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DOE OSTI2020

Generic Post-Closure Safety Assessment for Deep Borehole Disposal of Heat-Generating Waste - 20451

The deep borehole disposal (DBD) concept for high-activity waste consists of drilling a large-diameter borehole into crystalline basement rock to a depth of about 5,000 m, placing waste packages in the lower portion of the borehole - the waste emplacement zone - and sealing and plugging the upper portion of the borehole with a combination of bentonite, cement plugs, and sand or crushed rock ballast. The waste emplacement zone is several times deeper than typical mined repositories and is well below the typical maximum depth of fresh groundwater resources. Recent work describes a generic reference case for deep borehole disposal of Cs and Sr capsules stored at the Hanford Site. Two scenarios are described: an undisturbed (nominal) scenario, and disturbed scenario, in which a waste package is stuck adjacent to a transmissive fracture zone in crystalline basement. Simulations of the processes affecting radionuclide release and transport in the two scenarios provide the basis for quantitative post-closure performance assessment (PA) of the reference case. This paper presents a probabilistic PA of the stuck waste package scenario, i.e. uncertainties affecting radionuclide mobilization and transport are propagated through 200 realizations of a predictive model to quantify uncertainties in predicted radionuclide concentrations within the borehole and the fracture zone. Simulations predict no radionuclide transport in the borehole to distances greater than 100 m above the stuck waste package. An assumed lateral pressure gradient results in predictions of limited radionuclide transport in the fracture zone at a lateral distance of 200 m from the stuck waste package. These results complement previous results for the nominal scenario and contribute to the development of a generic safety case for DBD. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Integrated experimental studies of pore structure and fluid uptake in the Bossier Shale in eastern Texas, USA

Within the Haynesville-Bossier Shale complex, the Bossier Shale has not been extensively studied by either industry and academia, despite it being an unconventional gas reservoir and a potential caprock for carbon storage in the underlaying Haynesville Shale. The lack of knowledge of the complex pore structures and fluid-rock interactions hinders the effective extraction of gas and the characterization of fluid reservoirs and sealing capacity. Integrated experimental studies of pore structure and fluid-rock interactions were conducted in seven Bossier Shale core samples collected in eastern Texas. Petrographic, geochemical, and petrophysical properties such as mineral composition, organic richness, thermal maturity, porosity, pore/pore throat diameter distribution, water-accessible pores, liquid water imbibition, and water vapor adsorption were characterized using complementary approaches of thin-section petrography, scanning electron microscopy, X-ray diffraction, total organic matter, pyrolysis, mercury intrusion porosimetry, nuclear magnetic resonance, (Ultra-) small angle X-rays scattering as well as small angle neutron scattering with deuterated liquids and contrast variation. Further, the results show that the thermally mature Bossier Shales are composed of mixed argillaceous mudstone, mixed mudstone, and mixed carbonate mudstone. The shale contains both organic and inorganic pores, with porosities of 3.24-9.37 %, pore-to-throat ratios of 1.65 to 19.4, and water-accessible pores accounting for 28.7-72.6 % of total pores. Approaches of liquid water imbibition and water vapor adsorption, with and without direct contact of water with shale samples, indicate that liquid water first enters the nano-sized pores under high capillary pressures, and water vapor adsorption is mainly controlled by both clay minerals and pores with diameters less than 10 nm. These findings contribute to a better understanding of pore structures and water-shale interactions and their controlling factors in the Bossier Shale.

