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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 1,639 records · Page 91
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

New Development Activities at NASA Ames in Reusable TPS Materials

Over the last few years, new activities in rapid, low-cost access to low-earth orbit (LEO) and hypersonic flight have refreshed interest in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Development of novel systems having a greater consideration of full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance are needed to enable this new generation of space flight. NASA Ames has a long history of RTPS development including invention of flexible blankets such as Advanced Flexible Reusable Surface Insulation (AFRSI), rigid ceramic tiles like Fibrous Refractory Composite Insulation (FRCI) and Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). In much more recent times, NASA Ames is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts that span broadly from updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Reusable thermal protection materials↗
NASA NTRSDate not supplied

Reusable TPS Materials Development Activities at NASA Ames

Recent developments in low-cost access to low-earth orbit (LEO) and hypersonic flight are driving renewed demand in reusable thermal protection systems (RTPS) that have not had broad application since the Space Shuttle era. Modern systems will need to consider full cycle cost (lower cost raw materials, manufacturing, integration, and refurbishment) in addition to improved performance to enable this new generation of space flight. NASA Ames Research Center (ARC) has a long history of RTPS development including modern state-of-the-art materials like Alumina Enhanced Thermal Barrier (AETB), and multi-component systems like Toughened Uni-piece Fibrous Reinforced Oxidation-resistant Composite (TUFROC). Now, ARC is supporting the growing commercial space field through internal research and development efforts for high-risk low TRL materials and collaboration with commercial partners including technology transfer. This talk will discuss the current development efforts at ARC that span updating legacy insulating systems with modern raw materials and processes to totally novel designs for heat pipes with various low-TRL activities in between. It will also discuss Ames’ recent re-investment in experimental capabilities to enable characterization and material testing.

Adam Caldwell↗
NASA NTRSDate not supplied

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials↗
DOE OSTI2019

Conducting plastic cold plates

Cold plates are described herein. In one example, a cold plate can include a thermally conductive plastic forming a coolant channel that includes a heat spreader formed into the thermally conductive plastic and an exterior surface of the thermally conductive plastic with a coupling location to couple a heat pipe to the exterior surface of the thermally conductive plastic.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Review of Graphite Properties Relevant to Micro-Reactor Design

Microreactors are advanced reactors that are designed to be small, scalable, and portable with up to 20 MW power. These reactors could operate independently, or as part of a microgrid, without need of a frequent refueling. Micro-reactors are designed to be deployable to provide electric power in remote locations, therefore providing greater flexibility. Several micro-reactors are under development in the US. These reactors are based on advanced gas-cooled or heat-pipe concepts. While Graphite can be found in various applications, some high-temperature reactors plan to employ Graphite in their core components due to its role as a moderator and its ability to maintain its structural integrity when subjected to elevated temperatures and high neutron fluence. Although there is significant experience with use of Graphite in nuclear applications, there are still unknowns that should be addressed. Graphite properties depend on the graphite type and affected by the fabrication procedures. Material properties are functions of the temperature and irradiation dose. The fundamental properties also affected by the oxidation environment. Therefore, in-depth understanding of graphite properties, including the effect of irradiation, oxidation and other influencing parameters are required to evaluate the design accurately. This draft aims to provide a comprehensive review of material properties for Graphite relevant to micro reactor design. For this work, two distinct grades of graphite were considered, namely IG-110 and Mersen-2114. Physical, thermal, and mechanical properties for these grades were comparatively evaluated. The properties that are discussed in this draft aim to serve as a basis for design and safety analysis.

