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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Enhanced critical axial tensile strain limit of CORC ® wires: FEM and analytical modeling

Abstract Conductor on Round Core (CORC ® ) cables and wires are composed of spiraled high-temperature superconducting (HTS) rare-earth barium copper oxide (REBCO) tapes, wound in multiple layers, and can carry very high currents in background magnetic fields of more than 20 T. They combine isotropic flexibility and high resilience to electromagnetic and thermal loads. The brittle nature of HTS tapes limits the maximum allowable axial tensile strain in superconducting cables. An intrinsic tensile strain above about 0.45% will introduce cracks in the REBCO layer of straight HTS tapes resulting in irreversible damage. The helical fashion at which the REBCO tapes are wound around the central core allows tapes to experience only a fraction of the total axial tensile strain applied to the CORC ® wire. As a result, the critical strain limit of CORC ® wires can be increased by a factor of more than 10 that of REBCO tapes. Finite element (FE) and analytical models are developed to predict the performance of CORC ® wires under axial tensile strain. A parametric analysis is carried out by varying the winding angle, the Poisson’s ratio of the CORC ® wire core, the core diameter, and the tape width. The results show that a small variation in winding angle can have a significant impact on the cable’s axial tensile strain tolerance. While the radial contraction of the helically wound tapes in a CORC ® wire under axial tensile strain depends on its winding angle, it is mostly driven by the Poisson’s ratio of the central core, affecting the tape strain state and thus its performance. Contact pressure from multiple layers within the CORC ® wire also affects the CORC ® wire performance. The FE model can be used to optimize the cable design for specific application conditions, resulting in an irreversible strain limit of CORC ® cables and wires as high as 7%.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem

Evaluation of proposed Section III Division 5 Class B rules: Piping example problem to be presented include Z pipe geometry and model problem statement, Z pipe loads and design inputs problem statement, Primary Stress Limit overview, Primary stress limit pseudo yield stress calculation, Primary stress limited factored load procedure, Strain limit evaluation composite load cycle, Strain limit evaluation pseudo yield stress, Strain limit evaluation strain limit criteria and ratcheting check, Creep fatigue damage evaluation overview, Creep fatigue damage evaluation alternating stress calculations, Creep fatigue damage evaluation lower bound stress, Creep fatigue damage evaluation stress relaxation history, Creep fatigue damage evaluation damage fractions, and Recommendations to consider for Z-pipe problem.

42 ENGINEERING↗
DOE OSTI2021

Report on FY 2021 testing in support of integrating Alloy 800H and 2.25Cr-1Mo for EPP analysis

The use of simplified Elastic-Perfectly Plastic (EPP) design methods avoids the complexities and limitations of the elastic analysis approach in evaluating strain limits and creep-fatigue damage for Class A metallic coolant boundary components in ASME Boiler and Pressure Vessel Code, Section III, Division 5, Subsection HB, Subpart B. No stress classification and linearization are required in the EPP methods. Further, the strain limits and creep-fatigue damage evaluation procedures based on elastic analysis results were developed for the reactor operating conditions where uncoupled, rate-independent plasticity and stationary creep can be used to approximate the deformation in the component adequately. But at very high temperatures, the deformation is rate-dependent, and it can only be approximated adequately by unified viscoplastic model. Thus, for example, the elastic analysis approach cannot be used to evaluate strain limits and creep-fatigue damage for Alloy 617 above 650 °C. The EPP methods remove the temperature restriction. They can be used to evaluate strain limits and creep-fatigue damage for the full range of temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Protocols and methodologies for acquiring and analyzing critical-current versus longitudinal-strain data in Bi 2 Sr 2 CaCu 2 O 8+x wires