58 GEOSCIENCES↗

NASA NTRS1999

Customized Hermetic Feedthrough Developed to Isolate Fluids

A common problem occurs when refrigerant fluids wick inside the insulation of thermocouple wires through a compressor's casing feedthrough and then leak into the adjacent disconnect box outside the casing. Leaking fluids create an unfavorable situation inside the disconnect box and may contaminate the fluids. To address this problem, NASA Lewis Research Center s Manufacturing Engineering Division developed a customized hermetic feedthrough for a bank of Worthington compressors. In these compressors, bearing temperatures are measured by internal thermocouples embedded in bearings located inside the compressor casings. The thermocouple wires need to be routed outside the casing and read at another location. These wires are short and are terminated to a disconnect strip inside the casing. The bearings operate at about 170 F, but because the casing is filled with R12 refrigerant oil, the casing has a maximum temperature of about 100 F. The operating conditions of these compressors permit the use of an epoxy that is compatible with the R12 fluid. The desired finished product is a stainless steel tube that has been filled solid with epoxy after thermocouple wires bonded and sealed by epoxy have been inserted through its length. Shrink tubing extends from both ends of the tube. The process that was developed to isolate the thermocouple wires from the R12 fluid follows. For this application, use an 8-in.-long piece of 0.500-in. 304 stainless steel tube with six pairs of 24-gauge stranded, PTFE-insulated (polytetrafluoroethylene) type "T" thermocouple wires for each feedthrough. Use shrink tubing to strain relief the insulated wires at their exit from the stainless steel tube. Cut the wire to length and identify the location of the stainless steel tube sleeve with masking tape. Then, remove the outer insulation from a 2-in. section of wire that will be inside the tube, and carefully strip to bare wire a 1-in. section in the middle of the section with the outer insulation removed. For an effective seal, the epoxy must penetrate between the strands when stranded conductors are used. Make the seal with epoxy bond on the bare wire. The bare wire must be encapsulated with a thin layer of the epoxy that leaves only a very low profile. These encapsulated wires must cure before the assembly can be continued. Then, inspect the cured wires for complete encapsulation before going to the next step. Insert the wires in the stainless steel tube and orient them so that the epoxied stripped sections are staggered within the tube; then, apply shrink tubing to one end of the cleaned wires, positioning it inside the edge of the tube. The small gaps between the wires on the other end will be used to inject the epoxy into the tube. Let the epoxy cure inside the tube, free of any voids. Then, continue to fill the tube until the entire 8-in. length is nearly filled, allowing room for the other strain-relieving shrink tubing. Since this first design, the process has been adjusted to fit many needs and situations. Customized feedthroughs have been assembled from various wire types, wire gauges, and/or stainless steel tube passages. The fittings selected to mount these feedthroughs allow their use in other areas, such as pressure or vacuum systems.

Meredith, Roger D.↗

NASA NTRS2019

Design of P-3 Nadir Port

This project details the design and analysis of a structure to replace the interface of the P-3B nadir port with an optimized interface for science installations. A new nadir port plug has been designed to replace the OEM (Original Equipment Manufacturer) plug (Lockheed PN 910169) currently used in Nadir ports 1 and 2 on the NASA P-3B aircraft. The plug consists of a milled frame that can be outfitted with customizable flat plates to meet a broad range of science needs. The frame slides into place using the existing P-3B rail system using a lever and tie-rod assembly. The seal interface will contact the Fuselage skin of the aircraft and consists of a bulb E-seal that is riveted around the perimeter of the frame. The flat plate (20 inches x 31 inches) provides a large profile that can be outfitted based on science mission goals and requirements to attach multiple instruments. This is a significant increase to the aircraft capability. Previously, the OEM plug had to be modified to hold very small plates, windows, or instruments limiting the use of the ports.There were several challenges for this project that included a constrained schedule, lack of historical references, and reverse engineering. The unusually tight schedule for design, manufacture, and install limited potential approaches. In addition, design of a new interface to replace the existing plug, on an aircraft designed in the 1960's by Lockheed for the Navy with little to no documentation, required substantial reverse engineering. In order to accomplish this, a suitable method to determine interface requirements with the aircraft had to be solved. After several iterations, the solution was to implement laser scanning techniques to scan the aircraft and the OEM plug and generate a 3D model to capture the design envelope. The structure is designed to maintain a positive margin of safety when subjected to the inertial, pressure, and aerodynamic load requirements for an external installation on the P-3B, as described in the Wallops' P-3B Design Requirements 548-RQMT-0001 Rev. A . A finite element model is created in FEMAP (Finite Element Modeling And Postprocessing) and is run through NX Nastran solver to analyze the structure. After several iterations of analysis, the structure was enveloped to hold 115 pounds evenly distributed on the plate.

