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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Experimental Results on SS 304H and 2.25Cr-1Mo in Support of Developing Inelastic Constitutive Models

To address critical data gaps necessary for updating viscoplastic constitutive material models for Class A materials used in inelastic design analysis under the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors, Oak Ridge National Laboratory (ORNL) conducted experimental studies on stainless steel 304H (SS 304H) and 2¼Cr-1Mo steel (F22), to probe their temperature dependent deformation behaviors. These studies covered a range of temperatures up to the maximum limits specified in Division 5 and are intended to support the development of material models by collaborators at Argonne National Laboratory (ANL).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Nondestructive Evaluation of Carbon Fiber Reinforced Polymers

The American Society of Mechanical Engineers Boiler and Pressure Vessel Code requires repair and replacement of safety-related piping materials to meet the original Construction Code; however, no construction criteria currently exist for carbon fiber reinforced polymer (CFRP) materials in the nuclear industry. Although nondestructive examination (NDE) techniques for cast and wrought ferritic and austenitic steels are well established, licensees are increasingly deploying novel materials such as CFRP for which assessment of the use of NDE is required, as the inspectability of such materials and the influence of manufacturing processes on inspectability remain insufficiently understood. To address these gaps, Pacific Northwest National Laboratory (PNNL) evaluated the fabrication of several CFRP repair mockups and the effectiveness of NDE methods to support regulatory review of CFRP repairs in nuclear power plant applications. Representative flat-plate mockups containing realistic fabrication defects were manufactured and inspected using manual and automated tap testing, dynamic response spectroscopy (DRS), and ultrasonic testing (UT). The study identified significant fabrication variability, particularly in controlling defect size and epoxy thickness, which strongly influenced defect detectability by NDE methods. Tap testing was effective for shallow defects in thin epoxy configurations but unreliable for thicker repairs and deeper flaws. DRS demonstrated higher sensitivity to dry spots but produced unconfirmed indications for thicker plates, requiring further validation. Conventional UT, particularly at 1.0 MHz, showed the strongest overall capability for detecting a range of defects, although performance degraded with increasing repair thickness and complexity. The results highlight the need to better define critical defect sizes, develop reliable mockup fabrication methods, and validate NDE methods needed to support CFRP repairs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Cold Trap Replacement Project Report

This report documents the replacement of the Mechanisms Engineering Test Loop (METL) cold trap. The work involved preparation of the facility to replace the cold trap, removal of the existing welded cold trap from the sodium purification circuit, installation of a new replacement cold trap, completion of associated welds and examinations, restoration of instrumentation and heaters, and controlled return of the cold trap circuit to service. The replacement represented a significant maintenance evolution because the cold trap is an integral welded component of the sodium system. As a result, the work required coordinated control of sodium chemistry, deliberate formation of freeze plugs, inert gas management, precision cutting and welding, and a staged reheating and refill sequence. The activity was executed using procedural controls intended to protect personnel, preserve system cleanliness, and maintain the integrity of the sodium boundary throughout the work. This report provides a narrative summary of the milestone, including the purpose of the work, the pre-job system condition, the major field activities performed, observations made during execution, and the resulting post-work condition of the METL cold trap circuit.

42 ENGINEERING↗
DOE OSTI2026

An Educational Program on Concentrated Solar Power and Heliostats for Power Generation and Industrial Processes

