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DOE OSTI2021

Comprehensive Margin Assessment of the ASME Section III, Division 5, Class A Primary Load Design Rules

This report provides a comprehensive margin assessment of the ASME Section III, Division 5, Subsection HB, Subpart B rules for the design of high temperature reactor components against load controlled stress limits. These rules, often called the Code primary load design rules, provide protection against creep rupture and plastic collapse under steady conditions. The method adopted here is to compare the deterministic ASME design life, according to the primary load design rules, against the expected, statistical service life of the component, considering creep rupture as the relevant failure mode. The report provides the design margin of the ASME rules in terms of the probability of premature failure -- the probability that the component fails in service before reaching the ASME design life. To complete this assessment, the report describes the development of a statistical creep life assessment procedure accounting for variations in the component loading, material creep rate, and the material rupture time. This includes a novel method for correlating creep rupture data using a Gaussian process accounting for heat-to-heat variation in the Larson-Miller time-temperature parameter. The report applies the complete margin assessment process to quantify the design margin inherent in the ASME primary load design rules as a function of temperature for relevant component geometries and materials. The overall conclusion is that the ASME rules are conservative, providing designs with very small probability of premature failure, but some optimization of the Code design rules is possible to provide a more uniform design margin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and Their Weldments for Gen3 CSP

Generation 3 (Gen3) concentrating solar power (CSP) plants may require the use of molten chloride salt storage systems, solar receivers, and supercritical-CO 2 primary heat exchangers (PHX). The temperatures that would be expected in these parts and subcomponents could approach 760°C for hot side and 500°C for cold side at peak operating conditions. With the design limitations, highly corrosion- and creep-resistant alloys are needed for maximizing component lives. This report presents the results for the project "Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and their Weldments for Gen3 CSP", award number DE-EE00036334. In this project, creep enhanced ferritic alloy Grade 91, austenitic stainless-steel (SS) 304H, Ni claddings Ni201 and C22, and nickel-based superalloys Inconel 740H and Haynes 282 and 230 were evaluated for potential applications in Gen3 CSP systems. Advanced manufacturing of these parts, subcomponents and their welds, was investigated and a full technoeconomic analysis was made in comparison to conventional manufacturing techniques. The manufacturing techniques explored are explosion clad welding and combustion synthesis/combustion reaction for transfer pipes, additive manufacturing (AM) including laser-powder bed fusion (L-PBF) and electron beam AM (EBAM) with wire feedstock for PHX and solar receivers, and conventional fusion welding for similar and dissimilar joining of these various parts and subcomponents.

14 SOLAR ENERGY↗

DOE OSTI1991

Physical and Operational Status of the Photovoltaic Systems in the Municipality of Pinotepa de Don Luis, Oaxaca, One Year after Their Installation [Estado fisico y operativo de los sistemas fotovoltaicos en el municipio de Pinotepa de Don Luis, Oaxaca un ano despues de su instalacion]

In November 1990, an inspection visit was made to the residential lighting photovoltaic systems that had been installed approximately one year before in the rural communities of the Municipality of Pinotepa de Don Luis, in the State of Oaxaca. The main purpose of the visit was to evaluate the physical and operational status of these systems. The systems typically consist of a photovoltaic module with a capacity of 30 or 35 Watts, an automotive type battery, an indicator of the status of charge of the battery, 3 fluorescent lamps and the corresponding installation, including cables, connection or outlet box and switches. It can be seen that the systems are in good physical condition and do not show any signs of intentionally caused damage. However, the incidence of failures is higher than what had been expected; therefore the operational status of these systems is considered to be below a level that could be accepted, with a tendency to getting worse. The main problem that has been detected is the lack of automatic charge controllers. This problem has caused other important failures. Serious deficiencies were appreciated in the installations, which show evidence of the poor workmanship of the installers. The lack of system standardization is evident, both regarding the components and the installation. As a consequence, there are technical factors which indicate that the installed systems will keep deteriorating at a rate faster than normal, and will stop operating in a short time unless urgent preventive and corrective measures are taken. The attitude of the users with respect to the systems is generally positive. However, there are elements that make the correct operation and maintenance of these systems a very difficult task. The users did not receive any training regarding the best way to operate and take care of their systems, nor any other information in relation to their technical limitations.

