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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9

Analysis of Cutter Blade Wear in Rotary Shear Mills

Following development of an analytical abrasive wear model to predict wear of components in a rotary shear mill, the team used a finite element analysis (FEA) approach to calculate forces and loads acting on particles responsible for abrasive wear. The analytical model related critical rotary shear process parameters (shear geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) that enabled us to model the wear of shear cutters in a rotary shear milling system developed by Forest Concepts. With proper knowledge of the forces acting between abrasive particles and cutter components built into it, the model can accurately predict wear of the cutters and provides a quality by design (QbD) approach to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches. During this reporting period, researchers at Oak Ridge National Laboratory applied an FEA package to simulate the local stresses and forces between an abrasive silica particle and two rotary shear cutters as the distance between the cutters decreases. The output of the FEA was used to provide more accurate projections of the loads applied to the particles in the analytical wear model. Comparison of the FEA force calculations are in good agreement with the loads assumed in the analytical predictions.

36 MATERIALS SCIENCE↗

Real-time In-process Monitoring for Additive Manufacturing (Final CRADA Report)

Phase 3D has invented a real-time in-process monitoring system which can retrofit any industrial 3D printer to provide actionable part quality data. Designed to provide value to builders through dimensional measurements of several in-situ part features, the system reduces lost schedule time and wasted energy via allowing for earlier part scrap.

36 MATERIALS SCIENCE↗

Credible Criticality Safety Margin in the 30B Package with LEU+ UF 6 and Hypothetical Water Ingress

The commercial nuclear industry is pursuing advancements in fuel and reactor design that increase the uranium enrichment above 5 wt. % 235 U. These advancements will necessitate the ability to transport bulk quantities of UF 6 at increased enrichments. Currently, the 30B cylinder is the primary container used by the industry for UF 6 storage and transportation and has a long history of successful shipments. This container can support up to 2,277 kg of UF 6 at a maximum enrichment of 5 wt. % 235 U. Previous evaluations have assessed the potential impact of criticality safety for 30B transport at higher enrichments but assumed moderator intrusion would not require evaluation. Although current regulations allow for the exception of moderator intrusion for UF 6 packages through the design and quality control of the package content, this exception is limited to enrichments up to 5 wt. % 235 U. Thus, an investigation of moderator intrusion into a 30B cylinder should be performed. Moderator intrusion into a 30B cylinder is a unique condition for criticality safety evaluation in transportation because of the violent chemical reactions that occur between UF 6 and H 2 O. The resulting intrusion is strongly dependent on the breach size, breach location, breach interface solid/ullage of the UF 6 content, the UF 6 distribution (which is temperature dependent), and temperature/pressure conditions which are dynamic in accident conditions. Additionally, the complexity of the HF-UO 2 F 2 -H 2 O interface that occurs during the event can influence the potential solubility of uranium in the system, as well as influence the amount of UF 6 reaction with H 2 O. With the operating experience from Orano Federal Services LLC, the UF 6 chemical expertise from Oak Ridge National Laboratory (ORNL), and the criticality safety expertise from ORNL, this paper evaluates the neutronic conditions (i.e., k eff ) that apply the understood chemistry and experimental conditions that occur during moderator intrusion of a breached 30B cylinder under postulated accidents. This report examines the historical evaluations of UF 6 transport and expands these evaluations for the enrichments expected for nuclear industry advancement. These simulations primarily feature a homogeneous mixture of UF 6 and H 2 O as an infinite media system and as a sphere with water reflection given an impurity limit of 0.5 wt. % UF 6 . This report demonstrates that this H/U limit is valid up to 8 wt. % enrichment for both H 2 O and HF as the moderating mixture. The water-reflected homogeneous mixed spheres evaluated demonstrate the amount of safety margin applied by restricting the 30B cylinder impurity limit to 0.5 wt. %. Additionally, this report evaluates moderator ingress scenarios of a 30B cylinder. The 30B cylinder simulations vary the cylinder orientation, the mass of UF 6 in the system, the mass of H 2 O in the system, and how much H 2 O has reacted with UF 6 . The moderator ingress of a 30B cylinder was evaluated for the water-reflected homogeneous mixed spheres to demonstrate the amount of safety margin applied by restricting the 30B cylinder impurity limit to 0.5 wt. %. These simulations are standard practice and are independent of the UF 6 -H 2 O reaction. This work also explored more complex simulations that layer the H 2 O over the UF 6 , which incorporates the amount of reacted UF 6 as a separate layer and considers solubility limits of UO 2 F 2 in H 2 O as it is produced. This approach is intended to simulate the postulated event of a large hairline crack occurring on a submerged cylinder. Finally, this work considers the potential of H 2 O mixing into the UF 6 solid heterogeneously using a sponge-like model. The water ingress into the UF 6 is treated as random size spheres, and the reaction products form into a layer over the spheres.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Design and construction of Cosmic Muon Veto for the mini-ICAL detector at IICHEP, Madurai

