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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

A Multifaceted Approach to Modernizing NASA's Advanced Multi-Mission Operations System (AMMOS) System Architecture

The Advanced Multi-Mission Operations Systems (AMMOS) is NASA's premier space mission operations product line offering for use in deep-space robotic and astrophysics missions. The general approach to AMMOS modernization over the course of its 29-year history exemplifies a continual, evolutionary approach with periods of sponsor investment peaks and valleys in between. Today, the Multimission Ground Systems and Services (MGSS) office-the program office that manages the AMMOS for NASA-actively pursues modernization initiatives and continues to evolve the AMMOS by incorporating enhanced capabilities and newer technologies into its end-user tool and service offerings. Despite the myriad of modernization investments that have been made over the evolutionary course of the AMMOS, pain points remain. These pain points, based on interviews with numerous flight project mission operations personnel, can be classified principally into two major categories: 1) information-related issues, and 2) process-related issues. By information-related issues, we mean pain points associated with the management and flow of MOS data across the various system interfaces. By process-related issues, we mean pain points associated with the MOS activities performed by mission operators (i.e., humans) and supporting software infrastructure used in support of those activities. In this paper, three foundational concepts-Timeline, Closed Loop Control, and Separation of Concerns-collectively form the basis for expressing a set of core architectural tenets that provides a multifaceted approach to AMMOS system architecture modernization intended to address the information- and process-related issues. Each of these architectural tenets will be further explored in this paper. Ultimately, we envision the application of these core tenets resulting in a unified vision of a future-state architecture for the AMMOS-one that is intended to result in a highly adaptable, highly efficient, and highly cost-effective set of multimission MOS products and services.

Estefan, Jeff A.↗
DOE OSTI2019

Method and application of data integration at a nuclear power plant. Light Water Reactor Sustainability Program report

The data of a nuclear power plant (NPP) is stored in silos for the various plant tools. A previous study conducted by the LWRS program identified the different data sources that can benefit online monitoring in an NPP. These data have different structures and tools and are therefore used independently. Integrating data from various sources can result in multiple benefits to online monitoring by enhancing the ability to compare data, reduce statistical uncertainty due to a larger data set, increase data heterogeneity in space and time to reveal confounded information, develop intelligent methods, and share data. Data integration can result in direct cost saving by reducing the amount of effort needed to find needed information. It can also enable establishing a data warehouse, the backbone repository of data for an NPP, and is necessary to evolve NPPs to a holistic online monitoring approach and automate labor-intensive activities. Whether within an NPP or for a fleet of NPPs, deploying a data warehouse in a plant or data broker for a fleet of plants requires overcoming multiple challenges, including the lack of a standard form of storing and using data and the lack of integration methods to compare and map the different data sources. This effort demonstrates two methods and applications for data integration through an application integration pilot and a data fusion pilot. The application integration is targeted towards the software interfacing of data and data management. This approach is commonly used by data integrators. The data fusion pilot is targeted towards intelligently mapping or coupling data for optimized data use. The pilots were performed in collaboration with two NPPs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Wellbore Seal Repair Using Nanocomposite Materials

