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DOE OSTI2021

Modeling and Analysis for Spent Nuclear Fuel Seismic Testing

Note: This is the final public release version of PNNL-31671 Draft, which was previously released to the sponsor for review. The intent is the public release version will be PNNL-31671. There are no significant changes from the earlier draft version. This unlimited distribution report is the deliverable for M3SF-21PN010202014: Modeling and Analysis for Spent Nuclear Fuel Seismic Testing. This report summarizes the modeling, analysis, and test plan support completed by Pacific Northwest National Laboratory for the spent nuclear fuel dry storage system seismic test plan through May of 2021. Test plan preparation is planned to continue until the seismic test is completed in July of 2022. This report covers preliminary structural dynamic model development and computer-aided design of test hardware. Based on preliminary modeling, the strongest earthquakes under consideration in this test program provide mechanical loading on the spent nuclear fuel that is comparable to the 30 cm cask drop scenario, although the loads do not appear to be strong enough to cause significant permanent deformation of the fuel assembly spacer grids. The potential for grid deformation during the test will be assessed when the proposed shake table motion becomes available. The weakest earthquakes considered in this test are expected to be comparable to the mechanical loads witnessed in the multimodal transportation test of 2017. The horizontal canister system is predicted to provide nearly-uniform loading condition on the fuel assemblies it contains, while the vertical cask system is predicted to cause non-uniform dynamic loads on the fuel assemblies. In the horizontal case, gravity keeps the fuel assemblies in contact with one basket wall surface unless the loads are strong enough to cause a separation. In the vertical case, the fuel assemblies are relatively long and slender, and seismic motion in the anticipated test range is predicted to cause the assemblies to lean, tilt, and impact the basket walls throughout the seismic event. These gap closures are a nonlinear force transmission condition, so the vertical system is expected to have more variation and variability than the horizontal system. While the horizontal system is expected to have a relatively more linear response than the vertical system, there is still the potential for nonlinear behavior in the horizontal system because the fuel assemblies are free to slide, bounce, and impact the basket walls if the seismic loads are strong enough. One major conclusion of this study is that the use of mixed fuel assemblies in the canister will be acceptable. There are differences in overall system response when the mass, center of gravity, or gaps are changed, but the changes in response are within the bounds of a system that contains completely homogeneous fuel assemblies. One important observation is that the loading for each individual fuel assembly within the vertical canister is expected to be different from that of the others because of nonlinearities in the system. The horizontal canister system is expected to have a more uniform and more predictable response than the vertical canister, making variations in fuel assembly characteristics easier to account for. One important recommendation that comes from this modeling work is to repeat some of the strongest shake tests at different angles, particularly for the vertical cask system. Modeling predicts that strong seismic motion will cause the fuel assemblies to close initial gaps and impact the fuel basket walls when the canister is in the vertical cask configuration. Each shake test will impose a pre-defined three-dimensional time history on the cask system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2011

Comparison of Test and Finite Element Analysis for Two Full-Scale Helicopter Crash Tests

Finite element analyses have been performed for two full-scale crash tests of an MD-500 helicopter. The first crash test was conducted to evaluate the performance of a composite deployable energy absorber under combined flight loads. In the second crash test, the energy absorber was removed to establish the baseline loads. The use of an energy absorbing device reduced the impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to analytical results. Details of the full-scale crash tests and development of the system-integrated finite element model are briefly described along with direct comparisons of acceleration magnitudes and durations for the first full-scale crash test. Because load levels were significantly different between tests, models developed for the purposes of predicting the overall system response with external energy absorbers were not adequate under more severe conditions seen in the second crash test. Relative error comparisons were inadequate to guide model calibration. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used for the second full-scale crash test. The calibrated parameter set reduced 2-norm prediction error by 51% but did not improve impact shape orthogonality.

