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NASA NTRS2015

Replacement of HCFC-225 Solvent for Cleaning NASA Propulsion Oxygen Systems

Since the 1990's, when the Class I Ozone Depleting Substance (ODS) chlorofluorocarbon‐113 (CFC‐113) was banned, NASA's propulsion test facilities at Marshall Space Flight Center (MSFC) and Stennis Space Center (SSC) have relied upon hydrochlorofluorocarbon‐225 (HCFC‐225) to safely clean and verify the cleanliness of large scale propulsion oxygen systems. Effective January 1, 2015, the production, import, export, and new use of HCFC‐225, a Class II ODS, was prohibited by the Clean Air Act. In 2012 through 2014, leveraging resources from both NASA and the Defense Logistics Agency ‐ Aviation Hazardous Minimization and Green Products Branch, test labs at MSFC, SSC, and Johnson Space Center's White Sands Test Facility (WSTF) collaborated to seek out, test, and qualify a replacement for HCFC‐225 that is both an effective cleaner and safe for use with oxygen systems. This presentation summarizes the tests performed, results, and lessons learned. It also demonstrates the benefits of cross‐agency collaboration in a time of limited resources.

Lowrey, Nikki M.↗

DOE OSTI2025

Determination of Scale Bar for AGHCF Metallography Data

The DOE Nuclear Energy Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) has supported the development of several databases containing information on the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data represents one of the most critical types of post-irradiation examination (PIE) data being collected, organized, and archived in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Metallic Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three principal sets of metallography data. The first set comprises metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins examined in the Hot Fuel Examination Facility (HFEF). The second set consists of metallography data from EBR-II irradiated fuel pins examined in the Alpha-Gamma Hot Cell Facility (AGHCF). The third set includes metallography data from transient-tested fuel pins (including both out-of-pile furnace tests and TREAT tests) examined in AGHCF. Since both the second and third sets were generated in AGHCF, they are governed by identical specifications. The metallography data in the databases consist of digital images scanned from either positive or negative photographic films. To analyze the microstructure of a fuel pin, a series of preparatory steps are required, including sectioning, epoxy mounting, mechanical grinding and polishing, and etching. Following sample preparation, specimens are transferred for metallographic examination. The AGHCF and HFEF metallography data were generated using optical microscopes manufactured by Leitz and Bausch and Lomb (B&L). Images were recorded on Polaroid film at preset magnifications. Magnification verification for the Leitz and B&L metallographs was conducted every two months prior to 1989 and at least every six months from 1989 through the conclusion of the IFR program. Magnifications determined from imaging of microslide standards were compared to the instrument settings for magnifications ranging from 50× to 500×. If the magnifications determined from standards deviated from the instrument settings, adjustments were made to the bellows extension until agreement was achieved. The specifications for AGHCF and HFEF legacy metallography data have been established based on available hard-copy and digital records, most of which have been incorporated into the data repositories associated with FIPD, OPTD, and TREXR. Detailed specifications including hard-copy records, digitized records, cutting diagrams and sectioning schemes, high-magnification photographs, photomosaics (composites), information tags, scale bars, and magnification verification procedures can be found in a separate report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Irradiation dose and temperature dependence of fracture toughness in high dose HT9 steel from the fuel duct of FFTF

To expand the knowledge base for fast reactor core materials, fracture toughness has been evaluated for high dose HT9 steel using miniature disk compact tension (DCT) specimens. The HT9 steel DCT specimens were machined from the ACO-3 fuel duct of the Fast Flux Test Facility (FFTF), which achieved high doses in the range of 3–148 dpa at 378–504 C. The static fracture resistance (J-R) tests have been performed in a servohydraulic testing machine in vacuum at selected temperatures including room temperature, 200 C, and each irradiation temperature. Brittle fracture with a low toughness less than 50 MPa pm occurred in room temperature tests when irradiation temperature was below 400 C, while ductile fracture with stable crack growth was observed when irradiation temperature was higher. No fracture toughness less than 100 MPa pm was measured when the irradiation temperature was above 430 C. It was shown that the influence of irradiation temperature was dominant in fracture toughness while the irradiation dose has only limited influence over the wide dose range 3–148 dpa. A slow decrease of fracture toughness with test temperature above room temperature was observed for the nonirradiated and high temperature (>430 *C) irradiation cases, which indicates that the ductile–brittle transition temperatures (DBTTs) in those conditions are lower than room temperature. A comparison with the collection of existing data confirmed the dominance of irradiation temperature in the fracture toughness of HT9 steels.

