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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Computational Design of a Simple Flyer Plate Launcher

The response of materials to shock loading is important to understand for a variety of applications. When shock physics emerged during and after WWII, direct explosive loading or explosively driven plate impact was the primary tool for these studies. Subsequent decades have seen the widespread use of large caliber guns for plate impact studies, laser-shock facilities and pulsed power facilities. INL currently lacks a gun suitable for plate impact or explosives casting and machining facilities; however, it does possess explosives use and handling capabilities. An option for performing plate impact experiments was needed, therefore continuum scale models were utilized to explore a few simple donor-acceptor explosive plane wave lens designs, one of which could be hand packed with plastic explosives to launch flyer plates. 2D simulations were performed to study different geometries in an effort to minimize the difference in shock arrival across the central portion of a small copper flyer plate. A shock wave arrival time difference under 50 ns across 50 percent of the center of the flyer was achieved with a few designs. This work summarizes the computational models and results.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Strontium Effects on the Formation of Iron-Intermetallic Phases in Secondary Al–9Si–0.6Fe Alloys

The presence and morphology of Fe-containing intermetallic phases affect the mechanical properties of aluminum alloys, especially in secondary Al–Si-based cast alloys. Although strontium (Sr) addition of 50 to 500 ppm is known to refine the needle-type eutectic silicon structure, the influence of Sr on the formation of Fe-intermetallic phases remains unclear. The present work investigates the combined additions of Sr and Mn to Al–9Si–0.6Fe–0.35Mg (All compositions are in wt pct except otherwise stated.) alloys on the formation of Fe-intermetallic phases at different solidification rates from ~ 1.5 to ~ 60 °C/s. Long and branched-type AlFeSi phase with size ranging from 50 to 120 µm are more common when solidified at the rate of 1.5 °C/s regardless of Sr and Mn additions. However, at the fast solidification rate of 60 °C/s, a 60 ppm Sr addition significantly reduced the average length of needle-shaped AlFeSi phase to less than 3 to 5 µm. Thermodynamic simulations have been performed using CALculation of PHAse Diagrams (CALPHAD) models to predict the formation of various phases and their possible interactions during solidification. The results indicated that the combination of a high solidification rate and about 60 ppm of Sr is beneficial to refining the δ-Al 3 FeSi 2 phase in Al–Si–Mg alloys containing 0.6 pctFe. As a result, this unexpected finding of Fe-intermetallic refinement by low Sr addition (~60 ppm) provides an important guide in designing secondary alloys for sustainable casting applications.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Physical and optical properties of the International Simple Glass

Abstract Radioactive waste immobilization is a means to limit the release of radionuclides from various waste streams into the environment over a timescale of hundreds to many thousands of years. Incorporation of radionuclide-containing wastes into borosilicate glass during vitrification is one potential route to accomplish such immobilization. To facilitate comparisons and assessments of reproducibility across experiments and laboratories, a six-component borosilicate glass (Si, B, Na, Al, Ca, Zr) known as the International Simple Glass (ISG) was developed by international consensus as a compromise between simplicity and similarity to waste glasses. Focusing on a single glass composition with a multi-pronged approach utilizing state-of-the-art, multi-scale experimental and theoretical tools provides a common database that can be used to assess relative importance of mechanisms and models. Here we present physical property data (both published and previously unpublished) on a single batch of ISG, which was cast into individual ingots that were distributed to the collaborators. Properties from the atomic scale to the macroscale, including composition and elemental impurities, phase purity, density, thermal properties, mechanical properties, optical and vibrational properties, and the results of molecular dynamics simulations are presented. In addition, information on the surface composition and morphology after polishing is included. Although the existing literature on the alteration of ISG is not extensively reviewed here, the results of well-controlled static alteration experiments are presented here as a point of reference for other performance investigations.