Annett, Martin S.↗

NASA NTRS1994

Prediction of fatique crack growth under flight-simulation loading with the modified CORPUS model

The CORPUS (Computation Of Retarded Propagation Under Spectrum loading) crack growth prediction model for variable-amplitude loading, as introduced by De Koning, was based on crack closure. It includes a multiple-overload effect and a transition from plane strain to plane stress. In the modified CORPUS model an underload affected zone (ULZ) is introduced, which is significant for flight-simulation loading in view of the once per flight compressive ground load. The ULZ is associated with reversed plastic deformation induced by the underloads after crack closure has already occurred. Predictions of the crack growth fatigue life are presented for a large variety of flight-simulation test series on 2024-T3 sheet specimens in order to reveal the effects of a number of variables: the design stress level, the gust spectrum severity, the truncation level (clipping), omission of small cycles, and the ground stress level. Tests with different load sequences are also included. The trends of the effects induced by the variables are correctly predicted. The quantitative agreement between the predictions and the test results is also satisfactory.

Padmadinata, U. H.↗

NASA NTRS1993

An advanced test technique to quantify thermomechanical fatigue damage accumulation in composite materials

A mechanical test technique was developed to assist in quantifying the accumulation of damage in composite materials during thermomechanical fatigue (TMF) cycling. This was accomplished by incorporating definitive elastic mechanical property measurements into an ongoing load-controlled TMF test without disturbing the test specimen or significantly altering the test conditions. The technique allows two fundamental composite properties consisting of the isothermal elastic static moduli and the macroscopic coefficient of thermal expansion (CTE) to be measured and collected as functions of the TMF cycles. The specific implementation was incorporated into the commonly employed idealized in-phase and out-of-phase TMF cycles. However, the techniques discussed could be easily implemented into any form of load-controlled TMF mission cycle. By quantifying the degradations of these properties, tremendous insights are gained concerning the progression of macroscopic composite damage and often times the progression of damage within a given constituent. This information should also be useful for the characterization and essential for the verification of analytical damage modeling methodologies. Several examples utilizing this test technique are given for three different fiber lay-ups of titanium metal matrix composites.

Castelli, Michael G.↗

DOE OSTI2024

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates

Abstract The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure–property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Eswarappa Prameela, Suhas (ORCID:0000000334530184)↗

DOE OSTI2019

Flexibility Reserve in Power Systems: Definition and Stochastic Multi-Fidelity Optimization

This paper defines flexibility reserve trajectory as a single reserve product that not only supplies the energy imbalance in real-time operation but also the resulting ramping requirements by embedding the flexible ramping trajectories as time derivative of the reserve trajectories. Further, a stochastic optimization model is proposed for multi-fidelity co-optimization of energy and flexibility reserve in day-ahead power systems operation. The proposed model integrates operation decisions with different levels of modeling fidelity in a single stochastic optimization problem. More specifically, day-ahead energy trajectories, day-ahead flexibility reserve capacity trajectories, and real-time flexibility reserve deployment trajectories are modeled by Bernstein polynomials with different degrees as required to match the load and renewable generation with different levels of variability in day-ahead and real-time operations. The proposed model is implemented on the IEEE reliability test system using load and solar generation data of California ISO, where the numerical results demonstrate that the proposed model schedules a reserve capacity that more accurately matches the real-time energy imbalance and ramping requirements of net-load, while reducing the total operation cost of the system.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1988

Fatique crack growth behavior of a single crystal alloy as observed through an in situ fatigue loading stage

An in situ fatigue loading stage inside a scanning electron microscope (SEM) was used to determine the fatigue crack growth behavior of a PWA 1480 single-crystal nickel-based superalloy. The loading stage permits real-time viewing of the fatigue damage processes at high magnification. The PWA 1480 single-crystal, single-edge notch specimens were tested with the load axis parallel to the (100) orientation. Two distinct fatigue failure mechanisms were identified. The crack growth rate differed substantially when the failure occurred on a single slip system in comparison to multislip system failure. Two processes by which crack branching is produced were identified and are discussed. Also discussed are the observed crack closure mechanisms.