14 SOLAR ENERGY↗

NASA NTRS1982

Low NOx heavy fuel combustor concept program

Three simulated coal gas fuels based on hydrogen and carbon monoxide were tested during an experimental evaluation with a rich lean can combustor: these were a simulated Winkler gas, Lurgi gas and Blue Water gas. All three were simulated by mixing together the necessary pure component species, to levels typical of fuel gases produced from coal. The Lurgi gas was also evaluated with ammonia addition. Fuel burning in a rich lean mode was emphasized. Only the Blue Water gas, however, could be operated in such fashion. This showed that the expected NOx signature form could be obtained, although the absolute values of NOx were above the 75 ppm goals for most operating conditions. Lean combustion produced very low NOx well below 75 ppm with the Winkler and Lurgi gases. In addition, these low levels were not significantly impacted by changes in operating conditions.

White, D. J.↗

NASA NTRS1983

Large-scale counterstreaming of H(+) and He(+) along plasmaspheric flux tubes

An interhemispheric plasma transport model is used to study the flow characteristics of H(+), He(+), and O(+) along closed geomagnetic field lines for solstice conditions. The model corresponds to a time-dependent solution of the coupled continuity, momentum, and energy equations for the ions and electrons. The equations are solved along an entire flux tube from 120 km in one hemisphere to 120 km in the other hemisphere. The calculations are carried out for noon conditions for the flux tube passsing through Millstone Hill, at L = 3.2. The main conclusion is that H(+)-He(+) counterstreaming can be expected along a large segment of a plasmaspheric flux tube at solstice. For both symmetric and asymmetric wind patterns, the He(+) flow is from the winter to the summer ionosphere not only in the steady state, but during flux tube refilling due to the winter helium bulge and the depletion of N2.

Richards, P. G.↗

NASA NTRS1985

Preliminary measurement of the noise from the 2/9 scale model of the Large-scale Advanced Propfan (LAP) propeller, SR-7A

Noise data on the Large-scale Advanced Propfan (LAP) propeller model SR-7A were taken into the NASA Lewis 8- by 6-Foot Wind Tunnel. The maximum blade passing tone decreases from the peak level when going to higher helical tip Mach numbers. This noise reduction points to the use of higher propeller speeds as a possible method to reduce airplane cabin noise while maintaining high flight speed and efficiency. Comparison of the SR-7A blade passing noise with the noise of the similarly designed SR-3 propeller shows good agreement as expected. The SR-7A propeller is slightly noisier than the SR-3 model in the plane of rotation at the cruise condition. Projections of the tunnel model data are made to the full-scale LAP propeller mounted on the test bed aircraft and compared with design predictions. The prediction method is conservative in the sense that it overpredicts the projected model data.

Dittmar, J. H.↗

NASA NTRS1990

Users Manual for the NASA Lewis Ice Accretion Prediction Code (LEWICE)

LEWICE is an ice accretion prediction code that applies a time-stepping procedure to calculate the shape of an ice accretion. The potential flow field is calculated in LEWICE using the Douglas Hess-Smith 2-D panel code (S24Y). This potential flow field is then used to calculate the trajectories of particles and the impingement points on the body. These calculations are performed to determine the distribution of liquid water impinging on the body, which then serves as input to the icing thermodynamic code. The icing thermodynamic model is based on the work of Messinger, but contains several major modifications and improvements. This model is used to calculate the ice growth rate at each point on the surface of the geometry. By specifying an icing time increment, the ice growth rate can be interpreted as an ice thickness which is added to the body, resulting in the generation of new coordinates. This procedure is repeated, beginning with the potential flow calculations, until the desired icing time is reached. The operation of LEWICE is illustrated through the use of five examples. These examples are representative of the types of applications expected for LEWICE. All input and output is discussed, along with many of the diagnostic messages contained in the code. Several error conditions that may occur in the code for certain icing conditions are identified, and a course of action is recommended. LEWICE has been used to calculate a variety of ice shapes, but should still be considered a research code. The code should be exercised further to identify any shortcomings and inadequacies. Any modifications identified as a result of these cases, or of additional experimental results, should be incorporated into the model. Using it as a test bed for improvements to the ice accretion model is one important application of LEWICE.

