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Physics and technology considerations for the deuterium–tritium fuel cycle and conditions for tritium fuel self sufficiency

The tritium aspects of the DT fuel cycle embody some of the most challenging feasibility and attractiveness issues in the development of fusion systems. The review and analyses in this paper provide important information to understand and quantify these challenges and to define the phase space of plasma physics and fusion technology parameters and features that must guide a serious R&D in the world fusion program. We focus in particular on components, issues and R&D necessary to satisfy three 'principal requirements': (1) achieving tritium self-sufficiency within the fusion system, (2) providing a tritium inventory for the initial start-up of a fusion facility, and (3) managing the safety and biological hazards of tritium. A primary conclusion is that the physics and technology state-of-the-art will not enable DEMO and future power plants to satisfy these principal requirements. We quantify goals and define specific areas and ideas for physics and technology R&D to meet these requirements. A powerful fuel cycle dynamics model was developed to calculate time-dependent tritium inventories and flow rates in all parts and components of the fuel cycle for different ranges of parameters and physics and technology conditions. Dynamics modeling analyses show that the key parameters affecting tritium inventories, tritium start-up inventory, and tritium self-sufficiency are the tritium burn fraction in the plasma (f b ), fueling efficiency (η f ), processing time of plasma exhaust in the inner fuel cycle (t p ), reactor availability factor (AF), reserve time (tr) which determines the reserve tritium inventory needed in the storage system in order to keep the plant operational for time t r in case of any malfunction of any part of the tritium processing system, and the doubling time (t d ). Results show that η f f b > 2% and processing time of 1–4 h are required to achieve tritium self-sufficiency with reasonable confidence. For η f f b = 2% and processing time of 4 h, the tritium start-up inventory required for a 3 GW fusion reactor is ~11 kg, while it is <5 kg if η f f b = 5% and the processing time is 1 h. To achieve these stringent requirements, a serious R&D program in physics and technology is necessary. The EU-DEMO direct internal recycling concept that carries fuel directly from the plasma exhaust gas to the fueling systems without going through the isotope separation system reduces the overall processing time and tritium inventories and has positive effects on the required tritium breeding ratio (TBR R ). A significant finding is the strong dependence of tritium self-sufficiency on the reactor availability factor. Simulations show that tritium self-sufficiency is: impossible if AF < 10% for any η f f b , possible if AF > 30% and 1% ≤ η f f b ≤ 2%, and achievable with reasonable confidence if AF > 50% and η f f b > 2%. These results are of particular concern in light of the low availability factor predicted for the near-term plasma-based experimental facilities (e.g. FNSF, VNS, CTF), and can have repercussions on tritium economy in DEMO reactors as well, unless significant advancements in RAMI are made. There is a linear dependency between the tritium start-up inventory and the fusion power. The required tritium start-up inventory for a fusion facility of 100 MW fusion power is as small as 1 kg. Since fusion power plants will have large powers for better economics, it is important to maintain a 'reserve' tritium inventory in the tritium storage system to continue to fuel the plasma and avoid plant shutdown in case of malfunctions of some parts of the tritium processing lines. But our results show that a reserve time as short as 24 h leads to unacceptable reserve and start-up inventory requirements. Therefore, high reliability and fast maintainability of all components in the fuel cycle are necessary in order to avoid the need for storing reserve tritium inventory sufficient for continued fusion facility operation for more than a few hours. The physics aspects of plasma fueling, tritium burn fraction, and particle and power exhaust are highly interrelated and complex, and predictions for DEMO and power reactors are highly uncertain because of lack of experiments with burning plasma. Fueling by pellet injection on the high field side of tokamak has evolved to be the preferred method to fuel a burning plasma. Extrapolation from the DIII-D penetration scaling shows fueling efficiency expected in DEMO to be <25%, but such extrapolations are highly uncertain. The fueling efficiency of gas in a reactor relevant regime is expected to be extremely poor and not very useful for getting tritium into the core plasma efficiently. Gas fueling will nonetheless be useful for feedback control of the divertor operating parameters. Extensive modeling has been carried out to predict burn fraction, fueling requirements, and fueling efficiency for ITER, DEMO, and beyond. The fueling rate required to operate Q = 10 ITER plasmas in order to provide the required core fueling, helium exhaust and radiative divertor plasma conditions for acceptable divertor power loads was calculated. If this fueling is performed with a 50–50 DT mix, the tritium burn fraction in ITER would be ~0.36%, which is too low to satisfy the self-sufficiency conditions derived from the dynamics modeling for fusion reactors. Extrapolation to DEMO using this approach would also yield similarly low burn fraction. Extensive analysis presented shows that specific features of edge neutral dynamics in ITER and fusion reactors, which are different from present experiments, open possibilities for optimization of tritium fueling and thus to improve the burn fraction. Using only tritium in pellet fueling of the plasma core, and only deuterium for edge density, divertor power load and ELM control results in significant increase of the burn fraction to 1.8–3.6%. These estimates are performed with physics models whose results cannot be fully validated for ITER and DEMO plasma conditions since these cannot be achieved in present tokamak experiments. Thus, several uncertainties remain regarding particle transport and scenario requirements in ITER and DEMO. The safety standard requirements for protection of the public and release guidelines for tritium have been reviewed. General safety approaches including minimizing tritium inventories, reducing tritium permeation through materials, and decontaminating material for waste disposal have been suggested.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

