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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 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Estimating the value of jointly optimized electric power generation and end use: a study of ISO-scale load shaping applied to the residential building stock

A generation-to-load simulation estimated the impact, in terms of production costs and CO2 emissions, attributable to the joint optimization of electric power generation and flexible end uses to support increasing penetrations of renewable energy. Newly conceived, evaluated, and foundational in developing a U.S. National Standard was a transaction-less yet continuous demand response system based on a day-ahead optimum load shape (OLS) designed to encourage Internet-connected devices to autonomously and voluntarily explore options to favour lowest cost generators - without requiring two-way communications, personally identifiable information, or customer opt-in. Boundary conditions used for model calibration included historical weather, residential building stock construction attributes, home appliance and device empirical operating schedules, prototypical power distribution feeder models, thermal generator heat rates, startup and ramping constraints, and fuel costs. Results of an hourly-based annual case study of Texas indicate a 1/3 reduction in production costs and a 1/5 reduction in CO2 emissions are possible.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1982

Comparison of advanced thermal and electrical storage for parabolic dish solar thermal power systems

Parabolic dish solar concentrator cluster concepts are explored, with attention given to thermal storage systems coupled to Stirling and Brayton cycle power conversion devices. Sensible heat storage involving molten salt (NaOH), liquid sodium, and solid cordierite bricks are considered for 1500 F thermal storage systems. Latent heat storage with NaF-MgF2 phase change materials are explored in terms of passive, active, and direct contact designs. Comparisons are made of the effectiveness of thermal storage relative to redox, Na-S, Zn-Cl, and Zn-Br battery storage systems. Molten lead trickling down through a phase change eutectic, the NaF-MgF2, formed the direct contact system. Heat transport in all systems is effected through Inconel pipes. Using a cost goal of 120-150 mills/kWh as the controlling parameter, sensible heat systems with molten salts transport with either Stirling or Brayton engines, or latent heat systems with Stirling engines, and latent heat-Brayton engine with direct contact were favored in the analyses. Battery storage systems, however, offered the most flexibility of applications.

Fujita, T.↗
NASA NTRS2016

International Space Station (ISS) Payload Autonomous Operations Past, Present and Future

Draper Laboratorys Timeliner is a scripting and automation system that runs onboard computers in the International Space Station (ISS). Timeliner is fully integrated with ISS and can be used to automate ISS operations tasks. Some of the most challenging aspects of operating a payload in low earth orbit are communication delays, ground equipment failures, and human errors. How does a Payload Developer (PD) know their equipment is operating nominally and collecting science in the most efficient way possible or even powered at any given time? During a ground Loss of Signal (LOS) data outage, PDs have no insight into their experiments state, and benefit greatly from Timeliner scripts executing on ISS to perform telemetry monitoring and commanding operations. This paper will discuss current software designs, and new operational uses for Timeliner. Existing Timeliner capabilities discussed will include: autonomous EXPRESS Rack activation and deactivation; autonomous science data downlinks; Minus Eighty Degree Freezer (MELFI) Dewar autonomous safing; JAXA and ESA module autonomous payload facility safing; as well as many others. New operational concepts discussed will include allowing Timeliner on the payload computer to issue core commands (Thermal, Power, Fire Detection), creation of new ground tools that will monitor the current status of Payload Racks as well as all the messaging from autonomous scripts executing, decreasing approval time for Timeliner bundles, and opening up the Payload MDM Enhanced Processor Integrated Communications Card (EPIC) interface. The EPIC interface could provide a new crew interface for PL Timeliner execution. The new interface could operate on either a Payload Computer System (PCS) or a Station Support Computer (SSC) that is plugged into either the Payload LAN or the Operations LAN which will make communicating to the PL MDM more flexible and greatly increase band width for communication.

