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DOE OSTI2022

Predictive Tools for Customizing Heat Treatment of Additively Manufactured Aerospace Components

Laser-bed powder fusion (LBPF) additive manufacturing is increasingly being used to produce components of complex geometries using the Ni-base superalloy Inconel 718. The composition and the microstructure of the alloy are currently well optimized for wrought components made using conventional manufacturing processes such as rolling, forging, extrusion, etc. The attractive mechanical properties of the alloy result from the underlying austenitic matrix with fine equiaxed grains, and a high density and uniform distribution of the precipitation hardening phase, γ". Heat treatment steps such as homogenization, solutioning and aging are well documented for the wrought alloy. However, when the same wrought alloy compositions are used for the additive manufacturing (AM) processes, the asprocessed microstructure is significantly different, because of the different thermal history associated with LBPF, including rapid solidification and multiple temperature excursions that lead to multiple re-melting and reheating in the solid state. Rapid solidification introduces potential non-equilibrium effects at the moving solid-liquid interfaces that impact the extent of solute segregation, as well as the morphology of the dendritic grains that form. In order to recover the target mechanical properties, AM components have to undergo post-process heat treatments. However, such heat treatments have to be custom designed for the AM process and the component geometry because of the expected vast differences in the microstructure at various locations of a component with complex geometry. The homogenization and precipitation steps should be optimized for the component so that target mechanical properties can be obtained throughout the part. The objective of this research is to utilize High Performance Computing in phase field simulations of microstructure evolution during post-processing of AM components. The physics-based modeling will be beneficial in reducing the experimental effort required for heat treatment process selection, optimization, and certification, thus leading to a significant reduction in energy consumption for AM and post-processing heat treatment. The optimization study will help identify heat treatments steps that are critical for development of a final desired microstructure with the minimum energy input. This combined with shortening of the production cycle (time-to-market) by reducing the number of failed parts (property targets), and reduction in the number of iterations for process optimization, will enable 30-40% savings in the energy costs. Phase field simulations of the degree of homogenization and the effect of local matrix composition on the nucleation and growth of competing precipitating phases were performed using the Microstructure Evolution Using Massively Parallel Phase Field Simulations code developed in-house at the Oak Ridge National Laboratory. The simulations were able to successfully capture the kinetics of nucleation and growth, and morphologies of various precipitating phases as a function of local matrix compositions and composition gradients characteristic of local microstructures arising from location-dependent variations in the thermal conditions. Future work will involve extending the simulations to a length scale consisting of multiple dendrites, so that the effect of homogenization on the coarsening of the dendrites can be simulated and used as an additional input to the optimization of the heat treatment process.

36 MATERIALS SCIENCE↗

DOE OSTI2020

IEEE 1547-2018 Based Interoperable PV Inverter with Advanced Grid-Support Functions

Grid integration of photovoltaic (PV) inverters has been increasing in the past decade. As a result of the uncertainties introduced with high penetrations of PV, better monitoring and control of the PV inverters becomes crucial for improving overall system stability. This paper focuses on the communications capability of the inverter controller and on enabling interoperability. Multiple standards are available to enable interoperability in PV inverters. In this paper, an interoperable controller, enabled by Distributed Network Protocol 3 (DNP3) communications protocols, is developed for a grid-connected, three-phase PV inverter. The DNP3 server for the PV inverter is programmed on the real-time layer of the field-programmable gate array (FPGA)-based inverter controller. Set points for advanced inverter control functions, such as volt/VAr curves, ride-through curves, are sent from a DNP3 client, a simulated distribution management system application, to the PV inverter through DNP3. This communications capability of the inverter controller is validated using a controller-hardware-in-the-loop experimental setup. The code developed to achieve the interoperability is available in the public domain through open-source software licensing. This interoperability will enable smoother grid integration of smart PV inverters with advanced grid-support functions as well as allow better monitoring and control of PV inverters for grid stability.

