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DOE OSTI2020

Investigation of Failure Modes, Mechanisms and Driving Forces for Electrically Conductive Adhesives as Interconnects in PV Modules

In this work we describe our current progress into investigating the reliability of ECA interconnects for PV modules. Preliminary thermal cycling experiments demonstrated that both cohesive and adhesive failure of the ECA joint are relevant failure modes that result in an increase of the joints electrical resistance. A thorough viscoelastic characterization of the candidate ECA was conducted to enable accurate numerical modeling of the joint’s response to thermal cycling. Combined with critical and subcritical fracture measurements, the numerical model elucidates that an additional fatigue mechanism exists which can result in fracture well below subcritical debonding threshold values. It is also demonstrated that fracture of the ECA is more sensitive to humidity than temperature and subcritical debonding mechanisms do exist which are again more sensitive to humidity.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2022

Current Status of the DOE/NNSA Nuclear Criticality Safety Program Hands-On Criticality Safety Training

The U.S. Department of Energy/National Nuclear Security Administration (DOE/NNSA) Nuclear Criticality Safety Program (NCSP) has conducted two-week Nuclear Criticality Safety (NCS) Practitioner courses since 2011 to support the training and qualification of new NCS staff. The course was developed in accordance with the American National Standard Institute/American Nuclear Society (ANSI/ANS) standard for NCS training and qualifications (ANSI/ANS-8.26-2007). In 2013, an NCS Manager’s course was developed for process supervisors, managers, regulators, and other professionals with NCS-related responsibilities. This course was revised in 2019 for Criticality Safety Officers (CSOs) based on an NCSP Criticality Safety Support Group tasking (2018-01). This course was piloted at the Nevada Field Office and the National Criticality Experiments Research Center (NCERC) in June 2021. These courses consist of the following training components: classroom education, facility training, and hands-on subcritical and critical experiments training. The two-week Practitioner course offers a week of classroom training, with practical workshops and exercises focused on teaching students how to perform an NCS evaluation. The second week of training involves hands-on critical and subcritical experiments and measurements. The first week is offered in Las Vegas, Nevada, at the DOE Nevada Field Office or the National Atomic Testing Museum. Depending on the student’s clearance level, the second week is offered at Sandia National Laboratory (SNL) (uncleared and L-cleared students) or at the National Criticality Experiments Research Center (Q-cleared students). The one-week Manager’s course is offered at SNL or NCERC, depending on clearance or interest, and includes classroom and hands- on critical and subcritical experiments and measurements. This paper provides an overview and status report for the DOE/NNSA NCSP training courses in NCS and to provide information about future course offerings. This paper discusses the challenges associated with executing the training courses during the COVID-19 pandemic. The 2-week Practitioner and 1-week manager courses are currently offered twice per year and adjustments are made based upon demand.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Nuclear Data Libraries Sensitivity Studies for ORSA Using SCALE

Subcritical assemblies offer valuable training capabilities in nuclear criticality safety (NCS) for individuals handling fissile material. At Oak Ridge National Laboratory(ORNL), the Oak Ridge Subcritical Assembly (ORSA), a new experimental facility, is being established to provide hands-on training for the Nuclear Criticality Safety Program (NCSP).It is essential to accurately determine the neutron multiplication factor (keff) to ensure that ORSA remains subcritical and safe during operations. This study investigated the sensitivity of keff to variations across Evaluated Nuclear Data File (ENDF/B) libraries, consisting of ENDF/B-VII.1, ENDF/B-VIII.0, and ENDF/B-VIII.1. The analysis was conducted using the CSAS6 sequence in the SCALE-6.3 code system. Individual isotopes in the ORSA model were replaced one at a time with ENDF/B-VII.1 as the base library and changing to ENDF/B-VIII.0or ENDF/B-VIII.1. The results demonstrated that the changes in keffof the nuclides associated with the ORSA model were mostly within the uncertainty of the base model (~24 pcm), except for primary nuclides like Uranium-235and H-poly with few other nuclides. The relative delta keff values of Uranium-235 and H-poly, expressed in pcm, were +280 and -212 in ENDF/B-VIII.0 and +332 and -275 in ENDF/B-VIII.1, respectively, which were notable changes in reactivity. These results demonstrated that ORSA was largely insensitive to variations across these nuclear data libraries.