Space Mission Automation↗
DOE OSTI2020

Transporting Non-Compliant TRU Wastes in the OPTIMUS{sup TM} Packages - 20493

The OPTIMUS{sup TM} product line of packages was developed with the purpose of providing a versatile and modular packaging option for shipping problematic wastes and fissile material contents. The product line includes a high-activity design in the OPTIMUS-H and a low activity design in the OPTIMUS-L. The two variants utilize a singular containment vessel design, that is enclosed in different protective components that offer different levels of shielding along with thermal and impact protection. The thick shielding provided by the OPTIMUS-H packaging allows for higher activity contents than the OPTIMUS-L to be transported. But the lightweight design of the OPTIMUS-L packaging allows for more packages to be transported in a single shipment. The containment vessel design shared between the two packages provides leak-tight containment of all radioactive contents along with the capabilities to easily leak test and the option to inert and backfill the contents, as necessary, prior to each shipment of the package. Together the OPTIMUS package designs offer significant flexibility and are capable of handling a wide variety of waste materials and other radioactive contents. One of the primary contents covered in the initial design effort for these packages is TRU waste contents beyond the standard waste materials that are compliant with the WIPP Waste Acceptance Criteria. More specifically, the initial content of interest is TRU Waste drums containing sealed containers with potentially flammable gases. While there are multiple other packaging options available for transporting standard WIPP compliant TRU wastes, the goal of the OPTIMUS packages is to offer a superior option for transporting both standard TRU wastes as well as the more problematic non-compliant wastes, among other contents. The non-compliant TRU waste contents explicitly included for the OPTIMUS packages are standard aerosol cans and DOT 3E lecture bottles. However, the methods applied for the package containment can be easily adjusted to cover other sealed container types with potentially flammable gases. The primary challenges with including these items are both the obvious issue of potential for flammable gases (e.g. aerosol propellants) in the package, but also the uncertainty in the exact state of the contents. Because these desired contents are waste materials, the characterization of the materials present in the waste may include some uncertainties. For example, though it may be known that there are one or more aerosol cans in a TRU waste drum, it may not be known if this can is full, spent, or anywhere in between. Also there may be equal uncertainty in the contents of the aerosol can, specifically in the potentially flammable propellant remaining in the can. To include these types of non-compliant items as acceptable contents for the package, the methods utilized in the safety analyses of the OPTIMUS packages must consider all of the uncertainties in the characterization of the waste. The methods utilized cover a range of concerns with transporting contents of this nature including pressure buildup, gas generation, and gaseous combustion for demonstrating the containment of the package. The ability to transport these problematic contents in the OPTIMUS packages gives TRU waste generating sites the option to relocate these drums to an offsite location where the non-compliant items can be properly managed through removal or destruction. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2010

Nearly Seamless Vacuum-Insulated Boxes

A design concept, and a fabrication process that would implement the design concept, have been proposed for nearly seamless vacuum-insulated boxes that could be the main structural components of a variety of controlled-temperature containers, including common household refrigerators and insulating containers for shipping foods. In a typical case, a vacuum-insulated box would be shaped like a rectangular parallelepiped conventional refrigerator box having five fully closed sides and a hinged door on the sixth side. Although it is possible to construct the five-closed-side portion of the box as an assembly of five unitary vacuum-insulated panels, it is not desirable to do so because the relatively high thermal conductances of the seams between the panels would contribute significant amounts of heat leakage, relative to the leakage through the panels themselves. In contrast, the proposal would make it possible to reduce heat leakage by constructing the five-closed-side portion of the box plus the stationary portion (if any) of the sixth side as a single, seamless unit; the only remaining seam would be the edge seal around the door. The basic cross-sectional configuration of each side of a vacuum-insulated box according to the proposal would be that of a conventional vacuum-insulated panel: a low-density, porous core material filling a partially evacuated space between face sheets. However, neither the face sheets nor the core would be conventional. The face sheets would be opposite sides of a vacuum bag. The core material would be a flexible polymer-modified silica aerogel of the type described in Silica/Polymer and Silica/Polymer/Fiber Composite Aero - gels (MSC-23736) in this issue of NASA Tech Briefs. As noted in that article, the stiffness of this core material against compression is greater than that of prior aerogels. This is an important advantage because it translates to greater retention of thickness and, hence, of insulation performance when pressure is applied across the thickness, in particular, when the space between the face sheets is evacuated, causing the core material to be squeezed between the face sheets by atmospheric pressure. Fabrication of a typical vacuum-insulated box according to the proposal would begin with fabrication of a cross-shaped polymer-modified aerogel blanket. The dimensions of the cross would be chosen so that (1) the central rectangular portion of the cross would form the core for the back of the box and (2) the arms of the cross could be folded 90 from the back plane to form the cores of the adjacent four sides of the box. Optionally, the blanket could include tabs for joining the folded sides of the blanket along mating edges and tabs that could serve as hinges for the door. Vacuum bags in the form of similar five-sided boxes would be made of a suitable polymeric film, one bag to fit the outer core surface, the other to fit the inner core surface. By use of commercially available film-sealing equipment, these box-shaped bags would be seamed together to form a single vacuum bag encasing the box-shaped core. Also, a one-way valve would be sealed to the bag. Through this valve, the interior of the bag would be evacuated to a pressure between 1 and 10 torr (approximately between 0.13 and 1.3 kPa). The polymer-modified aerogel core material is known to perform well as a thermal insulator in such a partial vacuum.

