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DOE OSTI2020

Improving Predictability of Mixed-Phase Clouds and Aerosol Interactions in the Community Earth System Model (CESM) with ARM Measurements

The objective of this project is to improve the simulation and predictability of mixed-phase clouds and aerosol interactions in the Community Earth System Model (CESM) through comparisons with the DOE ARM observations. There are four major goals of the proposed study: (1) Improve the representation of ice microphysical processes in mixed-phase clouds; (2) Develop a long-term multi-sensor mixed-phase cloud dataset; (3) Test the performance of improved ice microphysics in CESM-CAM5 with the ARM data; and (4) Examine mixed-phase cloud microphysics-aerosol-dynamics-radiation interactions in CESM-CAM5. In this project, we have (1) Improved the representation of ice microphysical processes in mixed-phase clouds that include ice nucleation, ice depositional growth through the Wegener–Bergeron–Findeisen (WBF) process, feedbacks between cloud microphysics, dynamics and radiation, and provides links to aerosol properties in the Community Earth System Model (CESM)-Community Atmosphere Model version 5 (CAM5); (2) Developed a long-term multi-sensor mixed-phase cloud dataset. The mixed-phase cloud retrieval algorithms are improved by refining the phase determinations and ice number concentration retrievals. A multi-year mixed-phase cloud observation dataset (1999-2004; October 2013-February 2017) is regenerated at the ARM Barrow site with the improved algorithms. The dataset has been used in the global model evaluation to improve the model parameterizations; (3) Tested the performance of improved ice microphysics in CESM-CAM5 with the ARM data. CESM-CAM5 is run in the DOE Cloud-Associated Parameterizations Testbed (CAPT) and in the single-column model (SCM) mode to facilitate comparison with ARM observations. Multi-year CAPT simulations of seasonal variations of cloud microphysical properties, cloud liquid water path (LWP) and ice water path (IWP), cloud longwave and shortwave forcings, cloud occurrence frequency are evaluated against the ARM multi-sensor mixed-phase cloud retrievals; and (4) Examined mixed-phase cloud microphysics-aerosol-dynamics-radiation interactions in CESM-CAM5 that include the impacts of different ice nucleation mechanisms, sensitivity to dust IN concentration, treatment of the WBF process on mixed-phase cloud properties. Aerosol effect on mixed-phase clouds through the liquid phase (droplet activation) and ice phase processes (e.g., the glaciation indirect effect) is investigated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Design and Analysis of a Halo-Measurement Diagnostics

A large dynamical-range diagnostics (LDRD) design at Jefferson Lab will be used at the FAST-IOTA injector to measure the transverse distribution of halo associated with a high-charge electron beam. One important aspect of this work is to explore the halo distribution when the beam has significant angular momentum (i.e. is magnetized). The beam distribution is measured by recording radiation produced as the beam impinges a YAG:Ce screen. The optical radiation is split with a fraction directed to a charged-couple device (CCD) camera. The other part of the radiation is reflected by a digital micromirror device (DMD) that masks the core of the beam distribution. Combining the images recorded by the two cameras provides a measurement of the transverse distribution with over a large dynamical range. The design and analysis of the optical system will be discussed including optical simulation using SRW and the result of a mockup experiment to test the performances of the system will be presented.

43 PARTICLE ACCELERATORS↗

DOE OSTI2017

Measured Performance of a Varied Airflow Small-Diameter Duct System

This study tests the performance of a variable airflow small-diameter duct heating, ventilation, and air conditioning (HVAC) system in a new construction unoccupied low-load test house in Pittsburgh, Pennsylvania. The duct system was installed entirely in conditioned space and was operated from the winter through summer seasons. Measurements were collected on the in-room temperatures and energy consumed by the air handler and heat pump unit. Operation modes with three different volumes of airflow were compared to determine the ideal airflow scenario that maximizes room-to-room thermal uniformity while minimizing fan energy consumption. Black felt infrared imagery was used as a measure of diffuser throw and in-room air mixing. Measured results indicate the small-diameter, high velocity airflow system can provide comfort under some conditions. Solar heat gains resulted in southern rooms drifting beyond acceptable temperature limits. Insufficient airflow to some bedrooms also resulted in periods of potential discomfort. Homebuilders or HVAC contractors can use these results to assess whether this space conditioning strategy is an attractive alternative to a traditional duct system. The team performed a cost analysis of two duct system configurations: (1) a conventional diameter and velocity duct system, and (2) the small-diameter duct system. This work applies to both new and retrofit homes that have achieved a low heating and cooling density either by energy conservation or by operation in a mild climate with few heating or cooling degree days. Guidance is provided on cost trade-offs between the conventional duct system and the small-diameter duct system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Measured Performance of a Varied Airflow Small-Diameter Duct System