Nanocomposite wellbore repair materials have been developed, tested, and modeled through an integrated program of laboratory testing and numerical modeling. Numerous polymer-cement nanocomposites were synthesized as candidate wellbore repair materials using various combinations of base polymers and nanoparticles. Based on tests of bond strength to steel and cement, ductility, stability, flowability, and penetrability in opening of 50 microns and less, we identified Novolac epoxy reinforced with multi-walled carbon nanotubes and/or alumina nanoparticles to be a superior wellbore seal material compared to conventional microfine cements. A system was developed for testing damaged and repaired wellbore specimens comprised of a cement sheath cast on a steel casing. The system allows independent application of confining pressures and casing pressures while gas flow is measured through the specimens along the wellbore axis. Repair with the nanocomposite epoxy base material was successful in dramatically reducing the flow through flaws of various sizes and types, and restoring the specimen comparable to an intact condition. In contrast, repair of damaged specimens with microfine cement was less effective, and the repair degraded with application of stress. Post-test observations confirm the complete penetration and sealing of flaws using the nanocomposite epoxy base material. A number of modeling efforts have supported the material development and testing efforts. We have modeled the steel-repair material interface behavior in detail during slant shear tests, which we used to characterize bond strength of candidate repair materials. A numerical model of the laboratory testing of damaged wellbore specimens was developed. This investigation found that microannulus permeability can satisfactorily be described by a joint model. Finally, a wellbore model has been developed that can be used to evaluate the response of the wellbore system (casing, cement, and microannulus), including the use of either cement or a nanocomposite in the microannulus to represent a repaired system. This wellbore model was successfully coupled with a field-scale model of CO 2 injection, to enable predictions of stress and strains in the wellbore subjected to subsurface changes (i.e. domal uplift) associated with fluid injection.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Micromechanical combined stress analysis: MICSTRAN, a user manual

Composite materials are currently being used in aerospace and other applications. The ability to tailor the composite properties by the appropriate selection of its constituents, the fiber and matrix, is a major advantage of composite materials. The Micromechanical Combined Stress Analysis (MICSTRAN) code provides the materials engineer with a user-friendly personal computer (PC) based tool to calculate overall composite properties given the constituent fiber and matrix properties. To assess the ability of the composite to carry structural loads, the materials engineer also needs to calculate the internal stresses in the composite material. MICSTRAN is a simple tool to calculate such internal stresses with a composite ply under combined thermomechanical loading. It assumes that the fibers have a circular cross-section and are arranged either in a repeating square or diamond array pattern within a ply. It uses a classical elasticity solution technique that has been demonstrated to calculate accurate stress results. Input to the program consists of transversely isotropic fiber properties and isotropic matrix properties such as moduli, Poisson's ratios, coefficients of thermal expansion, and volume fraction. Output consists of overall thermoelastic constants and stresses. Stresses can be computed under the combined action of thermal, transverse, longitudinal, transverse shear, and longitudinal shear loadings. Stress output can be requested along the fiber-matrix interface, the model boundaries, circular arcs, or at user-specified points located anywhere in the model. The MICSTRAN program is Windows compatible and takes advantage of the Microsoft Windows graphical user interface which facilitates multitasking and extends memory access far beyond the limits imposed by the DOS operating system.

Naik, R. A.↗
NASA NTRS1992

Microgravity fluid physics research in the Space Station Freedom era

Microgravity fluid physics covers an exciting range of established and potential fields of scientific research. Areas in which the Microgravity Science and Applications Division of NASA's Office of Space Science and Applications is currently supporting research include: multiphase flow and phase change heat transfer, behavior of granular media and colloids; and interface dynamics, morphological stability, and contact line phenomena. As they contribute to our knowledge of fluid behavior, advances in these areas will enhance our understanding of materials processing on Earth and in space, and will contribute to technologies as diverse as chemical extraction, the prediction of soil behavior in earthquakes, and the production of oil reservoirs. NASA' s primary platform for research in microgravity fluid physics will soon be the Fluid Physics/Dynamics Facility on Space Station Freedom. This facility shares a rack for control and utilities with the Modular Combustion Facility, and has one rack for experiment-unique instruments. It is planned to change out the content of the experiment-unique rack at intervals on the order of one year. In order to obtain a maximum return on the operation of the facility during these intervals, the research community must carefully plan and coordinate an effort that brings the efforts of many investigators to bear on problems of particular importance. NASA is currently working with the community to identify research areas in which microgravity can make a unique and valuable contribution, and to build a balanced program of research around these areas or thrusts. Selections will soon be made from our first solicitation for research in fluid dynamics and transport phenomena. These solicitations will build the research community that will make Space Station Freedom a catalyst for scientific and technological discovery, and offer U.S. scientists in many disciplines a unique opportunity to participate in space science.