36 MATERIALS SCIENCE↗
DOE OSTI2018

On the Solidification and Structure Formation during Casting of Large Inserts in Ferritic Nodular Cast Iron

The graphite nodule count and size distributions for boiling water reactor (BWR) and pressurized water reactor (PWR) inserts were investigated by taking samples at heights of 2160 and 1150 mm, respectively. In each cross section, two locations were taken into consideration for both the microstructural and solidification modeling. The numerical solidification modeling was performed in a two-dimensional model by considering the nucleation and growth in eutectic ductile cast iron. The microstructural results reveal that the nodule size and count distribution along the cross sections are different in each location for both inserts. Finer graphite nodules appear in the thinner sections and close to the mold walls. The coarser nodules are distributed mostly in the last solidified location. The simulation result indicates that the finer nodules are related to a higher cooling rate and a lower degree of microsegregation, whereas the coarser nodules are related to a lower cooling rate and a higher degree of microsegregation. The solidification time interval and the last solidifying locations in the BWR and PWR are also different.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Multifrequency eddy-current detection of fast transient thermal signatures for in situ monitoring applications

Eddy-current (EC) nondestructive evaluation has a long history of use in a variety of ex situ defect monitoring applications because of its exquisite sensitivity to local material variations. Due to the relationship between a material's conductivity and its temperature, EC methods have also been used to investigate quasistatic, long-range temperature variations in casting applications. However, these techniques remain underutilized for the measurement of rapidly varying, spatially nonuniform temperature distributions. In this work, we construct a model system capable of generating repeatable temperature transients in steel plates and measure real-time eddy-current signals with millisecond time resolution and spatial resolution of the order of 1 mm. Using a combination of Multiphysics simulations, fast thermal imaging, and time-resolved holographic interferometry, we tease apart contributions to the eddy-current signals arising from temperature variations and transient plate deformation. Finally, we perform a systematic study in which we vary the plate thickness and the eddy-current excitation frequency to demonstrate that eddy-current techniques can provide information about a three-dimensional, time-varying, subsurface thermal distribution, which is inaccessible to the traditional thermal imaging techniques.

Rosenberg, Ethan R. [Lawrence Livermore National L↗
DOE OSTI2021

Creation of a prototype biomimetic fish to better understand impact trauma caused by hydropower turbine blade strikes

Biomimetic model organisms could be useful surrogates for live animals in many applications if the models have sufficient biofidelity. One such application is for use in field and laboratory tests of fish mortality associated with passage through hydropower turbines. Laboratory trials suggest that blade strikes are especially injurious and often causes mortality when fish are struck by thinner blades moving at higher velocities. Dose-response relationships have been created from these data, but the exact relationship between fish mortality and the actual forces enacted on fish during simulated blade strike testing remains unknown. Here, we describe the methods used to create a prototype biomimetic model fish composed of ballistic gelatin and covered with a surrogate skin to better approximate the biomechanical properties of a fish body. Frozen fish were scanned with high-fidelity laser scanners, and a 3D-printed, reusable mold was created from which to cast our gelatin model. Computed tomography scan data, imaged directly or taken from online data repositories, were also successfully used to create CAD models for use in additive manufacturing of molds. One 3-axis accelerometer was embedded into the gelatin to compare accelerometer data to dose-response data from previous laboratory research on live fish. The resulting model ( i.e. , Gelfish) had a statistically indistinguishable tissue durometer to that of real fish tissue and preliminary blade strike impact testing suggested its overall flexibility was similar to that of live fish. Gelfish was designed with biofidelity as its guiding principle and our results suggest initial experimentation was successful. Future research will include replication of initial Gelfish test results, quantitative measurement of model flexibility relative to real fish, and inclusion of surrogate skeletal structures to enhance biofidelity. Use of more sophisticated sensors would also better quantify the physical forces of blade strike impact and help determine how said forces correlate with rates of mortality observed during tests on live fish.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Shrinkage-induced deformations and creep of structural concrete: 1-year measurements and numerical prediction