Hong, Evan [North Carolina State University]↗

DOE OSTI2020

S/U Comparison Study with a Focus on USLs

Under a DOE Nuclear Criticality Safety Program (NCSP) task involving Analytical Methods, three Laboratories collaborated in a comparison of results obtained from Sensitivity/Uncertainty (S/U) packages relevant to validation of transport codes. The task involves Institut de Radioprotection et de Sûreté Nucléaire (IRSN), Los Alamos National Laboratory (LANL), and Oak Ridge National Laboratory (ORNL) comparing results of MORET 5/MACSENS V3.0, MCNP6.2/Whisper-1.1, and SCALE 6.2.3/TSUNAMI/USLSTATS respectively. All Monte Carlo transport code results utilize ENDF/B-VII.1. Four cases from the International Handbook of Evaluated Criticality Safety Benchmark Experiments (ICSBEP Handbook) were selected as application models: HEU-MET-FAST-013-001, HEU-SOL-THERM 001-008, PU-MET-FAST-022-001, and PU-SOL-THERM 001-001. Ultimately, comparison is made between Upper Subcritical Limits (USLs) obtained using each code package for each application case. Since differences exist in whether packages take into account margin of subcriticality (MOS), the USL may be computed using bias and bias uncertainty, also known as the calculational margin (CM) in ANSI/ANS 8.24. Application of portions of MOS to the USL for nuclear data uncertainty of and potential code margin is referred to as USL herein. In either case, additional MOS is considered for actual application cases.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Environmental influence on cracking and debonding of electrically conductive adhesives

Electrically conductive adhesives (ECAs) are starting to replace metallic solders in recent designs of photovoltaic (PV) modules. This transition represents a significant material change, and a proper understanding of the durability and reliability of the new interconnect needs to be established. This paper presents our continued work on developing a degradation model for ECA interconnects in PV modules. Here, we characterize the fracture mechanics properties of an epoxy-based ECA, for both critical and subcritical, mode I and mode II loading conditions. Emphasis is on the influence of different environmental conditions such as temperature and humidity. We use the Finite Element Method to account for residual stresses, induced by temperature changes and moisture absorption, and correct the apparent fracture toughness. We found that high moisture levels not only can weaken the fracture resistance of the ECA interconnect, but can also promote subcritical debonding at significantly lower driving forces than in dry environments.

42 ENGINEERING↗

DOE OSTI2023

Comparative Analysis of Standard and Advanced USL Methodologies for Nuclear Criticality Safety

The American National Standards Institute/American Nuclear Society national standards 8.1 and 8.24 provide guidance on the requirements and recommendations for establishing confidence in the results of the computerized models used to support operation with fissionable materials. By design, the guidance is not prescriptive, leaving freedom to the analysts to determine how the various sources of uncertainties are to be statistically aggregated. Due to the involved use of statistics entangled with heuristic recipes, the resulting safety margins are often difficult to interpret. Also, these technical margins are augmented by additional administrative margins, which are required to ensure compliance with safety standards or regulations, eliminating the incentive to understand their differences. With the new resurgent wave of advanced nuclear systems, e.g., advanced reactors, fuel cycles, and fuel concepts, focused on economizing operation, there is a strong need to develop a clear understanding of the uncertainties and their consolidation methods to reduce them in manners that can be scientifically defended. In response, the current studies compare the analyses behind four notable methodologies for upper subcriticality limit estimation that have been documented in the nuclear criticality safety literature: the parametric, nonparametric, Whisper, and TSURFER methodologies. Specifically, the work offers a deep dive into the various assumptions of the noted methodologies, their adequacies, and their limitations to provide guidance on developing confidence for the emergent nuclear systems that are expected to be challenged by the scarcity of experimental data. Here, to limit the scope, the current work focuses on the application of these methodologies to criticality safety experiments, where the goal is to calculate a bias, a bias uncertainty, and a tolerance limit for k eff in support of determining an upper subcriticality limit for nuclear criticality safety.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2022