Stepanian, Christopher J.↗
DOE OSTI2024

Synthesis and characterization of biobased copolyesters based on pentanediol: (2) Poly(pentylene adipate–co–terephthalate)

Traditionally, most flexible food packaging is made of linear low-density polyethylene (LLDPE) which cannot easily be recycled, nor will it degrade in a reasonable timescale. In this work, a biobased biodegradable polyester alternative was investigated as a possible replacement for LLDPE. High molecular weight poly (pentylene adipate-co-terephthalate) with a 40/60 adipic acid/terephthalic acid mole ratio was synthesized using direct esterification and polycondensation. Glycerol and hexane-1,2,5,6-tetrol were added as branching agents to better match the structure of the LLDPE which in turn might help the ability of these materials in film-blowing. Thermal, mechanical, and rheological properties of the copolyesters were thoroughly investigated. All copolyesters had a weight-average molecular weight of over 140,000 g/mol, which is necessary for proper rheology, and were thermally stable up to 350°C. Here, the addition of branching agents led to a slight decrease in crystallinity, d-spacing, melting temperature, enthalpy of melting, stress at break, and elongation at break. However, an increase in Young's modulus and complex viscosity at high frequency were observed compared to PPeAT60 without branching agent added. Although the improved crystallinity and mechanical properties of the copolyesters made them viable for film-blowing, the slow crystallization rate creates a major challenge.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2018

BioSentinel: An Adaptable Platform for Studying the Biological Effects of Deep Space Radiation

NASA's BioSentinel mission is a 6U nanosatellite with autonomous life support that will utilize the budding yeast Saccharomyces cerevisiae to study the DNA damage response to the deep space radiation environment. BioSentinel is planned to launch in 2019 as a secondary payload on the Space Launch System's first Exploration Mission (EM-1), and will undergo a lunar fly-by and enter heliocentric orbit after deployment. As the first biological mission beyond Low Earth Orbit (LEO) in nearly half a century, this mission will help fill critical gaps in knowledge about the effects of uniquely composed, chronic, low-flux deep space radiation on biological systems. Yeast is well-suited for this mission due to its desiccation tolerance and space-flight heritage. As a eukaryotic model organism, it also serves as a robust analog for human cells. Data gathered on this mission will thus inform us of the hazards involved in long-duration human exploration in deep space, and the protections necessary to mitigate them. Due to its low-cost, flexible and advanced technology, the 4U BioSensor payload contained within the nanosatellite is adaptable to other model microorganisms, exploration platforms and environments relevant to human exploration, such as the ISS, the Lunar Orbital Platform - Gateway and future lunar landers. In order to query the DNA damage response to deep space radiation, BioSentinel contains a wild type yeast strain as a positive control, and a radiation sensitive rad51 mutant strain that is defective for DNA repair. Yeast cells are desiccated in microfluidic cards, and rehydrated with growth medium and metabolic indicator dye at the desired time points during the mission. A thermal control system supports these stasis and growth states, and an optical system continuously measures cell growth and metabolism. An onboard radiation spectrometer and dosimeter allows us to correlate the dose, energy and particle-type of deep space radiation to the biological response. Data received from the deep space biosensor will be compared to control payloads on Earth and the ISS. Ongoing science testing for the BioSentinel project includes optimization for cell viability, desiccation tolerance, and long-term biocompatibility, as well as radiation experiments to understand the sensitivity and responsiveness of cells to varying radiation doses and particle types.

