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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 OSTI2025

Methods for Rotating Electrodes in High-Temperature Molten Salts

Abstract In this paper, we describe and validate a custom apparatus for performing high-speed (250-3,500 rpm) rotating electrode and dilatometer density experiments in molten salts. The reported details can aid in decreasing the difficulty and increasing the quality of such experiments. We discuss the design challenges and the solutions identified. We investigate methods for accurately measuring the solution resistance using electrochemical impedance spectroscopy, calculating the working electrode area using cyclic voltammetry, and measuring the mass transfer-limited current of rotating electrodes using a series of chronoamperometry pulses. We further demonstrate the efficacy of our methods in producing accurate results.

Fuller, Ranon (ORCID:0000000255400197)↗
NASA NTRS1996

Stress and Damage in Polymer Matrix Composite Materials Due to Material Degradation at High Temperatures

This report describes analytical methods for calculating stresses and damage caused by degradation of the matrix constituent in polymer matrix composite materials. Laminate geometry, material properties, and matrix degradation states are specified as functions of position and time. Matrix shrinkage and property changes are modeled as functions of the degradation states. The model is incorporated into an existing composite mechanics computer code. Stresses, strains, and deformations at the laminate, ply, and micro levels are calculated, and from these calculations it is determined if there is failure of any kind. The rationale for the model (based on published experimental work) is presented, its integration into the laminate analysis code is outlined, and example results are given, with comparisons to existing material and structural data. The mechanisms behind the changes in properties and in surface cracking during long-term aging of polyimide matrix composites are clarified. High-temperature-material test methods are also evaluated.

McManus, Hugh L.↗
DOE OSTI2024

Radiation Damage Mitigation in FeCrAl Alloy at Sub-Recrystallization Temperatures

Traditional defect recovery methods rely on high-temperature annealing, often exceeding 750 °C for FeCrAl. In this study, we introduce electron wind force (EWF)-assisted annealing as an alternative approach to mitigate irradiation-induced defects at significantly lower temperatures. FeCrAl samples irradiated with 5 MeV Zr 2+ ions at a dose of 10 14 cm −2 were annealed using EWF at 250 °C for 60 s. We demonstrate a remarkable transformation in the irradiated microstructure, where significant increases in kernel average misorientation (KAM) and low-angle grain boundaries (LAGBs) typically indicate heightened defect density; the use of EWF annealing reversed these effects. X-ray diffraction (XRD) confirmed these findings, showing substantial reductions in full width at half maximum (FWHM) values and a realignment of peak positions toward their original states, indicative of stress and defect recovery. To compare the effectiveness of EWF, we also conducted traditional thermal annealing at 250 °C for 7 h, which proved less effective in defect recovery as evidenced by less pronounced improvements in XRD FWHM values.

FeCrAl alloys↗
NASA NTRS1993

An overview of computational simulation methods for composite structures failure and life analysis

Three parallel computational simulation methods are being developed at the LeRC Structural Mechanics Branch (SMB) for composite structures failure and life analysis: progressive fracture CODSTRAN; hierarchical methods for high-temperature composites; and probabilistic evaluation. Results to date demonstrate that these methods are effective in simulating composite structures failure/life/reliability.

Chamis, Christos C.↗
NASA NTRS2005

Advanced Ablative Insulators and Methods of Making Them

Advanced ablative (more specifically, charring) materials that provide temporary protection against high temperatures, and advanced methods of designing and manufacturing insulators based on these materials, are undergoing development. These materials and methods were conceived in an effort to replace the traditional thermal-protection systems (TPSs) of re-entry spacecraft with robust, lightweight, better-performing TPSs that can be designed and manufactured more rapidly and at lower cost. These materials and methods could also be used to make improved TPSs for general aerospace, military, and industrial applications.

Congdon, William M.↗
DOE OSTI2021

A method for predicting failure statistics for steady state elevated temperature structural components

This paper presents the initial development of a high temperature life prediction method that accounts for the variability in the material properties of Grade 91 steel. The method accounts for material variability by fitting a variable 3-parameter Weibull distribution to experimental rupture data and accounts for the variability of creep deformation on the steady-state stresses via a Monte Carlo approach. To ensure reasonable computational times, the model represents the material as an extremely viscous Stokes fluid with a non-Newtonian viscosity, therefore solving the stress relaxation problem with a steady, static, instead of transient, analysis. Furthermore, the complete statistical analysis combines this model for creep deformation with a probabilistic model for creep rupture to evaluate the probability of premature failure for a set of sample problems, comparing the predicted failure statistics to the design life predicted by the ASME Boiler and Pressure Vessel Code rules.