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Improving GCM Predictability of Mixed-Phase Clouds and Aerosol Interactions at High Latitudes with ARM Observations

The goal of this project is to improve the predictability of mixed-phase clouds and aerosol interactions in the Community Atmosphere Model version 6 (CAM6) through comparison with the ARM observations. There are three main objectives of the proposed study: (1) Improve the representation of ice microphysical processes in mixed-phase clouds; (2) Test the performance of ice microphysics in CESM-CAM6 with the ARM observations in northern and southern high latitudes; and (3) Examine mixed-phase cloud microphysics-aerosol-turbulence-radiation interactions in CESM-CAM6. In this project, we have (1) Improved the representation of ice microphysical processes in mixed-phase clouds in CESM-CAM6 by implementing the marine organic aerosol (MOA) and treating the ice nucleating particles (INPs) from MOA and its impacts on mixed-phase clouds. We made a first attempt to represent different secondary ice production (SIP) mechanisms in a GCM (CESM2-CAM6). We found that misrepresentation of these ice formation processes in global climate models (GCMs) leads to too weak negative cloud feedback over the Southern Ocean (SO) and too high climate sensitivity in the models. In addition to ice formation processes, we improved the treatment of ice depositional growth through the Wegener–Bergeron–Findeisen (WBF) process by considering the subgrid heterogeneous distributions between liquid droplets and ice crystals in mixed-phase clouds; (2) Tested the performance of our improved representations of ice microphysics with the ARM observations at high latitudes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Investigating the Linear Thermal Expansion of Additively Manufactured Multi-Material Joining between Invar and Steel

This work investigated the linear thermal expansion properties of a multi-material specimen fabricated with Invar M93 and A36 steel. A sequence of tests was performed to investigate the viability of additively manufactured Invar M93 for lowering the coefficient of thermal expansion (CTE) in multi-material part tooling. Invar beads were additively manufactured on a steel base plate using a fiber laser system, and samples were taken from the steel, Invar, and the interface between the two materials. The CTE of the samples was measured between 40 °C and 150 °C using a thermomechanical analyzer, and the elemental composition was studied with energy dispersive X-ray spectroscopy. The CTE of samples taken from the steel and the interface remained comparable to that of A36 steel; however, deviations between the thermal expansion values were prevalent due to element diffusion in and around the heat-affected zone. The CTEs measured from the Invar bead were lower than those from the other sections with the largest and smallest thermal expansion values being 10.40 μm/m-K and 2.09 μm/m-K. In each of the sections, the largest CTE was measured from samples taken from the end of the weld beads. An additional test was performed to measure the aggregate expansion of multi-material tools. Invar beads were welded on an A36 steel plate. The invar was machined, and the sample was heated in an oven from 40 °C and 160 °C. Strain gauges were placed on the surface of the part and were used to analyze how the combined thermal expansions of the invar and steel would affect the thermal expansion on the surface of a tool. There were small deviations between the expansion values measured by gauges placed in different orientations, and the elongation of the sample was greatest along the dimension containing a larger percentage of steel. On average, the expansion of the machined Invar surface was 42% less than the expansion of the steel surface. The results of this work demonstrate that additively manufactured Invar can be utilized to decrease the CTE for multi-material part tooling.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Discrete and Continuum Plane-Hopper Flow Simulations with Experimental Validation Using X-Ray Imaging, Arch Profilometry and Wall Pressure Measurements