14 SOLAR ENERGY↗

DOE OSTI2023

Modeling of Prismatic High Temperature Reactors in Pronghorn

Pronghorn is a MOOSE based thermal-hydraulics code developed at Idaho National Laboratory (INL) for advanced nuclear reactor analysis. It has been previously applied to model pebble-bed high temperature reactors (HTRs), liquid-metal cooled reactors, and molten salt reactors, among others. This work leverages the coarse-mesh modeling capabilities in Pronghorn to model the Oregon State University (OSU)'s High Temperature Test Facility (HTTF). The HTTF is a 1:4 height scaled-down facility of General Atomics' Modular High Temperature Gas-cooled Reactor (MHTGR). The facility is primarily built to generate data for code and model validation, and does not precisely replicate MHTGR conditions. Nevertheless, it encompasses the main physics associated with MHTGR transients.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Towards automating structural discovery in scanning transmission electron microscopy *

Abstract Scanning transmission electron microscopy is now the primary tool for exploring functional materials on the atomic level. Often, features of interest are highly localized in specific regions in the material, such as ferroelectric domain walls, extended defects, or second phase inclusions. Selecting regions to image for structural and chemical discovery via atomically resolved imaging has traditionally proceeded via human operators making semi-informed judgements on sampling locations and parameters. Recent efforts at automation for structural and physical discovery have pointed towards the use of ‘active learning’ methods that utilize Bayesian optimization with surrogate models to quickly find relevant regions of interest. Yet despite the potential importance of this direction, there is a general lack of certainty in selecting relevant control algorithms and how to balance a priori knowledge of the material system with knowledge derived during experimentation. Here we address this gap by developing the automated experiment workflows with several combinations to both illustrate the effects of these choices and demonstrate the tradeoffs associated with each in terms of accuracy, robustness, and susceptibility to hyperparameters for structural discovery. We discuss possible methods to build descriptors using the raw image data and deep learning based semantic segmentation, as well as the implementation of variational autoencoder based representation. Furthermore, each workflow is applied to a range of feature sizes including NiO pillars within a La:SrMnO 3 matrix, ferroelectric domains in BiFeO 3 , and topological defects in graphene. The code developed in this manuscript is open sourced and will be released at github.com/nccreang/AE_Workflows .

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Application of an Embedded Fracture and Borehole Modeling Approach to the Understanding of EGS Collab Experiment 1

EGS Collab is a series of meso-scale experiments and associated numerical simulation activities being funded by the United States Department of Energy, Geothermal Technologies Office (GTO) to investigate enhanced geothermal system processes under in-situ stress and slightly elevated temperature conditions. This project is designed to provide scientists and engineers with immediate access to impermeable rock at scales larger than possible in the laboratory, but generally smaller than those for commercial production. Immediate access to rock is provided via the existing drifts of the former Homestake Gold Mine, now operated as the Sanford Underground Research Facility in Lead, South Dakota. The objectives of the EGS Collab project are to develop well controlled fracture networks between injector and producer boreholes using normal and shear stimulation for permeability enhancement. The first experimental site was located off the West Access drift on the 4850 Level (4850 feet below ground surface) in phyllite of the Precambrian Poorman formation, and involved the creation of a fracture network comprising a combination of hydraulic and natural fractures. A second experimental site is now being considered near the battery alcove on the 4100 Level in amphibolite and rhyolite of the Yates Unit. Data generated during these experiments will be compared against predictions of a suite of computer codes specifically designed to solve problems involving coupled thermal, hydrological, geomechanical, and geochemical processes. Comparisons between experimental and numerical simulation results will provide code developers with direction for improvements and verification of process models, build confidence in the suite of available numerical tools, and ultimately identify critical future development needs for the geothermal modeling community. Moreover, conducting thorough comparisons of models, modelling approaches, measurement approaches and measured data, via the EGS Collab project, will serve to identify techniques that are most likely to succeed at the Frontier Observatory for Research in Geothermal Energy (FORGE), the GTO’s flagship EGS research effort. Experiment 1 has comprised a series of successful tests, including a long-term chilled-water circulation test, but the testbed has two atypical EGS elements. Active ventilation in the adjacent drift over a 50-year period cooled the testbed rock mass and hydraulic fracturing intersected monitoring boreholes making them conduits for fluid flow. Numerical simulations executed in support of the design of the EGS Collab Experiment 1, computed a radial temperature distribution and stress gradient orthogonal to the drift axis, resulting in the forecast of an oblong hydraulic fracture geometry, extended in the direction of the drift from the stimulation borehole. This paper describes the numerical simulation of long-term chilled-water circulation test with an embedded fracture and borehole modeling approach. The principal objective of the simulation work is show agreement between experimental observations in terms of production fluid temperatures, monitoring borehole temperatures, injection and production pressures, and tracer recoveries using a single conceptual model for the fracture network, using characterization and monitoring data generally available for EGS. A secondary objective is to improve the numerical simulation result comparisons with additional data available from the broader monitoring equipment within the testbed versus deeper, hotter, and more remote EGS. One complicating factor for comparisons between the numerical simulation results and experimental observations, is the Joule-Thomson heating associated with large pressure drops across the fracture network.