A Structural Design Approach Tailored for the Rapid Preliminary Design of Microreactor Components

High-temperature microreactors can play a role in developing reliable, portable energy sources for off-grid remote locations, microgrid concepts, and industrial process heat. Portability and passive safety criteria tend to skew microreactor structural component designs toward complex geometries, high thermal stresses, and design bases with large numbers of startup/shutdown cycles. Current design rules, as typified by Section III of the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, are less than optimal for these conditions, particularly for preliminary component designs where developers need to rapidly consider a large number of potential component configurations. This paper presents a design method targeted toward rapid, efficient evaluation of preliminary component designs using modern finite element analysis. The new method retains key connections with the ASME Code rules and design data while streamlining the design approach. This paper presents the design method, several verification examples illustrating the similarities and differences between the new method and the current ASME rules, and the application of the new approach to the evaluation of a test article mimicking key features of a heat pipe–cooled microreactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Modulation and Modeling of Three-Dimensional Nanowire Assemblies Targeting Gas Sensors with High Response and Reliability

Despite improved sensitivity, simple downsizing of gas-sensing components to randomly arranged nanostructures often faces challenges associated with unpredictable electrical conduction pathways. In the present study, controlled fabrication of three-dimensional (3D) metal oxide nanowire networks is demonstrated that can greatly improve both signal stability and sensor response compared to random nanowire arrays. For example, the highest ever reported H 2 S gas response value, and a 5 times lower relative standard deviation of baseline resistance than that of random nanowires assemblies, are achieved with the ordered 3D nanowire network. Systematic engineering of 3D geometries and their modeling, utilizing equivalent circuit components, provide additional insights into the electrical conduction and gas-sensing response of 3D assemblies, revealing the critical importance of wire-to-wire junction points and their arrangement. Here these findings suggest new design rules for both enhanced performance and reliability of chemical sensors, which may also be extended to other devices based on nanoscale building blocks.

36 MATERIALS SCIENCE↗

Stochastic nonlinear analysis of unidirectional fiber composites using image-based microstructural uncertainty quantification

Here, we present a data-driven nonlinear uncertainty quantification and propagation framework to study the microstructure-induced stochastic performance of unidirectional (UD) carbon fiber reinforced polymer (CFRP) composites. The proposed approach integrates (1) microscopic image characterization, (2) stochastic microstructure reconstruction, and (3) efficient multiscale finite element simulations enabled by self-consistent clustering (SCA) analysis. To model the complex microstructural variability, the proposed UQ methods take the non-Gaussian uncertainty sources into account through a distribution-free sampling approach leveraging nonparametric and asymptotic statistical tools. A hierarchical conditional sampling strategy enables the simultaneous sampling of multiple sources of uncertainties. Our approach provides insights into the impact of microstructural variabilities, which are shown to have an increasing impact on the nonlinear responses of UD CFRP parts under progressive compression loading and ultimately on the failure rate over time. We discover that before CFRP parts start to fail, a characteristic time period emerges with distinctive uncertainty distributions specific to the microstructure variability and the probability of failure. Identifying the failure time period is crucial to the reliability prediction, which is an essential component of CFRP design.