BioSentinel↗
DOE OSTI2021

Cumulative short-lived photofission product yields for nuclear forensic application

Experiments have long been carried out with linear accelerator (linac) produced bremsstrahlung X-rays to study high-energy photon-induced fission, known as “photofission”. One benefit of photofission, when compared with neutron-induced fission, is the ability to investigate fundamental physics of fission at excitation energies lower than what is possible with neutrons [1]. Absorption of an incident neutron results in a compound nucleus with an excitation energy at least equal to the neutron binding energy; thus, the lowest energy region of the fission barrier cannot be studied. Fission product yield distributions are dependent on the incident particle energy and the target nucleus mass. They are generally represented by a double-humped curve, with low and high mass “peaks” and an intermediate mass “valley”. As incident particle energy increases, the excitation energy of the nucleus increases, thereby increasing the overall yield of isotopes in the valley with respect to the two maxima or peaks of the fission product curve [3]. Photofission is most probable for incident photons around 14 MeV due to the giant dipole resonance. Induced photofission around this energy results in a fission product yield distribution that resembles 14 MeV DT neutron fission more than thermal or fast (500 keV) neutron fission. In post-detonation nuclear forensics, the peak-to-valley ratio of the fission product yield curve could be used for characterizing device type by providing an indication of the neutron energy spectrum that had induced fission (e.g., 500 keV vs. 14 MeV). The goal of this work is to improve nuclear data for isotopes of interest in nuclear forensics and special nuclear material (SNM) detection, specifically the fission product yield data via photofission experiments for the isotopes of 238U and 232Th. Photofission has been proposed as a less costly and more flexible production method for the valley isotopes that are representative of DT neutron fission product yield distributions, which would benefit nuclear forensics exercises in testing for analysis techniques. Natural uranium and thorium targets were irradiated with bremsstrahlung photons (nominal endpoint energies of 8, 14, and 20 MeV), generated via impingement of high-energy electrons on a tungsten electron-to-photon radiator. Gamma-ray spectroscopy was used to observe and identify the decay of the resulting fission products. The photofission yields of 102 fission products were measured for the set of the 238U and 232Th targets at the three bremsstrahlung X-ray endpoint energies 8, 14, and 20 MeV. These fragments included masses ranging from A=84 to A=144, with half-lives as short as 1.07 seconds.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

Additive manufacturing of LiNi 1/3 Mn 1/3 Co 1/3 O 2 battery electrode material via vat photopolymerization precursor approach

Additive manufacturing, also called 3D printing, has the potential to enable the development of flexible, wearable and customizable batteries of any shape, maximizing energy storage while also reducing dead-weight and volume. In this work, for the first time, three-dimensional complex electrode structures of high-energy density LiNi 1/3 Mn 1/3 Co 1/3 O 2 (NMC 111) material are developed by means of a vat photopolymerization (VPP) process combined with an innovative precursor approach. This innovative approach involves the solubilization of metal precursor salts into a UV-photopolymerizable resin, so that detrimental light scattering and increased viscosity are minimized, followed by the in-situ synthesis of NMC 111 during thermal post-processing of the printed item. The absence of solid particles within the initial resin allows the production of smaller printed features that are crucial for 3D battery design. The formulation of the UV-photopolymerizable composite resin and 3D printing of complex structures, followed by an optimization of the thermal post-processing yielding NMC 111 is thoroughly described in this study. Based on these results, this work addresses one of the key aspects for 3D printed batteries via a precursor approach: the need for a compromise between electrochemical and mechanical performance in order to obtain fully functional 3D printed electrodes. In addition, it discusses the gaps that limit the multi-material 3D printing of batteries via the VPP process.

