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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
NASA NTRS2018

NASA Plum Brook Station In-Space Propulsion Facility Test Stand Characterization Hot Fire Test

A test facility modification to enable small scale altitude propulsion testing at the NASA Glenn Research Center's In-Space Propulsion (ISP) Facility was verified with a hot fire test campaign. As the facility's primary steam supply system undergoes refurbishment, the alternate facility configuration, known as the "vacuum accumulator" mode, would enable rocket engine testing up to 10,000 lbf thrust. The NASA Johnson Space Center developed the vehicle for the verification test campaign: the Integrated Cryogenic Propulsion Test Article (ICPTA). Constructed primarily from assets of the former Morpheus Project, the ICPTA provided an integrated liquid oxygen (LOX) / liquid methane (LCH4) propulsion system including a 2,800 lbf thrust main engine. The ISP Facility's vacuum accumulator configuration leveraged the large test volume of the facility and a diffuser insert to maintain altitude conditions. During hot fire, the ICPTA main engine "started" the diffuser insert constructed for the test campaign. As a result, the test chamber upstream of the diffuser insert remained at altitude conditions throughout the hot fire. Upon engine shut down, a backflow deflector mitigated blow back into the test chamber by restricting the mass flow and redirecting it away from the test article. The test campaign successfully characterized the performance of the vacuum accumulator configuration. In addition, it provided an opportunity to collect data for an integrated LOX / LCH4 propulsion system in an altitude and thermal vacuum environment.

Rocket Engine Testing↗
DOE OSTI2017

Test Methodologies for Hydrogen Sensor Performance Assessment: Chamber vs. Flow Through Test Apparatus: Preprint

Certification of hydrogen sensors to standards often prescribes using large-volume test chambers [1, 2]. However, feedback from stakeholders such as sensor manufacturers and end-users indicate that chamber test methods are often viewed as too slow and expensive for routine assessment. Flow through test methods potentially are an efficient, cost-effective alternative for sensor performance assessment. A large number of sensors can be simultaneously tested, in series or in parallel, with an appropriate flow through test fixture. The recent development of sensors with response times of less than 1s mandates improvements in equipment and methodology to properly capture the performance of this new generation of fast sensors; flow methods are a viable approach for accurate response and recovery time determinations, but there are potential drawbacks. According to ISO 26142 [1], flow through test methods may not properly simulate ambient applications. In chamber test methods, gas transport to the sensor can be dominated by diffusion which is viewed by some users as mimicking deployment in rooms and other confined spaces. Alternatively, in flow through methods, forced flow transports the gas to the sensing element. The advective flow dynamics may induce changes in the sensor behaviour relative to the quasi-quiescent condition that may prevail in chamber test methods. One goal of the current activity in the JRC and NREL sensor laboratories [3, 4] is to develop a validated flow through apparatus and methods for hydrogen sensor performance testing. In addition to minimizing the impact on sensor behaviour induced by differences in flow dynamics, challenges associated with flow through methods include the ability to control environmental parameters (humidity, pressure and temperature) during the test and changes in the test gas composition induced by chemical reactions with upstream sensors. Guidelines on flow through test apparatus design and protocols for the evaluation of hydrogen sensor performance are being developed. Various commercial sensor platforms (e.g., thermal conductivity, catalytic and metal semiconductor) were used to demonstrate the advantages and issues with the flow through methodology.

14 SOLAR ENERGY↗
DOE OSTI2025

Test Results of the LQXFA/B02 and LQXFA/B03 Cryo-Assemblies for the High Luminosity LHC Upgrade

Here, the US High-Luminosity LHC Accelerator Upgrade Project (AUP) is responsible for delivering cryo-assemblies for the Q1/Q3 quadrupole optical components of the High Luminosity LHC upgrade at CERN. Total of 10 cryo-assemblies containing two Nb3Sn quadrupole magnets per cold mass will be delivered within this program. After the successful test of the first pre-series cryo-assembly in 2023, two more cryo-assemblies were tested at Fermilab's horizontal test facility. Production overview and the test results of the LQXFA/B02 and LQXFA/B03 cryo-assemblies are summarized in this paper. After the first test, to increase the capability of the horizontal test facility, various improvements have been made. These improvements are also described in this paper.

Chlachidze, Guram [Fermi National Accelerator Labo↗
DOE OSTI2021

Controlled Pyroshock Test Transients Can Be Used To Better Match Operational Shock Transients and Reduce Artificial Pyroshock Test Failures [Slides]

Shock analysis is typically done via SRS (shock response spectrum). Oftentimes shock analysis is not performed because most loads specifications only supply SRS requirements with no representative shock transients that can be used for analysis. SRS analysis is too conservative. There is no structural dynamics involved as all modes are assumed to have peak responses simultaneously and in-phase with each other. It is possible that all other loads and combination of loads show the design to be good, whereas SRS analysis (1000 g’s are involved) results may require redesign. Multiple shock transients can satisfy a SRS, yet most loads documents don’t provide a representative shock transient that could be used for shock analysis. Shock testing is less common than harmonic and random vibration testing. Engineers typically go into shock tests with very little knowledge of what to expect. A pass/fail type of approach with very little engineering done to prepare for the test or to control the type of shock transient is used. Most engineers will not model the shock test fixture due to lack of knowledge about the details of the test setup. Shock analysis and testing is often an open loop type situation with no test setup modeling, no test correlation, and no control over the test shock transient. In this work, if we can create applied test force transient that comes close to matching calculated force transient then a more reasonable acceleration transient will be created at the test reference accelerometer that better matches operational shocks.