36 MATERIALS SCIENCE↗

Rethinking the ill-posedness of the spectral function reconstruction — Why is it fundamentally hard and how Artificial Neural Networks can help

Reconstructing hadron spectral functions through Euclidean correlation functions are of the important missions in lattice QCD calculations. However, in a Källen–Lehmann (KL) spectral representation, the reconstruction is observed to be ill-posed in practice. It is usually ascribed to the fewer observation points compared to the number of points in the spectral function. In this paper, by solving the eigenvalue problem of continuous KL convolution, we show analytically that the ill-posedness of the inversion is fundamental and it exists even for continuous correlation functions. We discussed how to introduce regulators to alleviate the predicament, in which include the Artificial Neural Networks (ANNs) representations recently proposed by the Authors in another study. The uniqueness of solutions using ANNs representations is manifested analytically and validated numerically. Reconstructed spectral functions using different regularization schemes are also demonstrated, together with their eigen-mode decomposition. We observe that components with large eigenvalues can be reliably reconstructed by all methods, whereas those with low eigenvalues need to be constrained by regulators.

97 MATHEMATICS AND COMPUTING↗

Evaluation of Centralized Model Based FLISR in a Lab Setup

Utilities are installing advanced distribution management systems (ADMS) around the globe to improve the sensing and control of distribution systems. ADMS is becoming a critical component to improve the resiliency and reliability of distribution systems. These management systems host a multitude of applications that can be used to sense, control, and operate distribution systems. Fault location, isolation, and service restoration (FLISR) is one of the ADMS applications that is critical to improving resilience during fault conditions. FLISR applications use smart, controllable devices that are installed in the distribution system for FLISR operation. These controllable devices include distributed energy resources (DER) and reclosers. Evaluating such ADMS applications before installation in the field can help de-risk the field implementation and avoid costly failures in the field. This paper presents a background on experimental setup that are typically used to evaluate ADMS applications. This is followed by briefly presenting the setup used to evaluate the FLISR application in an off-the-shelf ADMS tool. Finally, results from the evaluation experiments are presented.

94 GMLC - Grid Modernization Laboratory Consortium↗

Heliostat Consortium: Gap Analysis on State of the Art in Wind Load Design

Wind loads are a major driver of heliostat cost. Standardized methods and tools are needed for a more detailed understanding of the static and dynamic loads of a heliostat design. This will enable cost reduction of wind-dependent heliostats to avoid unnecessarily conservative heliostat designs and increase field efficiency and reliability to reduce the risk of component failures due to high-wind events. Gaps related to wind load include lack of site characterization for wind measurements, insufficient critical load cases for heliostat design, insufficient understanding of turbulence impacts on heliostat tracking error, lack of knowledge on wind load under various heliostat array configurations, and underexplored heliostat field wind-load reduction and operating strategies. Recommended pathway forward is to develop wind load and site characterization guidelines for heliostat design and develop heliostat field wind-load models with optical performance impacts.

