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DOE OSTI2018

South Carolina Solar Development - Tracking the Effects of Act 236 (2014-2017)

Since 2014, the installed solar capacity in South Carolina (SC) has mushroomed from 5.5 megawatts to more than 354 megawatts today. Concurrently, the number of customer-sited, load-centered solar generation was expected to grow from less than 600 statewide to as many over 10,000 today. This growth was the direct result of a landmark state policy initiative, Act 236, passed by the SC General Assembly and signed into law by the Governor in June of 2014. Local policy makers in SC were ill-equipped to handle the onslaught of solar permitting and zoning requests expected by 2021. Similarly, the state’s building inspectors, first responders, and tax assessors know little about photovoltaic (PV) technology and best practices. Finally, SC’s workforce and workforce trainers were underprepared to benefit from the tremendous opportunity created by the passage of Act 236. Each of these deficits in knowledge of and preparedness for solar PV translated into higher “soft costs” of installed solar PV in SC. The Savannah River National Laboratory (SRNL), together with almost a dozen electricity stakeholders in the Southeast, has studied the ability of Act 236 to serve as replicable model for solar PV cost reduction. In 2015, this study began with a focus on the effects of Act 236 to offer a unique perspective and understanding of the actual impact of rapidly integrating solar energy into the electric grid. This study would analyze the impact of starting at a solar PV penetration of 0.1% and increasing to over 2%, while expanding access, developing regional specific training and educational materials, and developing datasets to support expanding solar markets. Through targeted tracking and analysis, the team developed a baseline of the current market, identified the major obstacles in soft cost reduction, and cooperatively developed stakeholder-centric strategies. This work has enabled us to directly track and report on the growth and effects of recently enacted solar legislation on the industry. This report marks the final in a series of reports examining the effects of Act 236 on the solar economy in SC since 2014.

14 SOLAR ENERGY↗

DOE OSTI2023

Initial Results of PostProcess NDE Using Advanced Techniques

The U.S. Department of Energy, Office of Nuclear Energy Advanced Materials and Manufacturing Technologies Program is developing advanced materials and manufacturing technologies that will enable the safe and economical operation of both the current fleet and the next generation of advanced nuclear reactors. Post-process nondestructive evaluation capabilities are a key enabling technology that will be required to qualify and verify the condition of components produced using advanced materials and manufacturing technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1973

Development of a closed pore insulation material

A closed pore ceramic foam insulation material (CPI) has been developed that offers possibilities for use as a reusable external heat shield for the NASA manned space shuttle. The outstanding characteristics of CPI are: (1) negligible water absorption due to a noninterconnecting network of cells; (2) high emittance at room and elevated temperature; (3) ability to survive at least 10 simulated reentry cycles to 1500 K using radiant heat lamps to simulate the reentry heat fluxes; (4) ability to survive, with no change in properties or appearance, at least 10 simulated plasma arc jet cycles to 1500 K (with the exception of some stress cracks induced either by the unduly severe nature of the initial arc splash heating pulse or by improper mechanical holding of the specimen in the test fixture); (5) strength (flexure); and (6) a low thermal conductivity throughout the temperature range of interest for the space shuttle.

Tobin, A.↗

NASA NTRS1977

Evaluation of aircraft brake materials

A test program was carried out to evaluate several new high-temperature friction materials for use in aircraft disk brakes. A specially built test apparatus utilizing a disk brake and wheel half from a small jet aircraft was used. The apparatus enabled control of brake pressure, velocity and braking time. Tests were run under both constant and variable velocity conditions and covered a kinetic energy range similar to that encountered in aircraft brake service. The materials evaluation showed that two newly developed friction materials show potential for use in aircraft disk brakes. One of the materials is a nickel-based sintered composite, while the other is a molybdenum-based material. Both materials show much lower wear rates than conventional copper-based materials and are better able to withstand the high temperatures encountered during braking. Additional materials improvement is necessary, however, since both materials show a significant negative slope of the friction-velocity curve at low velocities.