Abstract In the literature on Bi 2 Sr 2 CaCu 2 O 8+ x (Bi-2212) superconducting wires, it is evident that measurement protocols for transport critical-current I c versus longitudinal strain ϵ and definitions of the so-called ‘strain limit’ are generally dissimilar. Yet, values obtained for the ‘strain limit’ are frequently assimilated to being those of the irreversible strain limit ϵ irr , regardless of the I c degradation-criterion used to define it. In effect, ϵ irr should correspond specifically to the I c ( ϵ ) irreversibility onset , where crack formation in Bi-2212 filaments presumably starts. Because I c ( ϵ ) degradation remains progressive over a fairly wide strain range beyond ϵ irr , the different I c degradation-criteria in use do not yield to the same result and, thus, are not equivalent from metrology perspective. Indeed, in studying densified samples of a modern Bi-2212 round wire, we found ϵ irr ≈ 0.4% and ϵ 5% ≈ 0.6% ( ϵ 5% being the strain where I c degrades by 5%). In this paper, we outline and suggest I c ( ϵ )-measurement protocols and data-analysis methodologies in the hope to converge the various approaches taken for studying Bi-2212 strain properties and, thus, remove related result discrepancies. A unified approach would enable more objective data comparisons among laboratories and among different Bi-2212 conductors. It would pave the way for more rigorous studies of effects potentially associated with wire design, powder, heat treatments, and other such parameters on the conductor’s strain properties.

protocols↗
DOE OSTI2021

High-temperature superconducting CORC ® wires with record-breaking axial tensile strain tolerance present a breakthrough for high-field magnets

Cuprate high-temperature superconductors (HTS), such as RE-Ba 2 Cu 3 O 7–δ (REBCO, RE = rare earth), (Bi,Pb) 2 Sr 2 Ca 2 Cu 3 O 10–x and Bi 2 Sr 2 CaCu 2 O 8–x , have enabled the development of high-field superconducting magnets capable of generating magnetic fields far exceeding 20 T. The brittle nature of HTS requires elaborate means to protect them against the high stresses and strains associated with high-field magnet operation, and so far, has prevented reliable high-field HTS magnets from becoming a reality. Here we report a more than tenfold increase in the irreversible strain limit under axial tension (epsilonirr) to over 7% in optimized high-current conductor on round core (CORC®) conductors, compared to the REBCO tapes from which the CORC® conductor is wound. Minimizing the tape winding pitch of the helical wind mechanically decouples the brittle REBCO film from the overall conductor. The REBCO tapes behave as springs, limiting the rate at which applied strain is transferred to the ceramic film. In addition, high-strength alloy cores allow the critical stress (ϵ crit ) under axial tension at which initial degradation of CORC® conductors occurs to exceed 600 MPa, making them one of the strongest superconductors available. Mechanically decoupling the ceramic REBCO films from the overall CORC® conductor allows effective protection against the high operating stresses in high-field magnets. Furthermore, this breakthrough presents a monumental shift for HTS magnet technology, bringing reliable high-field superconducting magnets for compact fusion machines, the next generation of particle accelerators, and 40–60 T research solenoids within reach.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Approaching the Strain-Free Limit in Ultrathin Nanomechanical Resonators

Ultrathin mechanical structures are ideal building platforms to pursue the ultimate limit of nanomechanical resonators for applications in sensing, signal processing, and quantum physics. Unfortunately, as the thickness of the vibrating structures is reduced, the built-in strain of the structural materials plays an increased role in determining the mechanical performance of the devices. As a consequence, it is very challenging to fabricate resonators working in the modulus-dominant regime, where their dynamic behavior is exclusively determined by the device geometry. In this Letter, we report ultrathin doubly clamped nanomechanical resonators with aspect ratios as large as L/t similar to 5000 and working in the modulus-dominant regime. Here, we observed room temperature thermomechanically induced motion of multiple vibration modes with resonant frequencies closely matching the predicted values of Euler-Bernoulli beam theory under an axial strain of 6.3 x 10 -8 . The low strain of the devices enables a record frequency tuning ratio of more than 50 times. These results illustrate a new strategy for the quantitative design of nanomechanical resonators with unprecedented performance.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Experimental Investigation on the Performance Loss of Cross-Linked Polymers During Photo-Oxidative Aging