Ruff, Gary A.↗

NASA NTRS1991

Gas chromatographic concepts for the analysis of planetary atmospheres

Over the last few years, new gas chromatographic (GC) concepts were developed for use on board spacecraft or any other restricted environments for determining the chemical composition of the atmosphere and surface material of various planetary bodies. Future NASA Missions include an entry probe that will be sent to Titan and various spacecraft that will land on Mars. In order to be able to properly respond to the mission science requirements and physical restrictions imposed on the instruments by these missions, GC analytical techniques are being developed. Some of these techniques include hardware and mathematical techniques that will improve GC sensitivity and increase the sampling rate of a GC descending through a planetary atmosphere. The technique of Multiplex Gas Chromatography (MGC) is an example of a technique that was studied in a simulated Titan atmosphere. In such an environment, the atmospheric pressure at instrument deployment is estimated to be a few torr. Thus, at such pressures, the small amount of sample that is acquired might not be enough to satisfy the detection requirements of the gas chromatograph. In MGC, many samples are pseudo-randomly introduced to the chromatograph without regard to elution of preceding components. The resulting data is then reduced using mathematical techniques such as cross-correlation of Fourier Transforms. Advantages realized from this technique include: improvement in detection limits of several orders of magnitude and increase in the number of analyses that can be conducted in a given period of time. Results proving the application of MGC at very low pressures emulating the same atmospheric pressures that a Titan Probe will encounter when the instruments are deployed are presented. The sample used contained hydrocarbons that are expected to be found in Titan's atmosphere. In addition, a new selective modulator was developed to monitor water under Martian atmospheric conditions. Since this modulator is selective only to water, the need for a GC column is eliminated. This results in further simplification of the instrument.

Valentin, J. R.↗

NASA NTRS1993

Spacecraft contamination issues from LDEF: Issues for design

Many contamination sources have been identified on the Long Duration Exposure Facility (LDEF). Effects of contamination from these sources are being quantified and have been reported on in several papers. For a designer, the essential question is how much contamination from all sources can be tolerated without causing a given spacecraft system to degrade below a critical performance level, or fail altogether. Even a rudimentary knowledge of the mechanisms by which molecular and particulate contamination can occur will allow simple design options to be chosen to circumvent potential contamination problems and reduce contamination levels. Because of the varied nature and condition of hardware used on LDEF experiments, examples of many types of contamination were seen and these provide a useful guide to expected performance of many types of materials in space environments.

Pippin, Gary↗

NASA NTRS1993

The effect of Na vapor on the Na content of chondrules

Chondrules contain higher concentrations of volatiles (Na) than expected for melt droplets in the solar nebula. Recent studies have proposed that chondrules may have formed under non-canonical nebular conditions such as in particle/gas-rich clumps. Such chondrule formation areas may have contained significant Na vapor. To test the hypothesis of whether a Na-rich vapor would minimize Na volatilization reaction rates in a chondrule analog and maintain the Na value of the melt, experiments were designed where a Na-rich vapor could be maintained around the sample. A starting material with a melting point lower that typical chondrules was required to keep the logistics of working with Na volatilization from NaCl within the realm of feasibility. The Knippa basalt, a MgO-rich alkali olivine basalt with a melting temperature of 1325 +/- 5 C and a Na2O content of 3.05 wt%, was used as the chondrule analog. Experiments were conducted in a 1 atm, gas-mixing furnace with the fO2 controlled by a CO/CO2 gas mixture and fixed at the I-W buffer curve. To determine the extent of Na loss from the sample, initial experiments were conducted at high temperatures (1300 C - 1350 C) for duration of up to 72 h without a Na-rich vapor present. Almost all (up to 98%) Na was volatilized in runs of 72 h. Subsequent trials were conducted at 1330 C for 16 h in the presence of a Na-rich vapor, supplied by a NaCl-filled crucible placed in the bottom of the furnace. Succeeding Knudsen cell weight-loss mass-spectrometry analysis of NaCl determined the P(sub Na) for these experimental conditions to be in the 10(exp -6) atm range. This value is considered high for nebula conditions but is still plausible for non-canonical environments. In these trials the Na2O content of the glass was maintained or in some cases increased; Na2O values ranged from 2.62% wt to 4.37% wt. The Na content of chondrules may be controlled by the Na vapor pressure in the chondrule formation region. Most heating events capable of producing chondrules are sufficient to volatile Na. Sodium volatilization reaction rates will be reduced to varying degrees from melt droplets, depending on the magnitude of the P(sub Na) generated. A combination of Na vapor during, and Na diffusion back into chondrules after, formation could maintain and/or enrich Na concentrations in chondrules.