Ho, T. L.↗

NASA NTRS1978

Analytical predictions of selenide RTG power degradation

A mathematical model for the performance and degradation analysis of an RTG using the newly developed selenide thermoelectric materials has been developed at JPL. The computerized model is quite comprehensive and enables the accurate detailing of the electrical and thermal effects that take place within the thermocouple under any desired set of operation conditions, including heat input, ambient temperature and load conditions. The paper discusses the logic flow of the computer model and presents the time and temperature dependent results for various degradation mechanisms and rates as they have been established to date.

Noon, E. L.↗

NASA NTRS1983

Elastohydrodynamic lubrication of smooth surfaces

Fully flooded, elastohydrodynamically lubricated contacts are considered. Elastohydrodynamic lubrication (EHL) analysis requires the simultaneous solution of the elastically, viscosity, density, and Reynolds equations. The most important practical aspect of elastohydrodynamic lubrication theory is the determination of the minimum film thickness within the conjunction. The maintenance of a fluid film of adequate magnitude is an essential feature of the correct operation of lubricated machine elements. The results show the influence of contact geometry on minimum film thickness as expressed by the ellipticity parameter and the dimensionless speed, load, and materials parameters. Film thickness equations are developed for materials of high elastic modulus, such as metal, and for materials of low elastic modulus, such as rubber.

Hamrock, B. J.↗

NASA NTRS1986

Characterization of elastomeric materials with application to design

Redesign of the Space Shuttle Solid Booster has necessitated re-evaluation of the material used in the field joint O-ring seals. The viscoelastic characteristics of five candidate materials were determined. The five materials are: two fluorocarbon compounds, two nitrile compounds, and a silicon compound. The materials were tested in a uniaxial compression test to determine the characteristic relaxation functions. These tests were performed at five different temperatures. A master material curve was developed for each material from the experimental data. The results are compared to tensile relaxation tests. Application of these results to the design analysis is discussed in detail.

Bower, Mark V.↗

NASA NTRS1989

Viscoelastic properties of elastomeric materials for O-ring applications

Redesign of the Space Shuttle Solid Rocket Booster necessitated re-evaluation of the material used in the field joint O-ring seals. This research project was established to determine the viscoelastic characteristics of five candidate materials. The five materials are: two fluorocarbon compounds, two nitrile compounds, and a silicon compound. The materials were tested in a uniaxial compression test to determine the characteristic relaxation functions. These tests were performed at five different temperatures. A master material curve was developed for each material from the experimental data. The results of this study are compared to tensile relaxation tests. Application of these results to the design analysis is discussed in detail.

Bower, Mark V.↗

NASA NTRS1990

Scattering from coated structures and antenna pattern control using impedance surfaces, part A/B

The scattering from coated, conducting structures, specifically the coated dihedral corner reflector configuration and the coated strip/plate configuration is examined. The formulation uses impedance-wedge Uniform Theory of Diffraction scattering coefficients to calculate the diffracted fields. A finite-thickness coating is approximated using the impedance boundary condition to arrive at an equivalent impedance for the coating. The formulation of the impedance wedge coefficients is outlined. Far-field, perfectly conducting approximations are discussed. Problems with the present dihedral corner reflector model for certain angles of incidence and observation are discussed along with a potentially rectifying modification. Also, the capacity to measure the electromagnetic properties of lossy materials was developed. The effects of using multiple material coatings on the radiation pattern of the horn antenna were studied. Numerous computations were devoted toward the inverse problem of synthesizing desired radiation patterns using the impedance surfaces. Stabilizing the equivalent sheet impedance using the linear control condition was attempted, and it was found to be a very difficult task.