Carpenter, Bradley M.↗
NASA NTRS2013

Flight Hardware Packaging Design for Stringent EMC Radiated Emission Requirements

This packaging design approach can help heritage hardware meet a flight project's stringent EMC radiated emissions requirement. The approach requires only minor modifications to a hardware's chassis and mainly concentrates on its connector interfaces. The solution is to raise the surface area where the connector is mounted by a few millimeters using a pedestal, and then wrapping with conductive tape from the cable backshell down to the surface-mounted connector. This design approach has been applied to JPL flight project subsystems. The EMC radiated emissions requirements for flight projects can vary from benign to mission critical. If the project's EMC requirements are stringent, the best approach to meet EMC requirements would be to design an EMC control program for the project early on and implement EMC design techniques starting with the circuit board layout. This is the ideal scenario for hardware that is built from scratch. Implementation of EMC radiated emissions mitigation techniques can mature as the design progresses, with minimal impact to the design cycle. The real challenge exists for hardware that is planned to be flown following a built-to-print approach, in which heritage hardware from a past project with a different set of requirements is expected to perform satisfactorily for a new project. With acceptance of heritage, the design would already be established (circuit board layout and components have already been pre-determined), and hence any radiated emissions mitigation techniques would only be applicable at the packaging level. The key is to take a heritage design with its known radiated emissions spectrum and repackage, or modify its chassis design so that it would have a better chance of meeting the new project s radiated emissions requirements.

Lortz, Charlene L.↗
DOE OSTI2017

Seamless Digital Environment – Data Analytics Use Case Study

Multiple research efforts in the U.S Department of Energy Light Water Reactor Sustainability (LWRS) Program studies the need and design of an underlying architecture to support the increased amount and use of data in the nuclear power plant. More specifically the three LWRS research efforts; Digital Architecture for an Automated Plant, Automated Work Packages, Computer-Based Procedures for Field Workers, and the Online Monitoring efforts all have identified the need for a digital architecture and more importantly the need for a Seamless Digital Environment (SDE). A SDE provides a mean to access multiple applications, gather the data points needed, conduct the analysis requested, and present the result to the user with minimal or no effort by the user. During the 2016 annual Nuclear Information Technology Strategic Leadership (NITSL) group meeting the nuclear utilities identified the need for research focused on data analytics. The effort was to develop and evaluate use cases for data mining and analytics for employing information from plant sensors and database for use in developing improved business analytics. The goal of the study is to research potential approaches to building an analytics solution for equipment reliability, on a small scale, focusing on either a single piece of equipment or a single system. The analytics solution will likely consist of a data integration layer, predictive and machine learning layer and the user interface layer that will display the output of the analysis in a straight forward, easy to consume manner. This report describes the use case study initiated by NITSL and conducted in a collaboration between Idaho National Laboratory, Arizona Public Service – Palo Verde Nuclear Generating Station, and NextAxiom Inc.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2010

Gas Flow Detection System

This system provides a portable means to detect gas flow through a thin-walled tube without breaking into the tubing system. The flow detection system was specifically designed to detect flow through two parallel branches of a manifold with only one inlet and outlet, and is a means for verifying a space shuttle program requirement that saves time and reduces the risk of flight hardware damage compared to the current means of requirement verification. The prototype Purge Vent and Drain Window Cavity Conditioning System (PVD WCCS) Flow Detection System consists of a heater and a temperature-sensing thermistor attached to a piece of Velcro to be attached to each branch of a WCCS manifold for the duration of the requirement verification test. The heaters and thermistors are connected to a shielded cable and then to an electronics enclosure, which contains the power supplies, relays, and circuit board to provide power, signal conditioning, and control. The electronics enclosure is then connected to a commercial data acquisition box to provide analog to digital conversion as well as digital control. This data acquisition box is then connected to a commercial laptop running a custom application created using National Instruments LabVIEW. The operation of the PVD WCCS Flow Detection System consists of first attaching a heater/thermistor assembly to each of the two branches of one manifold while there is no flow through the manifold. Next, the software application running on the laptop is used to turn on the heaters and to monitor the manifold branch temperatures. When the system has reached thermal equilibrium, the software application s graphical user interface (GUI) will indicate that the branch temperatures are stable. The operator can then physically open the flow control valve to initiate the test flow of gaseous nitrogen (GN2) through the manifold. Next, the software user interface will be monitored for stable temperature indications when the system is again at thermal equilibrium with the test flow of GN2. The temperature drop of each branch from its "no flow" stable temperature peak to its stable "with flow" temperature will allow the operator to determine whether a minimum level of flow exists. An alternative operation has the operator turning on the software only long enough to record the ambient temperature of the tubing before turning on the heaters and initiating GN2 flow. The stable temperature of the heated tubing with GN2 flow is then compared with the ambient tubing temperature to determine if flow is present in each branch. To help quantify the level of flow in the manifolds, each branch will be bench calibrated to establish its thermal properties using the flow detection system and different flow rates. These calibration values can then be incorporated into the software application to provide more detailed flow rate information.