The objective of this project was to design and implement a comprehensive educational and applied research program in Concentrated Solar Thermal Power (CSTP) and heliostat technologies at Northeastern University. In alignment with the U.S. Department of Energy's Heliostat Consortium (HelioCon) goals, the project aimed to expand student and public understanding of CSTP systems while simultaneously contributing to workforce development and the broader decarbonization strategy. A particular emphasis was placed on integrating hands-on student design projects and publicly disseminating educational content relevant to CSTP systems. The project addressed a critical gap in renewable energy education: CSTP and heliostats, despite their importance in utility-scale solar energy, are rarely included in standard mechanical engineering programs. This project established new pathways for students to engage with the topic through the creation of a 4-credit graduate/senior elective course, development of five industry-facing short courses, and the inclusion of CSTP-based capstone design projects. Over two academic years, 36 students across six senior design teams developed and tested technologies such as deformable heliostats, beacon-based tracking systems, and solar-powered pyrolizers for biomass-to-biochar conversion. Concurrently, 30 undergraduate and graduate students were enrolled in the new academic course centered around CSTP principles. To ensure the relevance and accessibility of the short course content, the project team engaged with industry professionals, technical policy stakeholders, and potential course participants through structured surveys and informal consultations. Feedback from 28 respondents guided the structure, length, and delivery format of the courses - resulting in a modular design broken into five workshops. The feedback emphasized the need for flexible, asynchronous delivery and practical case studies, particularly in areas such as heliostat control, thermal storage, and solar fuel production. This engagement helped align the courses with the evolving knowledge demands of the renewable energy workforce and ensured that participants from both technical and policy backgrounds could meaningfully benefit from the material. The research and educational activities advanced the understanding of heliostat control systems, optical performance under misalignment, and thermal system integration in solar-driven pyrolysis applications. Methods and designs explored in this project proved to be both technically effective and economically feasible at the lab scale. Prototypes were constructed using commercially available components and custom-fabricated elements, demonstrating that meaningful performance improvements can be achieved with modest material and fabrication costs, supporting the feasibility of student-led research in this field. The public benefit of this project is twofold. First, it cultivates a pipeline of engineers trained to be familiar with CSTP principles, an essential workforce need identified by the Department of Energy for achieving its 2030 cost and deployment targets. Second, it contributes openly accessible educational materials, course content, and experimental frameworks to the broader community, enabling other institutions to adopt or adapt similar programming. Through outreach activities, curriculum integration, and technical exposure, this project contributes to a more informed and capable renewable energy workforce while supporting innovation in heliostat and CSTP system design. A new technical report is being prepared to document the development of the course and its outcomes, with plans to publish it in the ASME Open Access Journal of Engineering to ensure global accessibility, free of cost.

14 SOLAR ENERGY↗
DOE OSTI2025

SpinQuest Polarized Target System

The SpinQuest experiment at Fermilab uses a solid-state polarized ammonia target held at a magnetic field of 5 T, immersed in liquid helium-4, which is held at approximately 1K by the evaporation refrigerator. The refrigerator provides the required cooling power during the dynamic nuclear polarization (DNP) process and the high intensity interaction with the 120 GeV proton beam from the Fermilab main injector. The refrigerator was designed in compliance with the American Society of Mechanical Engineers (ASME) to operate safely at Fermilab. The high pumping capacity ($17,000 \:m^3/h$) roots stack provides the required pumping speed during DNP production data taking and a custom-made radiation hard flow control valve regulates the refrigerator temperature during the thermal equilibrium calibration measurements. The frequency of the microwave generator, an Extended Interaction Oscillator (EIO), is automated to keep the maximum polarization while the (Nuclear Magnetic Resonance) NMR system continuously measures the polarization of the target material. In this talk, an overview of the SpinQuest polarized target system will be presented as well as a brief report of recent commissioning activities and target performance during the early production runs in 2024.

Bandara, Vibodha [Colombo U.]↗
DOE OSTI2022

Perspective on “code qualifying” new graphite grades for use in advanced nuclear reactors*

The American Society of Mechanical Engineers (ASME) publishes the Boiler and Pressure Vessel (BPV) Code, which include guidance for the safe development, construction, and operation of boilers and pressure vessels. ASME BPV Code Section III “Rules for Construction of Nuclear Facility Components” Division 5 focuses on “High Temperature Reactors”. Subsection HH, subpart A lists the different materials properties that are to be measured and how those properties change due to different environmental conditions (oxidation and irradiation damage) for a graphite to be accepted for use in a high temperature reactor core (i.e., “Code Qualified”). Currently there are no nuclear graphite grades that are “Code Qualified” (i.e., a reactor designer can select a graphite grade and build their reactor without any additional testing), which is due in part to development of new graphite grades in the last 20 years and the lack of comprehensive programs needed to produce the data for the code cases. This perspective is going to discuss the requirements, as called out in the ASME BPV Code, that are necessary to “code qualify” a nuclear graphite grade but will primarily focus on the practical and technical challenges associated with irradiation-induced property changes and how to address these to assist with getting graphite ready for use in advanced nuclear reactors. These same technical challenges can be expected to arise for other materials being developed for advanced reactor concepts.

