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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 1,405 records · Page 78
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Qualification Test Requirements Report for High-Temperature Irradiation-Resistant Thermocouples

The qualification of f high-temperature irradiation-resistant thermocouples (HTIR-TCs) is set forth utilizing the Advanced Gas Reactor (AGR) 5/6/7 test in the Advanced Test Reactor located at the Idaho National Laboratory (INL). The requirements to achieve the qualification are appropriate design, construction, and calibration followed by proper installation and performance parameters.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Effect of thermal aging on microstructure and crack growth response of Alloy 152 weld

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service). The microstructural characterization by means of synchrotron X-ray did not find evidence of LRO in any of the three heats aged to an equivalent of 60 years of service. Testing in a primary water environment of a heat of Alloy 152 aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. However, the SCC CGR response of the aged sample appears to show a deterioration in performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Final CRADA Report – NFE-21-08693

TAE Technologies is developing a magnetic fusion energy concept known as the beam-driven field-reversed configuration (FRC) with the ultimate goal of developing a reactor for commercial electricity production capable of burning aneutronic pB11 fuel. To achieve the high plasma temperatures this requires, auxiliary radiofrequency (RF) heating will likely be needed. High Harmonic Fast Wave (HHFW) heating has been identified as a candidate RF heating scheme to overcome the unique challenges posed to RF heating by the FRC, including the large distance from the plasma edge to the last closed flux surface and a magnetic field profile with strength decreasing from edge to core and reversing sign at a null point inside the plasma. The purpose of this project was to develop the experimental capabilities to test HHFW on TAE’s C-2W device through the design of a phased array antenna and accompanying matching network. The design was performed by ORNL and informed by experiments with a prototype four-strap phased antenna-array that was manufactured and installed on the LArge Plasma Device (LAPD) at UCLA and simulations conducted with the Petra-M code under the purview of a previous INFUSE grant. The ORNL team completed the conceptual design of the antenna and matching network which was then handed off to the TAE Mechanical Design team. The design was then iterated on to ensure changes to the mechanical design did not interfere with the RF performance. This process is now complete, and, with mechanical design in hand, TAE is proceeding with plans for final integration.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1982

Long titanium heat pipes for high-temperature space radiators

Titanium heat pipes are being developed to provide light weight, reliable heat rejection devices as an alternate radiator design for the Space Reactor Power System (SP-100). The radiator design includes 360 heat pipes, each of which is 5.2 m long and dissipates 3 kW of power at 775 K. The radiator heat pipes use potassium as the working fluid, have two screen arteries for fluid return, a roughened surface distributive wicking system, and a D shaped cross section container configuration. A prototype titanium heat pipe, 5.5 m long, was fabricated and tested in space simulating conditions. Results from startup and isothermal operation tests are presented. These results are also compared to theoretical performance predictions that were used to design the heat pipe initially.

Girrens, S. P.↗
NASA NTRS1982

Long titanium heat pipes for high-temperature space radiators

Titanium heat pipes are being developed to provide light weight, reliable heat rejection devices as an alternate radiator design for the Space Reactor Power System (SP-100). The radiator design includes 360 heat pipes, each of which is 5.2 m long and dissipates 3 kW of power at 775 K. The radiator heat pipes use potassium as the working fluid, have two screen arteries for fluid return, a roughened surface distributive wicking system, and a D-shaped cross-section container configuration. A prototype titanium heat pipe, 5.5-m long, has been fabricated and tested in space-simulating conditions. Results from startup and isothermal operation tests are presented. These results are also compared to theoretical performance predictions that were used to design the heat pipe initially.

