puts them in the context of control system development for hybrid electric aircraft propulsion. The three MATLAB®-based software packages are the Toolbox for the Modeling and Analysis of Thermodynamic Systems (T-MATS), the Electrical Modeling and Thermal Analysis Toolbox (EMTAT), and the Thermal Systems Analysis Toolbox (TSAT). These tools are interactive, complementary, and compatible with each other. T-MATS is a modular thermodynamic modeling framework designed for creating custom component level models of jet engines. EMTAT is a modeling framework used to simulate a variety of power electronic devices, using both physics-based and power flow calculations. TSAT is a framework for modeling and analysis of dynamic heat transfer. These packages all consist of graphical, drag-and-drop, parameterizable building blocks representing various components of the system to be modeled, e.g., compressors, turbines, motors, energy storage devices, etc. They are designed to enable the user to model and simulate the end-to-end dynamic operation of a hybrid electric gas turbine engine powertrain at the timescale of the turbomachinery, capturing mechanical, electrical, and thermal interactions. This paper demonstrates through multiple examples how these tools have been used successfully in a variety of applications, including several of the early stages of hybrid electric gas turbine engine propulsion system development, from the initial system modeling to real-time interactive pilot-in-the-loop simulation to physical hardware-in-the-loop testing, each step bringing the technology closer to fruition.

hybrid electric propulsion↗

NASA NTRSDate not supplied

The NASA DEVELOP Model of Community Science & Engagement: Localizing Earth Science Information

The NASA DEVELOP Program conducts 10 week feasibility studies that apply Earth observation data to address community priorities and support informed decision making. Part of NASA’s Earth Action Capacity Building Program, DEVELOP builds skills in both participants ( recent graduates, and early/transitioning career professionals), who work on small interdisciplinary project teams, and partner organizations (state and local governments, federal agencies, non profit and for profit organizations, universities, and international organizations) that work closely with DEVELOP to design the project. Projects address a wide variety of environmental issues, such as disaster risk and resilience, air pollution, and the impact of urban development, with a growing number of projects exploring how satellite data can help inform decision making around environmental injustices. A subset of DEVELOP partner organizations are local municipalities or community led non profits, with the co production model serving as an effective engagement tool and an introduction for communities to engage in Earth science research and become familiar with satellite remote sensing. This presentation will highlight the DEVELOP co production model, community project use cases, and lessons learned in partnering with local communities.

Michael Pazmino↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗

DOE OSTI2013

DEVELOPMENT OF A CERAMIC TAMPER INDICATING SEAL: SRNL CONTRIBUTIONS

Savannah River National Laboratory (SRNL) and Sandia National Laboratories (SNL) are collaborating on development of a Ceramic Seal, also sometimes designated the Intrinsically Tamper Indicating Ceramic Seal (ITICS), which is a tamper indicating seal for international safeguards applications. The Ceramic Seal is designed to be a replacement for metal loop seals that are currently used by the IAEA and other safeguards organizations. The Ceramic Seal has numerous features that enhance the security of the seal, including a frangible ceramic body, protective and tamper indicating coatings, an intrinsic unique identifier using Laser Surface Authentication, electronics incorporated into the seal that provide cryptographic seal authentication, and user-friendly seal wire capture. A second generation prototype of the seal is currently under development whose seal body is of Low Temperature Co-fired Ceramic (LTCC) construction. SRNL has developed the mechanical design of the seal in an iterative process incorporating comments from the SNL vulnerability review team. SRNL is developing fluorescent tamper indicating coatings, with recent development focusing on optimizing the durability of the coatings and working with a vendor to develop a method to apply coatings on a 3-D surface. SRNL performed a study on the effects of radiation on the electronics of the seal and possible radiation shielding techniques to minimize the effects. SRNL is also investigating implementation of Laser Surface Authentication (LSA) as a means of unique identification of each seal and the effects of the surface coatings on the LSA signature.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2013