numerical simulation, embedded fractures and boreh↗

DOE OSTI2020

VARI3D & PERSENT: Perturbation and Sensitivity Analysis

The nodal diffusion method is one of the most widely used approaches in modern reactor analysis. In the nodal diffusion method, a coarse multi-group set of “homogenized” parameters is constructed such that the complex geometry of a reactor core along with the energy dependence of neutron and gamma ray cross sections in a nuclear reactor are conserved in the simpler geometry. The homogenization is typically done on a fuel assembly level as is the case in the DIF3D code developed at Argonne National Laboratory. The nodal methodology is used primarily to predict fuel cycle behavior of nuclear systems of which there is a substantial amount of validation in the literature. Another use of the nodal method is to obtain reactivity coefficients and kinetics parameters for use in a safety analysis of a given nuclear reactor. While there are many ways to obtain reactivity worth and kinetics parameters, the work presented in this manuscript is unique as it provides the user with the ability to compute reactivity worths, kinetics parameters, and cross section sensitivities with a Cartesian and hexagonal geometry based transport code.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

VARI3D & PERSENT: Perturbation and Sensitivity Analysis

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

VARI3D & PERSENT: Perturbation and Sensitivity Analysis (Revision 5)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

AI to Predict Glass Compositions Satisfying Property and Cooling Rate Criteria

This project aimed to develop a predictive, artificial intelligence/machine learning-based model to identify glass compositions satisfying specified property requirements. Such a model would provide a systematic approach for narrowing down the nearly infinite range of possible compositions for glasses and minimize unnecessary experimental trial and error. A large empirical data set for training and testing the algorithm was obtained from the SciGlass database. It contains glass compositions and corresponding property data from a wide range of literature sources. However, the currently available form of this data, recently released under an open database license, is not conducive to easy querying and use. The data structure was deciphered and a customized parsing code developed to make this data more usable for the current and future work. Neural network models were developed and trained on viscosity data from the database and demonstrated potential for improving prediction accuracy over a traditional regression model.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Modeling Material Interfaces with the Six-Equation Model in FLEXO

FLEXO is a multiphysics code developed at Sandia National Laboratories for predictive simulation of pulsed power target physics with extended magnetohydrodynamics modeling. Given this application space, FLEXO must be able to perform high-fidelity simulations of pulsed-power systems that include multiple materials. This work presents the augmentation of FLEXO with a six-equation model for multimaterial flow. We design and analyze discretizations of the six-equation model, emphasizing desirable properties for robust multimaterial simulation. We also present solution limiting, bounds preservation, and pressure equilibration/relaxation techniques that enhance the robustness of the overall multimaterial scheme. We present a suite of test problems to document these new capabilities of the FLEXO code.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Advanced Simulation of ITER Core X-ray Crystal Spectroscopy

X-Ray Simulation Analysis (XRSA) is an analytical ray-tracing mixed code developed specifically for the ITER Core X-Ray Crystal Spectroscopy (XRCS-Core) diagnostic, which employs a dual-reflection configuration incorporating multiple pre-reflectors made of Highly Oriented Pyrolytic Graphite (HOPG) and spherically curved analyzing crystals. The ITER XRCS-Core is designed for high spectral resolution measurement in specific wavelength ranges, including narrow bands around 1.354 Å for W 64+ , 2.19 Å for Xe 51+ , and 2.555 Å for Xe 44+ and Xe 47+ , enabling diagnostic capability across a broad electron temperature range in the ITER plasma. XRSA facilitates efficient simulation of the spectral performance of this complex X-ray spectroscopic system. Recent updates to the XRSA code have incorporated two critical effects: auto-focusing, which specifically applies to HOPG, and polarization. These two effects are particularly important in the dual-reflection configuration used in the ITER XRCS-Core system to provide more accurate modeling results. Here, simulations conducted with the updated code demonstrate that polarization has a substantial impact on the performance of the dual-reflection system. Additionally, the combined influence of polarization and system layout introduces performance variations across channels through the same crystal.