A 51-kiloton magnetised Iron Calorimeter (ICAL) detector, using Resistive Plate Chambers (RPCs) as active detector elements, aims to study atmospheric neutrinos. A prototype - 1/600 of the weight of ICAL, called mini-ICAL was installed in the INO transit campus at Madurai. A modest proof-of-principle cosmic muon veto detector of about 1 m×1 m×0.3 m dimensions was set up a few years ago, using scintillator paddles. The measured cosmic muon veto efficiency of 99.98% and simulation studies of muon-induced background events in the ICAL detector surrounded by an efficient veto detector were promising. This led to the idea of constructing a bigger cosmic muon veto around the mini-ICAL detector. Details of the design, fabrication, quality control, and construction of the detector including the electronics, trigger, and DAQ systems planned will be briefly presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

The Robotic Multiobject Focal Plane System of the Dark Energy Spectroscopic Instrument (DESI)

Abstract A system of 5020 robotic fiber positioners was installed in 2019 on the Mayall Telescope, at Kitt Peak National Observatory. The robots automatically retarget their optical fibers every 10–20 minutes, each to a precision of several microns, with a reconfiguration time of fewer than 2 minutes. Over the next 5 yr, they will enable the newly constructed Dark Energy Spectroscopic Instrument (DESI) to measure the spectra of 35 million galaxies and quasars. DESI will produce the largest 3D map of the universe to date and measure the expansion history of the cosmos. In addition to the 5020 robotic positioners and optical fibers, DESI’s Focal Plane System includes six guide cameras, four wave front cameras, 123 fiducial point sources, and a metrology camera mounted at the primary mirror. The system also includes associated structural, thermal, and electrical systems. In all, it contains over 675,000 individual parts. We discuss the design, construction, quality control, and integration of all these components. We include a summary of the key requirements, the review and acceptance process, on-sky validations of requirements, and lessons learned for future multiobject, fiber-fed spectrographs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Calibration-interval adjustment indicator - A concept

Circuit, when used with decision table, permits relatively unskilled personnel to maintain effective quality control. Design determines required changes in calibration intervals. Interval readings are recorded to nearest integer, making high precision unnecessary. Specific required performance-history information is discussed.

Hedene, P. S.↗

Analytical techniques and instrumentation: A compilation

Technical information is presented covering the areas of: (1) analytical instrumentation useful in the analysis of physical phenomena; (2) analytical techniques used to determine the performance of materials; and (3) systems and component analyses for design and quality control.

Source record↗

Earth Observatory Satellite system definition study. Report no. 5: System design and specifications. Part 1: Observatory system element specifications

The performance, design, and quality assurance requirements for the Earth Observatory Satellite (EOS) Observatory and Ground System program elements required to perform the Land Resources Management (LRM) A-type mission are presented. The requirements for the Observatory element with the exception of the instruments specifications are contained in the first part.

Source record↗

Nickel-cadmium cells

A high energy density nickel cadmium cell of aerospace quality was designed. The approach used was to utilize manufacturing techniques which produce highly uniform and controlled starting materials in addition to improvements in the overall design. Parameters controlling the production of plaque and both positive and negative plate were studied. Quantities of these materials were produced and prototype cells were assembled to test the proposed design.