advanced nuclear reactors↗
DOE OSTI2023

Anomaly Detection in Liquid Sodium Cold Trap Operation with Multisensory Data Fusion Using Long Short-Term Memory Autoencoder

Sodium-cooled fast reactors (SFR), which use high temperature fluid near ambient pressure as coolant, are one of the most promising types of GEN IV reactors. One of the unique challenges of SFR operation is purification of high temperature liquid sodium with a cold trap to prevent corrosion and obstructing small orifices. We have developed a deep learning long short-term memory (LSTM) autoencoder for continuous monitoring of a cold trap and detection of operational anomaly. Transient data were obtained from the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The cold trap purification at METL is monitored with 31 variables, which are sensors measuring fluid temperatures, pressures and flow rates, and controller signals. Loss-of-coolant type anomaly in the cold trap operation was generated by temporarily choking one of the blowers, which resulted in temperature and flow rate spikes. The input layer of the autoencoder consisted of all the variables involved in monitoring the cold trap. The LSTM autoencoder was trained on the data corresponding to cold trap startup and normal operation regime, with the loss function calculated as the mean absolute error (MAE). The loss during training was determined to follow log-normal density distribution. During monitoring, we investigated a performance of the LSTM autoencoder for different loss threshold values, set at a progressively increasing number of standard deviations from the mean. The anomaly signal in the data was gradually attenuated, while preserving the noise of the original time series, so that the signal-to-noise ratio (SNR) averaged across all sensors decreased below unity. Results demonstrate detection of anomalies with sensor-averaged SNR < 1.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

Following the successful completion of a 15-year effort to develop and test materials that would allow coal-fired power plants to be operated at advanced ultra-supercritical (A-USC) steam conditions, a United States-based consortium is presently engaged in Phase 2 of a project which includes an advanced manufacturing effort to complete US-based supply chain development for full commercial scale (800-850 MWe) A-USC components made of nickel-based alloys, components operating at up to 760°C. The project, funded under U.S. Department of Energy Award No. DE-FE0025064, falls under the US DOE overall goal to Develop cost-effective, reliable technologies to improve the efficiency of new and existing coal-fired power plants. A-USC steam cycles have the potential to improve cycle efficiency, reduce fuel costs, and reduce greenhouse gas emissions. Current development and demonstration efforts are focused on enabling the construction of A-USC plants, operating with steam temperatures as high as 1400°F (760°C) and steam pressures up to 5000 psi (35 MPa), which can potentially increase cycle efficiencies to 47% HHV (higher heating value), or approximately 50% LHV (lower heating value), and reduce CO 2 emissions by roughly 25%, compared to today’s U.S. fleet. A-USC technology provides a lower-cost method to reduce CO 2 emissions, compared to CO 2 capture technologies, while retaining a viable coal option for owners of coal generation assets. Among the specific goals of Phase 2 of the ComTest Project are to: validate that components made from advanced nickel-based alloys can operate and perform under A-USC conditions accelerate the development of a U.S.-based supply chain for the full complement of A-USC components close the remaining gaps and reduce the risks for manufacturing components from advanced materials for commercial demonstration fabricate full-scale versions of selected key components made of nickel-based alloys validate a qualified U.S. supply chain, to provide greater cost certainty for components obtain American Society of Mechanical Engineers (ASME) code approval for new materials, components and processes Additional benefit: Manufacturing technology will be applicable to other advanced fossil energy high temperature cycles, and can support increased flexibility of existing power plants The ComTest project is managed by Energy Industries of Ohio, and technically directed by the Electric Power Research Institute, Inc., with General Electric designing the A-USC components. As stated earlier, the current phase of the effort is primarily funded by the U.S. Department of Energy, through the National Energy Technology Laboratory. This presentation outlines the motivation for the project, explains the project’s structure and schedule, and provides some of the technical details on the design of the ComTest components.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Update on the United States Advanced Ultra-Supercritical Program with Full Scale Component Fabrication to Develop Utility Scale Power Plants with 760°C Steam Temperature