Overview of the U.S. DOE Accident Tolerant Fuel Development Program

The United States Fuel Cycle Research and Development Advanced Fuels Campaign has been given the responsibility to conduct research and development on enhanced accident tolerant fuels with the goal of performing a lead test assembly or lead test rod irradiation in a commercial reactor by 2022. The Advanced Fuels Campaign has defined fuels with enhanced accident tolerance as those that, in comparison with the standard UO2-Zircaloy system currently used by the nuclear industry, can tolerate loss of active cooling in the reactor core for a considerably longer time period (depending on the LWR system and accident scenario) while maintaining or improving the fuel performance during normal operations and operational transients, as well as design-basis and beyond design-basis events. This paper provides an overview of the FCRD Accident Tolerant Fuel program. The ATF attributes will be presented and discussed. Attributes identified as potentially important to enhance accident tolerance include reduced hydrogen generation (resulting from cladding oxidation), enhanced fission product retention under severe accident conditions, reduced cladding reaction with high-temperature steam, and improved fuel-cladding interaction for enhanced performance under extreme conditions. To demonstrate the enhanced accident tolerance of candidate fuel designs, metrics must be developed and evaluated using a combination of design features for a given LWR design, potential improvements to that design, and the design of an advanced fuel/cladding system. The aforementioned attributes provide qualitative guidance for parameters that will be considered for fuels with enhanced accident tolerance. It may be unnecessary to improve in all attributes and it is likely that some attributes or combination of attributes provide meaningful gains in accident tolerance, while others may provide only marginal benefits. Thus, an initial step in program implementation will be the development of quantitative metrics. A companion paper in these proceedings provides an update on the status of establishing these quantitative metrics for accident tolerant LWR fuel.1 The United States FCRD Advanced Fuels Campaign has embarked on an aggressive schedule for development of enhanced accident tolerant LWR fuels. The goal of developing such a fuel system that can be deployed in the U.S. LWR fleet in the next 10 to 20 years supports the sustainability of clean nuclear power generation in the United States.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Geothermal Workforce Education, Development, and Retention

The work funded under this award was the formation of a National Geothermal Academy to develop the human resources that will be needed to transform and grow the US energy infrastructure to achieve the utilization of America’s vast geothermal resource base. The NGA has worked to create the new intellectual capital that will be needed by centralizing and unifying our national assets. The basic idea behind the Academy was to create a centrally located, convening organization for developing and conducting instructional programs in geothermal science and technology to educate and train the next generation of US scientists, engineers, plant operators, technicians, and policy makers. Broad participation of staff, faculty, and students from a consortium of US universities along with scientists and other professionals from industry and national laboratories were utilized. Geothermal experts from the US and other countries were recruited to serve as instructors to develop relevant curricula. Given the long history of geothermal development in the US, there is a large group of experienced individuals who effectively hold the “corporate memory” of geothermal development in the US, many of whom are nearing the end of their professional careers, while some have recently retired. We planned to capture this extremely valuable intellectual resource by engaging a number of these individuals in developing course curricula, leading training workshops, providing classroom instruction and mentoring future instructors.

15 GEOTHERMAL ENERGY↗

DOE OSTI2015

An Approach for Assessing Development and Deployment Risks in the DOE Fuel Cycle Options Evaluation and Screening Study

Abstract One of the key objectives of the U.S. Department of Energy (DOE) Nuclear Energy R&D Roadmap is the development of sustainable nuclear fuel cycles that can improve natural resource utilization and provide solutions to the management of nuclear wastes. Recently, an evaluation and screening (E&S) of fuel cycle systems has been conducted to identify those options that provide the best opportunities for obtaining such improvements and also to identify the required research and development activities that can support the development of advanced fuel cycle options. In order to evaluate and screen the E&S study included nine criteria including Development and Deployment Risk (D&DR). More specifically, this criterion was represented by the following metrics: Development time, development cost, deployment cost from prototypic validation to first-of-a-kind commercial, compatibility with the existing infrastructure, existence of regulations for the fuel cycle and familiarity with licensing, and existence of market incentives and/or barriers to commercial implementation of fuel cycle processes. Given the comprehensive nature of the study, a systematic approach was needed to determine metric data for the D&DR criterion, and is presented here. As would be expected, the Evaluation Group representing the once-through use of uranium in thermal reactors is always the highest ranked fuel cycle Evaluation Group for this D&DR criterion. Evaluation Groups that consist of once-through fuel cycles that use existing reactor types are consistently ranked very high. The highest ranked limited and continuous recycle fuel cycle Evaluation Groups are those that recycle Pu in thermal reactors. The lowest ranked fuel cycles are predominately continuous recycle single stage and multi-stage fuel cycles that involve TRU and/or U-233 recycle.

