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Results for “THERMAL FRACTURES”

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

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DOE OSTI2018

Fracture Resistance of Cast Stainless Steels after Thermal Aging for up to 10000 Hours

This work package, Cast Stainless Steel Aging, aims to achieve a comprehensive scientific understanding on the aging and failure phenomena in cast austenitic stainless steels (CASSs) using holistic experimental and modeling means and to provide a practical and science-based model to predict the degree of thermal degradation of CASS components in extended-term operations. The test materials in the project include four model CASSs (CF3, CF3M, CF8, and CF8M), four EPRI-provided CASSs (CF3, two CF8s, and CF8M), and two reference wrought materials (304L and 316L), which contain a wide variety of d-ferrite contents (2–33%). These materials have been thermally aged at two light water reactor (LWR)-relevant temperatures (290 and 330°C) and at two accelerated-aging temperatures (360 and 400°C) for up to three years. In the fiscal year, the fracture toughness testing and J-R curve calculation were completed for the ten CASS and wrought materials aged up to 10,000 hours. This report is to present the results of the static fracture (J-R) testing for the model and EPRI-provided CASS materials after thermal aging up to 10,000 hours. First, a new aging parameter (A) was defined to present the aging degradation of mechanical properties against the common variable. This definition is used to scale an aging time at a temperature to the effective aging time at a reference temperature based on Arrhenius equation, which is a rate theory equation for thermally activated mechanisms.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Development of an analytical solution for thermal single-well injection-withdrawal tests in horizontally fractured reservoirs

In this study, we have developed an analytical solution for thermal single-well injection-withdrawal tests in horizontally fractured reservoirs where fluid flow through the fracture is radial. The dimensionless forms of the governing equations and the initial and boundary conditions in the radial flow system can be written in a form identical to those in the linear flow system developed by Jung and Pruess [Jung, Y., and K. Pruess (2012), A Closed-Form Analytical Solution for Thermal Single-Well Injection-Withdrawal Tests, Water Resour. Res., 48, W03504, doi:10.1029/2011WR010979], and therefore the analytical solutions developed in Jung and Pruess (2012) can be applied to compute the time dependence of temperature recovery at the injection/withdrawal well in a horizontally oriented fracture with radial flow.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

Gold-titania interface toughening and thermal conductance enhancement using an organophosphonate nanolayer

We demonstrate that a mercaptan-terminated organophosphonate nanolayer at gold-titania interfaces can give rise to two- to three-fold enhancement in the interfacial fracture toughness and thermal conductance. Electron spectroscopy reveals that interfacial delamination occurs at the metal-molecule interface near the gold-sulfur bonds, consistent with density functional theory calculations of bond energies. Qualitative correlation between interfacial fracture toughness and bond energies suggest that organophosphonate nanolayers are resilient to humidity-induced degradation. These results, and the versatility of organophosphonates as surface functionalization agents for technologically relevant materials, unlock uncharted avenues for molecular engineering of interfaces in materials and devices for a variety of applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Analysis of FeCrAl cladding and UO 2 fuel including discrete and smeared cracks, and fuel relocation

As UO 2 fuel heats during the rise to operating power in an LWR, the fuel pellets begin to fracture due to thermal stresses arising due to the temperature profile radially across the fuel. As the fuel fractures, it expands diametrically, reducing the fuel cladding gap and improving the heat transfer characteristics of the fuel. By increasing the effective fuel diameter, gap closure is expected to occur much sooner and greater stresses are expected to form in cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Residual Stress and Opening-Mode Fracture Analysis of Multilayered Structures Subjected to Thermal Loading

Temperature change after formation commonly results in thermal residual stress in multilayered structures due to the different thermal and mechanical properties of each layer. In this paper, a three-dimensional (3D) elastic model is developed to study the residual stress and opening-mode fractures (OMFs) in a multilayered structure consisting of arbitrary number of layers under temperature change. The general solution of displacement field in the multilayered structure is derived by solving the elastic boundary value problem. In order to verify the proposed model, the elastic field in the advanced polymeric solar reflectors that consist of four layers is solved by applying the present model and compared with the finite-element (FE) simulation. In addition, parametric studies are conducted to investigate the effect of the thickness ratio between each layer on the accuracy of the developed model. As a result, based on the obtained elastic field, the fracture energy release rate (ERR) in the surface layer of the advanced polymeric reflector is obtained and used to study the fracture initiation, infilling, and saturation successfully.