Girrens, S. P.↗
DOE OSTI2021

Creating Hydride Rim Structures in Zircaloy 4 Cladding Tubes to Mimic High Burnup

During their long service in commercial light water reactors, zirconium alloy cladding tubes are subject to oxidation and subsequent hydrogen pickup which can degrade the materials mechanical properties [1]. These degradations can lead to premature cladding ruptures during reactor power transients [2] as well as negatively impact the claddings post quench ductility following high temperature steam oxidation in thermal hydraulic transients [3]. Hydrogen has low solid solubility in zirconium and usually precipitates as brittle zirconium hydride platelets in the cladding metal matrix. Due to temperature driven diffusion (Soret effect) and the grain texture of stress relieved zirconium metal tubes, these hydrides precipitate with a circumferential orientation near the outer surface of the cladding tubes forming a hydride rim which can serve as a site for crack initiation during circumferential ‘hoop’ loading of the cladding [4rim formation][5]. In order to better understand the effect of hydride rims on the fracture behavior of stress relieved zirconium alloy cladding tubes a procedure to produce these rim-like structures is being developed at Idaho National Laboratory (INL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Atom probe tomography characterization of ion and neutron irradiated Alloy 800H

Alloy 800H is a high temperature and creep resistant alloy, and is considered as a candidate alloy for use in Generation IV nuclear reactor systems. To clarify the alloy's behavior under irradiation, samples were subjected to single ion irradiations up to 20 dpa at 440°C, a dual ion/He irradiation to 17 dpa at 460°C, and a neutron irradiation to 17 dpa at 385°C. The irradiated microstructures were characterized using atom probe tomography to complement previously published transmission electron microscopy studies. Additionally, after single ion irradiation, sparse fine Al and Ti clusters were observed after 1dpa, while high number densities of nanoscale Ni-Al-Ti clusters, Cr-Ti rich carbides, and Si-decorated dislocation loops developed after 10 and 20 dpa. The microstructure formed during single ion irradiation exhibited a strong depth dependence. No significant differences were observed between the single and dual ion irradiations. While Ni-Al-Ti clusters, Cr-Ti rich carbides, and Si-decorated dislocation loops were also observed after neutron irradiation, the neutron-irradiated microstructure differed from those found in the ion-irradiated samples.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fiber-Based Distributed Hydrogen Measurement at High Temperatures

In this work, we discuss the implementation of evanescent field optical fiber sensors for distributed gas sensing of H2, focusing on results using a Ni / Gd-doped CeO2 nanocomposite sensing material for detection of low levels of H2 (0-4%) at 700 °C. This approach utilizes sensors prepared using a low-cost, wet chemical deposition process, in conjunction with a custom-built interrogator system leveraging optical time domain reflectometry (OTDR). Using a specially designed dual-gas flow reactor system, the sensor is tested by establishing a controlled equilibrium gradient of gas concentration. Initial results are shown using silica fiber, but provides a pathway for utilization with high temperature stable single crystal optical fiber for operation at higher temperatures and higher levels of H2 relevant for solid oxide fuel cell (SOFC) operating conditions.

Wuenschell, Jeffrey↗
DOE OSTI2023

Techno-Economic Analysis of a Nuclear Reactor System coupled with a Liquid Metal Battery

There is a need for nuclear reactor systems to become more dynamic as defossilization and renewable energy sources continue to reshape the energy grid. One option to meet these changing demands is to pair the reactor with an energy storage system. This work details a technoeconomic analysis and sensitivity analysis of a high temperature gas cooled microreactor, supercritical carbon dioxide power cycle, and liquid metal battery. Dynamic modeling has shown that these three systems compliment each other to provide load following and black-start capabilities to the grid. Current cost estimates for installing the systems yield a competitive levelized cost of electricity and levelized cost of storage, indicating that such a combined system may be economically viable as technological advances lead to them being technically feasible.