42 ENGINEERING↗
DOE OSTI2022

Towards a Benchmark Experiment with the Compact Nuclear Power Source

The Compact Nuclear Power Source (CNPS) was a high-assay low enriched uranium (HALEU) tristructural isotropic (TRISO)-fueled, graphite-moderated microreactor constructed in 1987 at Los Alamos National Laboratory. The reactor, conceived as a power source for short-range radar stations, was designed to be "walk-away safe," and was cooled by heat pipes and ambient air. Though the project was formally cancelled after the fuel and moderator material had been received, its potential to meaningfully advance the body of critical and integral data was evident, and critical experiments with a mock-up of the reactor proceeded at TA-18 until its disassembly in 1991. The reflector and some components of the core would later go on to see service as part of the New Production Reactor Modular High-Temperature Gas-Cooled Reactor (NP-MHTGR) critical experiments. In light of the progress made by groups like Westinghouse and X-Energy towards contemporary graphite-moderated microreactors, the system remains an attractive candidate for the basis of a benchmark experiment even today. Uncertainties remain, however, in some features of the system–inconsistencies in the dimensions and composition of the reactor’s components as described in literature and implemented in current computational models. The identification, quantification, and to the extent possible, the minimization of these uncertainties is a crucial task on the path towards creating a benchmark based on the CNPS system. The present work seeks to initiate this process with a survey of available documentation and improvements to the accuracy of CNPS neutronics models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Demonstration of ACCERT Software for Nuclear Power Plant Techno-Economics

In the past few years, there has been a renewed interest in the deployment of nuclear power for decarbonizing the electricity grid as well as a range of industrial applications. As the demonstrations of advanced nuclear power plants start to begin, there will likely be a further increase in this interest. As nuclear is being considered as a part of the energy mix, understanding the cost of nuclear energy becomes increasingly important for all stakeholders including advanced reactor vendors (for making design decisions and marketing their designs), users of nuclear energy (e.g., to estimate the cost of decarbonization of other industries using nuclear), and government (e.g., in capacity expansion models that are used in framing policy). In this summary, we demonstrate a software tool called ACCERT that is currently being developed with funding from the Systems Analysis and Integration (SA&I) program under the Department of Energy’s Office of Nuclear Energy (DOE NE). ACCERT is a cost estimation and techno-economics tool for nuclear power plant applications that includes a database of (a) cost estimates of various ‘reference’ nuclear power plant designs gathered from existing literature, and (b) algorithms developed from these costs that can be used extrapolate the existing costs and perform a bottom-up cost estimation of other designs. A companion summary describes the software and its design in more detail and this summary presents a demonstration for four different nuclear power plant designs: a pressurized water reactor (PWR), high-temperature gas reactor (HTGR), sodium fast reactor (SFR), and a heat-pipe microreactor. The demonstrations include the reference cost estimates and the cost estimates of a modified design for each reference case.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Review of HAYNES® 282® alloy for supercritical CO2 structural applications

In this paper, HAYNES® 282® alloy (282® alloy) properties, microstructure, high temperature oxidation resistance, weldability, and American Society of Mechanical Engineers (ASME) code case highlights are reviewed. The long term performance of high temperature, high strength, creep resistant alloys is critical to the success of supercritical carbon dioxide equipment. Several modern power generation technologies require alloys that can operate continuously at or above 700oC. 282® alloy is a precipitation strengthened nickel based super alloy that meets these requirements. The results of 282® alloy research reviewed in this paper include longterm cyclic oxidation behavior in air and sCO2, independent research and validation of 100k hour creep life, and successful welding of the alloy in the age hardened condition. The latter is critical for joining of hardened components (flanges, piping, heat exchanger internal, etc.) and field repair. Several highlights from the code case for this ASMEapproved material are also presented.