The flow of spherical glass beads, approximately cubic wood crumbles®, and wood microchips are investigated using a combination of discrete element modeling (DEM), finite element analysis (FEA), and physical experiments using a custom plane-flow hopper in which the flow is characterized using x-ray imaging, profilometry to measure arching geometry and pressure measurements at the wall. The purpose of this study is to investigate fundamental flow behavior, and for this purpose the simulations and physical tests are specially designed. During the physical tests and simulations, the hopper geometry begins as a V shape with the two opposing side walls touching at the bottom of the V. Basic tests are performed by first filling the hopper with material, and then rotating the opposing side walls inward about their common intersection axis to cause an approximately uniform stress condition throughout most of the hopper. The side walls then slide upward to effectively increase the size of the opening at the bottom of the hopper until the arch of material in the hopper breaks, and all of the material falls out of the hopper. More advanced tests are also performed in which the initial rotation of the walls is slightly reversed to decrease the pressure in the hopper, corresponding to “preshear” and “shear” conditions in standard shear tests. Shear tests of the materials are also performed using a Schulze automated ring shear tester with a standard size M shear cell, and the shear tests of the glass beads and wood crumbles® are also simulated using DEM to calibrate the DEM with the FEA. Reasonable agreement between predicted and measured flow behavior is obtained indicating that this type of physical tests and modeling shows promise for characterizing and predicting the flow behavior of compressible and anisotropic materials.

09 BIOMASS FUELS↗

DOE OSTI2022

CFD-DEM Modeling of Autothermal Pyrolysis of Corn Stover with a Coupled Particle- and Reactor-Scale Framework

Autothermal operation of fast pyrolysis is an efficient process-intensification technique wherein exothermic oxidation reactions are used to overcome the heat-transfer bottleneck of conventional pyrolysis. The development of accurate, reliable modeling toolsets is imperative to generating a deeper understanding of biomass autothermal pyrolysis systems to support scale-up and industrial deployment. This modeling effort describes the development of single-particle and reactor models which incorporate detailed reaction schemes and simultaneous exothermic oxidation reactions. The particle-scale model was parameterized for corn stover feedstock with particle morphology, density, ash content, and biopolymer composition, all of which impact the emergent conversion characteristics during pyrolysis. Results were then used to parameterize a reactor-scale autothermal pyrolysis model, which was developed using a coarse-grained computational fluid dynamic-discrete element method. The simulation results compared well with experimental results, with the predicted bio-oil, light gas, and biochar yield within 3.0 wt% of the experimental yields. Further analyses were performed to test the influence of equivalence ratio, biomass injection position, and particle size distribution on autothermal pyrolysis. The analysis of the physio-chemical properties of the fluid and solid phase inside the reactor and at the reactor outlet help reveal important process interactions of autothermal pyrolysis.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗

DOE OSTI2019

Dry Sliding Wear Resistance of Cobalt Boride Coatings Formed on ASTM F1537 Alloy

New results about the wear resistance of CoB-Co{sub 2}B coatings under dry sliding conditions were estimated in this work. The cobalt boride coatings were developed at the surface of the ASTM F1537 alloy by means of the powder-pack boriding process using two experimental conditions: 1223 K with 6 h of exposure and 1273 K with 10 h of exposure. Before the sliding wear tests, Vickers depth-sensing microindentation tests were conducted on the cross section of the cobalt boride coatings to estimate the distribution of hardness, Young’s modulus, and residual stresses. Otherwise, the sliding wear tests were performed on both boriding conditions and on the untreated material, using a ball-on-flat configuration comprised of an alumina ball as a counterpart with applied loads between 5 and 20 N. The wear rates of the borided ASTM F1537 alloy were ranged between 4.02 and 8.91 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1} compared with the values of the untreated material (13.90 and 15.78 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1}) for the overall set of experimental conditions; nevertheless, the influence of boriding conditions (1273 K with 10 h of exposure) tended to increase the CoB coating thickness, developing a more brittle layer that decreased the sliding wear resistance at the surface of the borided ASTM F1537 alloy. Finally, the presence of failure mechanisms on the surface of the wear tracks was analyzed for both borided ASTM F1537 alloy and untreated material.