Chance, Monica↗

DOE OSTI2024

Initial Laboratory Measurements Probing Hydrogen Interactions with Eagle Ford Shale and Pyrite: Potential Implications for Subsurface Hydrogen Storage

Hydrogen (H 2 ) has the potential to be a transformative technology as an enabler to a low-carbon future and promoter of renewable energy. When H 2 is injected and stored in the subsurface, it has the potential to interact with the caprock (usually shale) which overlies and seals the storage reservoir. Here, this study examines geochemical reactions or changes in surface morphology to Eagle Ford Shale, a proxy for caprock, upon exposure to H 2 at 50°C and 10.3 MPa. Reactions were also performed with N 2 to provide an experimental control. Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM-EDS), Atomic Force Microscopy (AFM), and Optical Photothermal-Infrared (O-PTIR) Spectroscopy were applied to quantify changes on the microscale and nanoscale level. Fluid chemistry changes were monitored with Ion Chromatography (IC) and Inductively Coupled Plasma Mass Spectrometry (ICP-MS). Exposure of Eagle Ford Shale to H 2 gas alone did not result in any alterations to the shale chemically or any changes in the surface morphology. Exposure of Eagle Ford Shale to both H 2 and water as well as N 2 and water resulted in changes to the surface morphology because of gypsum dissolution and reprecipitation, thus indicating that H 2 is not necessary to promote changes. Pure pyrite was the most reactive with H 2 possibly resulting in a reduction to pyrrhotite. These initial studies suggest that the extent of reactions activated by hydrogen with caprock are minor under the temperature and pressure conditions that would represent underground hydrogen storage.

08 HYDROGEN↗

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↗

NASA NTRS1964

Space-Cabin Atmospheres: Part II - Fire and Blast Hazards. A Literature Review

The rapid evolution of aircraft and, lately, space vehicles has brought with it the ever-increasing difficulty of designing for prevention of fires and explosions. The present-day sealed cabin with its limited work space, unusual atmospheric constituents, and lack of flexibility in emergency situations has brought new and ill-defined hazards into the picture. In the past, numerous data have been compiled on the fire and explosion characteristics of all things combustible. Unfortunately, much of the material is not pertinent to the actual operational problems in space. The confusion and controversy arising from attempts to evaluate the space-cabin fire problem appear to stem from past failure to compile the scattered data and to expose it to critical review and selection. In the compilation that follows, an attempt has been made to review the best available data that was deemed actually pertinent to the present problem. The effects of unusual atmospheres have been emphasized, but, as will soon be evident, other physical parameters also play a major role in determining the nature of the problem. Chapter 1 contains a discussion of pertinent definitions and theory. This is detailed only to the point of anticipating some of the problems of interpretation that may arise in other chapters of the report. Included in this chapter is speculation on the impact of unusual environmental conditions such as aerodynamic heating, reduced gravitational acceleration, and low ambient pressures. Chapter 2 covers flammable fabrics and carbonaceous solids; Chapter 3, specific fire hazards involving flammable liquids, vapors, and gases; and Chapter 4, electrical fires. Chapter 5 covers the fire, blast, and flash hazards from meteoroid penetration; and Chapter 6, the problems of fire prevention and extinguishment in space cabins. Chapter 7 reviews the factors of fire and blast hazards in selection of a space-cabin atmosphere.