Rubin, E. J.↗

Two dimensional thermal and charge mapping of power thyristors

The two dimensional static and dynamic current density distributions within the junction of semiconductor power switching devices and in particular the thyristors were obtained. A method for mapping the thermal profile of the device junctions with fine resolution using an infrared beam and measuring the attenuation through the device as a function of temperature were developed. The results obtained are useful in the design and quality control of high power semiconductor switching devices.

Hu, S. P.↗

Wideband heterodyne receiver for laser communication system

A heterodyne receiver for laser communication is described which includes a front end having a cooled photomixer contained in a hermetically sealed spaced quality housing designed for wide bandwidth transmission. The photomixer is coupled through a wideband preamplifier to the receiver back end which includes a frequency tracking network and demodulating equipment. The receiver is capable of tracking a Doppler frequency shift of 750 MHz, positive or negative, and has an instantaneous intermediate frequency information bandwidth of 400 MHz. The receiver system is also capable of operating over a wide temperature range and is designed to be suitable for use in outer space communication.

Flattau, T.↗

Army position on lithium battery safety

User requirements for lithium sulfur batteries are presented. They include careful analysis of design and quality control, along with certain equipment specifications. Some of the specifications include: hermetically sealed cells; lithium limited cells with stoichiometry of lithium to sulfur dioxide as a ratio of one; low moisture content in the cells; and battery capacity.

Reiss, E.↗

The interpretation of flying qualities requirements for flight control design

The flying requirements of MIL-F-8785(C) are interpreted in terms of command/response configurations, and pilot preference for flight control systems configurations of angle of attack, or pitch rate command, specified independently for the short period and phugoid dynamics, is determined using the Total-In-Flight-Simulator aircraft. The results show that for either command configuration, the short term response applies to the angle of attack response of the vehicle, and that this response must satisfy the omega(n) vs n/alpha requirement. The preference in the long term for angle of attack command indicates that the pilot wants the aircraft to fly in the direction it is pointing, and an attitude hold system is not found to be preferred unless attitude hold results in flight path angle hold.

Rynaski, E. G.↗

Design considerations for space flight hardware

The environmental and design constraints are reviewed along with some insight into the established design and quality assurance practices that apply to low earth orbit (LEO) space flight hardware. It is intended as an introduction for people unfamiliar with space flight considerations. Some basic data and a bibliography are included.

Glover, Daniel↗

NASA flight cell and battery issues

The author presents the important battery and cell problems, encompassing both test failures and accidents, which were encountered during the past year. Practical issues facing programs, which have to be considered in the development of a battery program strategy, are addressed. The problems of one program, the GRO (Gamma Ray Observatory), during the past year are focused on to illustrate the fundamental types of battery problems that occur. Problems encountered by other programs are briefly mentioned to complete the accounting. Two major categories of issues are defined, namely, whose which are quality and design related, i.e., problems having inherent manufacturing-process-related aspects with an impact on cell reliability, and these which are accident triggered or man induced, i.e., those operational issues having an impact on battery and cell reliability.

Schulze, N. R.↗

Improved compression molding technology for continuous fiber reinforced composite laminates. Part 2: AS-4/Polyimidesulfone prepreg system

AS-4/polyimidesulfone (PISO2) composite prepreg was utilized for the improved compression molding technology investigation. This improved technique employed molding stops which advantageously facilitate the escape of volatile by-products during the B-stage curing step, and effectively minimize the neutralization of the consolidating pressure by intimate interply fiber-fiber contact within the laminate in the subsequent molding cycle. Without the modifying the resin matrix properties, composite panels with both unidirectional and angled plies with outstanding C-scans and mechanical properties were successfully molded using moderate molding conditions, i.e., 660 F and 500 psi, using this technique. The size of the panels molded were up to 6.00 x 6.00 x 0.07 in. A consolidation theory was proposed for the understanding and advancement of the processing science. Processing parameters such as vacuum, pressure cycle design, prepreg quality, etc. were explored.

Baucom, Robert M.↗