Computer graphics↗

DOE OSTI2022

Code-to-code comparison and validation of the radiation-hydrodynamics capabilities of the FLASH code using a laboratory astrophysical jet

The potential for laser-produced plasmas to yield fundamental insights into high energy density physics (HEDP) and deliver other useful applications can sometimes be frustrated by uncertainties in modeling the properties and behavior of these plasmas using radiation-hydrodynamics codes. In an effort to overcome this and to corroborate the accuracy of the HEDP capabilities in the publicly available FLASH radiation-hydrodynamics code, we present detailed code-to-code comparisons between FLASH and the HYDRA code developed at Lawrence Livermore National Laboratory using previously published HYDRA simulations from Grava et al. [Phys. Rev. E 78, 016403 (2008)]. That study describes a laser experiment that produced a jet-like feature that the authors compare to astrophysical jets. Importantly, the Grava et al. [Phys. Rev. E 78, 016403 (2008)] experiment included detailed x-ray interferometric measurements of electron number densities and a time-integrated measurement of the soft x-ray spectrum. Despite markedly different methods for treating the computational mesh, and different equations of state and opacity models, the FLASH results resemble the results from HYDRA and, most importantly, the experimental measurements of electron density. Having validated the FLASH code in this way, we use the code to further investigate and understand the formation of the jet seen in the Grava et al. [Phys. Rev. E 78, 016403 (2008)] experiment and discuss its relation to the Wan et al. [Phys. Rev. E 55, 6293 (1997)] experiment at the NOVA laser.

Orban, Chris (ORCID:0000000312004538)↗

DOE OSTI2023

P2M Simulation Exercise on Past Fuel Melting Irradiation Experiments

This paper presents the results of the Power To Melt and Maneuverability (P2M) Simulation Exercise on past fuel melting irradiation experiments, organized within the Organisation for Economic Co-operation and Development/Nuclear Energy Agency Framework for IrraDiation ExperimentS (FIDES) framework by the Core Group (CEA, EDF, and SCK·CEN) and open to all FIDES members. The exercise consisted in simulating two past power ramps where fuel melting was detected: (1) the xM3 staircase power transient [ramp terminal level (RTL) 70 kW·m -1 , average burnup 27 GWd·tU -1 ], carried out in 2005 in the R2 reactor at Studsvik (Sweden), where the rodlet maintained its integrity, and (2) the HBC4 fast power transient (RTL 66 kW·m -1 , average burnup 48 GWd·tU -1 ), carried out in 1987 in the BR2 reactor at SCK·CEN (Belgium), where the cladding failed during the experiment. The exercise was joined by 13 organizations from 9 countries using 11 different fuel performance codes. In this paper, the main results of the Simulation Exercise are presented and compared to available postirradiation examinations (PIE) or on-line measurements during the power ramps (fuel and clad diameters, rod elongation, pellet-clad gap, and fission gas release). Since the focus of the Simulation Exercise is on fuel melting assessment, determination of the boundary between melted/nonmelted fuel and the consequent definition of a melting radius from PIE are first discussed. During the HBC4 ramp, fuel melting was predicted by most of the codes despite differences in the melting models. Higher discrepancies were observed for the xM3 rod that can be attributed partly to power uncertainty and partly to the limited capability of the models to describe partial melting of the fuel during this ramp. Finally, possible code developments to improve simulation results are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Benchmark of the KGMf with a coupled Boltzmann equation solver

The Kinetic Global Model framework (KGMf) is an open-source general-purpose global model (spatially averaged) simulation code developed to explore the reaction kinetics and pathways in plasma discharge systems. It contains species continuity and electron energy balance equations, with a time-dependent evaluated electron energy distribution function (EEDF) for electron impact reactions. The EEDF is utilized to determine the rate coefficients for electron impact reactions, which can have profound impact on the temporal evolutions of plasma parameters. Previously, the EEDF was commonly assumed as Maxwellian or an analytical function of the effective electron temperature. In this work, the KGMf is coupled with a Boltzmann equation (BE) solver to self-consistently compute the EEDF. The EEDF evolution frequency is determined based on relative changes of the reduced electric field. The KGMf is benchmarked with the ZDPlasKin code based on high-pressure low-temperature argon plasma discharge cases. Additionally, the temporal evolutions of reduced electric field, electron temperature, EEDF, reaction rates, and species densities, are obtained and compared under different discharge conditions, showing good agreement between the KGMf and the ZDPlasKin simulations. The application of the KGMf for predicting breakdown times in high power microwave discharges is also presented, which shows qualitative agreement with particle-in-cell simulations. The KGMf can be further applied for more complicated plasma discharge systems, where the reaction kinetics are more intricate (e.g., plasma-assisted combustion systems).