Roth, Emanuel M.↗

DOE OSTI2025

Williston Basin Resource Study for Commercial-Scale Subsurface Hydrogen Storage

The Energy & Environmental Research Center (EERC), in partnership with the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL), the EERC’s State Energy Research Center (SERC), MPLX Operations LLC, and TC Energy Development Holdings Inc. (a subsidiary of TC Energy Corporation), studied the potential for subsurface hydrogen storage and recovery in the Williston Basin of western North Dakota. The project’s goal was to evaluate the feasibility of large-scale, secure geologic H 2 storage to support future hydrogen generation, storage, and use. This work included laboratory testing, H 2 –rock–fluid exposure experiments, literature reviews on H 2 embrittlement, and reservoir modeling and simulations. The study included an assessment of storage potential across three types of storage reservoirs using both reservoir simulation and DOE’s web-based tool SHASTA-HELP (Subsurface Hydrogen Assessment, Storage, and Technology Acceleration – Hydrogen Estimator for Logistical Planning), as well as investigation of potential H 2 production and markets for commercial-scale deployment. Building on prior EERC gas storage research, three storage options were selected for detailed evaluation: the Broom Creek Formation (a clastic saline reservoir), the Dickinson Lodgepole Mounds (DLM) complex (carbonate mud mound structures) of the Lodgepole Formation (an active oil and gas producing reservoir), and the Dunham Salt Interval of the Piper Formation (to be used for engineered salt cavern development). These targets were prioritized based on prior EERC research using datasets related to seal capacity, reservoir quality, mechanical integrity, and injectivity. Exposure tests on Broom Creek and DLM samples showed mineral dissolution and precipitation that increased brine salinity and altered reservoir rock surfaces. Although these results provide useful insight, they are limited by small sample sizes and short-term (30-day) exposure, requiring further study to assess long-term storage integrity. Salt formations were not tested because of their known nonreactivity and established mechanical stability. Results of reservoir simulations performed for a single site demonstrated that the Broom Creek Formation may be capable of receiving up to 42,000 tonnes of injected H 2 over 7 months via one well. H 2 recovery took place over 5 months, resulting in approximately 26,000 tonnes (~62% without cushion gas [CG]). This work suggests water production may be important and subsequent cycles of injection and production may perform more efficiently; however, significant site-specific work in the future is needed to assess actual reservoir performance of injection and withdrawal of H 2 storage. For oil reservoir potential, a multiple-well model was used to simulate injection of approximately 32,000 tonnes of H 2 into a single wellbore while simultaneously producing in place reservoir fluids from four offset wells to maintain reservoir pressure. The simulation results suggested a high recovery (~98%); in addition, cost advantages through existing infrastructure could be realized. Challenges in this reservoir include vi managing gas purity and leakage risks. In both scenarios, production of H 2 takes place in a single-well scenario with 10 cycles (7 months of injection and 5 months of production) over 10 years. Finally, the use of engineered caverns in the Dunhan Salt was evaluated, and the results suggest that while they have a smaller capacity (<1000 tonnes per cavern), they exhibit nearly complete gas recovery (>99%), fast response times, and low purity risk. While caverns in North Dakota may be smaller in capacity, fields can be developed in galleries to accommodate the volumetric needs and rapid turnaround times necessary to meet market demands. Geographic limitations and thin salt intervals in North Dakota may represent less total storage potential than salt domes elsewhere, but significant opportunities exist to expand this market for gas storage in North Dakota. A basinwide assessment was performed to estimate a first-of-its-kind value for H 2 storage on a large scale. DOE’s SHASTA-HELP, combined with EERC simulation work, was used to perform the assessment. Estimated H 2 storage potential varied widely for each formation type. The Broom Creek saline formation was estimated to have a storage potential of approximately 1.7–90.5 million tonnes (MMt). The DLM oil reservoirs were estimated to have 0.07–0.19 MMt of capacity. Notably, each of these estimates relies on significant assumptions regarding reservoir thickness, porosity, permeability, and CG needed for operation. Much research is needed to understand the true site-specific storage resource potential of each formation. Using the Dunham Salt Interval for cavern development may result in as much as 4.79 MMt (up to 2.87 MMt working gas) of H 2 storage potential. An important note for consideration is that the values presented here need significantly more geological characterization and engineering assessments prior to gaining confidence in performance. This will be a focal point for future research and development needs. The basinwide evaluation also indicated that North Dakota has significant H 2 generation potential, with estimates up to a possible 13 MMt annually, suggesting a substantial opportunity for H 2 market development and thus the need for commercial-scale H 2 storage to facilitate growth and resilience. Key Recommendations 1. Conduct detailed site characterization (3D seismic, well logs, core sampling) to reduce geologic uncertainty. 2. Perform techno-economic analyses incorporating market, regulatory, and incentive frameworks. 3. Investigate long-term interactions among H 2 , CGs, well materials, and formations to assess risks. 4. Develop pilot- and field-scale demonstrations to validate models and establish best practices.