aerodynamics↗

Coastal Acoustic Buoy for Offshore Wind: Project Synthesis

The population of North Atlantic right whales is critically endangered and their habitat overlaps with offshore windfarm leases. It is therefore imperative that effective mitigation strategies be used to avoid impacts on right whales during the construction of offshore windfarms. The Department of Energy issued FOA Number DE-FOA-0001924 to encourage the development of technology that could monitor large exclusion zones for right whales in order to mitigate potential impact of construction noise on right whales. This report summarizes the past two years of the development and evaluation of the Coastal Acoustic Buoy for Offshore Wind (CABOW) project which aimed to develop technology to monitor large exclusion zones for North Atlantic right whales. Over the course of the project SMRU Consulting have implemented a rigorous design process including comparison of different approaches (e.g., single sensor vs multiple sensors), as well as consideration of placement and timing of acoustic monitoring. We have evaluated critical components of the CABOW system including, reliability, detection range, and bearing accuracy in areas adjacent to offshore windfarm leases in Maryland by conducting 3,536 playbacks of simulated right whale upcalls. The maximum call detection range was 7.5 km when noise was 99 dB re 1µPa rms (50-225 Hz), but this reduced to < 1 km when ambient noise levels were high. Our detection probability in the field was measured as a function of range as well as the source-to-noise level ratio allowing us to build a model to predict the probability of detection under various scenarios (sample size: 3,536 calls x 5 buoys = 17,680). The median bearing error was -0.25° but this is likely an underestimate of error due to experimental design. Using the published recall and precision of the two detectors we implemented in the CABOW system, we estimate that at a recall of 80%, our precision was > 80%, within the range of what we were aiming for in this project. To estimate our exclusion zone false negative and false positive rates, we built a simulation model using the empirical data from our field trial. We modelled three to nine CABOW units placed on the 10 km exclusion zone and estimated our false negative rate to be 1% or less (which was our project goal) and our false positive rate to be between seven and nine percent, slightly above our goal of 5%. However, we also modelled an equivalent PAM system that does not have bearing capabilities and found the false positive rates for that system to be six to eight times higher than the CABOW rate. This higher false positive rate of PAM systems with low spatial information could have significant cost repercussions for offshore wind developers by adding work shutdowns or delays without providing additional protection for right whales. The model we built allows us to explore the placement of PAM systems under various scenarios and will thus help facilitate planning of PAM mitigation systems to meet NOAA Incidental Harassment Authorizations for specific windfarms. We achieved an average system uptime of 98.3%, just below our goal of 99%. The issues that caused these short losses of data have been identified and fixed. Right whale detections and audio clips were typically transferred via radio from the buoys to the base station in two to four seconds. We therefore believe we have developed a highly robust real-time PAM system. Based on the above, we feel we have achieved the stated funding goal of developing a cost-effective and robust real-time PAM system that enables the monitoring of large exclusion zones for right whales during the constructions of offshore windfarms. This should lead to decreased costs and risks for the offshore wind sector while providing robust mitigation for right whales. It is important to state that PAM mitigation will need to be implemented with other mitigation strategies (e.g., visual observers) to provide a complete mitigation strategy to ensure that any effects on right whales from offshore windfarm construction is minimized.

17 WIND ENERGY↗

Hydrodynamic Modelling for Tidal Energy Kites: Cooperative Research and Development Final Report, CRADA Number CRD-24-30123

The primary goal of the work is to improve accuracy of hydrodynamic loads acting on the lifting surface of the kite turbine due to complex air-water-lifting body interaction in a low-order numerical model using high-fidelity numerical input. The result of this study will help the Participant better design control algorithms for the kite turbine so that the turbine can harvest more energy while maintaining stability of the platform as well as its reliability. The use of hydrodynamic coefficients/load components from computational fluid dynamic simulation will inform better inputs for a medium-fidelity dynamic model (specifically an OrcaFlex model) which is intended for use in rapid design iterations in the design process.

16 TIDAL AND WAVE POWER↗

Evaluation of Centralized Model-Based FLISR in a Lab Setup: Preprint

Utilities are installing advanced distribution management systems (ADMS) around the globe to improve the sensing and control of distribution systems. ADMS is becoming a critical component to improve the resiliency and reliability of distribution systems. These management systems host a multitude of applications that can be used to sense, control, and operate distribution systems. Fault location, isolation, and service restoration (FLISR) is one of the ADMS applications that is critical to improving resilience during fault conditions. FLISR applications use smart, controllable devices that are installed in the distribution system for FLISR operation. These controllable devices include distributed energy resources (DER) and reclosers. Evaluating such ADMS applications before installation in the field can help de-risk the field implementation and avoid costly failures in the field. This paper presents a background on experimental setup that are typically used to evaluate ADMS applications. This is followed by briefly presenting the setup used to evaluate the FLISR application in an off-the-shelf ADMS tool. Finally, results from the evaluation experiments are presented.