25 ENERGY STORAGE↗
DOE OSTI2022

Equipment Procurement and Final Design for the MARVEL High-Grade Heat Extraction System (HGHES)

This summer I worked on the design of a high-grade heat extraction system (HGHES) of the MARVEL Project. The MARVEL project at INL is a first-of-a-kind terrestrial microreactor to help provide a test platform to demonstrate the use of a microreactor to end customers and enable technology developers to test enabling microreactor technologies with a functional nuclear reactor. One of the project's main requirements is the reactors’ ability to deliver high-grade thermal power to end users, both for industrial and commercial use. The project required communication with multiple vendors for custom-made equipment, working with a high-temperature and high-pressure helium coolant system, and research of a Thermal Storage Unit (TSU).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Lignin Extraction and Condensation as a Function of Temperature, Residence Time, and Solvent System in Flow-through Reactors

Solvolytic extraction of lignin from biomass is a critical step in lignin-first biorefining, including the reductive catalytic fractionation (RCF) process. Key to optimal RCF processing is the ability to rapidly extract lignin from biomass at high delignification extents and transfer the lignin molecules to a catalyst surface in a time frame that minimizes lignin condensation reactions. Here, we use a flow-through reactor to study the effects of temperature (175-250 °C), residence time (9 to 36 min), and solvent composition (methanol and methanol-water) on lignin extraction and condensation. We evaluated three metrics at each condition: total delignification, delignification rate, and extent of condensation, the latter measured by a decrease in monomer yield for batch hydrogenolysis reactions of solvolysis liquor compared to batch RCF reactions. We observe that delignification is predominantly determined by temperature, while residence time dictates the lignin condensation extent. Moreover, the extent of both extraction and condensation increased in the methanol-water solvent system compared to that in the methanol system. Lignin extracted in methanol is stable up to 18-min residence times at or below 225 °C, while a majority of the lignin extracted in methanol-water is condensed with a 9-min residence time at 200 °C. These results can inform reactor designs and solvent selection for lignin-first biorefining processes that aim to physically separate the biomass and catalyst.

09 BIOMASS FUELS↗
DOE OSTI2026

Lignin Extraction and Condensation as a Function of Temperature, Residence Time, and Solvent System in Flow-through Reactors

Solvolytic extraction of lignin from biomass is a critical step in lignin-first biorefining, including the reductive catalytic fractionation (RCF) process. Key to optimal RCF processing is the ability to rapidly extract lignin from biomass at high delignification extents and transfer the lignin molecules to a catalyst surface in a time frame that minimizes lignin condensation reactions. Here, we use a flow-through reactor to study the effects of temperature (175–250 °C), residence time (9 to 36 min), and solvent composition (methanol and methanol–water) on lignin extraction and condensation. We evaluated three metrics at each condition: total delignification, delignification rate, and extent of condensation, the latter measured by a decrease in monomer yield for batch hydrogenolysis reactions of solvolysis liquor compared to batch RCF reactions. We observe that delignification is predominantly determined by temperature, while residence time dictates the lignin condensation extent. Moreover, the extent of both extraction and condensation increased in the methanol–water solvent system compared to that in the methanol system. Lignin extracted in methanol is stable up to 18-min residence times at or below 225 °C, while a majority of the lignin extracted in methanol–water is condensed with a 9-min residence time at 200 °C. These results can inform reactor designs and solvent selection for lignin-first biorefining processes that aim to physically separate the biomass and catalyst.

biorefining↗
DOE OSTI2020

A Novel Laser 3D Printing Method for the Advanced Manufacturing of Protonic Ceramics

Protonic ceramics (PCs) with high proton conductivity at intermediate temperatures (300–600 °C) have attracted many applications in energy conversion and storage devices such as PC fuel/electrolysis cells, PC membrane reactors, hydrogen pump, hydrogen or water-permeable membranes, and gas sensors. One of the essential steps for fulfilling the practical utilization of these intermediate-temperature PC energy devices is the successful development of advanced manufacturing methods for cost-effectively and rapidly fabricating them with high energy density and efficiency in a customized demand. In this work, we developed a new laser 3D printing (L3DP) technique by integrating digital microextrusion-based 3D printing and precise and rapid laser processing (sintering, drying, cutting, and polishing), which showed the capability of manufacturing PCs with desired complex geometries, crystal structures, and microstructures. The L3DP method allowed the fabrication of PC parts such as pellets, cylinders, cones, films, straight/lobed tubes with sealed endings, microchannel membranes, and half cells for assembling PC energy devices. The preliminary measurement of the L3DP electrolyte film showed a high proton conductivity of ≈7 × 10−3 S/cm. This L3DP technique not only demonstrated the potential to bring the PCs into practical use but also made it possible for the rapid direct digital manufacturing of ceramic-based devices.