Lewis, R. Dean↗

NASA NTRS2000

Process for Ignition of Gaseous Electrical Discharge Between Electrodes of a Hollow Cathode Assembly

The design and manufacturing processes for Hollow Cathode Assemblies (HCA's) that operate over a broad range of emission currents up to 30 Amperes, at low potentials, with lifetimes in excess of 17,500 hours. The processes include contamination control procedures which cover hollow cathode component cleaning procedures, gas feed system designs and specifications, and hollow cathode activation and operating procedures to thereby produce cathode assemblies that have demonstrated stable and repeatable operating conditions, for both the discharge current and voltage. The HCA of this invention provides lifetimes of greater than 10,000 hours, and expected lifetimes of greater than 17,500 hours, whereas the present state-of-the-art is less than 500 hours at emission currents in excess of 1 Ampere. Stable operation is provided over a large range of operating emission currents, up to a 6:1 ratio, and this HCA can emit electron currents of up to 30 Amperes in magnitude to an external anode that simulates the current drawn to a space plasma, at voltages of less than 20 Volts.

Patterson, Michael J.↗

NASA NTRS2002

Design and Manufacturing Processes of Long-Life Hollow Cathode Assemblies

Michael J Patterson↗

NASA NTRS2003

HEASARC Software Archive

(1) Chandra Archive: SAO has maintained the interfaces through which HEASARC gains access to the Chandra Data Archive. At HEASARC's request, we have implemented an anonymous ftp copy of a major part of the public archive and we keep that archive up-to- date. SAO has participated in the ADEC interoperability working group, establishing guidelines or interoperability standards and prototyping such interfaces. We have provided an NVO-based prototype interface, intending to serve the HEASARC-led NVO demo project. HEASARC's Astrobrowse interface was maintained and updated. In addition, we have participated in design discussions surrounding HEASARC's Caldb project. We have attended the HEASARC Users Group meeting and presented CDA status and developments. (2) Chandra CALDB: SA0 has maintained and expanded the Chandra CALDB by including four new data file types, defining the corresponding CALDB keyword/identification structures. We have provided CALDB upgrades for the public (CIAO) and for Standard Data Processing. Approximately 40 new files have been added to the CALDB in these version releases. There have been in the past year ten of these CALDB upgrades, each with unique index configurations. In addition, with the inputs from software, archive, and calibration scientists, as well as CIAO/SDP software developers, we have defined a generalized expansion of the existing CALDB interface and indexing structure. The purpose of this is to make the CALDB more generally applicable and useful in new and future missions that will be supported archivally by HEASARC. The generalized interface will identify additional configurational keywords and permit more extensive calibration parameter and boundary condition specifications for unique file selection. HEASARC scientists and developers from SAO and GSFC have become involved in this work, which is expected to produce a new interface for general use within the current year. (3) DS9: One of the decisions that came from last year's HEADCC meeting was to make the ds9 image display program the primary vehicle for displaying line graphics (as well as images). The first step required to make this possible was to enhance the line graphics capabilities of ds9. SAO therefore spent considerable effort upgrading ds9 to use Tcl 8.4 so that the BLT line graphics package could be built and imported into ds9 from source code, rather than from a pre-built (and generally outdated) shared library. This task, which is nearly complete, allows us to extend BLT as needed for the HEAD community. Following HEADCC discussion concerning archiving and the display of archived data, we extended ds9 to support full access to many astronomical Web-based archives sites, including HEASARC, MAST, CHANDRA, SKYVIEW, ADS, NED, SIMBAD, IRAS, NVRO, SAO TDC, and FIRST. Using ds9's new internal Web access capabilities, these archives can be accessed via their Web page. FITS images, plots, spectra, and journal abstracts can be referenced, down-loaded, and displayed directly and easily in ds9. For more information, see: http://hea-www.harvard.edu/saord/ds9. Also after the HEADCC discussion concerning region filtering, we extended the Funtools sample implementation of region filtering as described in: http://hea-www.harvard.edu/saord/funtools/regions.html. In particular, we added several new composite regions for event and image filtering, including elliptical and box annuli. We also extended the panda (Pie AND Annulus) region support to include box pandas and elliptical pandas. These new composite regions are especially useful in programs that need to count photons in each separate region using only a single pass through the data. Support for these new regions was added to ds9. In the same vein, we developed new region support for filtering images using simple FITS image masks, i.e. 8-bit or 16-bit FITS images where the value of a pixel is the region id number for that pixel. Other important enhancements to DS9 this year, include supporor multiple world coordinate systems, three dimensional event file binning, image smoothing, region groups and tags, the ability to save images in a number of image formats (such as JPEG, TIFF, PNG, FITS), improvements in support for integrating external analysis tools, and support for the virtual observatory. In particular, a full-featured web browser has been implemented within D S 9 . This provides support for full access to HEASARC archive sites such as SKYVIEW and W3BROWSE, in addition to other astronomical archives sites such as MAST, CHANDRA, ADS, NED, SIMBAD, IRAS, NVRO, SA0 TDC, and FIRST. From within DS9, the archives can be searched, and FITS images, plots, spectra, and journal abstracts can be referenced, downloaded and displayed The web browser provides the basis for the built-in help facility. All DS9 documentation, including the reference manual, FAQ, Know Features, and contact information is now available to the user without the need for external display applications. New versions of DS9 maybe downloaded and installed using this facility. Two important features used in the analysis of high energy astronomical data have been implemented in the past year. The first is support for binning photon event data in three dimensions. By binning the third dimension in time or energy, users are easily able to detect variable x-ray sources and identify other physical properties of their data. Second, a number of fast smoothing algorithms have been implemented in DS9, which allow users to smooth their data in real time. Algorithms for boxcar, tophat, and gaussian smoothing are supported.