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Resonant Slow Extraction Simulation using Bmad

Simulations of slow extraction and transport of charged particle beams from synchrotrons requires careful modeling and experimentation. In this paper, we outline how the Bmad modeling software was adapted and developed to run third-integer resonant extraction simulations of beams at Brookhaven National Laboratory’s Booster synchrotron. Further, we show experimental comparisons of the slowly extracted beams transferred to the NASA Space Radiation Laboratory (NSRL) transport line. In this process, beam passes through a stripping foil element at the extraction point, which, along with stripping remaining electrons from the beam ions, acts as a scatterer to modify the phase space, moving to a more Gaussian-like distribution. This modification to the beam helps generate a uniform beam at the beam line’s target location; which is necessary for the variety of experiments performed at the facility. During this work, beam energy loss and multiple scattering by foil routines were built in conjunction with the Bmad code developers and are now integrated into the software.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Convolutional Neural Network–Aided Temperature Field Reconstruction: An Innovative Method for Advanced Reactor Monitoring

In this study, the capabilities of a physics-informed convolutional neural network (CNN) for reconstructing the temperature field from a limited set of measurements taken at the boundaries of internal flows are demonstrated. Such an approach enables the development of less invasive monitoring methods for real-time plant diagnostics. As a test case, a Molten Salt Fast Reactor (MSFR) design was selected. This circulating fuel reactor has received interest from both scientific and industrial communities due to its intrinsic safety and sustainability. Molten salt flows in such reactors, however, can present highly localized temperature peaks that can induce significant thermal stresses onto the vessel walls. At these local maxima, the salt temperature may exceed a thousand kelvins, which makes a direct measurement challenging or even unfeasible. The proposed CNN algorithm allows one to detect indirectly such discontinuities through an accurate, albeit indirect, temperature measurement method during reactor operation. The datasets employed to train and test the machine learning models in the present work were generated with Nek5000, a computational fluid dynamics (CFD) code developed at Argonne National Laboratory. The CNN algorithm is trained with CFD results that span a set of MSFR operational power and flow ranges. Here, to demonstrate the efficacy of the algorithm, predictions are made for test cases contained within the training range but for which the CFD data were not used when training. Results demonstrate that the proposed technique properly characterizes temperature peaks and distributions within the domain for a broad range of scenarios.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Preliminary description of a new creep-fatigue design method that reduces over conservatism and simplifies the high temperature design process

The report provides the initial description of a new creep-fatigue design method for structural components in high temperature nuclear service. The new method is based on an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that reduces over conservatism, improves the treatment of elastic follow up, and simplifies the design procedure, when compared with the current creep-fatigue design methods in ASME Boiler and Pressure Vessel Code. Developing the design charts for the EPP-SMT design method requires extrapolating SMT test data as a function of hold time and follow up factor. The report develops the preliminary design charts for Alloy 617 at temperatures between 800°C and 950°C by combining two extrapolation approaches developed in a previous work. The report also presents a comparative analysis between the EPP-SMT design method and the current ASME creep-fatigue design methods by evaluating design life of two sample geometries under different loading conditions. Results from the comparative analysis verify the EPP-SMT design charts but suggest the requirement of additional test data in the low strain range regime for improving the extrapolation procedure that will further reduce the over conservatism in the creep-fatigue damage evaluation. The report also concludes that the EPP-SMT design procedure can account for effect of primary load on creep-fatigue life by using a fixed, bounding value of follow up in constructing the design charts. The conclusions to this report describe the future work required to complete this new design method so it can be codified through a nuclear Code Case.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Adopting occupancy-based HVAC controls in commercial building energy codes: Analysis of cost-effectiveness and decarbonization potential

Recent research has shown the energy-saving potential of occupancy-based HVAC controls (OBCs) in commercial buildings. However, building energy codes have not fully adopted this technology. This study aims to evaluate the cost-effectiveness and decarbonization benefits of OBCs and provide guidance for integrating occupancy sensors into building energy code development. To this end, a parametric simulation using EnergyPlus and a nationwide cost-effectiveness analysis are carried out considering three building types and 40 representative cities in the U.S. Here, the findings reveal that the current cost-effectiveness performance of OBCs is limited due to the high cost of occupancy sensors. However, incorporating the societal cost of carbon factor in future energy and environmental policy could greatly enhance the actual cost-effectiveness performance. Besides, a reduction in the cost of occupancy sensors to approximately 60% of the current price level could also greatly shorten the discounted payback period of OBCs. Additionally, OBCs demonstrate significant potential in building decarbonization, with potential CO 2 emissions savings of more than 5.56 million metric tons across the three building types and 40 selected cities. Finally, policy implications are provided to guide the incorporation of occupancy-based HVAC controls in future energy codes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