The fast neutron source at UTK: a project with Massimo Salvatores

This article is dedicated to the memory of Massimo Salvatores and offers an overview of the history of the design of the Fast Neutron Source (FNS) flexible experiment system at the University of Tennessee. Our collaboration with Massimo set much of the over-arching design goals and inspired the concept that we have today. The decision to design the FNS as a subcritical assembly rather than a critical one stems back to discussions with Massimo Salvatores and his advocacy for subcritical Accelerator Driven Systems (ADS) which coincides with lower licensing time, costs and greater safety for a university-operated nuclear experimental facility. The second contribution of Massimo to the design concept of the FNS was the direct instruction to design the FNS as an extremely flexible facility. This article provides an update on the current design concept and discusses the future innovations in design optimization of flexible, re-configurable nuclear experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Nuclear data covariances are critical input to determine upper sub-critical limits and to design experiments to increase it [Slides]

This presentation discusses how Upper Subcritical Limits (USL) are key parameters to determine operational limits in nuclear criticality safety evaluations. It also discusses an example of plutonium casting operation using tantalum at LANL PF-4. The Whisper tool at Los Alamos relies on many inputs, including covariance data, leading the presentation to ask if an existing benchmark data be used in Whisper to adjust nuclear data and covariances to justify a higher USL. If not, Whisper can be used to help design an optimal new benchmark experiment. The presentation also seeks to determine what the possible impacts are on USL and operational limits for plutonium casting. In conclusion, nuclear data covariances are used for by Whisper for: GSSL adjustment of nuclear data and covariances, identification of most similar existing benchmark experiments to application, simulation of Upper Subcritical Limit of application, and input to optimization techniques for designing most appropriate new benchmark experiment(s) to meet requirements. This requires a complete set of nuclear data covariances, benchmarks and k-effective sensitivity profiles (for both benchmarks and applications). The presentation concludes by asking if end users should trust results that depend on current covariance data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Unveiling the Fatigue Behavior of 2D Hybrid Organic–Inorganic Perovskites: Insights for Long-Term Durability

2D hybrid organic–inorganic perovskites (HOIPs) are commonly found under subcritical cyclic stresses and suffer from fatigue issues during device operation. However, their fatigue properties remain unknown. Here, the fatigue behavior of (C 4 H 9 -NH 3 ) 2 (CH 3 NH 3 ) 2 Pb 3 I 10 , the archetype 2D HOIP, is systematically investigated by atomic force microscopy (AFM). It is found that 2D HOIPs are much more fatigue resilient than polymers and can survive over 1 billion cycles. 2D HOIPs tend to exhibit brittle failure at high mean stress levels, but behave as ductile materials at low mean stress levels. These results suggest the presence of a plastic deformation mechanism in these ionic 2D HOIPs at low mean stress levels, which may contribute to the long fatigue lifetime, but is inhibited at higher mean stresses. The stiffness and strength of 2D HOIPs are gradually weakened under subcritical loading, potentially as a result of stress-induced defect nucleation and accumulation. The cyclic loading component can further accelerate this process. The fatigue lifetime of 2D HOIPs can be extended by reducing the mean stress, stress amplitude, or increasing the thickness. These results can provide indispensable insights into designing and engineering 2D HOIPs and other hybrid organic–inorganic materials for long-term mechanical durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

A Time-Dependent Directional Damage Theory for Brittle Rocks Considering the Kinetics of Microcrack Growth