03 NATURAL GAS↗

NASA NTRS2016

Generalized Fluid System Simulation Program, Version 6.0

The Generalized Fluid System Simulation Program (GFSSP) is a general purpose computer program for analyzing steady state and time-dependent flow rates, pressures, temperatures, and concentrations in a complex flow network. The program is capable of modeling real fluids with phase changes, compressibility, mixture thermodynamics, conjugate heat transfer between solid and fluid, fluid transients, pumps, compressors, and external body forces such as gravity and centrifugal. The thermofluid system to be analyzed is discretized into nodes, branches, and conductors. The scalar properties such as pressure, temperature, and concentrations are calculated at nodes. Mass flow rates and heat transfer rates are computed in branches and conductors. The graphical user interface allows users to build their models using the 'point, drag, and click' method; the users can also run their models and post-process the results in the same environment. Two thermodynamic property programs (GASP/WASP and GASPAK) provide required thermodynamic and thermophysical properties for 36 fluids: helium, methane, neon, nitrogen, carbon monoxide, oxygen, argon, carbon dioxide, fluorine, hydrogen, parahydrogen, water, kerosene (RP-1), isobutene, butane, deuterium, ethane, ethylene, hydrogen sulfide, krypton, propane, xenon, R-11, R-12, R-22, R-32, R-123, R-124, R-125, R-134A, R-152A, nitrogen trifluoride, ammonia, hydrogen peroxide, and air. The program also provides the options of using any incompressible fluid with constant density and viscosity or ideal gas. The users can also supply property tables for fluids that are not in the library. Twenty-four different resistance/source options are provided for modeling momentum sources or sinks in the branches. These options include pipe flow, flow through a restriction, noncircular duct, pipe flow with entrance and/or exit losses, thin sharp orifice, thick orifice, square edge reduction, square edge expansion, rotating annular duct, rotating radial duct, labyrinth seal, parallel plates, common fittings and valves, pump characteristics, pump power, valve with a given loss coefficient, Joule-Thompson device, control valve, heat exchanger core, parallel tube, and compressible orifice. The program has the provision of including additional resistance options through User Subroutines. GFSSP employs a finite volume formulation of mass, momentum, and energy conservation equations in conjunction with the thermodynamic equations of state for real fluids as well as energy conservation equations for the solid. The system of equations describing the fluid network is solved by a hybrid numerical method that is a combination of the Newton-Raphson and successive substitution methods. The application and verification of the code has been demonstrated through 30 example problems.

Majumdar, A. K.↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF

42 ENGINEERING↗

NASA NTRS2012

Adhesion in a Vacuum Environment and its Implications for Dust Mitigation Techniques on Airless Bodies

During the Apollo missions, the adhesion of dust to critical spacecraft systems was a greater problem than anticipated and resulted in functional degradation of thermal control surfaces, spacesuit seals, and other spacecraft components. Notably, Earth-based simulation efforts did not predict the magnitude and effects of dust adhesion in the lunar environment. Forty years later, we understand that the ultrahigh vacuum (UHV) environment, coupled with micrometeorite impacts and constant ion and photon bombardment from the sun result in atomically clean and high surface energy dust particles and spacecraft surfaces. However, both the dominant mechanism of adhesion in airless environments and the conditions for high fidelity simulation tests have still to be determined. The experiments presented in here aim to aid in the development of dust mitigation techniques for airless bodies (e.g., lunar surface, asteroids, moons of outer planets). The approach taken consists of (a) quantifying the adhesion between common polymer and metallic spacecraft materials and a synthetic noritic volcanic glass, as a function of surface cleanliness and of triboelectric charge transfer in a UHV environment, and (b) determining parameters for high fidelity tests through investigation of adhesion dependence on vacuum environment and sample treatment. Adhesion force has been measured between pins of spacecraft materials and a plate of synthetic volcanic glass by determining the pull-off force with a torsion balance. Although no significant adhesion is generally observed directly as a result of high surface energies, the adhesion due to induced electrostatic charge is observed to increase with spacecraft material cleanliness, in some cases by over a factor of 10. Furthermore, electrostatically-induced adhesion is found to decrease rapidly above pressures of 10-6 torr. It is concluded that high-fidelity tests should be conducted in high to ultrahigh vacuum and include an ionized surface cleaning process.