Abstract Polymeric substances have seen an unprecedented integration in countless applications and fields of life, subjecting them to a broad range of environmental conditions, which can cause a form of damage to the structural and mechanical properties of these components known as aging. In this study we investigate the effects of the degradation of polymeric materials due to the extended exposure to sunlight, which can be simulated through controlled photo-oxidative aging using ultraviolet (UV) radiation as the main catalyst of this phenomenon. The effects on mechanical behavior and chemical properties of four polymeric materials with different mechanical characteristics was accordingly monitored throughout the study. The materials range in hardness with the polyurethane adhesive being the hardest and acting plastically, followed by an acrylic which exhibits greater hardening with time, a polyurethane sealant, which behaves in an elastomeric manner, and a silicon sealant, which is the softest of the set. Samples were prepared and subjected to UV radiation at three different temperatures namely 45, 60 and 80°C, for different aging periods ranging from 1 day for higher temperatures to 150 days for lower ones. The samples were then subjected to the Fourier transform Infrared spectroscopy (FTIR) test to monitor the change in the chemical composition of the materials along the aging durations and conditions. The materials were then subjected to mechanical testing along two modes of mechanical loading, which are a simple tension until failure and a double-cyclic test with progressively increasing strain limits after every two successful cycles until the sample reaches failure. The samples are loaded at constant strain rates throughout both tests. These tests revealed the change of behavior of our materials along the aging periods and conditions. The changes in mechanical behavior vary across each individual material depending on the aging temperature and period, with the changes ranging from hardening to softening, embrittlement or an increase in the maximum strain the material can endure before failure. A general trend would be that most materials become harder after photo-oxidation, however due to the range of temperatures in the aging conditions, thermo-oxidation, which causes softening in some of the polymers, has an increasingly notable effect at higher temperatures. A visible correlation can be noted between the change in mechanical behavior and a change in absorbance of Infrared Radiation (IR) in the FTIR spectrum, as the greater the crosslinking throughout the polymer matrix, the lower the absorbance of IR radiation due to the increased stiffness of the overall macro-molecular structure.

Korayem, Abd-Elrahman↗
DOE OSTI2025

The classical-to-quantum crossover in the strain-induced ferroelectric transition in SrTiO3 membranes

Mechanical strain presents an effective control over symmetry-breaking phase transitions. In quantum paralelectric SrTiO3, strain can induce ferroelectric order via modification of the local Ti potential energy landscape. However, brittle bulk materials can only withstand limited strain range (~0.1%). Taking advantage of nanoscopically-thin freestanding membranes, we demonstrate an in- situ strain-induced reversible ferroelectric transition in freestanding SrTiO3 membranes. We measure the ferroelectric order by detecting the local anisotropy of the Ti 3d orbital signature using x-ray linear dichroism at the Ti-K pre-edge, while the strain is determined by x-ray diffraction. With reduced thickness, the SrTiO3 membranes remain elastic with >1% tensile strain cycles. A robust displacive ferroelectricity appears beyond a temperature-dependent critical strain. Interestingly, we discover a crossover from a classical ferroelectric transition to a quantum regime at low temperatures, which enhances strain-induced ferroelectricity. Our results offer new opportunities to strain engineer functional properties in low dimensional quantum materials and provide new insights into the role of ferroelectric fluctuations in quantum paraelectric SrTiO3.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Design by analysis rules for ASME Section III, Division 5, Class B components

The current rules for elevated temperature ASME Section III, Division 5, Class B components, other than piping, were basically adapted from the Design-by-Rule approach for Section VIII, Division 1 vessels. A goal of the proposed new rules is to explicitly account for the design life and cyclic service while recognizing the less-rigorous requirements commensurate with lesser safety consideration. Further goals are to maximize the use of modern computational technology, for example finite element analysis in conjunction with reference stress concepts, and to avoid the need for stress classification. This paper summarizes the work done to address these issues. A summary of the design-by-analysis for primary loads, strain limit evaluation, and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules and the experimental data obtained from a family of a simplified model test-based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2023

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Geomechanical Simulation of Big Hill Strategic Petroleum Reserve - Calibration of Model Containing Shear Zone

A finite element numerical analysis model, that consists of a realistic mesh capturing the geometries of Big Hill (BH) Strategic Petroleum Reserve (SPR) site using the multi-mechanism deformation (MD) salt constitutive model and including data taken daily of the wellhead pressure and level of the oil-brine interface, has been upgraded. The upgraded model contains the shear zone to examine the interbed behavior in a realistic manner. The salt creep rate is not uniform in the salt dome, and creep test data for BH salt is limited. Therefore, a model calibration is necessary to simulate the geomechanical behavior of the salt dome. Cavern volumetric closures of SPR caverns calculated from sonar survey reports are used for the field baseline measurement. The structure factor, A 2 , and transient strain limit factor, K 0 , in the M-D constitutive model are used for model calibration. An A 2 value obtained experimentally from the BH salt and K 0 value of WIPP salt are used as the baseline values. To adjust the magnitude of A 2 and K 0 , multiplication factors A 2 F and K 0 F are defined, respectively. The A 2 F and K 0 F values of the salt dome and salt drawdown layer of elements surrounding each SPR cavern have been determined through a number of back fitting analyses. The trendlines of the predictions and sonar data match up well for BH 101, 103, 104, 106, 110, 111, 112, and 113. The prediction curves are close to the sonar data for BH 102 and 114. However, the prediction curves for BH 105, 107, 108, and 109 are not close to the sonar data. An inconsistency was found in the sonar data, i.e. the volume measured later is larger than that before in some time intervals, even if the leached volume is taken into account, for BH 101, 104, 106, 107, and 112. Project discussions are needed to determine possibilities on how to resolve the issues and determine the best path forward for future computer modeling attempts.