Highlights: • Extensive experimental study on drying shrinkage, creep and microcracking of concrete • All specimens prepared from a single batch of ordinary-strength structural concrete • 1st year of measurements of (not only) non-uniformly drying beams with span up to 3-m • The database is downloadable from free-to-use research data repository • Modified MPS model for concrete creep used in blind prediction of all experiments The material models for creep and shrinkage operating on the material point level in FEM are usually intended for challenging complex applications and structures, where the average cross-sectional approach does not suffice. The identification of the growing number of material parameters induced by increasing model capabilities relies on very specific and narrow-oriented yet interconnected experiments which are scarce. The presented comprehensive experiments aim to provide a clearer image of the complicated interaction among the basic phenomena: drying, shrinkage, creep, and microcracking. The cornerstone of this ongoing research is a unique set of 30 partially-sealed unreinforced concrete beams with span 1.75–3.0 m subjected to drying. To minimize material variation, all specimens in this study were cast from a single batch of ordinary strength structural concrete with slag-blended binder. The resulting experimental database will be suitable both for validation and development of the constitutive models.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Imaging transient solidification behavior

Solidification processing offers the first opportunity to control microstructure, properties, and performance in metallic alloy components. Until recently, microstructural evaluations were limited to post-solidification characterization by destructive methods. We review the development of time-resolved, in situimaging techniques capable of capturing solid-liquid interfacial evolution in metallic alloys with high spatial and temporal resolution underdiverse solidification conditions relevant for applications ranging from conventional directional solidification, crystal growth, and casting,to welding and additive manufacturing. These experiments enable direct visualization of transient behaviors that would otherwise remain unknown, uniquely providinginsights into the physics that impact microstructure and defect development and strategies for microstructuralcontrol and defect mitigation. Understanding microstructural evolution and the characteristics that form under various solidification conditions is essential for the development of multiscale, experimentallyinformed predictive modeling. This is highlightedby solidification simulations that utilize in situmeasurements of solidification dynamics from state-of-the-art experimental techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Characterization of compositional variation and solidification condition on rapid solidification behavior of beta stabilized titanium

Rapid solidification (RS) is a field of study that has increased in importance due to the rise of additive manufacturing (AM) techniques. The breakdown of equilibrium at the solid-liquid interface results in an inability to use traditional solidification models that have been applied to great success in casting. As such, there is a current need for a high-throughput testing method to screen alloys at rapid solidification conditions without the significant cost for powder atomization. In this work, twin hammer splat quenching (SQ) is utilized and theoretically developed as a technique uniquely placed to test alloy systems for AM applications. Using analytical thermal spray models and numerical heat transfer simulations, the cooling rate and solidification conditions of splat quenching are compared across several parameters to evaluate the key parameters for generating cooling rates relevant to AM process. Once a framework for the cooling rates and relevancy of SQ are developed, SQ was used to process alloy compositions in the Ti5553 alloy space (AMS 7026) to study the formation of detrimental secondary phases occurring upon rapid quenching from the melt. A martensitic phase is found to occur at the lower end of the standard, but the composition listed in the standard were found to be safe. Finally, the rapid solidification behavior of Ti-5553 is evaluated by comparing splat quenching, laser welding, and plasma atomization that offer a wide window of solidification conditions. The segregation and solidification structure are analyzed and compared to models to provide a deeper understanding of the solidification behavior of beta stabilized titanium alloys.

Williamson, Christopher J.↗
DOE OSTI2019

The Influence of Segregation of Mn on the Recrystallization Behavior of C-Mn Steels

The influence of Mn segregation that occurs during casting on recrystallization kinetics has been explored for a C-Mn automotive steel. A homogenization heat treatment was used to remove Mn segregation, while maintaining a similar initial austenite grain size to the segregated condition, to provide base-line comparison data. Deformation trials were carried out in a Gleeble thermomechanical simulator to 0.3 strains at 900 °C, and significant differences in both recrystallization times and final grain sizes were seen between the two conditions. The segregated sample incurred a longer recrystallization time and a wider recrystallized grain size distribution than the homogenized sample. A finite element model was used to predict the local deformation strains based on variations in material properties caused by segregation; the model used data from XRF elemental mapping of Mn to define the local mechanical properties based on differences in solid solution strengthening. Local strain variations ranging from 0.19 to 0.49 were predicted in the segregated sample for an overall applied 0.3 strain (compared to 0.26 to 0.35 in the homogenized sample); using these strains to predict the recrystallized grain sizes gave a much better prediction for the grain size distribution.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design of Silicide-Strengthened Nb–Si–Cr–(Mo) alloys for additive manufacturing