Berkebile, Stephen↗

NASA NTRS2007

Robotics

Lunar robotic functions include: 1. Transport of crew and payloads on the surface of the moon; 2. Offloading payloads from a lunar lander; 3. Handling the deployment of surface systems; with 4. Human commanding of these functions from inside a lunar vehicle, habitat, or extravehicular (space walk), with Earth-based supervision. The systems that will perform these functions may not look like robots from science fiction. In fact, robotic functions may be automated trucks, cranes and winches. Use of this equipment prior to the crew s arrival or in the potentially long periods without crews on the surface, will require that these systems be computer controlled machines. The public release of NASA's Exploration plans at the 2nd Space Exploration Conference (Houston, December 2006) included a lunar outpost with as many as four unique mobility chassis designs. The sequence of lander offloading tasks involved as many as ten payloads, each with a unique set of geometry, mass and interface requirements. This plan was refined during a second phase study concluded in August 2007. Among the many improvements to the exploration plan were a reduction in the number of unique mobility chassis designs and a reduction in unique payload specifications. As the lunar surface system payloads have matured, so have the mobility and offloading functional requirements. While the architecture work continues, the community can expect to see functional requirements in the areas of surface mobility, surface handling, and human-systems interaction as follows: Surface Mobility 1. Transport crew on the lunar surface, accelerating construction tasks, expanding the crew s sphere of influence for scientific exploration, and providing a rapid return to an ascent module in an emergency. The crew transport can be with an un-pressurized rover, a small pressurized rover, or a larger mobile habitat. 2. Transport Extra-Vehicular Activity (EVA) equipment and construction payloads. 3. Transport habitats and power modules over long distances, pre-positioning them for the arrival of crew on a subsequent lander. Surface Handling 1. Offload surface system payloads from the lander, breaking launch restraints and power/data connections. Payloads may be offloaded to a wheeled vehicle for transport. 2. Deploy payloads from a wheeled vehicle at a field site, placing the payloads in their final use site on the ground or mating them with existing surface systems. 3. Support regolith collection, site preparation, berm construction, or other civil engineering tasks using tools and implements attached to rovers. Human-Systems Interaction 1. Provide a safe command and control interface for suited EVA to ride on and drive the vehicles, making sure that the systems are also safe for working near dismounted crew. 2. Provide an effective control system for IV crew to tele-operate vehicles, cranes and other equipment from inside the surface habitats with evolving independence from Earth. .. Provide a supervisory system that allows machines to be commanded from the ground, working across the Earth-Lunar time delays on the order of 5-10 seconds (round trip) to support operations when crew are not resident on the surface. Technology Development Needs 1. Surface vehicles that can dock, align and mate with outpost equipment such as landers, habitats and fluid/power interfaces. 2. Long life motors, drive trains, seals, motor electronics, sensors, processors, cable harnesses, and dash board displays. 3. Active suspension control, localization, high speed obstacle avoidance, and safety systems for operating near dismounted crew. 4. High specific energy and specific power batteries that are safe, rechargeable, and long lived.

Ambrose, Robert O.↗

NASA NTRS2000

Technical Challenges in Reliable Microelectronics Packaging of Microelectromechanical Systems (MEMS) for Space Applications

MEMS have shown a significant promise in the last decade for a variety of applications such as air-bag, pressure sensors, accelerometer, microgyro, chemical sensors, artificial nose, etc. Standard semiconductor microelectronics packaging needs the integrated circuits (IC) to be protected from the harsh environment, and provide electrical communication with the other parts of the circuit, facilitate thermal dissipation efficiently, and impart mechanical strength to the silicon die. Microelectronics packaging involves wafer dicing, bonding, lead attachment, encapsulation to protect from the environment, electrical integrity, and package leak tests to assure the reliable IC packaging technology. Active elements or microstructures in MEMS devices often interfaces with the hostile environment where packaging leak tests and testing of such devices using chemical and mechanical parameters will be very difficult and expensive. Packaging of MEMS is significantly complex as they serve to protect from the environment and microstructures interact with the same environment to measure or affect the desired physical or chemical parameters. The most of the silicon circuitry is sensitive to temperature, moisture, magnetic field, light, and electromagnetic interference. The package must then protect the on-board silicon circuitry while simultaneously exposing the microsensor to the effect it measures to assure the packaging technology of MEMS. MEMS technology has a major application in developing a microspacecraft for space systems provided reliability of MEMS packaging technology is sufficiently addressed. This MEMS technology would eventually miniaturize many of the components of the spacecraft to reach the NASA's goal by building faster, cheaper, better, smaller spacecraft to explore the space more effectively. This paper discusses the latest developments in the MEMS technology and challenging technical issues in the packaging of hermetically sealed and non-hermetically sealed MEMS sensor devices for microspacecraft applications.