25 ENERGY STORAGE↗
DOE OSTI2025

CityLearn v2: energy-flexible, resilient, occupant-centric, and carbon-aware management of grid-interactive communities

As more distributed energy resources become part of the demand-side infrastructure, quantifying their energy flexibility on a community scale is crucial. CityLearn v1 provided an environment for benchmarking control algorithms. However, there is no standardized environment utilizing realistic building-stock datasets for distributed energy resource control benchmarking without co-simulation or third-party frameworks. CityLearn v2 extends CityLearn v1 by providing a stand-alone simulation environment that leverages the End-Use Load Profiles for the U.S. Building Stock dataset to create grid-interactive communities for resilient, multi-agent, and objective control of distributed energy resources with dynamic occupant feedback. While the v1 environment used pre-simulated building thermal loads, the v2 environment uses data-driven thermal dynamics and eliminates the need for co-simulation with building energy performance software. This work details the v2 environment and provides application examples that use reinforcement learning control to manage battery energy storage system, vehicle-to-grid control, and thermal comfort during heat pump power modulation.

Nweye, Kingsley↗
DOE OSTI2023

Simulation and Analysis on Reactor Pressure Vessel (RPV) subjected to Pressurized Thermal Shock (PTS) under SBLOCA scenario by using Cardinal to support the fracture mechanics analyses

The structural components that comprise nuclear reactors and their supporting structures are subjected to harsh operating environments that can challenge their integrity, especially after exposure for extended durations or under accident condition. As one of the most significant components of a Reactor, the Reactor Pressure Vessel (RPV) is exposed to an aggressive environment during the operation time (e.g. more than 40 years). Ageing degradation mechanisms (e.g. thermos-fatigue) could grow initial defects up to a critical size, increasing the susceptibility to failure in the RPV. The conventional methods are mostly based on simple crack and structure geometries. Very limited studies consider the real conditions of the RPV subjected to a thermal shock due to a Loss of Coolant Accident (LOCA). During a LOCA event, the most severe conditions take place when the emergency core cooling (ECC) water is injected inside the cold legs filled initially with hotter water and/or steam. The rapid cooling of the down-comer and the internal RPV surface followed probably by re-pressurization of the RPV causes large temperature gradients and variation of pressure which induces thermal-mechanical stresses. In order to develop the model for integrity assessment of a reactor pressure vessel (RPV) subjected to pressurized thermal shock (PTS), a multi-physics simulation, which includes the thermo-hydraulic, thermo-mechanical and fracture mechanics analyses is necessary. The multi-physics simulations are performed using Cardinal, a wrapping of the GPU-oriented spectral element Computational Fluid Dynamics (CFD) code NekRS and other multi-physics sub-modules within the MOOSE framework. Cardinal now fully supports MOOSE stochastic perturbations of NekRS models with varying boundary conditions, initial conditions, material properties, and any other quantity which is defined by a kernel (such as coefficients in a momentum source model). The implementation is designed in a flexible manner so that scalar values are sent from MOOSE into a user scratch space in NekRS, which can then be applied for any purpose within the NekRS case files (both on the host and device). When modeling PTS, several factors can impact the results significantly. In this report, the impacts of the geometry of the model, Reynolds number and buoyancy effect are investigated. Two geometry, i.e., a simplified model and a realistic RPV model, with both laminar and turbulent flow condition are adopted for the PTS simulation with and without buoyancy effect. The purpose of the investigation is to understand the impact of these factors on the prediction of temperature history of RPV. The accurate prediction on the temperature evolution, which will be exported to Grizzly code for further analyses on the progression of aging mechanisms and their effects on the integrity of RPV structures, is very crucial. Based on the understanding of these factors, a more sophisticated model is built to analysis the PTS under SBLOCA scenario. A literature survey is conducted to pick the SBLOCA scenario for the multi-physics simulation. The analysis helps to explain the form and the transformation of the cold plum when the ECC is activated under SBLOCA. This model can be can be applied to study the PTS effect for different RPV configurations. The results can help to assess structural component degradation for advanced reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Polymer Nanocomposite Sensors with Improved Piezoelectric Properties through Additive Manufacturing