In this work, a novel microcrack damage theory for describing the time-dependent behavior of brittle rocks is proposed. Instead of using scalar or tensorial variables to approximate the effect of microcracks, the concept of directional damage is introduced by upscaling the directional distribution density of microcracks through the noninteracting homogenization scheme. The contribution of an individual crack on global strain is first derived from the crack-opening displacements including sliding, closure, and dilation. The model is then cast in the free energy form, and the range of parameters ensuring compliance with the second law of thermodynamics is derived rigorously. Considering that the subcritical propagation of microcracks is the dominant mechanism behind the time-dependent deformation and failure of brittle rocks, the driving force for directional damage is defined as the corresponding energy release rate, and the effect of time is introduced through a damage evolution law inspired from the kinetics of subcritical crack growth. The model is applied to simulate the behavior of basalt rock under various loading conditions. In addition to predicting the stress–strain–time response, the model offers enhanced resolution in representing the anisotropic characteristics of microcrack-induced damage in brittle rocks and their time-dependent evolutions.

58 GEOSCIENCES↗

DOE OSTI2020

Residually Stressed Bimaterial Beam Specimen for Measuring Environmentally Assisted Crack Growth

Background: Subcritical crack growth can occur in a brittle material when the stress intensity factor is smaller than the fracture toughness if an oxidizing agent (such as water) is present at the crack tip. Objective: Here we present a novel bi-material beam specimen which can measure environmentally assisted crack growth rates. The specimen is “self-loaded” by residual stress and requires no external loading. Methods: Two materials with different coefficient of thermal expansion are diffusion bonded at high temperature. After cooling to room temperature a subcritical crack is driven by thermal residual stresses. A finite element model is used to design the specimen geometry in terms of material properties in order to achieve the desired crack tip driving force. Results: The specimen is designed so that the crack driving force decreases as the crack extends, thus enabling the measurement of the crack velocity versus driving force relationship with a single test. The method is demonstrated by measuring slow crack growth data in soda lime silicate glass and validated by comparison to previously published data. Conclusions: The self-loaded nature of the specimen makes it ideal for measuring the very low crack velocities needed to predict brittle failure at long lifetimes.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A regularized-interface method as a unified formulation for simulations of high-pressure multiphase flows

The injection of multi-species fluids into high-pressure and high-temperature environments beyond the species' critical points is commonly found in engineering applications. At these conditions, for immiscible species, both subcritical interfacial dynamics and supercritical mixing can coexist due to variations in temperature around the mixture critical point. The modeling of these complex transcritical phenomena for large-scale configurations is so far not possible. To address this issue, we propose the Regularized-Interface Method (RIM) as a unified formulation that can describe both sub- and supercritical processes as well as the transition between them. The proposed method is derived via filtering of the nanoscale interface-resolving formulation based on van der Waals' linear gradient theory. Thus, this approach allows for the consistent modeling of interfacial dynamics that vanishes at supercritical conditions, while significantly reducing the temporal and spatial resolution constraints of the original nanoscale formulation. The resulting RIM formulation is examined in interface-capturing simulations of sub-, trans-, and supercritical fuel injection processes, involving droplets and jets. Furthermore, these results highlight the importance of resolving spatio-temporal transitions from subcritical interfacial dynamics to supercritical mixing in high-pressure multiphase simulations, in contrast to commonly employed diffused-interface methods, where interfacial dynamics are often neglected.

Interface capturing↗

DOE OSTI2023

Development of an accelerator-based neutron source to prototype Mo-99 production, Part II: A liquid LBE loop under a high vacuum