02 PETROLEUM↗
DOE OSTI2019

Predicting forming limit diagrams for magnesium alloys using crystal plasticity finite elements

The crystal plasticity finite element (CPFE) method was used to predict forming limit strains of hexagonal close-packed (HCP) polycrystalline magnesium alloy sheets, namely AZ31 and ZE10, under an isothermal temperature condition. The strain rate-dependent uniaxial tensile test data along various loading directions and an initial texture were used to determine the constitutive parameters of the crystal plasticity model. A hybrid representative volume element approach, which combines the CPFE and the Marciniak–Kuczynski model, was developed to obtain the forming limit diagram of the magnesium alloys. The predicted forming limits were in excellent agreement with the Nakazima test results. Moreover, the microscopic responses such as slip/twin activation and deformation texture changes during various loading paths from uniaxial tension to the balanced biaxial tension were comprehensively analyzed and discussed from the CPFE results to understand the underlying micro-mechanism for the macro-mechanical responses.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The transport–structural correspondence across the nematic phase transition probed by elasto X-ray diffraction

Electronic nematicity in iron pnictide materials is coupled to both the lattice and the conducting electrons, which allows both structural and transport observables to probe nematic fluctuations and the order parameter. Here we combine simultaneous transport and X-ray diffraction measurements with in-situ tunable strain (elasto X-ray diffraction) to measure the temperature dependence of the shear modulus and elastoresistivity above the nematic transition and the spontaneous orthorhombicity and resistivity anisotropy below the nematic transition, all within a single sample of Ba(Fe 0.96 Co 0.04 ) 2 As 2 . The ratio of transport to structural quantities is nearly temperature independent over a 74 K range and agrees between the ordered and disordered phases. These results show that elasto X-ray diffraction is a powerful technique to probe the nemato-elastic and nemato-transport couplings, which have important implications to the nearby superconductivity. Furthermore, it also enables the measurement in the large strain limit, where the breakdown of the mean-field description reveals the intertwined nature of nematicity.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Highly stretchable organic electrochemical transistors with strain-resistant performance

Realizing fully stretchable electronic materials is central to advancing new types of mechanically agile and skin-integrable optoelectronic device technologies. Here we demonstrate a materials design concept combining an organic semiconductor film with a honeycomb porous structure with biaxially prestretched platform that enables high-performance organic electrochemical transistors with a charge transport stability over 30-140% tensional strain, limited only by metal contact fatigue. In this work, the prestretched honeycomb semiconductor channel of donor-acceptor polymer poly(2,5-bis(2-octyldodecyl)-3,6-di(thiophen-2-yl)-2,5-diketo-pyrrolopyrrole-alt-2,5-bis(3-triethyleneglycoloxy-thiophen-2-yl) exhibits high ion uptake and completely stable electrochemical and mechanical properties over 1,500 redox cycles with 10(4) stretching cycles under 30% strain. Invariant electrocardiogram recording cycles and synapse responses under varying strains, along with mechanical finite element analysis, underscore that the present stretchable organic electrochemical transistor design strategy is suitable for diverse applications requiring stable signal output under deformation with low power dissipation and mechanical robustness. Highly stretchable organic electrochemical transistors with stable charge transport under severe tensional strains are demonstrated using a honeycomb semiconducting polymer morphology, thereby enabling controllable signal output for diverse stretchable bioelectronic applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design of a novel carbon/carbon composite microvascular solar receiver