94 GMLC - Grid Modernization Laboratory Consortium↗

Overview of H- radio frequency ion sources for particle accelerators

Particle accelerators are among the most important scientific tools of the modern era. Large accelerator complexes have supported scientific user facilities which have had an enormous societal impact spanning many decades and enabling the work of thousands of scientific users worldwide contributing to many Nobel prizes in physics, biology and chemistry [1]. Many of the large hadron facilities employ accelerator complexes which include cyclotrons, synchrotrons, storage rings, linear or tandem accelerators and deliver ion beams of very high-intensity and/or very high-energy to their user facilities. These accelerator complexes require the injection of high-intensity beams of ions which are produced within an ion source and formed within a plasma or by bombardment of a surface [2]. Increasingly, RF systems are being utilized, to generate these ion-rich plasmas due to their high reliability and minimal use of consumable components. This report will first discuss the basic mechanisms of ion formation and plasma generation as well as some specifics of RF/microwave generators, matching circuits and plasma coupling structures typically employed. A detailed discussion will then be given of the RF-driven negative ion source systems employed by US Spallation Neutron Source as well as those used in similar facilities located around the globe. REFERENCES [1]Vladimir Shiltsev, “Particle beams behind physics discoveries”, Physics Today 73, Issue 4, 32 (2020) [2]Robert Welton et al, “Negative hydrogen ion sources for particle accelerators: Sustainability issues and recent improvements in long-term operations”, Journal of Physics Conf Series, 2244 012045

Welton, Robert F.↗

Optics and Systems Design of the Ring-to-Second Target Transport Beam-Line for the SNS Second Target Station

The Second Target Station (STS) project at the Spallation Neutron Source (SNS) is being developed to provide world-leading cold neutron brightness for next-generation neutron scattering experiments. The STS Accelerator Systems (AS) scope includes the design and implementation of the Ring-to-Second Target (RTST) proton beam transport line, which extracts 1.3 GeV proton beam pulses from the existing Ring-to-Beam Transport (RTBT) system and delivers them to the STS target. The RTST design emphasizes operational reliability [high reliability], low activation [minimum activation of components and the tunnel], maintainability, and compatibility with existing SNS infrastructure through extensive reuse of proven RTBT systems and components. The beamline includes a new extraction region, a transport lattice consisting of dipole, quadrupole, and corrector magnets, beam instrumentation systems, vacuum systems, personnel protection systems, and radiation shielding systems. Beam optics and particle tracking studies were performed using PyORBIT to validate extraction trajectories, beam transport, and target beam spot requirements [60–90 cm² beam spot area]. This paper presents the optics design philosophy, extraction system architecture, transport lattice design, instrumentation strategy, vacuum system approach, and radiation protection integration for the RTST beamline. Particle tracking simulations indicate successful beam transport without beam loss under nominal operating conditions. The RTST is designed to transport 1.3 GeV proton beam pulses at repetition rates up to 15 Hz, delivering nominal beam power of 700 kW to the Second Target Station.

Baron, Alex [ORNL]↗

Failure Mode and Effects Analysis (FMEA) for Photovoltaic Inverter

Photovoltaic (PV) inverters are critical yet vulnerable components in modern energy systems, often acting as reliability bottlenecks that increase the levelized cost of energy (LCOE). To address this, this paper presents a comprehensive Failure Mode and Effects Analysis (FMEA) tailored for PV inverters. Leveraging field data and literature, we identify failure-prone components, such as capacitors,, and relays, and prioritize their risks based on quantitative Risk Priority Numbers (RPNs). The analysis reveals that surge-induced MOV short circuits, capacitor degradation, and environmental cooling fan failures dominate the risk profile. These findings provide a targeted framework for reliability improvement, guiding future efforts in predictive diagnostics, design optimization, and accelerated life testing strategies.