42 ENGINEERING↗
DOE OSTI2022

SAS4A/SASSYS-1 Validation with EBR-II Tests Performed During the SHRT Testing Program

The EBR-II sodium-cooled fast reactor supported a wide range of fast reactor research activities. The final fifteen years of operations at EBR-II were used for experiments and tests to demonstrate the importance of passive safety in liquid metal reactors and the capability of such systems to provide strong passive responses during off-normal conditions. The Shutdown Heat Removal Test program at EBR-II provided test data supporting the validation of computer codes for design, licensing, and operation of LMRs, among other objectives. The program included nearly sixty tests, most of which were protected and unprotected loss of flow and loss of heat sink tests run at various initial powers and flow rates. This report documents the results of modeling and simulation of tests from the Shutdown Heat Removal Test program to support validation of Argonne’s SAS4A/SASSYS-1 fast reactor safety analysis code. SHRT-17 was a protected loss of flow test where a loss of electrical power to all sodium coolant pumps was simulated to demonstrate the effectiveness of natural circulation cooling characteristics. SHRT-45R was an unprotected loss of flow test where the control rod scram function of the plant protection system was disabled to demonstrate the effectiveness of EBR-II’s passive reactivity feedbacks. BOP-301 and BOP-302R were unprotected loss of heat sink tests that demonstrated how reactivity feedback effects driven by changes to the core inlet temperature can shut down the fission process. This validation activity leverages modeling and simulation efforts that originated under an International Atomic Energy Agency Coordinated Research Project for benchmark analysis of the EBR-II Shutdown Heat Removal Tests. The SAS4A/SASSYS-1 models originally developed for the CRP have been modernized to utilize new code features and modeling practices. Differences between the predicted and measured test data were explored and the causes of these differences were identified as being due to modeling approximations, uncertainty in transient component behavior, and instrumentation uncertainties. Overall, it was concluded that for SHRT-17, SHRT-45R, BOP-301, and BOP-302R there was good agreement between the flow, power, and temperature predictions and the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024

Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗
NASA NTRS2014

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption during Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customers aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facilitys available acoustic power capability becomes maximized with the test-article installed during the actual test then the customers environment requirement may become compromised. In order to understand the risk of not achieving the customers in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Stations Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

acoustic↗
NASA NTRS2014

An Evaluation of the Additional Acoustic Power Needed to Overcome the Effects of a Test-Article's Absorption During Reverberant Chamber Acoustic Testing of Spaceflight Hardware

The exposure of a customer's aerospace test-article to a simulated acoustic launch environment is typically performed in a reverberant acoustic test chamber. The acoustic pre-test runs that will ensure that the sound pressure levels of this environment can indeed be met by a test facility are normally performed without a test-article dynamic simulator of representative acoustic absorption and size. If an acoustic test facility's available acoustic power capability becomes maximized with the test-article installed during the actual test then the customer's environment requirement may become compromised. In order to understand the risk of not achieving the customer's in-tolerance spectrum requirement with the test-article installed, an acoustic power margin evaluation as a function of frequency may be performed by the test facility. The method for this evaluation of acoustic power will be discussed in this paper. This method was recently applied at the NASA Glenn Research Center Plum Brook Station's Reverberant Acoustic Test Facility for the SpaceX Falcon 9 Payload Fairing acoustic test program.

absorption↗
NASA NTRS2023

Measurement of Test Time in the NASA Ames EAST Expansion Cone Facility in Entry 63 and Possible Techniques for Increasing Test Time

The Ames EAST facility and its modes of operation (expansion tube, expansion cone) are described. A buffer section may or may not be used between the driver and the driven tube. Previous expansion tube (without the cone) entries are reviewed. Test times of 4 to 5 microsec were achieved at shock speeds up to 11 km/s. The test conditions and results of the present entry (entry 63) (with the cone) are given. Test times were found to correlate roughly with the density ratio across the buffer gas - driven gas or driver - driven gas interface. Tests with a 12 inch long conical driver without a buffer yielded three runs with test times of ~8 km/s and 3 runs with test times of 4 to 6 microsecs. With a buffer, test times for 4 runs of ~9 microsecs and for 2 runs of 3 to 6 microsecs were obtained. Adding argon to the buffer was found not to improve the test time. Tests with a 30 inch long driver without a buffer yielded test times of 14+, ~10, 7.5 (2 runs) and 5.5 (2 runs) microsecs. Based on one shot, data for the 30 inch driver suggests that test times up to ~14 microseconds could be obtained. The repeatability of that shot, of course, must be established. Suggestions are given to increase test times further.