Telesman, Jack↗

NASA NTRS1988

Fatigue crack growth behavior of a single crystal alloy as observed through an in situ fatigue loading stage

Telesman, Jack↗

DOE OSTI2020

Deformation behavior of nanoscale Al–Al 2 Cu eutectics studied by in situ micropillar compression

We report deformation behavior of nanoscale laser processed Al–Al 2 Cu eutectics at room temperature is characterized through in situ micro-pillar compression testing in a scanning transmission microscope. Interlamellar spacing of Al–Al 2 Cu eutectics varies from hundreds of nanometers to 20 nm. Three different sizes of micro-pillars are fabricated in order to study the deformation behaviors of single colony and multiple colonies, corresponding to the single crystal and polycrystal respectively. For single colonies, lamellar orientations parallel, normal or inclined to the loading direction were tested. The main findings are: 1) the plasticity mechanisms strongly depend on loading orientation: buckling and kinking in the parallel-loaded eutectics, planar sliding along Al–Al 2 Cu lamellar interfaces in the incline-loaded eutectics and localized shearing in the normal-loaded eutectics. 2) the incline-loaded eutectics exhibits the lowest compression flow strength, and the normal-loaded eutectics has the highest compression flow strength. 3) with decreasing inter-lamellar spacing, the strength increases and plasticity is uniformly distributed, as opposed to shear localization. Highest compressive plasticity is observed in polycrystalline eutectics with an ensemble of lamellar orientations with ~20 nm average spacing: 17.9% at flow stress of 1.63 GPa, and degenerate, bimodal morphology: 11.1% at flow stress of 1.36 GPa.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Evaluation of dynamic testing of full-scale wind turbine drivetrains with hardware-in-the-loop

Dynamometer testing of full-scale wind turbine drivetrains involves subjecting integrated components to extreme static loads, fatigue loads, or dynamic loads to replicate field conditions. This paper provides a detailed evaluation of the uncertainty and errors in applied loads and measured responses, and their magnitude relative to established repeatability bounds for a drivetrain subjected to static and dynamic loads on the 7.5 MW test bench at the Clemson University Wind Turbine Drivetrain Testing Facility. An ideal drivetrain simulation model is utilized to isolate the influence of load tracking errors on test article responses. It is shown that the test article response variations are mainly driven by run out and clearances inherent to the drivetrain. For the dynamic profiles, the load tracking errors are within acceptable limits. Furthermore, a frequency analysis is used to show that the test bench controller tracking performance is acceptable for profiles with frequency content up to 1.5 Hz.

17 WIND ENERGY↗

NASA NTRS1991

Acousto-ultrasonic evaluation of ceramic matrix composite materials

Acousto-ultrasonic nondestructive evaluation of ceramic composite specimens with a lithium-alumino-silicate glass matrix reinforced with unidirectional silicon carbide (NICALON) fibers was conducted to evaluate their reserve of strength. Ceramic composite specimens with different amount of damage were prepared by four-point cyclic fatigue loading of the specimens at 500 C for a different number of cycles. The reserve of strength of the specimens was measured as the maximum bending stress recorded during four-pointed bending test with the load monotonically increased until failure occurs. It was observed that the reserve of strength did not correlate with the number of fatigue cycles. However, it was also observed that higher values of the stress wave factor measurements correspond to higher values of the reserve of strength test data. Therefore, these results show that the acousto-ultrasonic approach has the potential of being used to monitor damage and to estimate the reserve of strength of ceramic composites.