42 ENGINEERING↗
DOE OSTI2025

Summary Report Of The FY25 Reactor Physics Verification And Validation Exercises In The Advanced Reactor Technologies - Gas-cooled Reactor Program

Valdiation and verification of numerical tools is critical for ensuring reasonable predictions for design scoping, licensing, and safety analsyis. In this report, two reactor physics verification and validation exercises are presented. The first of these exercises focuses on burnup analysis with data from the Advanced Gas Reactor (AGR) program. Simulations are performed with Monte Carlo N-Particle (MCNP) and are compared with the experimental measurements for the AGR 1 and 2 experiments that utilize both UCO and UO2 fuel. The second exercises utilizes data from the HTR-Proteus experiments to perform reactor physics validation. Specifications of the experimental facility are provdied, along with a demonstration of initial modeling efforts in Serpent for one of the determistic packing experiments. Both cases are part of the Generation-IV international forum (GIF) Very High-Temperature Reactor (VHTR) Computational Methods, Validation, and Benchmarking (CMVB) program, an international collaborative organization dedicated to the verification and validation of High-Temperature Gas-Cooled Reactor (HTGR) analysis. Participation in the CMVB allows the US Department of Energy (DOE) to leverage these existing validation activities to provide extra value through benchmarking activities with other CMVB members.

and Benchmarking (CMVB) program↗
NASA NTRS1987

Apparatus ad method for quiescent containerless processing of high temperature metals and alloys in low gravity

The electron bombardment furnace consists of two confinement grid sections which may be moved and separated from each other. Inside the bombardment furnace, a tungsten element is enclosed. The material specimen is located within the tungsten element and grounded by means of grounded support wires connected to the respective sections of the furnace. The material specimen is supported on the ground wires and heated by electron bombardment until melt occurs. The furnace sections are separated in opposite directions causing the ground wires to pull from the surfaces of the specimen, leaving the specimen freely suspended in the process chamber without the action of external forces. The specimen remains in its melt condition in the processing chamber where it can be undercooled without external forces acting on the specimen, which would cause dynamic nucleation.

Robinson, Michael B.↗
NASA NTRS1960

An Investigation of a Photographic Technique of Measuring High Surface Temperatures

A photographic method of temperature determination has been developed to measure elevated temperatures of surfaces. The technique presented herein minimizes calibration procedures and permits wide variation in emulsion developing techniques. The present work indicates that the lower limit of applicability is approximately 1,400 F when conventional cameras, emulsions, and moderate exposures are used. The upper limit is determined by the calibration technique and the accuracy required.

Siviter, James H., Jr.↗
NASA NTRS2004

Method of Assembling a Silicon Carbide High Temperature Anemometer

A high temperature anemometer includes a pair of substrates. One of the substrates has a plurality of electrodes on a facing surface, while the other of the substrates has a sensor cavity on a facing surface. A sensor is received in the sensor cavity, wherein the sensor has a plurality of bondpads, and wherein the bondpads contact the plurality of electrodes when the facing surfaces are mated with one another. The anemometer further includes a plurality of plug-in pins, wherein the substrate with the cavity has a plurality of trenches with each one receiving a plurality of plug-in pins. The plurality of plug-in pins contact the plurality of electrodes when the substrates are mated with one another. The sensor cavity is at an end of one of the substrates such that the sensor partially extends from the substrate. The sensor and the substrates are preferably made of silicon carbide.

Robert S Okojie↗
NASA NTRS2014

In-Service Monitoring of Steam Pipe Systems at High Temperatures

A system and method for monitoring the properties of a fluid, such as water, in a steam pipe without mechanically penetrating the wall of the pipe. The system uses a piezoelectric transducer to launch an ultrasonic probe signal into the pipe. Reflected ultrasonic signals are captured in a transducer, which can be the same transducer that launched the probe signal. The reflected signals are subjected to data processing, which can include filtering, amplification, analog-to-digital conversion and autocorrelation analysis. A result is extracted which is indicative of a property of the fluid, such as a height of the condensed fluid, a cavitation of the condensed fluid, and a surface perturbation of the condensed fluid. The result can be recorded, displayed, and/or transmitted to another location. One embodiment of the system has been constructed and tested based on a general purpose programmable computer using instructions recorded in machine-readable non-volatile memory.