Balanis, Constantine A.↗

NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗

NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kg/sq m (3.1 lb/cu ft (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗

NASA NTRS2024

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains - Task 2: Power Quality Filtering Using Nanocrystalline Soft Magnetic Inductor

The NASA RTAPS program on AC and DC Fault Management for Megawatt Electrified Power Train is a multi-year joint project with Pratt & Whitney (P&W), Collins Aerospace (CA), and RTX Technology Research Center (RTRC). This research program focuses on the high-voltage distribution issues that present a significant technological obstacle in the adoption of Electrified Aviation Propulsion (EAP) systems. One challenge to the adoption of high-voltage distribution systems with power electronic converters is the need for filter elements to limit the generation and propagation of noise, protect the cable systems from premature aging and prevent against excessive heating within subcomponents due to high-frequency induced currents. While increased distribution voltages aide in reducing the cable mass for a fixed power system, the associated mass with the filtering elements for power electronic converter can grow with increasing distribution voltages – thereby mitigating any benefit associated with increasing the distribution system voltage. To enable high-voltage distribution systems with high system specific power densities, new magnetic materials must be developed. Therefore, the second task of the NASA RTAPS program is associated with the design and application of advanced soft magnetic components for Megawatt class electric propulsion systems, specifically the motor drive system. This report covers the collaborative work between NASA Glenn Research Center (GRC), RTRC, P&W and CA in the development of three types of magnetic components over the span of the three-year program. These critical magnetic components are the DC side EMI filter, which limits the propagation of harmful electromagnetic noise to the rise of the distribution system, and the AC side damping with the dv/dt filter, which limits the fast rise time of the power electronic converter output voltage to limit the degradation on the cable/motor insulation systems. Each of these components are investigated from component level design and are optimized at the system level with a combined modelling and testing effort. In the final experimental evaluation of the NASA developed soft magnetic material with a dv/dt filter, a commercial-off-the-shelf (COTS) magnetic core and the GRC magnetic core are optimized and loaded at 320Arms to evaluate their difference in performance. After a run time of 30 minutes in a MW-class motor driver at RTRC, the NASA GRC cores were found to not only offer a lower temperature rise of nearly 25°𝐶, but also a reduction in measured core loss of 25% (12.75W to 9.5W).

Elecrified Aircraft Propulsion↗

NASA NTRS1998

Constitutive Theory Developed for Monolithic Ceramic Materials

With the increasing use of advanced ceramic materials in high-temperature structural applications such as advanced heat engine components, the need arises to accurately predict thermomechanical behavior that is inherently time-dependent and that is hereditary in the sense that the current behavior depends not only on current conditions but also on the material's thermomechanical history. Most current analytical life prediction methods for both subcritical crack growth and creep models use elastic stress fields to predict the time-dependent reliability response of components subjected to elevated service temperatures. Inelastic response at high temperatures has been well documented in the materials science literature for these material systems, but this issue has been ignored by the engineering design community. From a design engineer's perspective, it is imperative to emphasize that accurate predictions of time-dependent reliability demand accurate stress field information. Ceramic materials exhibit different time-dependent behavior in tension and compression. Thus, inelastic deformation models for ceramics must be constructed in a fashion that admits both sensitivity to hydrostatic stress and differing behavior in tension and compression. A number of constitutive theories for materials that exhibit sensitivity to the hydrostatic component of stress have been proposed that characterize deformation using time-independent classical plasticity as a foundation. However, none of these theories allow different behavior in tension and compression. In addition, these theories are somewhat lacking in that they are unable to capture the creep, relaxation, and rate-sensitive phenomena exhibited by ceramic materials at high temperatures. The objective of this effort at the NASA Lewis Research Center has been to formulate a macroscopic continuum theory that captures these time-dependent phenomena. Specifically, the effort has focused on inelastic deformation behavior associated with these service conditions by developing a multiaxial viscoplastic constitutive model that accounts for time-dependent hereditary material deformation (such as creep and stress relaxation) in monolithic structural ceramics. Using continuum principles of engineering mechanics, we derived the complete viscoplastic theory from a scalar dissipative potential function.