Gehin, Jess C↗

DOE OSTI2016

Development of a CO 2 Chemical Sensor for Downhole CO 2 Monitoring in Carbon Sequestration

Geologic storage of carbon dioxide (CO 2 ) has been proposed as a viable means for reducing anthropogenic CO 2 emissions. The means for geological sequestration of CO 2 is injection of supercritical CO 2 underground, which requires the CO 2 to remain either supercritical, or in solution in the water/brine present in the underground formation. However, there are aspects of geologic sequestration that need further study, particularly in regards to safety. To date, none of the geologic sequestration locations have been tested for storage integrity under the changing stress conditions that apply to the sequestration of very large amounts of CO 2 . Establishing environmental safety and addressing public concerns require widespread monitoring of the process in the deep subsurface. In addition, studies of subsurface carbon sequestration such as flow simulations, models of underground reactions and transports require a comprehensive monitoring process to accurately characterize and understand the storage process. Real-time information about underground CO 2 movement and concentration change is highly helpful for: (1) better understanding the uncertainties present in CO 2 geologic storage; (2) improvement of simulation models; and (3) evaluation of the feasibility of geologic CO 2 storage. Current methods to monitor underground CO 2 storage include seismic, geoelectric, isotope and tracer methods, and fluid sampling analysis. However, these methods commonly resulted low resolution, high cost, and the inability to monitor continuously over the long time scales of the CO 2 storage process. A preferred way of monitoring in-situ underground CO 2 migration is to continuous measure CO 2 concentration change in brine during the carbon storage process. An approach to obtain the real time information on CO 2 concentration change in formation solution is highly demanded in carbon storage to understand the CO 2 migration subsurface and to answer the public safety problem. The objective of the study is to develop a downhole CO 2 sensor that can in-situ, continuously monitor CO 2 concentration change in deep saline. The sensor is a Severinghaus-type CO 2 sensor with small size, which renders it can be embedded in monitoring well casing or integrated with pressure/temperature transducers, enabling the development of “smart” wells. The studies included: (1) prepare and characterize metal-oxide electrodes. Test the electrodes response to pH change. Investigate different ions and brine concentration effects on the electrode’s performance. Study the stability of the electrode in brine solution; (2) fabricate a downhole CO 2 sensor with the metal-oxide electrodes prepared in the laboratory. Test the performance of the CO 2 sensor in brine solutions. Study high pressure effects on the performance of the sensor; (3) design and conduct CO 2 /brine coreflooding experiments with the CO2 sensor. Monitor CO 2 movement along the core and test the performance of the sensor in coreflooding tests. Develop a data acquisition system that can digitize the sensor’s output voltage. Our completed research has resulted in deep understanding of downhole CO 2 sensor development and CO 2 monitoring in CO 2 storage process. The developed downhole CO 2 sensor included a metal-oxide electrode, a gas-permeable membrane, a porous steel cup, and a bicarbonate-based internal electrolyte solution. Iridium oxide-based electrode was prepared and used for preparation the CO 2 sensor. The prepared iridium oxide-based electrode displayed a linearly response to pH change. Different factors such as different ions and ions concentration, temperature, and pressure effects on the electrode performance on pH response were investigated. The results indicated that the electrode exhibited a good performance even in high salt concentration of produced water. To improve the electrode performance under high pressure, IrO 2 nanoparticles with the particle size in the range of 1-2 nm were prepared and electrodeposited on stainless steel substrate by cyclic voltammetry. It was observed that the thin film of iridium oxide was formed on the substrate surface and such iridium oxide-based electrode displayed excellent performance under high pressure for longer term. A downhole CO 2 sensor with the iridium oxide-based electrode was prepared. The working principle of the CO 2 sensor is based on the measurement of the pH change of the internal electrolyte solution caused by the hydrolysis of CO 2 and then determination of the CO 2 concentration in water. The prepared downhole CO 2 sensor had the size of diameter of 0.7 in. and length of 1.5 in. The sensor was tested under the pressures of 500 psi, 2,000 psi, and 3,000 psi. A linear correlation was observed between the sensor potential change and dissolved CO 2 concentration in water. The response time of the CO 2 sensor was in the range of 60-100 minutes. Further tests indicated that the CO 2 sensor exhibited good reproducibility under high pressure. A CO 2 /brine coreflooding system was constructed to simulate the real-world CO 2 storage process. The prepared downhole CO 2 sensor was loaded in the system to monitor CO 2 movement during CO 2 /brine coreflooding test. The results indicated that the sensor could detect CO 2 movement in the tests. Further studies showed that the sensor could be recovered by brine flooding after CO 2 /brine flushed the core. The results of the coreflooding tests demonstrated that the sensor had potential application for CO 2 monitoring in carbon sequestration. A data acquisition system for the downhoe CO 2 sensor was developed and coded. The system converted the sensor output signal into digital data and transported the data from downhole to wellhead surface. The data acquisition system was tested and evaluated in the laboratory with the prepared sensor for data collection.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Development of Bulk Nanocrystalline Tungsten Alloys for Fusion Reactor Structures