Moss, Thomas↗
DOE OSTI2023

TAMM: Tensor algebra for many-body methods

Tensor algebra operations such as contractions in computational chemistry consume a significant fraction of the computing time on large-scale computing platforms. The widespread use of tensor contractions between large multi-dimensional tensors in describing electronic structure theory has motivated the development of multiple tensor algebra frameworks targeting heterogeneous computing platforms. In this paper, we present Tensor Algebra for Many-body Methods (TAMM), a framework for productive and performance-portable development of scalable computational chemistry methods. TAMM decouples the specification of the computation from the execution of these operations on available high-performance computing systems. With this design choice, the scientific application developers (domain scientists) can focus on the algorithmic requirements using the tensor algebra interface provided by TAMM, whereas high-performance computing developers can direct their attention to various optimizations on the underlying constructs, such as efficient data distribution, optimized scheduling algorithms, and efficient use of intra-node resources (e.g., graphics processing units). The modular structure of TAMM allows it to support different hardware architectures and incorporate new algorithmic advances. We describe the TAMM framework and our approach to the sustainable development of scalable ground- and excited-state electronic structure methods. We present case studies highlighting the ease of use, including the performance and productivity gains compared to other frameworks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2016

Geocam Space: Enhancing Handheld Digital Camera Imagery from the International Space Station for Research and Applications