Following the successful completion of a 15-year effort to develop and test materials that would allow coal-fired power plants to be operated at advanced ultra-supercritical (A-USC) steam conditions, a United States-based consortium is presently engaged in Phase 2 of a project which includes an advanced manufacturing effort to complete US-based supply chain development for full commercial scale (800-850 MWe) A-USC components made of nickel-based alloys, components operating at up to 760°C. The project, funded under U.S. Department of Energy Award No. DE-FE0025064, falls under the US DOE overall goal to Develop cost-effective, reliable technologies to improve the efficiency of new and existing coal-fired power plants. A-USC steam cycles have the potential to improve cycle efficiency, reduce fuel costs, and reduce greenhouse gas emissions. Current development and demonstration efforts are focused on enabling the construction of A-USC plants, operating with steam temperatures as high as 1400°F (760°C) and steam pressures up to 5000 psi (35 MPa), which can potentially increase cycle efficiencies to 47% HHV (higher heating value), or approximately 50% LHV (lower heating value), and reduce CO 2 emissions by roughly 25%, compared to today’s U.S. fleet. A-USC technology provides a lower-cost method to reduce CO 2 emissions, compared to CO 2 capture technologies, while retaining a viable coal option for owners of coal generation assets. Among the specific goals of Phase 2 of the ComTest Project are to: validate that components made from advanced nickel-based alloys can operate and perform under A-USC conditions accelerate the development of a U.S.-based supply chain for the full complement of A-USC components close the remaining gaps and reduce the risks for manufacturing components from advanced materials for commercial demonstration fabricate full-scale versions of selected key components made of nickel-based alloys validate a qualified U.S. supply chain, to provide greater cost certainty for components obtain American Society of Mechanical Engineers (ASME) code approval for new materials, components and processes Additional benefit: Manufacturing technology will be applicable to other advanced fossil energy high temperature cycles, and can support increased flexibility of existing power plants The ComTest project is managed by Energy Industries of Ohio, and technically directed by the Electric Power Research Institute, Inc., with General Electric designing the A-USC components. As stated earlier, the current phase of the effort is primarily funded by the U.S. Department of Energy, through the National Energy Technology Laboratory. This presentation outlines the motivation for the project, explains the project’s structure and schedule, and provides some of the technical details on the design of the ComTest components.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Status of INL Aged A709 Mechanical Testing

A709 was selected to be qualified in Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code. Idaho National Laboratory (INL), Argonne National Laboratory and Oak Ridge National Laboratory are collaborating to develop and qualify A709 plate. Aging A709 to form beneficial precipitates prior to service is investigated. One tensile test, five creep-rupture tests, and eight cyclic tests have been completed on aged A709. Two creep-rupture tests are in progress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Effects of Notches on the Intermediate Creep-Rupture Life of Alloy 617 Weldment

A Code Case has recently been completed that adds Alloy 617 to Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, which covers high temperature nuclear components. However, additional information is needed to address concerns raised by the Nuclear Regulatory Commission that are not covered by the Code Case. The effects of notches (geometric discontinuities) and multiaxial stress on the expected creep life of a component are among these concerns. This report covers the current state of testing of Alloy 617 notched specimens at Idaho National Laboratory, with particular focus on intermediate length (8,000 – 20,000 hours) creep tests of Alloy 617 weld metal. While most of this testing is ongoing, the current state of the tests indicate that the multi-axial stress state imposed by the notch geometry does not negatively impact the creep rupture life of the Alloy 617 weld metal. While the weld metal is notch strengthening in short-term (1,000 – 2,000 hours) testing, it is not clear if this characteristic will continue to hold for intermediate and long-term testing. Ongoing tests will provide additional information to address this concern of a crossover from notch strengthening to notch weakening for intermediate and long-term creep lives.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Report Documenting Activity for Second Alloy 709 Commercial Heat

SUMMARY Qualification of the advanced austenitic stainless steel material Alloy 709 for use in Section III Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code is being pursued by the US Department of Energy Advanced Reactor Technology Program. Qualification of this alloy will allow its use in design and construction of components for elevated temperature nuclear reactor systems. Code qualification requires extensive characterization of three commercial scale heats of the alloy. This report describes progress in procuring the second of three required heats of Alloy 709 plate from ATI Flat Rolled Products.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Long Reach Robotic Arm