Byun, Thak Sang↗

NASA NTRS2009

A3 Subscale Rocket Hot Fire Testing

This paper gives a description of the methodology and results of J2-X Subscale Simulator (JSS) hot fire testing supporting the A3 Subscale Diffuser Test (SDT) project at the E3 test facility at Stennis Space Center, MS (SSC). The A3 subscale diffuser is a geometrically accurate scale model of the A3 altitude simulating rocket test facility. This paper focuses on the methods used to operate the facility and obtain the data to support the aerodynamic verification of the A3 rocket diffuser design and experimental data quantifying the heat flux throughout the facility. The JSS was operated at both 80% and 100% power levels and at gimbal angle from 0 to 7 degrees to verify the simulated altitude produced by the rocket-rocket diffuser combination. This was done with various secondary GN purge loads to quantify the pumping performance of the rocket diffuser. Also, special tests were conducted to obtain detailed heat flux measurements in the rocket diffuser at various gimbal angles and in the facility elbow where the flow turns from vertical to horizontal upstream of the 2nd stage steam ejector.

Saunders, G. P.↗

DOE OSTI2025

Specifications of Legacy U(Pu)Zr Metallography Data

The DOE Nuclear Energy Advanced Reactor Technologies (ART) Program has supported the creation of several databases with information describing the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data is one of the most important types of PIE data being collected, organized and stored in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three main sets of metallography data. The first set is the metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins measured in the Hot Fuel Examination Facility (HFEF); the second set is the metallography data from EBR-II irradiated fuel pins measured in the Alpha-Gamma Hot Cell Facility (AGHCF); the third set is the metallography data from transient tested fuel pins (the transients tests include the out-of-pile tests and TREAT tests) measured in AGHCF. Since both the second and third sets of data were measured in AGHCF, they are governed by the same specification. The metallography data in the databases are digital images scanned from either positive or negative photos. The quality of the images, including their resolution and contrast, relies on the preserved quality of the pictures and the scanning conditions. To analyze the microstructure of a fuel pin, a series of preparatory steps must be undertaken. These include sectioning, epoxy mounting, mechanical grinding and polishing, and often etching. The resulting samples were then transferred to a secondary hot cell, or glovebox (depending the strength of radiation field) for microscopy examination. The specifications provided herein focus on the metallography examinations. The sample grinding, polishing and etching processes are also discussed. The procedures involving sectioning and epoxy mounting are out of the scope of the current specification; details can be found in the corresponding operation manuals. If more data are collected and added to the ART Fast Reactor Databases, this specification will be updated to accommodate the additional data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine

03 NATURAL GAS↗

DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data (Final Report)

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components: (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2016

Results of the Test Program for Replacement of AK-225G Solvent for Cleaning NASA Propulsion Oxygen Systems

Since the 1990's, when the Class I Ozone Depleting Substance (ODS) chlorofluorocarbon-113 (CFC-113) was banned, NASA's propulsion test facilities at Marshall Space Flight Center (MSFC) and Stennis Space Center (SSC) have relied upon the solvent AsahiKlin AK-225 (hydrochlorofluorocarbon-225ca/cb or HCFC-225ca/cb) and, more recently AK-225G (the single isomer form, HCFC-225cb) to safely clean and verify the cleanliness of large scale propulsion oxygen systems. Effective January 1, 2015, the production, import, export, and new use of Class II Ozone Depleting Substances, including AK-225G, was prohibited in the United States by the Clean Air Act. In 2012 through 2014, NASA test labs at MSFC, SSC, and Johnson Space Center's White Sands Test Facility (WSTF) collaborated to seek out, test, and qualify a solvent replacement for AK-225G that is both an effective cleaner and safe for use with oxygen systems. This paper summarizes the tests performed, results, and lessons learned.