36 MATERIALS SCIENCE↗

DOE OSTI2015

D and D knowledge management information tool feasibility study for cross-platform mobile applications - 15704

The D and D Knowledge Management Information tool (D and D KM- IT) is a web-based knowledge management information tool built for the D and D user community. A feasibility study is being conducted on cross-platform application frameworks for their viability to the D and D KM-IT mobile needs. Currently, three main Operating Systems comprise the majority of the mobile market IOS, Android, and Windows, requiring a separate application for each device. Cross-development software allows the development of one application using one language, that can be ported or deployed on multiple devices with little effort. Using Xamarin, a native cross-platform framework, create a shared mobile application using Visual Studio. Build a D and D KMIT mobile application designed for the three major mobile platforms. Use Xamarin to compile the application into native applications for the three target platforms. Build and deploy the application on all three mobile platforms. Perform benchmark tests of the developed applications to analyze the performance on the three platforms. A large portion of the business logic of the application has been shared, eliminating development redundancy and minimizing planning, design, and validation time. The user interface development could not fully be shared cross-platform and some platform specific code must be individually implemented for each device. Maintenance, testing and design phases of the software engineering process were reduced from one for each device to having just one shared cycle processes. A less diverse skill-set for developers is required with cross-platform development. Some processes within the development cycle still require redundant activities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Enhancement of EM Pump Performance through Modeling and Testing

Liquid sodium has seen development as a nuclear reactor coolant in the United States for over 50 years. While sodium has many desirable characteristics as a heat transfer fluid, its reactivity poses numerous engineering challenges for even the most basic plant components like pumps. Despite the challenges, mechanical pumps have seen success in sodium service albeit at the expense of simplicity and flexibility. In fact, significant failures of these pumps have been recorded which can be attributed to their complexity. Notwithstanding the complexity, mechanical pumps are still widely proposed for the main circuit pump of sodium cooled reactors. However, an alternative to mechanical pumps are Electromagnetic Induction Pumps (EMIPs) which use the principle of the Lorentz Force. EMIPs avoid mechanically moving parts in contact with sodium which simplifies the design by avoiding mechanical wear and seals. Therefore, these pumps are generally safer and more reliable than their mechanical counterparts. That being said, EMIPs suffer from relatively low efficiencies that range from 5% to 45%. Some of the inefficiencies are inherent to the EMIPs pumps; namely, inefficiencies arise in the form of resistive heating losses in the fluid itself. However, other inefficiencies arise from Edge Effects which include Finite Length and Finite Width effects. Due to the significant safety advantages EMIPs have compared to mechanical pumps, there is a strong motivation to integrate these technologies into the design of Generation IV liquid-metal-cooled nuclear power plants. However, EMIPs have low efficiencies partly attributed to Edge Effects. Much of the literature focusing on Edge Effects is dated or simply does not exist in the public domain. More recently, numerical models of EMIPs have shown promising results. However, these models are often custom solvers or use complex software suits which limit their application. This report describes the work completed to understand Edge Effects in two EMIPs designs. These designs are the Annular Linear Induction Pump (ALIP) and Permanent Magnet Induction Pump (PMIP) also known as a Moving Magnet Pump (MMP). The methodology developed during this project aim at measuring key performance parameters (pressure-flowrate and efficiency-slip performance) using high temperature liquid-sodium. Baseline experimental measurements were then used to verify the accuracy of numerical models developed in the software suit ANSYS/FLUENT. On the experimental side, instrumentation was developed to characterize the pressure-flowrate and efficiency-slip performance of both the ALIP and PMIP in high-temperature liquid-sodium. Additionally, instrumentation was developed to measure potential output pressure pulsations and the magnetic field distributions. Moreover, a specialized ALIP was constructed to study the impacts magnetic field tapering, also known as coil grading, on the Finite Length Effect. Lastly, experimental performance curves of the PMIP were collected at 300 oC and 600 oC and compared to analytical theory which accounted for Finite Width Effects. These results showed that the Finite Width Effect and non-uniform magnetic field in a PMIP impact the performance. On the numerical side, models were developed using the software suit FLUENT/ANSYS. These methods were initially compared against a simple MHD flow in a Permanent Magnet Electromagnet Flowmeter (PMEMFM). The results were significant in that they showed agreeance between the numerical model and demonstrated that PMEMFM’s could be calibrated numerically. These modeling methods were then applied to a prototypic PMIP. Results showed that this simple model provided reasonably accurate results of the PMIP p-Q performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Fuel cladding post-quench LOCA embrittlement: mechanical test relevance