Handheld astronaut photography of the Earth has been collected from the International Space Station (ISS) since 2000, making it the most temporally extensive remotely sensed dataset from this unique Low Earth orbital platform. Exclusive use of digital handheld cameras to perform Earth observations from the ISS began in 2004. Nadir viewing imagery is constrained by the inclined equatorial orbit of the ISS to between 51.6 degrees North and South latitude, however numerous oblique images of land surfaces above these latitudes are included in the dataset. While unmodified commercial off-the-shelf digital cameras provide only visible wavelength, three-band spectral information of limited quality current cameras used with long (400+ mm) lenses can obtain high quality spatial information approaching 2 meters/ground pixel resolution. The dataset is freely available online at the Gateway to Astronaut Photography of Earth site (http://eol.jsc.nasa.gov), and now comprises over 2 million images. Despite this extensive image catalog, use of the data for scientific research, disaster response, commercial applications and visualizations is minimal in comparison to other data collected from free-flying satellite platforms such as Landsat, Worldview, etc. This is due primarily to the lack of fully-georeferenced data products - while current digital cameras typically have integrated GPS, this does not function in the Low Earth Orbit environment. The Earth Science and Remote Sensing (ESRS) Unit at NASA Johnson Space Center provides training in Earth Science topics to ISS crews, performs daily operations and Earth observation target delivery to crews through the Crew Earth Observations (CEO) Facility on board ISS, and also catalogs digital handheld imagery acquired from orbit by manually adding descriptive metadata and determining an image geographic centerpoint using visual feature matching with other georeferenced data, e.g. Landsat, Google Earth, etc. The lack of full geolocation information native to the data makes it difficult to integrate astronaut photographs with other georeferenced data to facilitate quantitative analysis such as urban land cover/land use classification, change detection, or geologic mapping. The manual determination of image centerpoints is both time and labor-intensive, leading to delays in releasing geolocated and cataloged data to the public, such as the timely use of data for disaster response. The GeoCam Space project was funded by the ISS Program in 2015 to develop an on-orbit hardware and ground-based software system for increasing the efficiency of geolocating astronaut photographs from the ISS (Fig. 1). The Intelligent Robotics Group at NASA Ames Research Center leads the development of both the ground and on-orbit systems in collaboration with the ESRS Unit. The hardware component consists of modified smartphone elements including cameras, central processing unit, wireless Ethernet, and an inertial measurement unit (gyroscopes/accelerometers/magnetometers) reconfigured into a compact unit that attaches to the base of the current Nikon D4 camera - and its replacement, the Nikon D5 - and connects using the standard Nikon peripheral connector or USB port. This provides secondary, side and downward facing cameras perpendicular to the primary camera pointing direction. The secondary cameras observe calibration targets with known internal X, Y, and Z position affixed to the interior of the ISS to determine the camera pose corresponding to each image frame. This information is recorded by the GeoCam Space unit and indexed for correlation to the camera time recorded for each image frame. Data - image, EXIF header, and camera pose information - is transmitted to the ground software system (GeoRef) using the established Ku-band USOS downlink system. Following integration on the ground, the camera pose information provides an initial geolocation estimate for the individual film frame. This new capability represents a significant advance in geolocation from the manual feature-matching approach for both nadir and off-nadir viewing imagery. With the initial geolocation estimate, full georeferencing of an image is completed using the rapid tie-pointing interface in GeoRef, and the resulting data is added to the Gateway to Astronaut Photography of Earth online database in both Geotiff and Keyhole Markup Language (kml) formats. The integration of the GeoRef software component of Geocam Space into the CEO image cataloging workflow is complete, and disaster response imagery acquired by the ISS crew is now fully georeferenced as a standard data product. The on-orbit hardware component (GeoSens) is in final prototyping phase, and is on-schedule for launch to the ISS in late 2016. Installation and routine use of the Geocam Space system for handheld digital camera photography from the ISS is expected to significantly improve the usefulness of this unique dataset for a variety of public- and private-sector applications.

Stefanov, William L.↗
NASA NTRS2020

Development of a Photosynthesis Measurement Chamber under Different Airspeeds for Applications in Future Space Crop-Production Facilities

Space crop production systems are being developed to grow fresh produce in-situ to supplement the astronauts’ diet, but the required ventilation rates for crops in different gravity environments remains poorly understood. The reduction or lack of buoyancy-driven convection in reduced gravity environments leads to impaired gas exchange (CO2 absorption, water transpiration and O2 release) at the leaf surface if no extra ventilation is provided, and this could lead to a reduction in biomass production in the long run. To better characterize the influence of different airspeeds on photosynthesis and be able to model this in low gravity, a chamber was designed to interface with a LI-6800 portable photosynthesis system. This paper details the design of this chamber, specifically made to measure whole-plant and small canopy gas exchange at different airspeeds. The fans provide turbulent mixing in the chamber to ensure that it behaves like a continuous stirred tank reactor (CSTR)and that the residence time distribution (RTD) is the same for any fan speed; the computational fluid dynamic (CFD) model of the gas domain (the air in the chamber) hence uses a k-omega turbulence model. An airflow map of the chamber was created using anemometer measurements for the different airspeeds tested, and this was used together with the CFD simulation results to relate the experimentally measured fan outputs to actual airspeeds on top of an artificial plant. Environmental parameters (air temperature, relative humidity, CO2level) are controlled by the LI-6800. This work was funded by NASA Space Biology through the NASA postdoctoral program / USRA.