White, Nicholas↗

NASA NTRS2003

Oxidation of Carbon Fibers in Water Vapor Studied

T-300 carbon fibers (BP Amoco Chemicals, Greenville, SC) are a common reinforcement for silicon carbide composite materials, and carbon-fiber-reinforced silicon carbide composites (C/SiC) are proposed for use in space propulsion applications. It has been shown that the time to failure for C/SiC in stressed oxidation tests is directly correlated with the fiber oxidation rate (ref. 1). To date, most of the testing of these fibers and composites has been conducted in oxygen or air environments; however, many components for space propulsion, such as turbopumps, combustors, and thrusters, are expected to operate in hydrogen and water vapor (H2/H2O) environments with very low oxygen contents. The oxidation rate of carbon fibers in conditions representative of space propulsion environments is, therefore, critical for predicting component lifetimes for real applications. This report describes experimental results that demonstrate that, under some conditions, lower oxidation rates of carbon fibers are observed in water vapor and H2/H2O environments than are found in oxygen or air. At the NASA Glenn Research Center, the weight loss of the fibers was studied as a function of water pressure, temperature, and gas velocity. The rate of carbon fiber oxidation was determined, and the reaction mechanism was identified.

Opila, Elizabeth J.↗

NASA NTRS2003

Thermal Response of Cooled Silicon Nitride Plate Due to Thermal Conductivity Effects Analyzed

Lightweight, strong, tough high-temperature materials are required to complement efficiency improvements for next-generation gas turbine engines that can operate with minimum cooling. Because of their low density, high-temperature strength, and high thermal conductivity, ceramics are being investigated as materials to replace the nickelbase superalloys that are currently used for engine hot-section components. Ceramic structures can withstand higher operating temperatures and a harsh combustion environment. In addition, their low densities relative to metals help reduce component mass (ref. 1). To complement the effectiveness of the ceramics and their applicability for turbine engine applications, a parametric study using the finite element method is being carried out. The NASA Glenn Research Center remains very active in conducting and supporting a variety of research activities related to ceramic matrix composites through both experimental and analytical efforts (ref. 1). The objectives of this work are to develop manufacturing technology, develop a thermal and environmental barrier coating (TBC/EBC), develop an analytical modeling capability to predict thermomechanical stresses, and perform a minimal burner rig test on silicon nitride (Si3N4) and SiC/SiC turbine nozzle vanes under simulated engine conditions. Moreover, we intend to generate a detailed database of the material s property characteristics and their effects on structural response. We expect to offer a wide range of data since the modeling will account for other variables, such as cooling channel geometry and spacing. Comprehensive analyses have begun on a plate specimen with Si3N4 cooling holes.