This project developed a technology for manufacturing bulk ultrafine tungsten materials that are at or near full density for fusion reactor structural applications, aiming to improve ductility and toughness of tungsten before and after irradiation. The project involved the development of fabrication processes for making bulk ultrafine grained W, the development of new alloys of ultrafine grained W and evaluations of properties of these specific materials. The goal of this fabrication process is to produce fully dense bulk W with ultrafine grain sizes, with uniform distributions of grain size and additives. To date there is no known process that could be used to make ultrafine grained tungsten in a fully dense state and in a cost-acceptable fashion. The specific technology described in this proposal for making ultrafine grained tungsten involves a suite of nano-particle processing and sintering techniques. The program also developed new alloys of ultrafine grained W, e.g. W-(Ta,V,Ti)-TiC alloys to improve ductility and toughness before and after irradiation. By completing this project, we achieved the following objectives: • Demonstrated experimentally the feasibility of producing bulk ultrafine grained tungsten alloys (at or near 100% dense, <1000 nm grain size) using the proposed process • Demonstrated the proposed ultrafine grained W alloys, namely, W-(Ta, V, Ti)-TiC, can indeed be made using the proposed process • Demonstrated that the properties of nano tungsten alloys meet the requirements for fusion reactor applications. The overall goal was to harness the potential of ultrafine grained W produced using the proposed processes as the core structural materials for future fusion reactors. The project was very successful overall, meeting all milestones and surpassing project goals in terms of process development and material’s blistering resistance properties. A novel process similar to the conventional press-and-sinter powder metallurgy method was developed for producing ultrafine grain tungsten from nanosize tungsten powders. Grain growth was significantly controlled during sintering by certain alloy compositions, particularly Ti, and most compositions sintered to maximum densification. To optimize this process, the effect of processing parameters on the densification and grain growth of nano-W powders was investigated. Near-fully densified tungsten was obtained at sintering temperatures between 1100 and 1300 °C, and both Ar and H2 sintering atmospheres were investigated. The Ar sintering atmosphere was determined to more favorably promote densification and minimize grain growth. The nanosized tungsten powder compacts were subjected to reduction in H2 as a part of the sintering cycle. The reduction temperature was found to have significant effects on the sintering of nano-W powder, primarily as a result of grain coarsening, which was seen at temperatures as low as 700 °C. In an effort to inhibit grain growth, the effect of Ti-based additives on the densification and grain growth of nano-W powders was investigated in this project. The addition of 1 wt.% Ti into tungsten led to more than a 63% decrease in average grain size of sintered samples at comparable density levels. Compared to conventional high temperature sintering, a lower temperature sintering cycle for a longer hold time resulted in both near-full density and fine grain size. The roles of the Ti additives include not only the inhibition of grain growth, but also the potential absorption of oxygen from W particles. The project has resulted in the publication; thus far, of six peer reviewed journal articles and seven conference presentations, as well as a master’s thesis. Two additional journal articles are currently in preparation. Presentations and articles were a particular focus of the second half of the project, once significant experimentation had been performed and analyzed. As part of our efforts to disseminate information of our results, the W research teams with Prof. Fang had a strong presence at multiple international conferences during 2015 and 2016. Several research groups in the US are now performing experiments using the ultrafine grained W materials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