Lowrey, Nikki M.↗

DOE OSTI2024

ACCELERATING MICROREACTOR DEVELOPMENT AND DEPLOYMENT THROUGH JOINT PUBLIC TEST BEDS AND PRIVATE ADVANCED REACTOR DEVELOPMENT

The United States Department of Energy (DOE) has funded the National Reactor Innovation Center (NRIC) to accelerate the development and commercialization of small modular reactors and other advanced reactor technologies. As part of this effort NIRC is building two strategic assets at the Idaho National Laboratory (INL) to facilitate public-private partnerships for the development and testing of advanced nuclear microreactors and Small Modular Reactors (SMR). One will provide a safe, secure, and affordable location for High-Assay Low Enriched Uranium (HALEU) fueled reactors and a second for Highly Enriched Uranium (HEU) fueled reactors. Together these testbeds fill a nuclear testing infrastructure gap. The availability of such comprehensive testing facilities at the national labs eliminates the significant financial and operational burdens associated with each developer building and licensing their own test facilities. Consequently, this approach will not only accelerate technological innovation and reduce time-to-market for advanced nuclear solutions but it also underscores the DOE's commitment to fostering an ecosystem where nuclear energy will thrive as a clean, reliable, and efficient source of power. The Demonstration of Microreactor Experiments (DOME) and Laboratory for Operations and Testing in the United States (LOTUS) have planned availability in 2026, and 2027 respectively.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Fermilab’s horizontal test stand upgrade overview and commissioning

Cryo-assemblies with the low-beta Nb3Sn quadrupoles for the High Luminosity LHC (HL-LHC) upgrade will be tested at Fermilab’s magnet test facility. Total of 10 cryo-assemblies will be delivered to CERN within the US HL-LHC Accelerator Upgrade Project (AUP). The horizontal test stand at Fermilab already has been used for testing the existing LHC inner-triplet quadrupoles, but the stand and corresponding electrical and cryogenic sub-systems were not operational more than a decade. In order to restore the test stand functions and meet the design and test requirements for the high luminosity LHC magnets, the existing horizontal test facility at Fermilab underwent a significant refurbishment of the cryogenic and mechanical components. Most of the upgrades were completed and verified during so called zero-magnet test by late 2020, and then final commissioning of the upgraded test stand was completed during the first cryo-assembly test in 2023. These tests verified all the cryo-mechanical installations, as well as the test stand operations, including controlled cooldown and operation at 1.9 K, the helium recovery capabilities, magnet protection and process controls.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1972

UK-4 prototype spacecraft magnetic tests

The spacecraft was tested in a magnetic test facility which uses a 42 ft. diameter coil system to produce a controlled magnetic field of high uniformity over a large central volume. The primary objectives of the tests were: (1) to determine the permanent, induced, and stray magnetic moments of the spacecraft and to assess its magnetic stability; (2) to evaluate the magnetorquer coil system; and (3) to deperm, compensate, and make other adjustments necessary to achieve satisfactory magnetic characteristics for the spacecraft. The test facility and procedures are described together with the results obtained. In addition, the problems encountered during the tests and the significance of the test findings are discussed.

Pruett, W. E.↗

NASA NTRS1981

The NTF as a national facility

The future evolution of the NTF as a national facility was discussed. The aerodynamic test facility is charged with maintaining the test data and operating the facility with maximum productivity to increase the utility as well as to minimize the test costs. Efforts are under way to increase productivity of the wind tunnels. The future developments needed include: (1) the elimination of wall interference uncertainties; (2) the elimination of minimization of sting interference; and (3) the achievement of free air quality low turbulence airflow. Research in the wall interference area, smart walls, is reported.

Brown, C. E.↗

NASA NTRS1990

Liquid hydrogen turbopump ALS advanced development program. Volume 1: Hot fire unit

The interface criteria for the Turbopump Test article (TPA) and the Component Test Facility located at NASA, Stennis Space Center is defined by this interface Control Document (ICD). TPA ICD Volume 2 is submitted for the Cold Gas Drive Turbopump Test Article, which is generally similar but incorporates certain changes, particularly in fluid requirements and in instrumentation needs. For the purposes of this ICD, the test article consists of the Hot Fire Drive Turbopump mounted on its test cart, readied for installation in the component test facility. It should be emphasized that the LH2 turbopump program is still in its early concept design phase. Design of the turbopump, test cart, and spools are subject to revisions until successful conclusion of the Detail Design Review (DDR).

Lindley, Bruce↗

NASA NTRS1976

Rotor Systems Research Aircraft (RSRA)

A description of the Rotor Systems Research Aircraft (RSRA) was presented, with particular emphasis on the unique systems that provide the potential for good flight/ground test facility correlation. These flight research vehicles are designed specifically with the capabilities necessary for the effective and efficient in-flight test and verification of promising new rotor concepts and supporting technology developments. The research mission and unique features of the RSRA will provide the capability to measure and separate the flight loads of the airframe and rotor, thereby allowing direct flight/ground test facility correlation of rotors as well as correlation with analytical models.