Janosik, Lesley A.↗

NASA NTRS1985

Encapsulant selection and durability testing experience

The Flat Plate Solar Array Project (FSA) has established technically challenging cost and service life goals for photovoltaic modules. These goals are a cost of $70 sq m and an expected 30 years of service life in an outdoor weathering environment. out of the cost goal, $14 sq m is allocated for encapsulation materials, which includes the cost of a structural panel. At FSA's inception in 1975, the cumulative cost of encapsulation materials in popular use, such as room temperature vulcanized (RTV) silicones, aluminum panels, etc., greatly exceeded $14/sq m. Accordingly, it became necessary to identify and/or develop new materials and new material technologies to achieve the goals. Many of these new materials are low cost polymers that satisfy module engineering and encapsulation processing requirements but unfortunately are not intrinsically weather stable. This necessitates identifying lifetime and/or weathering deficiencies inherent in these low cost materials and developing specific approaches to enhancing weather stability.

Cuddihy, E. F.↗

DOE OSTI2013

Integrated experimental setup for angle resolved photoemission spectroscopy of transuranic materials

We have developed the Angle Resolved Photoemission Spectroscopy (ARPES) system for transuranic materials. The ARPES transuranic system is an endstation upgrade to the Laser Plasma Light Source (LPLS) at Los Alamos National Laboratory. The LPLS is a tunable light source for photoemission with a photon energy range covering the vacuum ultraviolet (VUV) and soft x-ray regions (27–140 eV). The LPLS was designed and developed for transuranic materials. Transuranic photoemission is currently not permitted at the public synchrotrons worldwide in the VUV energy range due to sample encapsulation requirements. With the addition of the ARPES capability to the LPLS system there is an excellent opportunity to explore new details centered on the electronic structure of actinide and transuranic materials.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2017

Complete Report on the Development of Welding Parameters for Irradiated Materials

The advanced welding facility at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory, which was conceived to enable research and development of weld repair techniques for nuclear power plant life extension, is now operational. The development of the facility and its advanced welding capabilities, along with the model materials for initial welding trials, were funded jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, with additional support from Oak Ridge National Laboratory. Welding of irradiated materials was initiated on November 17, 2017, which marked a significant step in the development of the facility and the beginning of extensive welding research and development campaigns on irradiated materials that will eventually produce validated techniques and guidelines for weld repair activities carried out to extend the operational lifetimes of nuclear power plants beyond 60 years. This report summarizes the final steps that were required to complete weld process development, initial irradiated materials welding activities, near-term plans for irradiated materials welding, and plans for post-weld analyses that will be carried out to assess the ability of the advanced welding processes to make repairs on irradiated materials.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Isotope-Specific Analysis of Neutron-Irradiated Lithium Aluminate Ceramics by Nuclear Magnetic Resonance Spectroscopy

The effects of neutron irradiation on lithium aluminate targets and the permeation of tritium into surrounding components are primary concerns in the development of materials for use in tritium production. The high specific activity and volatility of the tritium in activated samples greatly increase the challenges of experimental analysis. This paper reports the determination of the chemical forms and quantities of H-3 and Li-6 in irradiated and non-irradiated LiAlO2 by nuclear magnetic resonance (NMR) spectroscopy, and demonstrates that measurements can be performed in a non-destructive, safe manner to obtain isotope-selective, quantitative information on highly hazardous materials.

Tritium, solid state nuclear magnetic resonance sp↗

NASA NTRS1980

Filter development for the extreme ultraviolet explorer

Thin film filters with extreme ultraviolet bandpasses unattainable with previously available filter materials were developed. Titanium and antimomy were identified as the most promising materials for providing the scientifically important 350-500 A bandpass heretofore unattainable with thin film filters. Titanium foils and titanium-antimony sandwich foils of the required uniformity and durability were fabricated. Transmission measurements and optimization studies indicate that the titanium-antimony combination provides an ideal bandpass for scientifically valuable, high-sensitivity observations with EUVE. Environmental testing of the mechanical strength, moisture sensitivity and aging characteristics of the newly developed filter materials demonstrate flightworthy performance.

Kimble, R.↗