Progress In Developing An In-Pile Acoustically Telemetered Sensor Infrastructure

A salient grand challenge for a number of Department of Energy programs such as Fuels Cycle Research and Development ( includes Accident Tolerant Fuel research and the Transient Reactor Test Facility Restart experiments), Light Water Sustainability, and Advanced Reactor Technologies is to enhance our fundamental understanding of fuel and materials behavior under irradiation. Robust and accurate in-pile measurements will be instrumental to develop and validate a computationally predictive multi-scale understanding of nuclear fuel and materials. This sensing technology will enable the linking of fundamental micro-structural evolution mechanisms to the macroscopic degradation of fuels and materials. The in situ sensors and measurement systems will monitor local environmental parameters as well as characterize microstructure evolution during irradiation. One of the major road blocks in developing practical robust, and cost effective in-pile sensor systems, are instrument leads. If a wireless telemetry infrastructure can be developed for in-pile use, in-core measurements would become more attractive and effective. Thus to be successful in accomplishing effective in-pile sensing and microstructure characterization an interdisciplinary measurement infrastructure needs to be developed in parallel with key sensing technology. For the discussion in this research, infrastructure is defined as systems, technology, techniques, and algorithms that may be necessary in the delivery of beneficial and robust data from in-pile devices. The architecture of a system’s infrastructure determines how well it operates and how flexible it is to meet future requirements. The limiting path for the effective deployment of the salient sensing technology will not be the sensors themselves but the infrastructure that is necessary to communicate data from in-pile to the outside world in a non-intrusive and reliable manner. This article gives a high level overview of a promising telemetry infrastructure based on acoustic wireless transmission of data that is being developed and tested by the INL, Penn State and Westinghouse.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

Quenching and Partitioning Process Development to Replace Hot Stamping of High Strength Automotive Steel

The present project investigated Quenching and Partitioning (Q&P) to process cold rolled steels to develop high strength sheet steels that exhibit superior ductility compared to available grades with the intent to allow forming of high strength parts at room temperature to provide an alternative to hot stamping of parts. Hot stamping of boron alloyed steel is the current technology to manufacture thinner gauge sections in automotive structures to guarantee anti-intrusion during collisions whilst improving fuel efficiency by decreasing vehicle weight. Hot stamping involves reheating steel to 900 °C or higher followed by deformation and quenching in the die to produce ultra-high strength materials. Hot stamping requires significant energy to reheat the steel and is less productive than traditional room temperature stamping operations. Stamping at elevated temperature was developed due to the lack of available steels with strength levels of interest possessing sufficient ductility enabling traditional room temperature forming. This process is seeing growing demand within the automotive industry and, given the reheating step in this operation, increased energy consumption during part manufacturing results. The present research program focused on the development of steel grades via Q&P processing that exhibit high strength and formability enabling room temperature forming to replace hot stamping. The main project objective consisted of developing sheet steels exhibiting minimum ultimate tensile strength levels of 1200 MPa in combination with minimum tensile elongation levels of 15 pct using Q&P processing through judicious alloy design and heat treating parameter definition. In addition, detailed microstructural characterization and study of properties, processing and microstructure interrelationships were pursued to develop strategies to further enhance tensile properties. In order to accomplish these objectives, alloy design was conducted towards achieving the target properties. Twelve alloys were designed and laboratory produced involving melting, alloying, casting, hot rolling, and cold rolling to obtain sheet steels of approximately 1 mm thickness. Q&P processing of the samples was then conducted. Target properties were achieved and substantially exceeded demonstrating success in the developed and employed alloy design approaches. The best combinations of tensile properties were found at approximately 1550 MPa with a total elongation in excess of 20 pct clearly showing the potential for replacement of hot stamping to produce advanced high strength steels.

36 MATERIALS SCIENCE↗