Ramesham, Rajeshuni↗

DOE OSTI2024

HERO CarbonSAFE Phase 2 Project in the Columbia River Basalt Group

The Hermiston, Oregon Basalt CarbonSAFE Phase II project (HERO CarbonSAFE) seeks to accelerate the deployment of commercial carbon dioxide (CO2) storage projects in basaltic rocks. Basalt CO2 storage has several advantages to conventional saline storage reservoirs including 1. The potential for rapid mineralization of CO2, 2. Associated decreases in pressure and CO2 migration risks, 3. Reduced long-term monitoring requirements with respect to plume tracking, 4. Widespread geographic distribution and, 5. Large storage potential due to thickness, porosity, and CO2 interactions with basalt. And for locations such as the Pacific Northwest, Hawaii, Iceland, India and Japan, basalts may offer the only economically feasible option for local CO2 storage. However, there are limited field-scale assessments of CO2 storage in basalt, and current carbon capture utilization and storage (CCUS) permitting and regulatory frameworks were developed for conventional saline reservoirs. HERO CarbonSAFE is designed to address research gaps and uncertainties associated with basalt storage. Specifically, the project will assess the feasibility of CO2 injection in the deep layered basalts, long-term storage (mineralization), practical approaches for large-scale implementation (50+ million metric tons of CO2 over 30 years), lithology-specific risks, and the technoeconomic potential for CO2 storage in basalts. The HERO CarbonSAFE project will assess feasibility of developing a commercial-scale (50+ million metric tons of CO2) geological storage complex within the Columbia River Basalt Group (CRBG), a layered continental flood basalt complex that underlies Calpine’s natural gas-fired Hermiston Power Project (HPP) in Hermiston, OR (Figure 1). Under this 2-year CarbonSAFE Phase II project, the HERO team will conduct a data acquisition campaign that includes drilling a stratigraphic well to a total depth of ~1,500 m into the thick layered basalts proximal to HPP. A comprehensive well logging and hydrologic testing program will be augmented with new core collected from flow zones and sealing units, and comprehensive laboratory testing to help refine the kinetic rates of mineralization. The newly acquired information will be integrated with existing data from regional wells to correlate basalt injection zone properties to develop storage hub/commercial-scale models. Using these models, the project team will evaluate injection scenarios to define the technical and economic potential for storing a minimum of 50 million metric tons of CO2 over a 30-year period, along with a robust sensitivity analysis on key parameters governing reservoir viability for sustainable injection over a commercial project lifetime. Specific technical objectives of HERO are: (1) assessing the reservoir response of a series of stacked layered reservoir flowtop sequences occurring in this area of the CRBG to commercial-scale injection volumes; (2) extending prior efforts by the project team to characterize the deep layered basalts encountered in regional studies, to leverage prior investments by U.S. Department of Energy’s (DOE) Carbon Storage program; (3) leveraging DOE’s mineralization characterization efforts to advance model parametrization for commercial scale injection of CO2 in basalts; (4) conducting risk assessments associated with scaling up to commercial storage hub injection goals, while validating DOE’s National Risk Assessment Partnership (NRAP) tools, to identify potential constraints that would prevent the CRBG from serving as a commercial-scale storage complex; (5) developing mitigation plans to address identified risks; (6) developing a commercial-scale injection and monitoring, verification and accounting (MVA) strategy; (7) utilizing computational models to define and minimize, if possible, the Area of Review (AoR) under Class VI regulations; and (8) developing a robust CO2 management strategy for CRBG that also considers a regional source/sink approach that is responsive to stakeholder needs and industrial demand. Specific institutional objectives are: (1) identifying and developing plans to mitigate the nontechnical challenges associated with the build-out of a commercial-scale storage complex within the CRBG with integrated CO2 sources; (2) implementing the community outreach plan; (3) conducting regulatory research, including a survey of issues related to pore space ownership, MVA and long-term assurance of mineralization-based storage, to support an eventual application for a UIC Class VI permit; (4) advancing the project’s plan for CO2 liability management; and (5) continuing to refine and update the project’s economic model. The final objective is the preparation of a comprehensive Site Characterization Plan that draws upon the technical and institutional feasibility assessments to prepare the project for future commercialization efforts.

58 GEOSCIENCES↗

NASA NTRS1994

Fiber Optic Control System integration for advanced aircraft. Electro-optic and sensor fabrication, integration, and environmental testing for flight control systems

This report describes the design, development, and testing of passive fiber optic sensors and a multiplexing electro-optic architecture (EOA) for installation and flight test on a NASA-owned F-18 aircraft. This hardware was developed under the Fiber Optic Control Systems for Advanced Aircraft program, part of a multiyear NASA initiative to design, develop, and demonstrate through flight test 'fly-by-light' systems for application to advanced aircraft flight and propulsion control. This development included the design and production of 10 passive optical sensors and associated multiplexed EOA hardware based on wavelength division multiplexed (WDM) technology. A variety of sensor types (rotary position, linear position, temperature, and pressure) incorporating a broad range of sensor technologies (WDM analog, WDM digital, analog microbend, and fluorescent time rate of decay) were obtained from different manufacturers and functionally integrated with an independently designed EOA. The sensors were built for installation in a variety of aircraft locations, placing the sensors in a variety of harsh environments. The sensors and EOA were designed and built to have the resulting devices be as close as practical to a production system. The integrated system was delivered to NASA for flight testing on a NASA-owned F-18 aircraft. Development and integration testing of the system provided valuable information as to which sensor types were simplest to design and build for a military aircraft environment and which types were simplest to operate with a multiplexed EOA. Not all sensor types met the full range of performance and environmental requirements. EOA development problems provided information on directions to pursue in future fly-by-light flight control development programs. Lessons learned in the development of the EOA and sensor hardware are summarized.