Lucie Poulet↗
DOE OSTI2020

Joining Techniques for Novel Metal Polymer Hybrid Heat Exchangers

In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (< 220°C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for HX applications due to their low thermal conductivity (~0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. An ongoing work explores different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using numerical simulations. This paper explores a manufacturing pathway for producing such layered hybrid tubes that involves directly rolling and bonding tapes made of polymer and copper foil into tubes. A critical problem in the fabrication process is the bonding of metal and polymers. We explore approaches involving adhesives (epoxy, acrylic and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterizations of the thermomechanical properties of these joining processes. This work paves the way for realizing cost-effective manufacturing of heat exchangers for low grade waste heat recovery.

Kuntumalla, Gowtham↗
NASA NTRS2002

LWS/SET Technology Experiment Carrier

This paper examines the approach taken to building a low-cost, modular spacecraft bus that can be used to support a variety of technology experiments in different space environments. It describes the techniques used and design drivers considered to ensure experiment independence from as yet selected host spacecraft. It describes the technology experiment carriers that will support NASA's Living With a Star Space Environment Testbed space missions. NASA has initiated the Living With a Star (LWS) Program to develop a better scientific understanding to address the aspects of the connected Sun-Earth system that affect life and society. A principal goal of the program is to bridge the gap between science, engineering, and user application communities. The Space Environment Testbed (SET) Project is one element of LWS. The Project will enable future science, operational, and commercial objectives in space and atmospheric environments by improving engineering approaches to the accommodation and/or mitigation of the effects of solar variability on technological systems. The SET Project is highly budget constrained and must seek to take advantage of as yet undetermined partnering opportunities for access to space. SET will conduct technology validation experiments hosted on available flight opportunities. The SET Testbeds will be developed in a manner that minimizes the requirements for accommodation, and will be flown as flight opportunities become available. To access the widest range of flight opportunities, two key development requirements are to maintain flexibility with respect to accommodation constraints and to have the capability to respond quickly to flight opportunities. Experiments, already developed to the technology readiness level of needing flight validation in the variable Sun-Earth environment, will be selected on the basis of the need for the subject technology, readiness for flight, need for flight resources and particular orbit. Experiments will be accumulated by the Project and manifested for specific flight opportunities as they become available. The SET Carrier is designed to present a standard set of interfaces to SET technology experiments and to be modular and flexible enough to interface to a variety of possible host spacecraft. The Carrier will have core components and mission unique components. Once the core carrier elements have been developed, only the mission unique components need to be defined and developed for any particular mission. This approach will minimize the mission specific cost and development schedule for a given flight opportunity. The standard set of interfaces provided by SET to experiments allows them to be developed independent of the particulars of a host spacecraft. The Carrier will provide the power, communication, and the necessary monitoring features to operate experiments. The Carrier will also provide all of the mechanical assemblies and harnesses required to adapt experiments to a particular host. Experiments may be hosted locally with the Carrier or remotely on the host spacecraft. The Carrier design will allow a single Carrier to support a variable number of experiments and will include features that support the ability to incrementally add experiments without disturbing the core architecture.

Sherman, Barry↗
DOE OSTI2017

Characterization of the liquid Li-solid Mo (1 1 0) interface from classical molecular dynamics for plasma-facing applications

An understanding of the wetting properties and a characterization of theinterface between liquid lithium (Li) and solid molybdenum (Mo) are relevant to assessing the efficacy of Li as a plasma-facing component in fusion reactors. Here, a new second-nearest neighbor modified embedded-atom method (2NN MEAM) force eld is parameterized to describe the interactions between Li and Mo. The new force eld reproduces several benchmark properties obtained from first-principles quantum mechanics simulations, including binding curves for Li at three different adsorption sites and the corresponding forces on Li atoms adsorbed on the Mo (110) surface. This force field is then used to study the wetting of liquid Li on the (110) surface of Mo and to examine the Li-Mo interface using molecular dynamics simulations. From droplet simulations, we nd that liquid Li tends to completely wet the perfect Mo (110) surface, in contradiction with previous experimental measurements that found non-zero contact angles for liquid Li on a Mo substrate. However, these experiments were not carried out under ultra-high vacuum conditions or with a perfect (110) Mo surface, suggesting that the presence of impurities, such as oxygen, and surface structure play a crucial role in this wetting process. From thin- lm simulations, it is observed that the first layer of Li on the Mo (110) surface has many solid-like properties such as a low mobility and a larger degree of ordering when compared to layers further away from the surface, even at temperatures well above the bulk melting temperature of Li. Our findings are consistent with temperature-programmed desorption experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Physics based Reliability Models for Supercritical CO 2 Turbomachinery Components