To provide US domestic supply of Mo-99 without using high-enriched uranium (HEU), a subcritical uranium target assembly (UTA) is irradiated by an accelerator-based neutron source to create Mo-99 through fission. Part I of this work discusses the design of a liquid lead–bismuth eutectic (LBE) windowless target for an accelerator-based neutron source development. Part II discusses how to couple this windowless target to an accelerator operating at an ultra-high vacuum and the subcritical UTA cooled by water at room temperature. Due to the windowless design of the target, the liquid LBE flow shares an ultra-high vacuum (<1.3 × 10 -7 Pa or 10 -9 Torr) space with the accelerator. As a result of this shared vacuum space, the LBE system must operate at a high vacuum (10 -3 ~10 -6 Pa or 10 -5 ~10 -8 Torr). A magnetic rotary motion feedthrough unit utilizes magnetic fluid to allow rotation of the pump while maintaining a high vacuum environment. Prior to testing the LBE system under vacuum, a pump curve measurement is performed to estimate flowrate in the system. This measurement also generates data on orifice loss coefficients, which are compared to correlations in literature. The second experiment investigates vacuum level in the LBE system during operation. High vacuum is maintained (10 -3 ~10 -5 Pa or 10 -5 ~10 -7 Torr) during system operation, and a residual gas analyzer (RGA) scan shows that partial pressures of residual gases in the LBE system lower over the duration of LBE system operations. The third experiment investigates the gravity driven liquid LBE flowing out of the target chamber in the return line, which is partially full. If the liquid LBE is not drained quickly enough, flooding in the target chamber could occur. The coefficient n in the Manning equation is found to be around 0.008 s/m 1/3 . The last experiment performed is a demonstration that a vacuum jacket could provide sufficient thermal insulation to allow coupling between 300 °C LBE loop and a water tank at room temperature. In conclusion, the results from these experiments have influenced the development of the neutron source for the future commercial scale Mo-99 production system.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Pressurized in situ X-ray diffraction insights into super/subcritical carbonation reaction pathways of steelmaking slags and constituent silicate minerals

This study explores mineral carbonation of industrial stainless steelmaking slags and relevant synthetic constituent minerals via in situ pressurized X-ray diffraction, to clarify carbonation reaction pathways and efficiency for carbon storage and waste valorization. The primary mineral phases of Argon Oxygen Decarburization (AOD) and Continuous Casting (CC) slags, namely, åkermanite, bredigite, cuspidine, merwinite, and β- and γ-C 2 S, were reacted in a custom-built beryllium-capped XRD reactor filled with either water-saturated (wet) subcritical CO 2 (g), or wet supercritical CO 2(SC) , in a series of carbonation experiments. Formation of calcite and aragonite was observed for most Ca-bearing minerals, transient precipitation of metastable vaterite was observed, while carbonation of AOD and CC slags in CO 2(SC) resulted in hydrated crystalline calcium carbonates and indirect evidence of amorphous carbonate. Overall, results obtained suggest that low-pressure subcritical carbonation routes are attractive for standalone slag carbonation processes, while high-pressure supercritical carbonation routes are amiable to symbiotic integration with CO 2(SC) -generating green technologies.

42 ENGINEERING↗

DOE OSTI2021

Hyporheic Exchange in Sand Dunes Under a Freely Deforming River Water Surface

Bedform-driven hyporheic exchange is conditioned by the head gradients at the sediment-water interface. Local exchange phenomena between the surface and the subsurface are often driven by the dynamic forces related to the velocity distributions around sediment waves. In open channels, the static forces are represented by the water depth, yet most computational fluid dynamics models use a rigid-lid approximation. Here, we investigated whether and when the deformation of the river’s free-surface influences bedform-driven hyporheic exchange. This was done through simulations of coupled open channel and hyporheic flows with the air-water interface modeled either as a free-surface or a rigid-lid across increasing subcritical Froude numbers from ~0.05 to ~0.95. The normalized hyporheic flux was higher when considering free-surface deformation across most of the range of Froude numbers considered. When the Froude number was larger than 0.6 and smaller than 0.85, both hydrostatic and nonhydrostatic-driven fluxes increased significantly compared to the rigid-lid approach and the total flux was about five times that predicted with the rigid-lid. These results indicate that bedform-driven hyporheic fluxes are underestimated in most studies that use a rigid-lid assumption in subcritical flows.