08 HYDROGEN↗
DOE OSTI2026

Hazard and risk analysis framework for nuclear power plant–based integrated energy systems

Employing integrated energy systems (IESs) with nuclear power plants (NPPs) can improve NPP utilization by leveraging dedicated thermal and electric power delivery, but it may also increase operational safety risks. This paper presents a framework to identify and quantify hazards and risks for such IESs. The framework combines accidentology to review past industrial accidents with failure modes and effects analysis (FMEA) to identify potential future incidents. Hydrogen explosion and toxic chemical release hazards are of particular concern. Explosion consequences are quantified using the Bauwens-Dorofeev (Bauwens) and trinitrotoluene equivalent mass (TNT-EM) methods, while chemical release consequences are computed using the Gaussian atmospheric dispersion method. Operational disturbances from direct electrical and thermal integration that may affect NPP safety are modeled using probabilistic risk analysis (PRA). Hazards and risks are then evaluated for regulatory compliance. The framework is applied to IESs comprising pressurized or boiling water reactors supplying three levels of thermal and electrical power to industrial customers. Case studies include high-temperature steam electrolysis hydrogen plants of varying capacities and a synthetic fuel production plant. Sensitivity analysis examines piping component failures in the PRA model as a precursor to cost estimation for thermal extraction line design. Additionally, Fussel-Vessely (FV) and risk increase importance (RII) measures identify risk-informed design improvements for the thermal extraction system. FMEA highlights hazards such as loss of offsite power, prompt loss of electrical load, loss of thermal output, and immediate steam diversion, in addition to hydrogen explosions and toxic chemical releases. Both Bauwens and TNT-EM methods suggest maintaining several hundred meters of separation between the NPP and hydrogen facility to mitigate explosion risks. PRA results show a maximum initiating event frequency increase of 1.15% and an overall risk increase of 0.28%. Importance measure analysis identifies upstream pipe leak isolation components as critical. Evaluating the results against safety regulations, it is concluded that hazards and risks can be managed to comply with regulations through risk-informed thermal and electrical connection designs, component selection, maintenance programs, and safe separation distances between NPPs and integrated industrial facilities.