Condon, G. W.↗

DOE OSTI2021

Structural Testing Technology Development: Cooperative Research and Development Final Report, CRADA Number CRD-06-00200

NREL is the only organization in the US that is accredited to conduct tests of wind turbine systems and components in accordance with International Electrotechnical Commission (IEC) test standards. The National Wind Technology Center houses the only full-scale wind turbine blade drivetrain test facilities in the US. To maintain these facilities, accreditation, and the acceptance of the wind industry, NREL must strive continuously to maintain and improve staff capabilities, procedures, facility and equipment. In addition, as wind turbines continue to increase in size, NREL must improve its capability to test the larger components associated with these new turbines. NREL is currently investigating methods to increase blade and drivetrain testing capabilities. Mitsubishi Power Systems (MPS) must also strive to meet the demands of the evolving wind energy industry by developing, proving and manufacturing new, cost-effective blades for its turbines. Mitsubishi has established a joint venture with TPI composites of Rhode Island for manufacturing blades to be installed on US wind turbines. There is an obvious advantage to test these prototype blades in a US facility. The NREL blade test facility is uniquely capable of fulfilling this need. In addition, NREL can provide other testing support to MPS through the use of its dynamometer facility for drivetrain testing and through the use of NREL’s field-testing capabilities for testing wind turbine systems. This CRADA provides the opportunity for both organizations to achieve critical goals in development of wind energy in the US. MPS obtains verification of its wind turbine components and system. NREL obtains improved test capabilities.

17 WIND ENERGY↗

NASA NTRS1995

Shock Tunnel Studies of Scramjet Phenomena 1993

Reports by the staff of the University of Queensland on various research studies related to the advancement of scramjet technology and hypervelocity pulse test facilities are presented. These reports document the tests conducted in the reflected shock tunnel T4 and supporting research facilities that have been used to study the injection, mixing, and combustion of hydrogen fuel in generic scramjets at flow conditions typical of hypersonic flight. In addition, topics include the development of instrumentation and measurement technology, such as combustor wall shear and stream composition in pulse facilities, and numerical studies and analyses of the scramjet combustor process and the test facility operation. This research activity is Supplement 10 under NASA Grant NAGw-674.

Stalker, R. J.↗

DOE OSTI2016

Northwest National Marine Renewable Energy Center

In 2008, the US Department of Energy’s (DOE) Wind and Water Power Program issued a funding opportunity announcement to establish university-led National Marine Renewable Energy Centers. Oregon State University and the University of Washington combined their capabilities in wave and tidal energy to establish the Northwest National Marine Renewable Energy Center, or NNMREC. NNMREC’s scope included research and testing in the following topic areas: • Advanced Wave Forecasting Technologies; • Device and Array Optimization; • Integrated and Standardized Test Facility Development; • Investigate the Compatibility of Marine Energy Technologies with Environment, Fisheries and other Marine Resources; • Increased Reliability and Survivability of Marine Energy Systems; • Collaboration/Optimization with Marine Renewable and Other Renewable Energy Resources. To support the last topic, the National Renewable Energy Laboratory (NREL) was brought onto the team, particularly to assist with testing protocols, grid integration, and testing instrumentation. NNMREC’s mission is to facilitate the development of marine energy technology, to inform regulatory and policy decisions, and to close key gaps in scientific understanding with a focus on workforce development. In this, NNMREC achieves DOE’s goals and objectives and remains aligned with the research and educational mission of universities. In 2012, DOE provided NNMREC an opportunity to propose an additional effort to begin work on a utility scale, grid connected wave energy test facility. That project, initially referred to as the Pacific Marine Energy Center, is now referred to as the Pacific Marine Energy Center South Energy Test Site (PMEC-SETS) and involves work directly toward establishing the facility, which will be in Newport Oregon, as well as supporting instrumentation for wave energy converter testing. This report contains a breakdown per subtask of the funded project. Under each subtask, the following are presented and discussed where appropriate: the initial objective or hypothesis; an overview of accomplishments and approaches used; any problems encountered or departures from planned methodology over the life of the project; impacts of the problems or rescoping of the project; how accomplishments compared with original project goals; and deliverables under the subtasks. Products and models developed under the award are also included.

16 TIDAL AND WAVE POWER↗

DOE OSTI2016

Northwest National Marine Renewable Energy Center

16 TIDAL AND WAVE POWER↗