During a loss-of-coolant-accident (LOCA), the fuel cladding is submitted to a high temperature increase in a steam environment, along with an internal pressure increase which would eventually lead to ballooning and burst of the cladding. Steam could then penetrate through the burst opening and lead to inner surface oxidation and secondary-hydriding of the cladding. Post-quench cladding rupture can then occur either in two-sided oxidized area with wall thinning due to ballooning, or in single-sided oxidized area with large hydrogen content. Common tests involved in the evaluation of the post-quench ductility are Ring Compression Tests (RCT), Expansion Due to Compression Test (EDC) or Axial Tensile Tests (AT). Questions arise about these mechanical tests, as for instance, the influence on sample failure of the oxide layer thickness partitioning between inner and outer diameter. A systematic study was carried out to compare several mechanical tests on both single-sided and two-sided Zircaloy-4 oxidized samples. Five different mechanical tests were compared, including RCT: C-shaped ring Compression Test (CCT), Axial Tensile test (AT), Ring Tensile Test with well-defined machined gage section (RTT) and plain Ring Tensile Test (pRTT). All samples were taken from cladding tubes which had been oxidized in steam at 1200 Celsius degrees and then water-quenched. Mechanical tests were performed at room temperature and two to three samples were tested for each oxidation conditions and for every sample geometry to assess the reproducibility. Metallographic examinations were carried out to measure the ZrO{sub 2} and αZr(O) layer thicknesses and the ex-β/α(O) phase fraction. Mean hydrogen content measurements were also performed systematically on each sample. Results indicate that the different mechanical tests have not the same sensitivity to the oxide layer partitioning: RTT and pRTT load at failure seems to depend mainly on the cumulated oxide layer thickness rather than on its partitioning, whereas this parameter has an impact on CCT and AT test results. For all tensile tests, stresses at failure were derived from load-displacement curves. The failure of brittle samples was assumed to be governed by linear elastic fracture mechanics. Using conventional stress intensity factor solution, a value of the material fracture toughness controlling the sample failure was determined from experimental results and discussed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Performance Evaluation of a Single-Phase Grid-Forming Inverter Through Hardware Experiments: Preprint

Existing state-of-the-art of single-phase grid-forming (GFM) inverter are primarily focused on electromagnetic transient simulation, and there are very few works performing hardware test, and there is no clear understanding how the single-phase GFM inverter should behave from a hardware perspective. Therefore, this paper addresses the gap by performing hardware experiment to evaluate the performance of a single-phase GFM hardware inverter. We enrich the existing GFM testing protocols by investigating transient performance of GFM inverters under different grid dynamic events, and quantifiable performance metrics are made to have a common understanding of expected performance of single-phase GFM inverters. A commercial single-phase GFM inverter is used to verify the test protocols and understand the inverter's performance and functionalities.

dynamic events↗

DOE OSTI2024

A Theory for the Balance between Warm Rain and Ice Crystal Processes of Precipitation in Mixed-Phase Clouds

Abstract Mixed-phase clouds contain both supercooled cloud liquid and ice crystals. In principle, precipitation may be initiated either by the liquid phase or by the ice phase. Ice crystals may grow by vapor diffusion to become snow (“ice crystal process”), forming “cold” precipitation. Equally, cloud droplets, when large enough, coalesce to form “warm” precipitation by the “warm rain process.” Warm rain could be supercooled and freeze as “warm” graupel. In the present paper, a new simplified theoretical analysis is provided to examine the microphysical system consisting of three species of hydrometeor, namely, cloud liquid, “cold ice” (crystals, snow), and “warm rain” (frozen or supercooled). This is obtained by nondimensionalizing and simplifying the evolution equations for the mass of each species. Analytical formulas are given for equilibria. Feedback analysis shows that the sign of the feedback is linked to the abundance of precipitation, with a neutral surface in the 3D phase space. The system’s precipitation amount explodes while in the initial unstable regime, crossing the neutral surface and approaching the equilibrium point that is a stable attractor. Positive and negative feedbacks are elucidated. In a standard case, the cold ice mass is about 1000 times larger than the warm rain mass. To illustrate the physical behavior of the theory, sensitivity tests are performed with respect to environmental conditions (e.g., aerosol, updraft speed) and microphysical parameters (e.g., riming and sedimentation rates for cold ice). Cold ice prevails, especially in fast ascent, due to its low bulk density, favoring slow sedimentation and a wide cross-sectional area for riming. Significance Statement The theory elucidates how the ice phase can prevail in the precipitation from any mixed-phase clouds with supercooled cloud liquid and crystals. The ice phase radically suppresses cloud liquid by riming when active and “wins” the competition against coalescence. This prevalence of ice is shown to arise from the low bulk density of snow. The cloud is viewed as a system of negative and positive feedbacks that prevail in realms of stability and instability in a 3D phase space.