14 SOLAR ENERGY↗

Digital Twin Based Condition Monitoring of LCC-LCC Inductive Power Transfer Systems

Inductive power transfer (IPT) systems provide a flexible, hands-free charging opportunity to electric vehicles (EV). The resonant network components and the transmitter and receiver coils are often subjected to high voltages or currents. Component aging in the compensation network and coils of resonant IPT systems is detrimental to the reliability and power transfer efficiency of the IPT system. Monitoring the component health of such multi-element complex systems requires robust optimization algorithms. This paper discusses condition monitoring of a resonant IPT system for an EV charger using a digital twin model. A hybrid estimation algorithm based on genetic algorithms and adaptive particle swarm optimization is developed to estimate the parameters of the digital twin model. Simulation results are used to verify the monitoring capabilities of the developed algorithm under various operating conditions of the IPT system.

Weldehawaryat, Lidya Mussie [graduate research ass↗

Evaluation of the Reliability of Passive Infrared (PIR) Occupancy Sensors for Residential Indoor Lighting

Solid-state lighting (SSL) technologies have penetrated the general illumination market in recent years, largely replacing conventional technologies such as incandescent and fluorescent lighting. Most of the initial excitement about light-emitting diode (LED) sources for SSL devices focused on their energy savings potential resulting from vast improvements in source efficiency and luminous efficacy compared with conventional illumination products. More recently, the focus has shifted toward other aspects of lighting application efficiency, namely intensity effectiveness and spectral efficiency, because of the ease of controlling both the light intensity of LEDs with drive voltage and the color properties of the LED-based illuminators. To capitalize on the energy savings of increased intensity effectiveness and spectral efficiency, a lighting control system (LCS) is often used. While the current penetration of LCSs is relatively modest, it is anticipated that lighting controls (i.e., connected lighting, controls and LED and conventional lighting) could have an installed penetration as higher as 46% by the year 2035, saving an additional 1.3 quads of energy. Despite the large energy savings that can be gained from using LCSs, standard test methods for evaluating sensors employed in LCSs and reliability data of the LCSs and their components are generally lacking. The National Electrical Manufacturers Association (NEMA) developed the only standard, NEMA WD 7-2011 (R2016), to test occupancy and motion sensor performance (herein referred to as “the NEMA protocol”). In a previous U.S. Department of Energy (DOE) effort, some concerns of the NEMA protocol were identified (e.g., strict height and weight limits on test subjects, large amounts of manual effort, sometimes inconsistent repeatability). During the current work, a consistent detection length test (DLT) and a Robotic Sensor Evaluation System (RoboSES) were developed to alleviate some of these concerns. RoboSES acts as a human surrogate by using thermal pads on a mannequin and a remote-controlled mobile base to test a sensor’s field of view (FOV). This report builds on the earlier DOE efforts to understand sensor technologies used in LCSs for general illumination. Specifically, this report describes the optimization of RoboSES, characterizes and establishes test methods to assess the reliability of multiple passive infrared (PIR) sensors, and reports the findings of robustness and reliability testing on two commercial PIR sensors intended for residential applications. The information presented in this report is gained from up to 4,000 hours (hrs) of accelerated stress tests (ASTs).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Predicting bulge to total luminosity ratio of galaxies using deep learning

ABSTRACT We present a deep learning model to predict the r-band bulge-to-total luminosity ratio (B/T) of nearby galaxies using their multiband JPEG images alone. Our Convolutional Neural Network (CNN) based regression model is trained on a large sample of galaxies with reliable decomposition into the bulge and disc components. The existing approaches to estimate the B/T ratio use galaxy light-profile modelling to find the best fit. This method is computationally expensive, prohibitively so for large samples of galaxies, and requires a significant amount of human intervention. Machine learning models have the potential to overcome these shortcomings. In our CNN model, for a test set of 20 000 galaxies, 85.7 per cent of the predicted B/T values have absolute error (AE) less than 0.1. We see further improvement to 87.5 per cent if, while testing, we only consider brighter galaxies (with r-band apparent magnitude <17) with no bright neighbours. Our model estimates the B/T ratio for the 20 000 test galaxies in less than a minute. This is a significant improvement in inference time from the conventional fitting pipelines, which manage around 2–3 estimates per minute. Thus, the proposed machine learning approach could potentially save a tremendous amount of time, effort, and computational resources while predicting B/T reliably, particularly in the era of next-generation sky surveys such as the Legacy Survey of Space and Time (LSST) and the Euclid sky survey which will produce extremely large samples of galaxies.