CSP plants using sCO 2 power cycle can potentially achieve high thermal conversion efficiency at low capital cost due to compact turbo-machinery and other components. An sCO 2 expander and improved heat exchanger is expected to provide a major stepping stone for achieving CSP power at $0.06/kW-hr LCOE, energy conversion efficiency > 50%, and total power block cost < $1,200/kW installed. Hybrid gas bearings (HGB) and Dry gas seals (DGS) are two key components that are critical for robust and efficient operation of future sCO 2 power cycles. From a system perspective, HGBs can provide substantial benefits (~3 to 5%) to the modular CSP operation, while use of DGSs limits the leakage losses as well as the windage losses in the generator and can increase overall generator efficiency by ~ 8%. The life limiting mechanisms of HGBs and DGSs in high pressure, high temperature sCO2 environment were not well understood and hence this program aims at developing physics-based performance prediction and life prediction models for these two components. The output of the performance models serves as input to the life models. The performance models were validated using experimental data and using data from literature. DGS and HGB models have shed light on some risks associated with its operation in sCO2 expander and will guide more robust designs tailored towards sCO 2 cycle applications. A DGS was tested in 1MWe sCO2 turbo expander to study its performance and validate the performance models. To understand the effect of high pressures, high temperatures and sCO 2 environment on crack initiation, crack propagation and LCF/HCF life of these components, a novel experimental setup was developed. The LCF test data was used to calibrate and validate the life prediction models. The effect of sCO 2 corrosion on the life of Ni-based super-alloys is quantified using long duration experiments. Advanced microstructure and spectroscopic analyses conducted shed light on some key differences between IN718 and IN617 in terms of oxidation morphology, chemical species diffusion and trapping, the formation of protective corrosion resistant layers and changes in surface properties. A novel crack initiation model was developed which takes into account strain distribution, temperature, hold times and activation energy at the gas-metal interface and predicts the number of cycles to initiate the crack in the Inconel alloy. An advanced 3D fracture mechanics-based crack propagation model was also developed which takes into account the transient loading mission of the component and predict how fast the crack will grow and what will be its final shape and size. High energy X-Ray tomography measurements were conducted to study and validate 3D morphology of crack growth inside the specimen. These two models along with chemical kinetics models obtained from corrosion tests can be combined to predict the total life of the component under given long term operating conditions. A Bayesian Hybrid Modeling (BHM) probabilistic framework was developed to quantify uncertainty in physics-based performance models and in crack initiation and crack propagation models, to calibrate the models and to validate the models with statistical confidence. Advanced coupled physics multi-phase flow models were developed to study condensation, boiling and phase change behavior of CO 2 under various sCO 2 turbomachinery and heat exchanger conditions. A novel experimental setup was also designed to observe phase change of CO 2 during its transition across liquid-gas-supercritical state lines.