Electric arc shock tube↗
NASA NTRSDate not supplied

Comparison of Anthropomorphic Test Device and human Volunteer Responses in Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to validate the safety of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and the vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded in human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa Reiber↗
NASA NTRS2024

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber↗
NASA NTRS2024

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber↗
NASA NTRSDate not supplied

Comparison of Anthropomorphic Test Device and Human Volunteer Responses in Simulated Landing Impact Tests of U.S. Space Vehicles

United States (U.S.) crewed vehicles are being designed to support the National Aeronautics and Space Administration’s (NASA’s) human spaceflight programs. Vehicles must be designed to meet NASA’s occupant protection requirements including landing injury assessment with anthropomorphic test devices (ATDs) and analytical models. However, these tools are limited in capturing all injuries that might occur during spacecraft landings. A NASA study of injuries during Soyuz vehicle landings has shown that analytical models are underpredicting occupant injury. Because of the inherent limitations with our analytical tools, human volunteer impact testing was employed to assess flight-like landing conditions of U.S. crewed vehicles. A total of 84 human volunteer tests in 11 different test orientations and g-levels were completed as part of this effort in collaboration with the Air Force Research Laboratory (AFRL) at Wright-Patterson Air Force Base and U.S. vehicle development companies. Human subjects were tested at various realistic landing loads and in the highest fidelity seat and suit components that were available at the time of testing for two U.S. vehicles. Matched-pair ATD tests in the same test conditions were also conducted with small female and midsized male Hybrid III ATDs. ATDs were fully instrumented. Head accelerations and subjective responses were recorded for human subjects. In some cases, chest accelerations were captured. Responses of the ATDs and humans in matched-pair tests were compared. No ATD tests showed evidence for risk of injury based on NASA occupant protection requirements. Human subjects reported 17 cases of discomfort or pain, and 1 human subject was diagnosed with a minor injury that was not evident in the ATD tests. These results provide evidence that ATDs do not capture all potential injury risks, namely lower severity injuries, discomfort, pain, and fit issues. Overall, human testing is beneficial to understanding the true risk of injury to crewmembers during Earth landings.

Teresa M Reiber↗
DOE OSTI2016

The Uranium from Seawater Program at the Pacific Northwest National Laboratory: Overview of Marine Testing, Adsorbent Characterization, Adsorbent Durability, Adsorbent Toxicity, and Deployment Studies

The Pacific Northwest National Laboratory’s (PNNL) Marine Science Laboratory (MSL) located along the coast of Washington State is evaluating the performance of uranium adsorption materials being developed for seawater extraction under realistic marine conditions with natural seawater. Two types of exposure systems were employed in this program: flow-through columns for testing of fixed beds of individual fibers and pellets and a recirculating water flume for testing of braided adsorbent material. Testing consists of measurements of the adsorption of uranium and other elements from seawater as a function of time, typically 42 to 56 day exposures, to determine the adsorbent capacity and adsorption rate (kinetics). Analysis of uranium and other trace elements collected by the adsorbents was conducted following strong acid digestion of the adsorbent with 50% aqua regia using either Inductively Coupled Plasma Optical Emission Spectrometry (ICP-OES) or Inductively Coupled Plasma Mass Spectrometer (ICP-MS). The ORNL 38H adsorbent had a 56 day adsorption capacity of 3.30 ± 0.68 g U/ kg adsorbent (normalized to a salinity of 35 psu), a saturation adsorption capacity of 4.89 ± 0.83 g U/kg of adsorbent material (normalized to a salinity of 35 psu) and a half-saturation time of 28 ± 10 days. The AF1 adsorbent material had a 56 day adsorption capacity of 3.9 ± 0.2 g U/kg adsorbent material (normalized to a salinity of 35 psu), a saturation capacity of 5.4 ± 0.2 g U/kg adsorbent material (normalized to a salinity of 35 psu) and a half saturation time of 23 ± 2 days. The ORNL amidoxime-based adsorbent materials are not specific for uranium, but also adsorb other elements from seawater. The major doubly charged cations in seawater (Ca and Mg) account for a majority of the cations adsorbed (61% by mass and 74% by molar percent). For the ORNL AF1 adsorbent material, U is the 4th most abundant element adsorbed by mass and 7th most abundant by molar percentage

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Analytic Considerations and Design Basis for the IEEE Distribution Test Feeders

One of the greatest challenges for the analysis of distribution systems is the high level of diversity across the world. For nearly 20 years the Test Feeder Working Group of the Distribution System Analysis Subcommittee has been developing distribution test feeders. The purpose of these test feeders is to provide openly-available models of distribution systems that reflect the diversity in systems and the analytic challenges they present. Because of their utility and accessibility, the test feeders have been used for a wide range of research, some of which they were not originally intended to cover. The purpose of this paper is to provide an overview of the variety of existing distribution systems, and to clarify the specific analytic challenges that each test feeder was originally designed to examine. Additionally, the paper will provide guidance on which feeders are best suited for various types of analysis. The purpose of this paper is to provide the original intent of the Working Group and to inform researchers so that they may make an informed decision on which of the test feeders are most appropriate for their work.

Schneider, Kevin P.↗
DOE OSTI2021

Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