Solar thermal power tower systems are the primary technology being proposed for solar electricity from thermal energy. Operational limits on these towers are often driven by mechanical properties under significant thermal loads, particularly at the receiver where incoming flux is converted to thermal energy. While the solar receiver’s efficiency is largely driven by its optical properties, thermomechanical stresses on the receiver limits the operational envelope. One pathway to higher efficiency is greater allowable solar fluxes on the receiver but novel materials are required. The present study uses computational fluid dynamics to describe a parametric design space for a microvascular carbon/carbon composite solar receiver as a new material option for high flux solar receivers. Simulations are conducted for different microvascular geometries considering the role of material properties and heat transfer fluids, for the impact on thermal efficiency, and allowable strain. Results show that microscale receiver modules made of the proposed carbon/carbon composite could achieve thermal efficiencies over 90% and full-scale receivers can achieve up to 85% thermal efficiency for the design explored considering realistic strain limits, flux levels, and material properties. These values are highly dependent on the heat transfer fluid pairing, the through plane thermal conductivity of the carbon/carbon composite, the path architecture of the microscale receiver, and the incident solar flux profiles.

14 SOLAR ENERGY↗
DOE OSTI2023

Fuel performance evaluation of two high burnup PWR core designs during normal operation, control rod withdrawal, and control rod ejection scenarios

There is interest among utilities to extend the current, 18-month operating cycle to 24 months. Economically, this extension would require greater than 5 % enrichment and peak rod average discharge burnup levels above 62 GWd/MTU. A notable challenge of increasing enrichment is the resulting additional excess reactivity encountered during the early stages of fuel life. To accommodate, burnable absorbers beyond soluble boron are introduced into the fuel system. In high burnup fuels, the possibilities of cladding lift-off and fuel melting increase due, in part, to increased rod internal pressures and limited fuel thermal conductivity, respectively. This work collaboratively employs PARCS, RELAP5-3D, and BISON to compare the fuel performance of two high burnup fuel candidates with higher than 5 % enrichment. Here, the fuel performance parameters were compared to current NRC guidance. The results demonstrate an annular fuel design with homogenously blended gadolinium as a burnable absorber operates with greater safety margins during normal operation, allowing for additional operational flexibility. During normal operation, the core design utilizing Integral Fuel Burnable Absorber pins contained fuel pins which reached plenum pressures above 15.5 MPa by the end of the first fuel cycle and fuel pins experienced cladding hoop strains above 1 %. In the Gd core design, only two observed pins experienced plenum pressures above 15.5 MPa and no pins exceeded 1 % cladding hoop strain. During the control rod withdrawal scenario, plenum pressures for pins in both designs marginally exceeded system pressure, however neither experienced excessive hoop strain. The Gd core design experienced a maximum fuel temperature of 2418 K, which is significantly higher than the Integral Fuel Burnable Absorber design at 2157 K, but still within regulatory guidance. We predicted that the fuel in both could return to service after the CRW event. We also predicted that cladding would not fail during the Control Rod Ejection in either core design. Generally, the Integral Fuel Burnable Absorber core design performed with greater safety margin with regards to temperature during normal operation and the transient events. However, the Gd core design performed with greater safety margin regarding plenum pressure and hoop strain limits during normal operation and both transient events.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Initial Development of Variable Design Lifetimes and Creep-Fatigue Evaluations for ASME Section III, Division 5, Class B Code Rules

This report summarizes the initial development of new ASME Section III, Division 5, Class B rules to address the gaps identified for new high temperature reactor designs. The overall objective is to introduce the design-by-analysis approach, the variable design lifetimes for primary load design, and the strain limits and creep-fatigue damage evaluations for Class B components. It is also desired that the new evaluation procedures do not require stress classification and stress linearization. Further, the data requirements to support the development of design parameters for the new Class B rules would not be overly burdensome, and less extensive than those supporting Class A rules. We have identified the Elastic, Perfectly Plastic (EPP) method as the design by-analysis approach for primary load design, and developed allowable stress criteria for variable design lifetimes, up to 500,000 hours, that only require data typical for the allowable stresses in Section II, Part D, Tables 1A and 1B. We have also adapted the elastic analysis approach from HBB-T-1400 and Section III, Mandatory Appendix XIII, XIII-2400 and XIII-3520(e) for the new Class B creep-fatigue evaluation procedure. A new elastic follow-up-based Isochronous Stress Strain Curve (ISSC) stress relaxation procedure has been developed to provide adequate conservatism commensurate with Class B constructions. No stress classification and stress linearization are required in the new procedure. Future work needed to complete the development is also summarized.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