Three high–intermetallic volume Nb–Si–Cr–(Mo) alloys were designed using CALPHAD modeling with the goal of identifying high–specific strength, oxidation-resistant alloys that can be additively manufactured using powder bed fusion. The silicides Nb 5 Si 3 and Nb 9 Si 2 Cr3 were targeted as the primary strengthening phases, and the addition of Cr promoted the NbCr 2 phase. These alloys were cast and surface-processed with electron beam welding at different speeds to simulate additive manufacturing, and the phases and microstructures of both cast and welded regions were characterized. The weld processing was found to produce fine-grained microstructures in each alloy with fine-scale intermetallics uniformly distributed among a body-centered cubic Nb matrix. Microstructural refinement and hardness were found to increase with weld velocity; one alloy reached its highest hardness of approximately 16 GPa before the brittleness at higher velocities became detrimental. One alloy was found to be qualitatively the least brittle while also attaining a hardness of 13 GPa and was therefore identified as a good candidate for additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Improved Gamma-Ray Point Source Quantification in Three Dimensions by Modeling Attenuation in the Scene

We discuss using a series of detector measurements taken at different locations to localize a source of radiation as a well-studied problem. The source of radiation is sometimes constrained to a single point-like source, in which case the location of the point source can be found using techniques such as maximum likelihood. Recent advancements have shown the ability to locate point sources in 2D and even 3D, but few have studied the effect of intervening material on the problem. In this work we examine gamma-ray data taken from a freely moving system and develop voxelized 3-D models of the scene using data from the onboard LiDAR. Ray casting is used to compute the distance each gamma ray travels through the scene material, which is then used to calculate attenuation assuming a single attenuation coefficient for solids within the geometry. Parameter estimation using maximum likelihood is performed to simultaneously find the attenuation coefficient, source activity, and source position that best match the data. Using a simulation, we validate the ability of this method to reconstruct the true location and activity of a source, along with the true attenuation coefficient of the structure it is inside, and then we apply the method to measured data with sources and find good agreement.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Computational Modeling of Fracture Toughness of Al-Si and Al-Zn-Mg-Cu Alloys with Detected Porosity

This article presents the results of an experimental and numerical analysis of the fracture resistance of cast aluminum alloys subjected to variable loads over time based on the fracture mechanics method. The subjects of the analysis were the AlSi9 and AlZn6MgCu alloys (usually used for plastic processing) in which the presence of porosities in the form of separate or dispersed voids was revealed experimentally. The material for the experimental procedures was obtained directly from a casting or from casting samples. Depending on the type of the defect detected, different numerical models were proposed. The results of the numerical calculations were verified experimentally. Static tensile tests, fatigue low-cycle tests, fracture mechanics tests, fatigue crack propagation tests, a microscopic examination of the sample fracture area, and an x-ray tomographic analysis were all performed. A correlation of the results between the numerical analysis and the experimental work has been found. On the basis of the proposed calculation models, the fatigue life of castings of the analyzed alloys can be predicted in the case of concentrated and dispersed defects.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Cementitious Barriers Partnership FY2013 End-Year Report