36 MATERIALS SCIENCE↗

DOE OSTI2026

3D probabilistic fracture mechanics / computational fluid dynamics simulation of a reactor pressure vessel under transient conditions

Reactor pressure vessels (RPVs) are safety-critical light-water-reactor components that, under irradiation, experience long-term material degradation in the form of embrittlement. This can increase their susceptibility to fracture under thermal-shock conditions, which could occur during off-normal transients such as loss-of-coolant accidents (LOCAs). During a LOCA, the most severe conditions for the RPV occur when emergency core cooling water is injected through the cold legs into the water-and-steam-filled RPV. The rapid cooling of the downcomer and internal RPV surface causes decreased temperature and elevated thermally driven tensile stresses in the RPV wall. This, combined with long-term material embrittlement, may cause fracture initiation at pre-existing flaws, challenging the integrity of the RPV. Assessing RPV integrity during transients with a large spatial variation in the coolant temperature requires a modeling approach that considers the effects of spatially varying coolant temperature on the fracture probability of a population of flaws distributed throughout the RPV, accounting for spatially varying embrittlement. Here, the present study addresses this need by demonstrating first-of-its-kind coupling of a high-fidelity 3D computational fluid dynamics code with 3D probabilistic fracture mechanics This was accomplished using representative models of a pressurized-water reactor subjected to small- and medium-break LOCA conditions, both of which can result in large spatial temperature variations. While the observed impact of accounting for 3D effects was minimal under the small-break LOCA this study indicates a significant increase in the probability of fracture initiation under the medium-break LOCA when 3D effects are considered, relative to a spatially uniform cooling scenario.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Ceramic nuclear fuel fracture modeling with the extended finite element method

Ceramic fuel pellets used in nuclear light water reactors experience significant fracture due to the high thermal gradients experienced under normal operating conditions. This has important effects on the performance of the fuel system. Because of this, a realistic, physically based fracture modeling capability is essential to predict fuel behavior in a wide variety of normal and off-normal conditions. The extended finite element method (X-FEM) is a powerful method to represent arbitrary propagating discrete cracks in finite element models, and has many characteristics that make it attractive for nuclear fuel performance analysis. This paper describes the implementation of X-FEM in a multiphysics fuel performance code and presents applications of that capability. These applications include several thermal mechanics fracture benchmark problems, which demonstrate the accuracy of this approach. It also includes application of this capability to study nuclear fuel fracture, both on stationary and propagating cracks. The study on stationary cracks shows the effects that varying the number of radial cracks and the length of those cracks have on the energy release rate. Here, the propagating crack case demonstrates random initiation and subsequent propagation of interacting thermally induced cracks during an initial ramp to full power with fresh fuel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Predicting Thermal Performance of an Enhanced Geothermal System From Tracer Tests in a Data Assimilation Framework

Abstract Predicting the thermal performance of an enhanced geothermal system (EGS) requires a comprehensive characterization of the underlying fracture flow patterns from practically available data such as tracer data. However, due to the inherent complexities of subsurface fractures and the generally insufficient geological/geophysical data, interpreting tracer data for fracture flow characterization and thermal prediction remains a challenging task. The present study aims to tackle the challenge by leveraging a data assimilation method to maximize the utilization of information inherently contained in tracer data, and meanwhile maintain the flexibility to handle various uncertainties. A tracer data interpretation framework was proposed with the following three components integrated: (a) We use principal component analysis (PCA) to reduce the dimensionality of model parameter space. (b) We use ES‐MDA (ensemble smoother with multiple data assimilation) to invert for fracture aperture/flow fields and obtain posterior model ensembles for uncertainty quantification. Various data types are assimilated jointly to improve the predictive ability of the posterior ensemble. (c) The inverted fracture aperture fields are then incorporated into reservoir models to predict thermal performance. We developed a field‐scale EGS model to verify the ability of the framework to characterize highly heterogeneous fracture aperture/flow fields and predicting thermal performance. We also applied the framework to a mesoscale field experiment to demonstrate its potential application in real‐world geothermal reservoirs. The results indicate that the proposed framework can effectively retrieve fracture flow information from tracer data for thermal prediction and uncertainty quantification, and thus provide informative guidance for EGS optimization and risk management.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Towards an Era of Low-Temperature Integral Critical Experiments: Surrogate Testing of Low-Temperature TEX Configurations

United States and IAEA regulations for the transportation of radioactive materials require that fissile materials must be subcritical under expected ambient temperatures ranging from -40°C to 38°C. While historical experiments have been conducted at room and elevated temperatures, no criticality integral benchmarks exist for temperatures below room temperature. The Low-Temperature Thermal Epithermal eXperiments (LT-TEX) aim to provide benchmark evaluations down to -40°C. The LT-TEX design incorporates stacked HEU plates interspersed with varying thicknesses of polyethylene disks to provide varying levels of moderation, with five configurations at 20°C having already been benchmarked. A novel vacuum/cryogenic chamber was fabricated to contain the LT-TEX configurations in a thermally isolated environment and cool it to -40°C. Prior to testing with fissile materials, testing with surrogate fuel plates was performed to characterize the thermal properties of the system, ensure no condensation forms on the stack, and to test that the uranium plates would not warp, or fracture during the thermal cycling. Surrogate testing has characterized the cryogenic chamber and verified its viability to perform the benchmark experiments, allowing for the next steps in the LT-TEX experimental campaign. The results of the surrogate testing are discussed and compared to heat transfer calculations performed as part of the experiment design process, to establish confidence in the thermal behavior of the system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Thermomechanical properties and microstructures of yttrium hydride