Tossey, Brett↗
DOE OSTI2023

HIGH-LOW FIDELITY THERMAL HYDRAULIC COUPLING USING AI/MACHINE LEARNING ALGORITHMS

The primary goal of the US Department of Energy (DOE) office of Nuclear Energy Integrated Energy Systems (IES) program is to develop the tools and framework for coupling multi-scale and multi-physical thermal and electrical energy usage and storage systems. High- and low-fidelity (high–low) coupling is a key feature of multi-scale, multi-component systems and has been an important focus of research in the nuclear energy community for the past two decades. An essential feature of demonstrating the capability to couple high-fidelity and low-fidelity systems for real-time applications are surrogate/reduced order models (ROM). For the purposes of this study, surrogate models are essentially Blackbox models, typically developed using supervised Machine learning (ML) algorithms. The surrogate models can be used to mimic the response of high-fidelity models to represent large historical datasets and coupled with more general low-fidelity system models distributed as Functional Mock-up Interface (FMI) or Functional Mock-up Units (FMU) modules. The example is demonstrated with Spallation Neutron Source (SNS) First Target Station flow loop data. The flow loop is a liquid mercury loop with a pump, piping, heat exchange, and internal heat generation in the target window. This work elucidates some of the potential benefits and future needs of developing tools for high–low system coupling of energy systems.

Williams, Wesley↗
DOE OSTI2022

Physics demonstration and verification of MOOSE framework reactor module meshing capabilities

The recently developed Reactor module in the open-source MOOSE framework includes finite element meshing capabilities for analysis of common reactor geometries. Capabilities in the Reactor module have been employed to generate meshes for physics applications including a sodium-cooled fast reactor core analysis using Griffin, a fast reactor assembly thermal deformation analysis using MOOSE Tensor Mechanics, and a heat-pipe cooled microreactor coupled analysis using Griffin, Bison, and Sockeye. The process to build these meshes using MOOSE's meshing capabilities is described. Physics simulation results using MOOSE-based meshes have been verified to match results which leverage external meshing software such as Cubit or Argonne's Mesh Tools. MOOSE's Reactor module provides significant advantages compared to the use of external meshing tools when analyzing Cartesian and hexagonal reactor lattices using MOOSE-based applications: accessibility to the end user, low barrier to entry for new users, speed of mesh generation, volume preservation of meshed fuel pins, and simplification of analysis workflow when using MOOSE applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Recent Advanced Reactor Multiphysics Model Highlights in the Virtual Test Bed (VTB)

The Virtual Test Bed (VTB) host over 30 distinct simulations that showcase state-of-the art capabilities across the national lab complex. An update on the status of models on the VTB is summarized here, along with a more detailed overview of select recent new capabilities to showcase. All of the major advanced reactor types are represented in the VTB. The first example consists of a multiphysics simulation to track the transport of species in Molten Salt Reactors using depletion, advection, and thermochemical calculations. The second consists of a coupled neutronic and thermal hydraulic simulation to validate a gas cooled reactor. The third consist of pebble-bed equilibrium model for a fluoride high-temperature reactor. The fourth is a high-fidelity neutronic and thermal hydraulic model of a liquid metal reactor assembly. And lastly the fifth consists of transient multiphysics simulations of heat pipe microreactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Overview of Virtual Test Bed (VTB)

The Virtual Test Bed (VTB) was established to support the deployment of advanced reactors by facilitating the use of state-of-the-art modeling and simulation capabilities. These tools can solve previously prohibitive challenge problems with greater levels of fidelity and in a multiphysics framework. A VTB repository was recently set up to host models for a wide variety of reactor types and using a range of Nuclear Energy Advanced Modeling and Simulation-developed software. The repository currently includes models for High-Temperature Gas-Cooled Reactors, Sodium Fast Reactors, Fluoride-salt-cooled High-temperature Reactors, Molten Salt Reactors, and Heat-Pipe Microreactors. This article provides an overview of the capabilities currently in the VTB repository.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