Additive manufacturing (AM) technology has recently seen increased utilization due to its versatility in using functional materials, offering a new pathway for next-generation conformal electronics in the smart sensor field. However, the limited availability of polymer-based ultraviolet (UV)-curable materials with enhanced piezoelectric properties necessitates the development of a tailorable process suitable for 3D printing. This paper investigates the structural, thermal, rheological, mechanical, and piezoelectric properties of a newly developed sensor resin material. The polymer resin is based on polyvinylidene fluoride (PVDF) as a matrix, mixed with constituents enabling UV curability, and boron nitride nanotubes (BNNTs) are added to form a nanocomposite resin. The results demonstrate the successful micro-scale printability of the developed polymer and nanocomposite resins using a liquid crystal display (LCD)-based 3D printer. Additionally, incorporating BNNTs into the polymer matrix enhanced the piezoelectric properties, with an increase in the voltage response by up to 50.13%. This work provides new insights for the development of 3D printable flexible sensor devices and energy harvesting systems.

42 ENGINEERING↗
NASA NTRS1976

Laser heterodyne detection techniques

The principles of heterodyne radiometry are examined, taking into account thermal radiation, the Dicke microwave radiometer, photomixing in the infrared, and signal-to-noise considerations. The passive heterodyne radiometer is considered and a description is presented of heterodyne techniques in active monitoring systems. Attention is given to gas emissivities in the infrared, component requirements, experimental heterodyne detection of gases, a comparison of the passive heterodyne radiometer with the Michelson interferometer-spectrometer, airborne monitoring applications, turbulence effects on passive heterodyne radiometry, sensitivity improvements with heterodyning, atmosphere-induced degradation of bistatic system performance, pollutant detection experiments with a bistatic system, and the airborne laser absorption spectrometer. Future improvements in spectral flexibility are also discussed.

Menzies, R. T.↗
NASA NTRS1993

Flight testing of a fiber optic temperature sensor

A fiber optic temperature sensor (FOTS) system consisting of an optical probe, a flexible fiber optic cable, and an electro-optic signal processor was fabricated to measure the gas temperature in a turbine engine. The optical probe contained an emissive source embedded in a sapphire lightguide coupled to a fiber-optic jumper cable and was retrofitted into an existing thermocouple probe housing. The flexible fiber optic cable was constructed with 200 micron core, polyimide-coated fiber and was ruggedized for an aircraft environment. The electro-optic signal processing unit was used to ratio the intensities of two wavelength intervals and provided an analog output value of the indicated temperature. Subsequently, this optical sensor system was installed on a NASA Dryden F-15 Highly Integrated Digital Electronic Control (HIDEC) Aircraft Engine and several flight tests were conducted. Over the course of flight testing, the FOTS system's response was proportional to the average of the existing thermocouples sensing the changes in turbine engine thermal conditions.

Finney, M. J.↗
NASA NTRS2011

Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings

In order to generate advanced multilayer thermal and environmental protection systems, a new deposition process is needed to bridge the gap between conventional plasma spray, which produces relatively thick coatings on the order of 125-250 microns, and conventional vapor phase processes such as electron beam physical vapor deposition (EB-PVD) which are limited by relatively slow deposition rates, high investment costs, and coating material vapor pressure requirements. The use of Plasma Spray - Physical Vapor Deposition (PS-PVD) processing fills this gap and allows thin (< 10 microns) single layers to be deposited and multilayer coatings of less than 100 microns to be generated with the flexibility to tailor microstructures by changing processing conditions. Coatings of yttria-stabilized zirconia (YSZ) were applied to NiCrAlY bond coated superalloy substrates using the PS-PVD coater at NASA Glenn Research Center. A design-of-experiments was used to examine the effects of process variables (Ar/He plasma gas ratio, the total plasma gas flow, and the torch current) on chamber pressure and torch power. Coating thickness, phase and microstructure were evaluated for each set of deposition conditions. Low chamber pressures and high power were shown to increase coating thickness and create columnar-like structures. Likewise, high chamber pressures and low power had lower growth rates, but resulted in flatter, more homogeneous layers