Dosreis, Henrique L. M.↗

DOE OSTI2016

Preliminary test results in support of integrated EPP and SMT design methods development

The proposed integrated Elastic Perfectly-Plastic (EPP) and Simplified Model Test (SMT) methodology consists of incorporating a SMT data-based approach for creep-fatigue damage evaluation into the EPP methodology to avoid using the creep-fatigue interaction diagram (the D diagram) and to minimize over-conservatism while properly accounting for localized defects and stress risers. To support the implementation of the proposed code rules and to verify their applicability, a series of thermomechanical tests have been initiated. One test concept, the Simplified Model Test (SMT), takes into account the stress and strain redistribution in real structures by including representative follow-up characteristics in the test specimen. The second test concept is the two-bar thermal ratcheting tests with cyclic loading at high temperatures using specimens representing key features of potential component designs. This report summaries the previous SMT results on Alloy 617, SS316H and SS304H and presents the recent development on SMT approach on Alloy 617. These SMT specimen data are also representative of component loading conditions and have been used as part of the verification of the proposed integrated EPP and SMT design methods development. The previous two-bar thermal ratcheting test results on Alloy 617 and SS316H are also summarized and the new results from two bar thermal ratcheting tests on SS316H at a lower temperature range are reported.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Dynamics of plankton populations in upwelling areas

There are no author-identified significant results in this report. Repeated coverage over the test site along the northwest coast of Africa showed that the structure of chlorophyll distribution is much more complicated than expected from continuous recordings. ERTS-1 data showed a very fast change in the chlorophyll distribution and it seems that also the concentration changes quickly. ERTS-1 showed on some frames offshore transportation of dust from the Sahara. All frames from Channel 7 will be arranged as a montage to derive the transportation pattern of dust. This step is important in biological aspects of interpreting ERTS-1 data, because the dissolution kinetics of eolian dust particles may influence significantly the chemistry of the surface water. Since visibility and the biochemistry of the test site off Africa are influenced by the dust transport, dust collection will be included in the ground truth program. Besides chlorophyll and other hydrographical parameters, the dust load in the test area will be measured. The collection plan is discussed along with a description of the high volume air sampler and the Anderson particle sizing head sampler to be used for the dust measurements.

Szekielda, K.↗

NASA NTRS1939

Resume of air-load data on slats and flaps

A resume of the generally available test data regarding air loads on slats and flaps is presented and data attained up to the fall of 1938 are included. The data are given in the form of N.A.C.A. standard coefficients of air forces and moments on the lift-increasing device and, when available, the aerodynamic characteristics of the combined wing and high-lift device are included. Slats of the Handley Page type, fixed auxiliary airfoils, and flaps of several different types are covered.

Wenzinger, Carl J↗

NASA NTRS2014

Imparting Motion to a Test Object Such as a Motor Vehicle in a Controlled Fashion

An apparatus imparts motion to a test object such as a motor vehicle in a controlled fashion. A base has mounted on it a linear electromagnetic motor having a first end and a second end, the first end being connected to the base. A pneumatic cylinder and piston combination have a first end and a second end, the first end connected to the base so that the pneumatic cylinder and piston combination is generally parallel with the linear electromagnetic motor. The second ends of the linear electromagnetic motor and pneumatic cylinder and piston combination being commonly linked to a mount for the test object. A control system for the linear electromagnetic motor and pneumatic cylinder and piston combination drives the pneumatic cylinder and piston combination to support a substantial static load of the test object and the linear electromagnetic motor to impart controlled motion to the test object.

Southward, Stephen C.↗

NASA NTRS1995

Full-scale hingeless rotor performance and loads

A full-scale BO-105 hingeless rotor system was tested in the NASA Ames 40- by 80-Foot Wind Tunnel on the rotor test apparatus. Rotor performance, rotor loads, and aeroelastic stability as functions of both collective and cyclic pitch, tunnel velocity, and shaft angle were investigated. This test was performed in support of the Rotor Data Correlation Task under the U.S. Army/German Memorandum of Understanding on Cooperative Research in the Field of Helicopter Aeromechanics. The primary objective of this test program was to create a data base for full-scale hingeless rotor performance and structural blade loads. A secondary objective was to investigate the ability to match flight test conditions in the wind tunnel. This data base can be used for the experimental and analytical studies of hingeless rotor systems over large variations in rotor thrust and tunnel velocity. Rotor performance and structural loads for tunnel velocities from hover to 170 knots and thrust coefficients (C(sub T)/sigma) from 0.0 to 0.12 are presented in this report. Thrust sweeps at tunnel velocities of 10, 20, and 30 knots are also included in this data set.