Meteorology & Atmospheric Sciences↗

DOE OSTI2014

An efficient polyenergetic SART (pSART) reconstruction algorithm for quantitative myocardial CT perfusion

Purpose: In quantitative myocardial CT perfusion imaging, beam hardening effect due to dense bone and high concentration iodinated contrast agent can result in visible artifacts and inaccurate CT numbers. In this paper, an efficient polyenergetic Simultaneous Algebraic Reconstruction Technique (pSART) was presented to eliminate the beam hardening artifacts and to improve the CT quantitative imaging ability. Methods: Our algorithm made threea priori assumptions: (1) the human body is composed of several base materials (e.g., fat, breast, soft tissue, bone, and iodine); (2) images can be coarsely segmented to two types of regions, i.e., nonbone regions and noniodine regions; and (3) each voxel can be decomposed into a mixture of two most suitable base materials according to its attenuation value and its corresponding region type information. Based on the above assumptions, energy-independent accumulated effective lengths of all base materials can be fast computed in the forward ray-tracing process and be used repeatedly to obtain accurate polyenergetic projections, with which a SART-based equation can correctly update each voxel in the backward projecting process to iteratively reconstruct artifact-free images. This approach effectively reduces the influence of polyenergetic x-ray sources and it further enables monoenergetic images to be reconstructed at any arbitrarily preselected target energies. A series of simulation tests were performed on a size-variable cylindrical phantom and a realistic anthropomorphic thorax phantom. In addition, a phantom experiment was also performed on a clinical CT scanner to further quantitatively validate the proposed algorithm. Results: The simulations with the cylindrical phantom and the anthropomorphic thorax phantom showed that the proposed algorithm completely eliminated beam hardening artifacts and enabled quantitative imaging across different materials, phantom sizes, and spectra, as the absolute relative errors were reduced from [−7.5%, 12.1%] for SART to [−0.1%, 0.1%] for pSART. When using low kVp spectra and high reference energies, pSART also showed improved reconstruction efficiency in terms of convergence speed compared to the conventional SART algorithm. The phantom experiment on a clinical CT scanner indicated that the quantitative advantage of pSART is realizable in experimental CT acquisition, as the absolute relative errors across material inserts were less than 0.4%. Conclusions: By incorporatinga priori information (material attenuation coefficients, x-ray source spectrum, and region type information) into the reconstruction process, the proposed pSART algorithm could effectively eliminate beam hardening artifacts, reconstruct the accurate attenuation coefficients for precise quantitative imaging, and accelerate the reconstruction process.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2016