14 SOLAR ENERGY↗
DOE OSTI2018

CRADA 376 Final Report Development of Protective Coatings for 1 kW Hot Zone

Pacific Northwest National Laboratory (PNNL) has extensive experience in the development, fabrication, and evaluation of surface treatments and protective coatings for metallic solid oxide fuel cell (SOFC) components. For example, modified (Mn,Co)3O4 spinel coatings and coating/metal interfaces have been shown to substantially improve oxidation resistance, electrical performance, and oxide scale adhesion of ferritic stainless steel interconnects in planar SOFC stacks. At the time of the establishment of this CRADA, Protonex Technology Corporation had been working in the field of SOFC development for over 12 years and had demonstrated more than 250 thermal cycles with a less than 15 minutes start time and more than 2000 hours of continuous operation on a 250W tubular solid oxide hot zone module as part of a program for the Office of the Secretary of Defense (OSD). An industrial version of the military system, denoted P200i, had been developed that was launched at the 2015 Fuel Cell Expo in Tokyo. Feedback during beta testing of this unit was very positive. However, Protonex recognized that to transition from military markets, the commercial system would require longer life time and higher power. Leveraging their novel thermal management strategy from the tubular hot zone that allowed for rapid and repeated thermal cycling, Protonex developed a planar 1kW module aimed at the industrial and commercial market. However, more robust interconnect coatings were needed to bring the system into the 1000+ hour life time requested by customers. Therefore, PNNL’s experience and technology were engaged to enable the 1kw system to transition from military applications to commercial and industrial applications. In this CRADA, PNNL teamed with Protonex to leverage PNNL’s expertise in protective coating techniques for solid oxide fuel cell (SOFC) applications. As the first step in the collaboration, protective spinel coatings were fabricated at PNNL onto ten AISI 440 stainless steel bus bars provided by Protonex. A precursor slurry containing spinel powder was applied to the steel surfaces via an ultrasonic spray process. The coated bars were then subjected to a reducing atmosphere heat treatment (i.e., heated to 850°C at 3°C/min in a hydrogen atmosphere and held at that temperature for five hours). Five of the bars were left in this reduced condition; the other five bars were subjected to an oxidizing heat treatment (i.e., heated to 1000°C at 3°C/min in air and held at that temperature for one hour). The bars were then sent to Protonex for testing. Subsequently, Protonex decided to discontinue their SOFC development activities, so they had no further interest in continuing the collaboration with PNNL, and the CRADA activities were terminated.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Assessment of buffer-IPyC thermomechanical debonding behavior using new experimental strength data in BISON

TRIstructural ISOtropic (TRISO) fuel is a nuclear fuel commonly used in High Temperature Gas-cooled Reactors (HTGRs). A single sub-millimeter-diameter TRISO fuel particle consists of a spherical fuel kernel surrounded by four coating layers: a low-density pyrocarbon buffer layer, an inner pyrolytic carbon (IPyC) layer, a silicon carbide (SiC) layer, and an outer pyrolytic carbon (OPyC) layer. The kernel is commonly made of UO2 or a mixture of uranium carbide and uranium oxide (UCO). During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. Not all irradiated particles will experience buffer-IPyC gap formation. The debonding may be partial, or it may be nearly total. However, from post-irradiation examination of UCO TRISO fuels irradiated as part of the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program, it was concluded that partial buffer-IPyC debonding was the most common type of buffer-IPyC interaction. To predict TRISO thermomechanical performance, multi-physics models have been built that are being continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for 1D, 2D, and 3D TRISO particle simulations. This code is used to calculate fuel temperature, kernel swelling, buffer densification, thermal and irradiation creep, fracture, and fission gas production and release. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated AGR TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. That observation is also implemented in the TRISO interface debonding model. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Topology-Aware Performance Optimization and Modeling of Adaptive Mesh Refinement Codes for Exascale

Here, we introduce a topology-aware performance optimization and modeling workflow for AMR simulation that includes two new modeling tools, ProgrAMR and Mota Mapper, which interface with the BoxLib AMR framework and the SSTmacro network simulator. ProgrAMR allows us to generate and model the execution of task dependency graphs from high-level specifications of AMR-based applications, which we demonstrate by analyzing two example AMR-based multigrid solvers with varying degrees of asynchrony. Mota Mapper generates multiobjective, network topology-aware box mappings, which we apply to optimize the data layout for the example multigrid solvers. While the sensitivity of these solvers to layout and execution strategy appears to be modest for balanced scenarios, the impact of better mapping algorithms can be significant when performance is highly constrained by network hop latency. Furthermore, we show that network latency in the multigrid bottom solve is the main contributing factor preventing good scaling on exascale-class machines.

97 MATHEMATICS AND COMPUTING↗