Bar-Cohen, Yoseph↗
DOE OSTI2021

Systems and methods for enhancing isolation of high-temperature reactor containments

A high-temperature containment-isolation system for transferring heat from a nuclear reactor containment to a high-pressure heat exchanger is presented. The system uses a high-temperature, low-volatility liquid coolant such as a molten salt or a liquid metal, where the coolant flow path provides liquid free surfaces a short distance from the containment penetrations for the reactor hot-leg and the cold-leg, where these liquid free surfaces have a cover gas maintained at a nearly constant pressure and thus prevent high-pressures from being transmitted into the reactor containment, and where the reactor vessel is suspended within a reactor cavity with a plurality of refractory insulator blocks disposed between an actively cooled inner cavity liner and the reactor vessel.

Peterson, Per F.↗
DOE OSTI2024

Synthesizing Highly Crystalline Graphite Powder from Bulk Polyethylene Waste for Lithium-Ion Battery Anodes

Upcycling plastic waste into graphite can potentially be used, in conjunction with other methods, to manage existing waste materials and diversify graphite supply chains. However, synthesizing large quantities of crystalline graphite powder from plastic waste, particularly polyethylene (PE), remains a challenge because PE decomposes into light gases during thermal processing and simple methods do not exist at any appreciable size scale to address this challenge. In this work, a method is developed for air processing bulk forms of PE waste to create stable carbon char that does not readily decompose during high-temperature processing. This method employs solid additives in the form of salts, which are combined with the PE melt during air processing to increase the effective surface area of the melt and improve the oxygen-driven chemistry that stabilizes PE for high-temperature processing. After removal of the solid salt additives from the PE-derived char, it is converted into a highly crystalline bulk graphite powder using an Fe-based catalytic process. The PE-derived graphite anode in a lithium-ion coin cell showed a specific capacity of 345 mAh/g at 0.05C with an initial Coulombic efficiency of 87% and reversible capacity retention of ~100% at different current rates. It also showed a specific capacity of up to 313 mAh/g at 0.5 discharge/charge cycles per hour (0.5C) and Coulombic efficiency of 99.9% after 250 cycles, indicating excellent electrochemical performance as an anode material for lithium-ion batteries. This method illustrates that there are opportunities for upcycling large quantities of PE waste to produce graphite powders suitable for use in LIBs.

25 ENERGY STORAGE↗
DOE OSTI2021

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Oxidation Resistance in 1200°C Steam of a FeCrAl Alloy Fabricated by Three Metallurgical Processes

Abstract FeCrAl alloys are a leading candidate material for accident tolerant fuel cladding due to their good performance in both normal light-water reactor operating conditions as well as their resilience to high-temperature accident scenarios. For commercial-scale production, new fabrication techniques need to be investigated. In this study, the effects of fabrication methods on the high-temperature steam oxidation performance of C26M (Fe12Cr6Al2Mo in wt.%) were investigated. Three variants of C26M were manufactured: wrought (cast and forged) (WC26M), powder metallurgy hot isostatic pressing (PMC26M), and laser powder bed fusion additive manufacturing (AMC26M). All three variants were exposed to steam at 1200°C for 2 h. Results showed no significant variation in mass change between the variants after steam exposure. All three variants effectively formed stable protective alumina films with ~0.6–1.3 µ m thickness. This study suggests FeCrAl alloys have excellent resilience to high-temperature steam in nuclear reactor accident scenarios regardless of the fabrication method.

Materials Science↗
NASA NTRS2009

Thermoelectric properties by high temperature annealing

The present invention generally provides methods of improving thermoelectric properties of alloys by subjecting them to one or more high temperature annealing steps, performed at temperatures at which the alloys exhibit a mixed solid/liquid phase, followed by cooling steps. For example, in one aspect, such a method of the invention can include subjecting an alloy sample to a temperature that is sufficiently elevated to cause partial melting of at least some of the grains. The sample can then be cooled so as to solidify the melted grain portions such that each solidified grain portion exhibits an average chemical composition, characterized by a relative concentration of elements forming the alloy, that is different than that of the remainder of the grain.

Ren, Zhifeng↗