A New Light Weight Structural Material for Nuclear Structures

Radiation shielding materials are commonly used in nuclear facilities to attenuate the background ionization radiations to a minimum level for creating a safer workplace, meeting regulatory requirements and maintaining high quality performance. The conventional radiation shielding materials have a number of drawbacks: heavy concrete contains a high amount of elements that are not desirable for an effective shielding such as oxygen, silicon, and calcium; a well known limitation of lead is its low machinability and toxicity, which is causing a major environmental concern. Therefore, an effective and environmentally friendly shielding material with increased attenuation and low mass density is desirable. Close-cell composite metal foams (CMFs) and open-cell Al foam with fillers are light-weight candidate materials that we have studied in this project. Close-cell CMFs possess several suitable properties that are unattainable by conventional radiation shielding materials such as low density and high strength for structural applications, high surface area to volume ratio for excellent thermal isolation with an extraordinary energy absorption capability. Open-cell foam is made up of a network of interconnected solid struts, which allows gas or fluid media to pass through it. This unique structure provided a further motive to investigate its application as radiation shields by infiltrating original empty pores with high hydrogen or boron compounds, which are well known for their excellent neutron shielding capability. The resulting open-cell foam with fillers will not only exhibit light weight and high specific surface area, but also possess excellent radiation shielding capability and good processability. In this study, all the foams were investigated for their radiation shielding efficiency in terms of X-ray, gamma ray and neutron. X-ray transmission measurements were carried out on a high-resolution microcomputed tomography (microCT) system. Gamma-emitting sources: 3.0mCi 60 Co, 1.8mCi 137 Cs, 13.5mCi 241 Am, and 5.0mCi 133 Ba were used for gamma-ray attenuation analysis. The evaluations of neutron transmission measurements were conducted at the Neutron Powder Diffractometer beam facility at North Carolina State University. The experimental results were verified theoretically through XCOM and Monte Carlo Z-particle Transport Code (MCNP). A mechanical investigation was performed by means of quasi-static compressive testing. Thermal characterizations were carried out through effective thermal conductivity and thermal expansion analyses in terms of high temperature guarded-comparative-longitudinal heat flow technique and thermomechanical analyzer (TMA), respectively. The experimental results were compared with analytical results obtained from, respectively, Brailsford and Major’s model and modified Turner’s model for verification. Flame test was performed in accordance with United States Nuclear Regulatory Commission (USNRC) standard. CMF sample and a 304L stainless steel control sample were subjected to a fully engulfing fire with an average flame temperature of 800°C for a period of 30 minutes. Finite Element Analysis was conducted to secure the credibility of the experimental results. This research indicates the potential of utilizing the light-weight close-cell CMFs and open-cell Al foam with fillers as shielding material replacing current heavy structures with additional advantage of high-energy absorption and excellent thermal characteristics.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Smart manufacturing approach to manufacture bulk nanocrystalline aluminum for lightweight applications

In this research, a smart manufacturing approach was used to enhance the mechanical properties of aluminum (Al) for lightweight applications. The smart manufacturing involved cryomilling of Al powders with and without 5 wt.% magnesium (Mg) powders for varying durations followed by a high-pressure cold spray (HPCS) additive manufacturing process to prepare bulk components. The morphological changes, crystallite size, and composition of the cryomilled powders and cold sprayed (CS’ed) components were examined using scanning electron microscopy (SEM), x-ray diffraction (XRD), and transmission electron microscopy (TEM) techniques. The results showed that the crystallite size reduces with an increase in cryomilling time and the addition of Mg dopant. To test the mechanical properties of the bulk CS’ed components, microhardness tests were performed using a Vickers microhardness tester. Uniaxial tensile tests were also carried out to ascertain the material’s tensile properties. The mechanical testing results showed great improvement in the hardness and tensile strength of CS’ed Al–Mg samples as compared to pure Al samples. Subsequently, fractography analysis of the tensile failed samples was carried out to determine the nature of the failure. Here, the research article also discusses the inherent mechanisms for the improvement in mechanical properties of smart manufactured components as a result of Mg doping and cryomilling.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Design and Evaluation of an Experimental Technique for Mechanical and Fatigue Testing of Sub-Sized Samples

Some recently developed processing techniques allow fabrication of small specimens. The fatigue behavior of these small samples cannot be characterised according to the existing standards due to size limitations. The main objective of the present work is to develop an original technique for both mechanical and fatigue testing of sub-sized specimens produced by a high pressure torsion (HPT) method. The fatigue behavior of the sub-sized Ti-6Al-4 V samples, made from HPT-processed disks, is compared with that of the standard samples prepared according to the ASTM standards. Finite element method (FEM) analysis of the stress distribution under applied static load, for both sub-sized specimens and grips designed for their testing, is performed. Good agreement between the outcomes of tensile testing of the standard ASTM samples and sub-sized samples is observed. Fatigue data, represented by Wöhler curves for both types of samples, showed significant divergence of high cycle fatigue properties caused by incompliance of specimen geometries and surface/defect size ratio. The obtained results can be used to scale up the fatigue behavior from sub-sized specimens to the standard ones, as well as to predict the fatigue behavior of the bulk nanostructured metals and alloys produced by HPT.

77 NANOSCIENCE AND NANOTECHNOLOGY↗