Peterson, Randall L.↗

DOE OSTI2011

Neutron Screening Measurements of 110 gallon drums at T Plant

The Pacific Northwest National Laboratory (PNNL) Nondestructive Assay (NDA) Service Center was contracted to develop and demonstrate a simple and inexpensive method of assaying 110 gallon drums at the Hanford Site’s T-Plant. The drums contained pucks of crushed old drums used for storage of transuranic (TRU) waste. The drums were to be assayed to determine if they meet the criteria for TRU or Low Level Waste (LLW). Because of the dense matrix (crushed steel drums) gamma measurement techniques were excluded and a mobile, configurable neutron system, consisting of four sequentially connected slab detectors was chosen to be used for this application. An optimum measurement configuration was determined through multiple test measurements with californium source. Based on these measurements the initial calibration of the system was performed applying the isotopic composition for aged weapon-grade plutonium. A series of background and blank puck drum measurements allowed estimating detection limits for both total (singles) and coincidence (doubles) counting techniques. It was found that even conservative estimates for minimum detection concentration using singles count rate were lower than the essential threshold of 100 nCi/g. Whereas the detection limit of coincidence counting appeared to be about as twice as high of the threshold. A series of measurements intended to verify the technique and revise the initial calibration obtained were performed at the Waste Receiving and Processing (WRAP) facility with plutonium standards. Standards with a total mass of 0.3 g of plutonium (which is estimated to be equivalent of 100 nCi/g for net waste weight of 300 kg) loaded in the test puck drum were clearly detected. The following measurements of higher plutonium loadings verified the calibration factors obtained in the initial exercise. The revised and established calibration factors were also confirmed within established uncertainties by additional measurements of plutonium standards in various locations in the test drum. Due to necessity to dispense the blank test drum an alternative method of baseline determination was established during field measurements. Count rates of ambient background were corrected by the differences between observed background and blank test drum count rates which were previously determined over a series of measurements. Only 31 drums out of 352 counted during the intensive measurement campaign at T-Plant were determined to be Suspect TRU. 25 of these drums were re-measured at the WRAP facility using the SuperHENC. Of the 25 drums measured, 21 were confirmed to be TRU and the remaining four LLW.

neutron measurements, TRU waste, T-Plant, configur↗

DOE OSTI2025

TEAMER – Enhanced Flow Measurement for Aquantis Tidal Turbine Test

The AQ10 is a floating, two-bladed, passive yawing tidal turbine developed by Aquantis that has a 10-meterrotor diameter, 160 kW rating, and employs reliable off-the-shelf powertrain and power conversion hardware. Aquantis is planning on-water turbine power performance and loads (blade loading and thrust)testing, where the turbine will be pushed through still water up to 4 knots and placed in a ‘station keeping’ tow in a tidal race up to its rated speed. On-water testing will be conducted using vessels and floating platforms on the sea surface to improve ease of testing and reduce disturbance to the environment. In this TEAMER project, Pacific Northwest National Laboratory (PNNL) will conduct water velocity and turbulence measurements in front of the turbine during on-water testing using acoustic Doppler instrumentation. By measuring both the tidal current flowing past the turbine and the resulting electrical power output, test results will provide a power curve (power vs flow speed) for the turbine up to rated power. Measurements of turbulence and velocity shear in front of the rotor will also provide information to assess the structural response of the rotor blades. With this analysis, Aquantis can use the performance and loads data to validate Tidal Bladed and OpenFAST simulations of the measured operating conditions. Measuring the power performance of a prototype turbine is a valuable step to improving device development and conducting a complete power performance assessment to IEC/TS 62600-200 standards in the future.

16 TIDAL AND WAVE POWER↗