The Accelerator Division at Fermilab began a robotics program, known as the AD Robotics Initiative. A multi-axis robotic arm was proposed to be included in the program. This summer internship, our team began the planning and design for this project, called the Long Reach Robotic Arm. The problem is that critical systems around the magnets require analysis when water leaks cause them to fail. However, the tightly compacted parts and the quadrupole magnet, weighing approximately 1,000 pounds, cause access viewing problems. The process of having to dismantle and remove the magnet is time-consuming; it is not an efficient solution. The goal for the Long Reach Robotic Arm was to extend and reach behind the component of the Main Injector while "snaking" around and avoiding obstructions. At the start of the project, my teammate, Amanda Hoeksema, and I coded a program in the C language that will determine the number of links and their respective lengths for the robot arm. After, we began the 3D CAD model of the robot arm, base, and counterweight system. The design of the Long Reach Robotic Arm provided a learning experience in learning how to code in the C programming language, using SDL libraries and understanding mechanical engineering.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Integrated FY21 Elevated Temperature Mechanical Testing Results for Alloy 709 Code Case

This report provides the status of creep, fatigue, and creep-fatigue testing that transpired in Fiscal Year 2021 at Argonne National Laboratory, Idaho National Laboratory and Oak Ridge National Laboratory. This testing is being conducted to develop the data package to qualify Alloy 709 in Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code. This would permit the use of Alloy 709 for elevated-temperature nuclear construction. Preliminary results continue to demonstrate the improved creep and fatigue resistance of Alloy 709 compared to 316H stainless steel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Recommendation for Limiting Conditions for ASME BPVC Section III Division 5 Allowable Stress Criteria

Section III, Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) specifies rules for elevated temperature nuclear reactors. Time dependent allowable stresses are an important aspect of the high temperature design models and are related to the time to 1% strain, time to rupture, and time to onset of tertiary creep. The time to onset of tertiary creep criterion has an overly strong negative influence on the allowable stresses for some structural materials, likely due to very limited datasets and misidentification of microstructural changes rather than onset of significant creep damage, as tertiary creep is meant to represent. It is recommended that the onset of tertiary creep be determined through an alloy specific ratio between onset of tertiary creep and creep rupture time, which would give access to the significantly larger creep rupture time datasets.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Assessment of Overmatched Filler (Alloy 617) to Improve Alloy 800H Stress Rupture Factors

Section III, Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) specifies rules for elevated temperature nuclear reactors. Currently, only six metals are qualified in Section III, Division for construction of Class A metallic pressure boundary components for elevated-temperature service, one of these being Alloy 800H. There are only two permissible filler metals Alloy 800H is qualified to be welded with: Alloy A and Alloy 82. The stress rupture factors for these two filler metals are low near the maximum temperatures and service lives Alloy 800H is qualified for. This may preclude vendors from being able to use Alloy 800H for elevated-temperature nuclear construction. In this work, an overmatched filler metal, Alloy 617 is assessed to determine its potential to offer improved stress rupture factors. Scoping creep-rupture tests of cross-welds with Alloy 800H base metal and Alloy 617 filler metal were conducted. Preliminary results do not indicate that Alloy 617 will offer significantly improved stress rupture factors. Consequently, a matching filler metal, UTP A 2133, is now being investigated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Environmental and Energy Research at the Texas Center for Advanced Scientific Computing and Modeling (CASCaM)

The funding enabled the creation of the (University of North) Texas Center for Advanced Scientific Computing and Modeling (CASCaM). Due to its success, CASCaM has continued to grow beyond the initial team focused on the biological and environmental research discussed herein, with investments by the University of North Texas in new faculty and researchers who contribute to CASCaM research. CASCaM is now a sustainable effort, with researchers across multiple fields including chemistry, physics, biology, mechanical engineering, materials science, and other fields, with multiple researchers engaged in a broad variety of research, including other DOE projects. Over 20 PI’s and ~100 researchers are engaged in CASCaM research. The overall goal of the research effort was to provide greater understanding about carbon capture, storage, and utilization. As part of this effort, the development of computational methods and identification of novel strategies to support the CO2 and CO studies were necessary. Three primary themes were investigated: carbon dioxide and CO catalysis; protein- and amino acid-based strategies towards carbon dioxide capture, storage, and utilization; and, finally, the methodology improvements for modeling carbon dioxide chemistry

54 ENVIRONMENTAL SCIENCES↗