Yttrium hydride is an optimal choice for a high-temperature moderator material in advanced thermal neutron spectrum reactors that require small core volumes. However, a complete database of the thermomechanical properties of yttrium hydride is not available yet, although it is much needed to understand and predict the moderator performance during service in reactors. In this paper, we report the properties of unirradiated bulk yttrium hydride as a function of hydrogen concentration—including density, crystal structure, specific heat capacity, thermal diffusivity, thermal conductivity, hardness, elastic/shear moduli, Poisson’s ratio, fracture strength, microstructure, and thermal stability—providing a baseline measurement for the subsequent neutron irradiation response study of yttrium hydride. Furthermore, the recommended empirical treatment of the data is suggested. In addition, other properties (i.e., hydrogen retention, thermal hydrogen migration, and irradiation response) that needs to be investigated are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Handbook on the Material Properties of Yttrium Hydride for High Temperature Moderator Applications

Yttrium hydride is an optimal choice for a high-temperature moderator material in advanced thermal neutron spectrum reactors that require small core volumes. A complete database of the thermomechanical properties of yttrium hydride is not yet available, although it is much needed to understand and predict the moderator performance during service in reactors. This milestone report presents the properties of unirradiated bulk yttrium hydride as a function of hydrogen concentration—including density, crystal structure, specific heat capacity, thermal diffusivity, thermal conductivity, hardness, elastic/shear moduli, Poisson’s ratio, fracture strength, microstructure, and thermal stability. This information provides a baseline measurement for the subsequent neutron irradiation response study of yttrium hydride. The recommended empirical treatment of the data is suggested. In addition, other properties (i.e., hydrogen retention, thermal hydrogen migration, and irradiation response) requiring investigation are discussed. Also included are the Preliminary post-irradiation examination (PIE) data of yttrium hydride irradiated at 600 and 900°C to 0.1 dpa in the High Flux Isotope Reactor (HFIR). The thermophysical properties have insignificant change following this low dpa irradiation for both irradiation temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stainless Steel

Additive manufacturing (AM) includes a diverse suite of innovative manufacturing processes for producing near-net shape components, typically from powder or wire feedstock. Reported mechanical properties of AM materials vary significantly depending on the details of the manufacturing process and the characteristics of the processing defects (namely, lack of fusion defects). However, an excellent combination of strength, ductility and fracture resistance can be achieved in AM type 304L and 316L austenitic stainless steels by minimizing processing defects. It is also important to recognize that localized solidification processing during AIVI produces microstructures more analogous to weld microstructures than wrought microstructures. Consequently, the mechanical behavior of AM austenitic stainless steels in harsh environments can diverge from the performance of wrought materials. This report gives an overview of the fracture and fatigue response of type 304L materials from both directed energy deposition (DED) and powder bed fusion (PBF) techniques. In particular, the mechanical performance of these materials is considered for high-pressure hydrogen applications by evaluating fatigue and fracture resistance after thermally precharging of test specimens in high-pressure gaseous hydrogen. The mechanical behaviors are considered with respect to previous reports on hydrogen-assisted fracture of austenitic stainless steel welds and the unique characteristics of the AM microstructures. Fatigue crack growth can be relatively insensitive to processing defects, displaying similar behavior as wrought materials. Fracture resistance of dense AM austenitic stainless steel, on the other hand, is more consistent with weld metal than with compositionally-similar wrought materials. Hydrogen effects in the AM materials are generally more severe than in wrought materials, but comparable to measurements on welded austenitic stainless steels in hydrogen environments. While hydrogenassisted fracture manifests differently in welded and AM austenitic stainless steel, the fracture process appears to have a common origin in the compositional microsegregation intrinsic to solidification processes.

additive manufacturing, austenitic stainless steel↗

NASA NTRS1990

Reliability analysis of a structural ceramic combustion chamber

The Weibull modulus, fracture toughness and thermal properties of a silicon nitride material used to make a gas turbine combustor were experimentally measured. The location and nature of failure origins resulting from bend tests were determined with fractographic analysis. The measured Weibull parameters were used along with thermal and stress analysis to determine failure probabilities of the combustor with the CARES design code. The effect of data censoring, FEM mesh refinement, and fracture criterion were considered in the analysis.