58 GEOSCIENCES↗

DOE OSTI2020

Secondary-Source Core Reload Modeling with VERA

The CASL reactor simulation package VERA has been adapted to provide high-fidelity simulation capabilities for modeling source range detector response during subcritical reactor configurations. New features include the activation and shuffling of secondary-source assemblies, use of burned fuel neutron emission data from the ORIGEN depletion solver to the MPACT deterministic neutron transport solver, allowance of user-defined sources in MPACT based on material composition, ability to solve the subcritical source-driven system with neutron multiplication using the MPACT diffusion solver, and transfer of the calculated fission source from MPACT to the continuous-energy Monte Carlo solver Shift for final detector response evaluation using the CADIS methodology for variance reduction. These new capabilities were benchmarked against Watts Bar Unit 1 plant operating data for the first few fuel loading steps and were found to demonstrate excellent agreement with the measured data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

The MUSIC Critical Benchmark and Nuclear Data

The Measurement of Uranium Subcritical and Critical (MUSIC) experiment was a series of measurements of critical and subcritical configurations of bare highly enriched uranium. The goal was to compare measurement methods, analysis techniques, and simulation methods across regimes of criticality and to provide high-quality validation of 235 U nuclear data. A benchmark evaluation of the two critical configurations of the MUSIC experiments will soon be published in the release of the International Criticality Safety Benchmark Evaluation Project Handbook. The recent execution of the experiment aids in proper quantification of model simplifications and all uncertainties associated with the experiment. Historical benchmark evaluations are heavily relied on for uranium nuclear data validation despite the fact that the same level of documentation and comparable uncertainty analysis may not be present. The MUSIC evaluation is less likely to include “unknown unknowns” that could impede accurately modeling the system. Presented are both highly detailed and very simplified models, which represent the experimental configurations accurately, aiding the users of the benchmark for nuclear data or transport code validation. The sensitivities of k eff to nuclear data and nuclear data–related uncertainties are very similar between this experiment and previous bare uranium sphere experiments. In addition, the nuclear data uncertainties to any nuclides other than 235 U are small. For all these reasons, the recently evaluated MUSIC benchmark critical configurations could prove very useful for 235 U nuclear data validation. Currently, major libraries have good agreement with the experimental results, within 200 pcm for all nuclear data libraries, and within one standard deviation of the experimental result for most. Suggested nuclear data adjustments based on MUSIC and Lady Godiva are also presented, with posterior improvements to both the agreement in k eff and the uncertainty associated with the nuclear data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Comparative Evaluation of Spectral Methods for Robust Reactor Noise Estimation

Reactor noise analysis provides a noninvasive means to determine neutron kinetic parameters from stochastic fluctuations in detector signals. However, standard cross-power spectral density (CPSD) analyses can be sensitive to numerical processing choices, which may introduce processing-dependent systematic shifts in estimates of the prompt neutron decay constant (α) and limit reproducibility. This study uses a hybrid multitaper–Welch spectral estimator to analyze subcritical noise measurements from a fast-spectrum critical assembly. The decay constant α was extracted using three frequency-domain methods: the CPSD, the magnitude-squared coherence (MSC), and the generalized magnitude-squared coherence (GMSC). These coherence-based estimators normalize detector auto-spectral structure and are expected to reduce the sensitivity of fitted α values to processing parameters. A Sobol global sensitivity analysis identified which numerical inputs most strongly influence the fitted values of α. All estimators produced a linear dependence of α on inverse count rate, with delayed-critical extrapolations near 1.7 × 10 4 s −1 , in agreement within 8% of MCNP6.3 KOPTS benchmark calculations. Sensitivity results show that while the CPSD depends on both time-bin width and taper selection, the MSC and GMSC are dominated by time-bin width alone, indicating reduced parameter coupling and greater robustness to processing variability. These findings demonstrate the feasibility and practical value of coherence-based spectral estimators for extracting α from reactor noise and support their broader application to multi-detector and irregular datasets in subcritical system characterization.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