08 - HYDROGEN↗
DOE OSTI2021

VERA-Grizzly Ex-Core Calculations: Watts Bar Unit 1 Cycles 1-2

The critical structures that comprise light-water reactor (LWR) nuclear power plants are subjected to operating environments that can challenge their integrity. Structures in close proximity to the reactor core, such as the reactor pressure vessel (RPV) and the biological shield wall, are subjected to high levels of radiation emanating from the core, as well as elevated temperatures. As the US fleet of operating LWRs ages, the effects of these operating environments on the integrity of these structures must be considered to ensure their continued safe operation. Extending the lifetime of commercial reactors and maintaining the aging reactor fleet require accurate prediction of the exposure of ex-core components to neutron and photon radiation. In particular, concrete degradation studies must be performed to evaluate the safety and long-term operation of reactors with lifetime extensions. The concrete reactor bioshield is important for providing radiological protection during operation and must last for the entire lifetime of the reactor. Recent interest in lifetime extensions furthers the need to accurately simulate concrete material degradation in the reactor bioshield. As a result of this need, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has funded this study to couple its tools, Virtual Environment for Reactor Applications (VERA) and Grizzly. VERA allows users to set up models to calculate time-dependent and fully coupled solutions (with thermal feedback) for ex-core quantities of interest such as vessel and coupon fluence and detector responses for multiple statepoints and cycles. Grizzly is a finite-element application based on the Multiphysics Object Oriented Simulation Environment (MOOSE) framework that is used to enable aging materials calculations. This report highlights the work performed to calculate the fluence in the vessel and concrete for Watts Bar Nuclear Plant Unit 1 (WBN1) Cycles 1 and 2. The fluences obtained from VERA were successfully transferred to Grizzly using a Python script. Four simulations were run with Grizzly: (1) the Mazars model with the initial Young’s modulus being the instantaneous modulus, (2) the Mazars model with the initial Young’s modulus being the delayed modulus, (3) the Mazars model with the initial Young’s modulus being the delayed modulus with the addition of the effects of micro-damage caused by irradiation, and (4) the Mazars model with the initial Young’s modulus being the instantaneous modulus, and with the addition of micro-damage and creep. Details regarding the methods used to obtain the fluence and the statistical errors associated with the VERA Monte Carlo Shift calculations are discussed in greater detail in this report. The results obtained from the four Grizzly models are also presented in this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1975

Preparation of tantalum-based alloys by a unique CVD process

The paper describes a sequential pulsing technique for deposition of refractory alloys and evaluates the technique for the deposition of the tantalum-base alloys Ta-10W (Ta-10 st% W) and T-111 (Ta-8 wt% W-2 wt% Hf). The deposition cycle for Ta-10W was chosen as alternate injections of TaCl5 plus hydrogen and WCl6 plus hydrogen. The cycle for T-111 was chosen as injections of TaCl5 plus hydrogen interspersed with injections of WCl6 plus hydrogen. A temperature range of 900-1300 C was chosen for both alloys. The ability of the pulse process to blanket a uniformly heated section of substrate with a mixture of gases, whose composition varies not with position on the substrate but instead with time of residence in the reactor, allows metal of uniform thickness to be deposited. It is shown that Ta and W can be deposited at high temperature with the formation of a dense columnar grain structure, so that the feasibility of preparing uniformly thick deposits of these elements by a 'pulsing' modification of CVD is demonstrated. A similar attempt to deposit T-111 was unsuccessful due to the difficulty in reducing HfCl4.

Bryant, W. A.↗
NASA NTRS1981

High temperature (Al2O3) insulation and light weight conductors

The of an aluminum conductor with an aluminum oxide insulation film was investigated. Aluminum oxide insulated wire or strip (with a melting point of 2050 C) is unique for applications in the electronic, missile, atomic reactor, aerospace, and aircraft industries. The oxide film is highly flexible, suitable for all windings of any size and shape of coil (magnetic). Briefly touched upon are the ultraviolet, proton gamma radiation uses, as well as high vacuum and cryogenic applications. Since the film is inorganic and chemically inert, it does not age or deteriorate in storage and has good dielectric properties (1000 volts per mil).

Walker, H.↗
NASA NTRS1981

Advanced high temperature thermoelectrics for space power

Preliminary results from a spacecraft system study show that an optimum hot junction temperature is in the range of 1500 K for advanced nuclear reactor technology combined with thermoelectric conversion. Advanced silicon germanium thermoelectric conversion is feasible if hot junction temperatures can be raised roughly 100 C or if gallium phosphide can be used to improve the figure of merit, but the performance is marginal. Two new classes of refractory materials, rare earth sulfides and boron-carbon alloys, are being investigated to improve the specific weight of the generator system. Preliminary data on the sulfides have shown very high figures of merit over short temperature ranges. Both n- and p-type doping have been obtained. Pure boron-carbide may extrapolate to high figure of merit at temperatures well above 1500 K but not lower temperature; n-type conduction has been reported by others, but not yet observed in the JPL program. Inadvertant impurity doping may explain the divergence of results reported.

Lockwood, A.↗