Salem, Jonathan A.↗

NASA NTRS1991

Reliability analysis of a structural ceramic combustion chamber

Salem, Jonathan A.↗

DOE OSTI2021

Compressed gas energy storage

Methods and systems for thermal energy storage and enhanced oil recovery are described herein. In some embodiments, natural gas may be injected down a well which has been previously hydraulically fractured to store thermal energy and to stimulate the well to greater hydrocarbon production.

Augustine, Chad↗

NASA NTRS2004

Formulations for Stronger Solid Oxide Fuel-Cell Electrolytes

Tests have shown that modification of chemical compositions can increase the strengths and fracture toughnesses of solid oxide fuel-cell (SOFC) electrolytes. Heretofore, these solid electrolytes have been made of yttria-stabilized zirconia, which is highly conductive for oxygen ions at high temperatures, as needed for operation of fuel cells. Unfortunately yttria-stabilized zirconia has a high coefficient of thermal expansion, low resistance to thermal shock, low fracture toughness, and low mechanical strength. The lack of strength and toughness are especially problematic for fabrication of thin SOFC electrolyte membranes needed for contemplated aeronautical, automotive, and stationary power-generation applications. The modifications of chemical composition that lead to increased strength and fracture toughness consist in addition of alumina to the basic yttria-stabilized zirconia formulations. Techniques for processing of yttria-stabilized zirconia/alumina composites containing as much as 30 mole percent of alumina have been developed. The composite panels fabricated by these techniques have been found to be dense and free of cracks. The only material phases detected in these composites has been cubic zirconia and a alumina: this finding signifies that no undesired chemical reactions between the constituents occurred during processing at elevated temperatures. The flexural strengths and fracture toughnesses of the various zirconia-alumina composites were measured in air at room temperature as well as at a temperature of 1,000 C (a typical SOFC operating temperature). The measurements showed that both flexural strength and fracture toughness increased with increasing alumina content at both temperatures. In addition, the modulus of elasticity and the thermal conductivity were found to increase and the density to decrease with increasing alumina content. The oxygen-ion conductivity at 1,000 C was found to be unchanged by the addition of alumina.

Bansal, Narottam P.↗

DOE OSTI2014

Nanocrystalline SiC and Ti 3 SiC 2 Alloys for Reactor Materials: Thermal and Mechanical Properties

SiC-polymers (pure polycarbosilane and polycarbosilane filled with SiC-particles) are being combined with Si and TiC powders to create a new class of polymer-derived ceramics for consideration as advanced nuclear materials in a variety of applications. Compared to pure SiC these materials have increased fracture toughness with only slightly reduced thermal conductivity. Future work with carbon nanotube (CNT) mats will be introduced with the potential to increase the thermal conductivity and the fracture toughness. At present, this report documents the fabrication of a new class of monolithic polymer derived ceramics, SiC + SiC/Ti 3 SiC 2 dual phase materials. The fracture toughness of the dual phase material was measured to be significantly greater than Hexoloy SiC using indentation fracture toughness testing. However, thermal conductivity of the dual phase material was reduced compared to Hexoloy SiC, but was still appreciable, with conductivities in the range of 40 to 60 W/(m K). This report includes synthesis details, optical and scanning electron microscopy images, compositional data, fracture toughness, and thermal conductivity data.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Micron-gap spacers with ultrahigh thermal resistance and mechanical robustness for direct energy conversion

Abstract In thermionic energy converters, the absolute efficiency can be increased up to 40% if space-charge losses are eliminated by using a sub-10-µm gap between the electrodes. One practical way to achieve such small gaps over large device areas is to use a stiff and thermally insulating spacer between the two electrodes. We report on the design, fabrication and characterization of thin-film alumina-based spacers that provided robust 3–8 μm gaps between planar substrates and had effective thermal conductivities less than those of aerogels. The spacers were fabricated on silicon molds and, after release, could be manually transferred onto any substrate. In large-scale compression testing, they sustained compressive stresses of 0.4–4 MPa without fracture. Experimentally, the thermal conductance was 10–30 mWcm −2 K −1 and, surprisingly, independent of film thickness (100–800 nm) and spacer height. To explain this independence, we developed a model that includes the pressure-dependent conductance of locally distributed asperities and sparse contact points throughout the spacer structure, indicating that only 0.1–0.5% of the spacer-electrode interface was conducting heat. Our spacers show remarkable functionality over multiple length scales, providing insulating micrometer gaps over centimeter areas using nanoscale films. These innovations can be applied to other technologies requiring high thermal resistance in small spaces, such as thermophotovoltaic converters, insulation for spacecraft and cryogenic devices.

42 ENGINEERING↗