The MOOSE fluid properties module

The fluid properties module in MOOSE~\cite{lindsay2022moose} serves a variety of fluid simulation applications based on MOOSE, including the MOOSE Navier Stokes module~\cite{moose_ns}, Pronghorn~\cite{pgh}, the MOOSE thermal hydraulics module, SAM~\cite{sam}, RELAP-7~\cite{relap7}, Sockeye~\cite{sockeye}, Pronghorn-subchannel~\cite{subchannel} and the MOOSE porous flow module~\cite{porous}. These applications are used to solve coarse mesh multi-dimensional thermal-hydraulics~\cite{pgh}, 1D systems analysis~\cite{sam,relap7} in nuclear reactor analysis, heat pipe modeling~\cite{sockeye} and porous flow simulations~\cite{porous} for underground gas storage and water seepage. The use of consistent fluid properties across fluid flow applications facilitates coupled flow simulations~\cite{anl_sam_pgh,osti_1889653}. Each application has historically driven the implementation of several fluid properties, which were later extended to be compatible with other applications. The unique diversity of applications of the module, due to its presence in MOOSE, has driven its expansion to new fluids, such as advanced nuclear reactor coolants and, more recently, arbitrary functions or tables-based property definitions, as detailed in section~\ref{content}, as well as numerous thermophysical properties and variable sets, as detailed in subsection~\ref{sec:prop}. The need for different discretizations of flow equations based on the compressibility of the fluid has motivated support for both primitive (pressure- and temperature-based) and conservative (internal energy- and specific volume-based) flow variables in the module. Thermodynamic relations are used to convert between these two formulations, as needed. The module serves a dual purpose of providing fluid properties for direct use in flow simulations and facilitating the implementation of user-specific fluid properties. Contributions of new properties for existing fluids or new fluids are strongly encouraged.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Adaptive, Active Learning, and Multifidelity Monte Carlo Methods in the MOOSE Stochastic Tools Module

MOOSE is an open-source computational platform for constructing multi-physics models and executing them in a massively parallel fashion. It has a stochastic tools module (STM) for forward/inverse uncertainty quantification (UQ) and surrogate modeling. This presentation details some recent developments to the STM with respect to the implementation of adaptive, active learning, and multifidelity Monte Carlo methods for forward UQ of computational models. Specifically, the adaptive Monte Carlo methods include Markov Chain Monte Carlo (MCMC)-driven algorithms like adaptive importance sampling and parallelized subset simulation for statistical QoI estimation, rare events analysis, and stochastic gradient-free optimization. The active learning methods include Gaussian Process (GP) surrogates and their training via Adam optimization, design of acquisition functions, and integration with samplers like Monte Carlo, adaptive importance, and parallelized subset simulation. These active learning methods are also designed to work in a batch mode, wherein, the required calls to the full computational model are executed in parallel whenever a user-specified batch size is met. The multifidelity methods in STM are broadly divided into two categories: hierarchical, where a defined hierarchy exists among the low-fidelity models, and peer, where all the low-fidelity models are treated equally. A GP surrogate is used to learn the differences between the low- and high-fidelity models in both multifidelity categories, and acquisition functions from the active learning classes are used to decide whether to rely on a low-fidelity model or call the expensive high-fidelity model. Alongside the software description and usage, applications are also presented to nuclear engineering computational models including a TRISO nuclear fuel particle, a reactor pressure vessel, and a heat-pipe microreactor.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

MAGNET Digital Twin Demo Report

This brief report details the activities of the first MAGNET test using a single heat pipe test article, with an emphasis on the digital twin activities, interactions, and areas in which the digital twin can improve for future testing.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