Harder, Bryan J.↗
DOE OSTI2020

Demonstration of NEAMS Multiphysics Tools for Fast Reactor Applications

The SHARP toolkit is a high-fidelity reactor simulation tool developed under the U.S. Department of Energy, Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Campaign. SHARP toolkit is comprised of the neutronics module PROTEUS thermal hydraulics module Nek5000, and structural mechanics module Diablo. During FY17 and FY18, the PROTEUS and Nek5000 components of SHARP were applied to solve challenging sodium-cooled fast reactor (SFR) problems. In particular, selected hot channel factors (HCF) for a prototype metal-fueled SFR design (the AFR-100) were analyzed in high fidelity, and the “SHARP zooming capability” for SFRs was developed and demonstrated to reduce computational expense for full core problems in cases where detailed data is needed in selected fuel assemblies. After the previous success applying SHARP to challenging SFR problems, the focus in FY19 and FY20 expanded to additional fast reactor applications including lead cooled fast reactors (LFR) and sodium cooled fast reactors (SFR). The specific technical tasks were (1) assessment of hot channel factors for LFR, for which no data currently exists, and (2) demonstration of zooming capability in assemblies of the Versatile Test Reactor (VTR). First-of-a-kind hot channel factor (HCF) estimation for LFR with high fidelity codes (PROTEUS/Nek5000) was successfully demonstrated in this study which began in FY19 and continued in FY20. Selected HCF were computed and compared with SFR data (AFR-100, EBR-II). The findings confirm that different reactor types, design parameters and uncertainties lead to different HCFs. Careful estimation of HCF for a specific design is necessary to obtain appropriate HCFs. In addition to improvement in HCF accuracy, high fidelity tools generate data to help the designer better understand the mechanism of the impact from these uncertainties. For example, the impact of cladding thickness manufacturing tolerance resulted in non-intuitive effects in the corner pins of the LFR assembly. This procedure of computing HCF using high fidelity models shows promise and flexibility for being repeated for any arbitrary reactor of choice. Along with the application on SFR and LFR, the capability of the tools has also been matured to deal with different reactor types and designs. Progress was made towards extending the previously demonstrated SHARP zooming capability to non-fueled SFR assemblies. In particular, in FY19 a gamma transport capability was implemented in both high fidelity PROTEUS solvers in order to accurately account for heat deposition caused by gamma particles, which accounts for ~10% of total core power. Neutronics verification cases were carried out for a candidate Versatile Test Reactor (VTR) design using the new gamma transport capability in PROTEUS. Comparisons were made with continuous energy MCNP calculations and shown to agree well. The models for the full core design with heterogeneous control and fuel assemblies is in progress for PROTEUS-SN and completed with MCNP. The MCNP power distributions were transferred to Nek5000 to perform thermal hydraulic calculations of the control and fuel assembly.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Uncovering grain and subgrain microstructure at the scale of additive manufacturing melt tracks with a scalable cellular automaton solidification model

Metal additive manufacturing, characterized by rapid solidification, yields refined grains with a distinctive cellular subgrain microstructure that plays a pivotal role in determining material properties. Due to the significant computational expense demanded to simulate the required physics with submicron spatial resolution, their numerical simulations have been limited to proof-of-concept studies to either 2D or small subregions of a melt pool. In this study, an open-source, scalable, solidification code, muMatScale, based on the cellular automaton method, has been developed to predict the grain and the underlying subgrain microstructure over an entire melt pool. The model incorporates flexible parallelization schemes, utilizing MPI and OpenMP GPU Offloading, in addition to appropriate multi-physics specific to non-equilibrium rapid solidification in AM. The impact of nucleation parameters on grain microstructures was investigated with a focus on grain size variations and morphology transitions. With selected nucleation parameters, the simulation predicted the grain size, subgrain morphology, crystallographic orientation, and microsegregation aligned with experimental measurements. The model demonstrates that epitaxial grain growth is a dominant factor at the melt pool boundary, influencing grain size variation under different grain sizes in the build plate while maintaining consistent primary dendrite arm spacing under identical thermal conditions. Here, the highly efficient numerical model enables large-scale simulations with a spatial resolution of 100 nm or less, unveiling unprecedented insights into thermal and solutal diffusion driven grain growth, and the subgrains with microsegregation within grains in 3D across scales. muMatScale will enable the linking of submicron length-scale microstructure to part-level material behavior by investigating fundamental solidification problems at the intercellular scale in many-track and many-layer builds.

36 MATERIALS SCIENCE↗