Baaklini, George Y.↗

NASA NTRS2004

PS300 Tribomaterials Evaluated at 6500C by Bushing Test Rig

A new facility has been developed to test the tribological behavior (friction and wear) of PS300 solid lubricant bushings at high temperatures. PS300 is a commercially available solid lubricant invented at the NASA Glenn Research Center. It can be prepared as a plasma spray coating or as a free-standing powder metallurgy component, designated PM300. PS300 and PM300 composites are designed to lubricate sliding components at temperatures above the capability of today's best oils, greases, and solid lubricants. One of the primary applications being pursued for PM300 is the development of bushings for use in high-temperature machinery. Examples include inlet guide vane bushings for gas turbines and conveyors, and bearings for industrial furnaces and ovens. Encouraging preliminary field trials indicate that PS300 and PM300 lubricant materials have been commercialized successfully in several industrial applications. However, the lack of laboratory performance data has hindered further commercialization especially for new applications that differ significantly from the established experience base. The purpose of the newly developed bushing test rig will be to determine the performance characteristics of PM300, and other materials, under conditions closely matching intended applications. The data will be used to determine engineering friction and wear rates and to estimate the life expectancy of bushings for new applications. In the new rig, the bushing is loaded against a rotating shaft inside a furnace enclosure (see the preceding photograph). Loads can vary from 5 to 200 N, speeds from 1 to 400 rpm, and temperatures from 25 to 800 C. Furnace temperature, bushing temperature, shaft speed, and torque are monitored during the test, and wear of both the bushing and the shaft is measured after testing is completed. Initially, PM300 bushings will be evaluated and compared with lower temperature, traditional bushing materials like graphite and porous bronze. The baseline PM304 composition is 60 wt% NiCr (a binder), 20 wt% Cr2O3 (a hardener), 10 wt% BaF2/CaF2 (a high-temperature lubricant), and 10 wt% Ag (a low-temperature lubricant). Future research efforts will include determining the effects of load, sliding speed, and temperature on tribological performance and, possibly, tailoring composition for specific applications. We expect that the availability of measured performance data will enhance the market penetration of PM300 technology.

Striebing, Donald R.↗

NASA NTRS2007

Spatial Pattern of Cell Damage in Tissue from Heavy Ions

A new Monte Carlo algorithm was developed that can model passage of heavy ions in a tissue, and their action on the cellular matrix for 2- or 3-dimensional cases. The build-up of secondaries such as projectile fragments, target fragments, other light fragments, and delta-rays was simulated. Cells were modeled as a cell culture monolayer in one example, where the data were taken directly from microscopy (2-d cell matrix). A simple model of tissue was given as abstract spheres with close approximation to real cell geometries (3-d cell matrix), as well as a realistic model of tissue was proposed based on microscopy images. Image segmentation was used to identify cells in an irradiated cell culture monolayer, or slices of tissue. The cells were then inserted into the model box pixel by pixel. In the case of cell monolayers (2-d), the image size may exceed the modeled box size. Such image was is moved with respect to the box in order to sample as many cells as possible. In the case of the simple tissue (3-d), the tissue box is modeled with periodic boundary conditions, which extrapolate the technique to macroscopic volumes of tissue. For real tissue, specific spatial patterns for cell apoptosis and necrosis are expected. The cell patterns were modeled based on action cross sections for apoptosis and necrosis estimated based on BNL data, and other experimental data.

Ponomarev, Artem L.↗

NASA NTRS2004

Process for testing a xenon gas feed system of a hollow cathode assembly

Patterson, Michael J.↗