A Bottom-Up Cost Estimation Tool for Nuclear Microreactors

The rising interest in nuclear microreactors has highlighted the need for comprehensive technoeconomic assessments. However, the scarcity of publicly available designs and cost data has posed significant challenges. To address this issue, the Microreactor Optimization Using Simulation and Economics (MOUSE) tool is developed. MOUSE is a tool that integrates nuclear microreactor design with reactor economics. The design calculations encompass core simulations using the OpenMC Monte Carlo Particle Transport Code [romano2015], along with simplified balance of plant calculations. On the economic side, MOUSE provides detailed bottom-up cost estimates, calculating both the total capital cost and the levelized cost of energy for first-of-a-kind and nth-of-a-kind microreactors. The cost estimation correlations are developed using data from the MARVEL project and additional literature sources. MOUSE has released as an open-source tool on GitHub (MOUSE Tool). By combining design calculations with cost equations, MOUSE enables users to evaluate the impact of various technological consideration, advanced moderators, design changes, material/fuel changes, and geometry modifications—as well as economic parameters like interest rates and construction duration. This comprehensive framework can guide stakeholders towards technological solutions that enhance microreactor competitiveness. Additionally, powered by the WATTS toolkit [romano2022], MOUSE supports optimization studies, parametric analyses, and uncertainty calculations/propagation. Currently, preconceptual designs of three microreactor types are included in MOUSE: a liquid metal thermal microreactor (LTMR), gas cooled TRISO-fueled microreactor (GCMR) and heat-pipe TRISO fueled microreactor (HPMR). To showcase its ability, MOUSE was used to conduct detailed bottom-up cost estimates for the first of a kind (FOAK) and Nth of a kind (NOAK) of the following microreactors • A 20MWt LTMR that is built on the ongoing MARVEL demonstration at Idaho National Laboratory (INL) • A 15 MWt GCMR that was designed to be more representative of the typical commercial microreactor • A 7 MWt HPMR that was built on previous work (Choi 2024) The The reader should note that these three designs and corresponding cost estimates are examples to demonstrate the MOUSE capability. The designs are pre-conceptual, the reactor designs were not optimized, and the cost estimates were developed with incomplete information. Additionally, stakeholders might be interested in a variety of designs that may differ from the examples provided in this report. The MOUSE tool can also be used to study how design choices affect economics. To demonstrate its capability, MOUSE was used conduct parametric studies such as examining the economic impact of the reflector's material and thickness, the moderator's booster material and dimensions, fuel composition and enrichment, core size, and power level. Several insights were gained from these parametric studies.

Hanna, Botros↗
DOE OSTI2024

BlueCRAB Multiphysics in Support of the U.S.NRC

This presentation provides an overview of the nonLWR modeling and simulation project at INL. It includes a discussion of the various reference plant models developed since 2019 and a more detailed view at results from a monolith-based heat pipe cooled micro reactor.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE neams program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework. This report summarizes recent advances in developing an integrated system- and engineering-scale modeling capability for the msr concept, which has gained significant interest in recent years. A consistent framework was established by coupling Pronghorn and SAM through the Saline interface, with thermophysical properties provided by the Molten Salt Thermal Property Database (MSTDB-TP). Further improvements were made to the coupling schemes and domain-overlapping strategies, enhancing the stability and robustness of multi-code simulations. Verification and validation efforts demonstrate the accuracy of this integration across a range of benchmark problems, including one-dimensional heated pipe flows, three-dimensional natural convection loops with evolving isotopic compositions, and \gls{msre} demonstration cases. Within Pronghorn, new capabilities were introduced to model corrosion and noble-metal plating phenomena, supported by an extended thermal-hydraulics framework and refined turbulence treatments. To capture two-phase flow behavior, a multiphase Euler–Euler model was implemented in Pronghorn, including advanced closure relations, high-resolution advection techniques, and capillary force reconstruction. Preliminary verification cases confirm the fidelity of the approach, while planned validation efforts target canonical multiphase benchmarks and application to msr components such as the msre pump bowl. Finally, updates to SAM’s msr mass transfer modeling were extended to consider noble gas migration into porous structures like graphite. The point kinetics model was updated to include reactivity feedback contributions from any defined species, such as xenon. The gas transport model was expanded for applicability to gas mixtures, bubble efflux phenomena, and species transport between liquid and gas phases. A selection of multi-scale Sherwood number correlations from MOSCATO/NekRS and multi-phase correlations from literature have been added for improved accuracy in calculating mass transfer coefficients. A companion effort on developing system-level redox corrosion has also been incorporated into SAM. Collectively, these enhancements strengthen the predictive capability of SAM and Pronghorn for simulating MSR thermal-hydraulics, corrosion, multiphase behavior, and fission-product transport, providing a more complete toolset for design, safety analysis, and licensing support of next-generation \gls{msr}s.

42 - ENGINEERING↗