In FY2013, the Cementitious Barriers Partnership (CBP) demonstrated continued tangible progress toward fulfilling the objective of developing a set of software tools to improve understanding and prediction of the long-term structural, hydraulic and chemical performance of cementitious barriers used in nuclear applications. In November 2012, the CBP released “Version 1.0” of the CBP Software Toolbox, a suite of software for simulating reactive transport in cementitious materials and important degradation phenomena. In addition, the CBP completed development of new software for the “Version 2.0” Toolbox to be released in early FY2014 and demonstrated use of the Version 1.0 Toolbox on DOE applications. The current primary software components in both Versions 1.0 and 2.0 are LeachXS/ORCHESTRA, STADIUM, and a GoldSim interface for probabilistic analysis of selected degradation scenarios. The CBP Software Toolbox Version 1.0 supports analysis of external sulfate attack (including damage mechanics), carbonation, and primary constituent leaching. Version 2.0 includes the additional analysis of chloride attack and dual regime flow and contaminant migration in fractured and non-fractured cementitious material. The LeachXS component embodies an extensive material property measurements database along with chemical speciation and reactive mass transport simulation cases with emphasis on leaching of major, trace and radionuclide constituents from cementitious materials used in DOE facilities, such as Saltstone (Savannah River) and Cast Stone (Hanford), tank closure grouts, and barrier concretes. STADIUM focuses on the physical and structural service life of materials and components based on chemical speciation and reactive mass transport of major cement constituents and aggressive species (e.g., chloride, sulfate, etc.). THAMES is a planned future CBP Toolbox component focused on simulation of the microstructure of cementitious materials and calculation of resultant hydraulic and constituent mass transfer parameters needed in modeling. Two CBP software demonstrations were conducted in FY2013, one to support the Saltstone Disposal Facility (SDF) at SRS and the other on a representative Hanford high-level waste tank. The CBP Toolbox demonstration on the SDF provided analysis on the most probable degradation mechanisms to the cementitious vault enclosure caused by sulfate and carbonation ingress. This analysis was documented and resulted in the issuance of a SDF Performance Assessment Special Analysis by Liquid Waste Operations this fiscal year. The two new software tools supporting chloride attack and dual-regime flow will provide additional degradation tools to better evaluate performance of DOE and commercial cementitious barriers. The CBP SRNL experimental program produced two patent applications and field data that will be used in the development and calibration of CBP software tools being developed in FY2014. The CBP software and simulation tools varies from other efforts in that all the tools are based upon specific and relevant experimental research of cementitious materials utilized in DOE applications. The CBP FY2013 program involved continuing research to improve and enhance the simulation tools as well as developing new tools that model other key degradation phenomena not addressed in Version 1.0. Also efforts to continue to verify the various simulation tools through laboratory experiments and analysis of field specimens are ongoing and will continue into FY2014 to quantify and reduce the uncertainty associated with performance assessments. This end-year report summarizes FY2013 software development efforts and the various experimental programs that are providing data for calibration and validation of the CBP developed software.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Model Uncertainties for Valencia RPA Effect for MINERvA

This technical note describes the application of the Valencia RPA multi-nucleon effect and its uncertainty to QE reactions from the GENIE neutrino event generator. The analysis of MINERvA neutrino data in Rodrigues et al. PRL 116 071802 (2016) paper makes clear the need for an RPA suppression, especially at very low momentum and energy transfer. That published analysis does not constrain the magnitude of the effect; it only tests models with and without the effect against the data. Other MINERvA analyses need an expression of the model uncertainty in the RPA effect. A well-described uncertainty can be used for systematics for unfolding, for model errors in the analysis of non-QE samples, and as input for fitting exercises for model testing or constraining backgrounds. This prescription takes uncertainties on the parameters in the Valencia RPA model and adds a (not-as-tight) constraint from muon capture data. For MINERvA we apply it as a 2D ($q_0$,$q_3$) weight to GENIE events, in lieu of generating a full beyond-Fermi-gas quasielastic events. Because it is a weight, it can be applied to the generated and fully Geant4 simulated events used in analysis without a special GENIE sample. For some limited uses, it could be cast as a 1D $Q^2$ weight without much trouble. This procedure is a suitable starting point for NOvA and DUNE where the energy dependence is modest, but probably not adequate for T2K or MicroBooNE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