Seal, Daniel W.↗

DOE OSTI2021

Solid-State Welding of the Nanostructured Ferritic Alloy 14YWT Using a Capacitive Discharge Resistance Welding Technique

Joining nanostructured ferritic alloys (NFAs) has proved challenging, as the nano-oxides that provide superior strength, creep resistance, and radiation tolerance at high temperatures tend to agglomerate, redistribute, and coarsen during conventional fusion welding. In this study, capacitive discharge resistance welding (CDRW)—a solid-state variant of resistance welding—was used to join end caps and thin-walled cladding tubes of the NFA 14YWT. The resulting solid-state joints were found to be hermetically sealed and were characterized across the weld region using electron microscopy (macroscopic, microscopic, and nanometer scales) and nanoindentation. Microstructural evolution near the weld line was limited to narrow (~50–200 μm) thermo-mechanically affected zones (TMAZs) and to a reduction in pre-existing component textures. Dispersoid populations (i.e., nano-oxides and larger oxide particles) appeared unchanged by all but the highest energy and power CDRW condition, with this extreme producing only minor nano-oxide coarsening (~2 nm → ~5 nm Ø). Despite a minimal microstructural change, the TMAZs were found to be ~10% softer than the surrounding base material. These findings are considered in terms of past solid-state welding (SSW) efforts—cladding applications and NFA-like materials in particular—and in terms of strengthening mechanisms in NFAs and the potential impacts of localized temperature–strain conditions during SSW.

36 MATERIALS SCIENCE↗

NASA NTRS2000

Assessment and Assurance of Microelectronics Packaging Technology of Microelectromechanical Systems (MEMS)

Microelectromechanical systems (MEMS) have shown a significant promise in the last decade for a variety of applications such as air-bag, pressure sensors, accelerometer, microgyro, etc. Standard semiconductor microelectronics packaging needs the integrated circuits to be protected from the harsh environment, and provide electrical communication with the other parts of the circuit, facilitate thermal dissipation efficiently, and impart mechanical strength to the silicon die. Microelectronics packaging involves wafer dicing, bonding, lead attachment, encapsulation to protect from the environment, electrical integrity, and package leak tests to assure the packaging technology. In the case of MEMS the microstructures (active elements) often interfaces with the hostile environment where packaging leak tests and testing of such devices using chemical and mechanical parameters will be very difficult and expensive. Packaging of MEMS is significantly complex as they serve to protect from the environment and microstructures interact with the same environment to measure or affect the desired physical or chemical parameters. The most of the silicon circuitry is sensitive to temperature, moisture, magnetic field, light, and electromagnetic interference. The package must then protect the on-board silicon circuitry while simultaneously exposing the microsensor to the effect it 'measures to assure the MEMS technology by lowering the risk to zero. MEMS technology has a major application in developing a microspacecraft for space systems provided assurance of MEMS technology is sufficiently addressed nondestructively. This technology would eventually miniaturize many of the components of the spacecraft to reach the NASA's safety and mission assurance goal by building faster, cheaper, better, smaller spacecraft to explore the space more effectively by teaming-up with the other NASA centers using the limited resources available. This paper discusses the latest developments in the MEMS technology and challenging issues in the packaging of hermetically sealed and non-hermetically sealed MEMS sensor devices based on silicon, poly-silicon, and other materials for microspacecraft applications considering the space environment and reliability assurance qualification guidelines in perspective. Acknowledgments: The above research work is supported by the NASA Electronics Parts and Packaging Program (NEPP) and performed by the Jet Propulsion Laboratory, California Institute of Technology, Pasadena, CA under a contract with the NASA - Code Q for the Office of Safety and Mission Assurance Program 323-79.

Ramesham, Rajeshuni↗