Grover, Harsh (ORCID:0000000321338142)↗

Modelling the Milky Way – I. Method and first results fitting the thick disc and halo with DES-Y3 data

ABSTRACT We present a technique to fit the stellar components of the Galaxy by comparing Hess Diagrams (HDs) generated from trilegal models to real data. We apply this technique, which we call mwfitting, to photometric data from the first 3 yr of the Dark Energy Survey (DES). After removing regions containing known resolved stellar systems such as globular clusters, dwarf galaxies, nearby galaxies, the Large Magellanic Cloud, and the Sagittarius Stream, our main sample spans a total area of ∼2300 deg2. We further explore a smaller subset (∼1300 deg2) that excludes all regions with known stellar streams and stellar overdensities. Validation tests on synthetic data possessing similar properties to the DES data show that the method is able to recover input parameters with a precision better than 3 per cent. We fit the DES data with an exponential thick disc model and an oblate double power-law halo model. We find that the best-fitting thick disc model has radial and vertical scale heights of 2.67 ± 0.09 kpc and 925 ± 40 pc, respectively. The stellar halo is fit with a broken power-law density profile with an oblateness of 0.75 ± 0.01, an inner index of 1.82 ± 0.08, an outer index of 4.14 ± 0.05, and a break at 18.52 ± 0.27 kpc from the Galactic centre. Several previously discovered stellar overdensities are recovered in the residual stellar density map, showing the reliability of mwfitting in determining the Galactic components. Simulations made with the best-fitting parameters are a promising way to predict Milky Way star counts for surveys such as the LSST and Euclid.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Convergent Manufacturing of Large-Scale Components for Nuclear Applications, via Additive Manufacturing and Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy (PM)–hot isostatic pressing (PM-HIP) has long been recognized as a powerful route for producing fully dense, near net shape metallic components. By consolidating powders under high temperature and pressure, HIP provides isotropic properties, uniform microstructures, and scalability to complex geometries that are vital for sectors such as aerospace, energy, and nuclear power. Yet despite these advantages, the technology has remained constrained by costly trial and error canister fabrication, limitations of conventional forging, and incomplete knowledge about how the canister design influences final part properties. Additive manufacturing (AM), by contrast, thrives on design freedom and geometric flexibility but struggles with speed, scalability, and cost when applied to very large structures. The research presented in this report investigated how a convergent manufacturing approach, combining AM with PM-HIP, can merge the strengths of both technologies, leveraging AM’s flexibility for canister design and HIP’s consolidation capability to deliver reliable, large, and complex parts. The work progressed through three case studies that built on one another in scale and complexity. Small cylindrical canisters fabricated by conventional methods, laser powder bed fusion, and directed energy deposition were filled with stainless steel powders and subjected to HIP. The resulting parts demonstrated near-full density and mechanical properties on par with wrought stainless steel, showing for the first time that AM canisters can be a direct substitute for conventional ones without sacrificing quality. The next step involved a medium-scale, noncentrosymmetric T-valve, which is an enclosed, multibranch geometry that tested the limits of AM + PM-HIP integration. The T-valve achieved predictable shrinkage and uniform densification, confirming feasibility for enclosed designs. However, this study also revealed oxide inclusions and interfacial challenges at the AM + HIP boundary, underscoring the critical importance of controlling interface chemistry and employing robust, in situ strategies, such as melt pool monitoring and thermal monitoring, coupled with nondestructive evaluation techniques such as x-ray computed tomography. Finally, the effort culminated in fabricating a large-scale impeller weighing nearly 2000 lb and spanning 5 ft in diameter. Produced via multirobot wire arc AM and hot isostatic pressed to near-full density, the impeller validated industrial-scale feasibility. Predictive models closely matched experimental shrinkage, tensile properties were spatially uniform across the component, and the AM + PM-HIP interface proved mechanically sound despite the presence of oxide-decorated prior particle boundaries. This large-scale demonstration is a major milestone, showing that hybrid AM + PM‑HIP can reliably deliver components at reactor-relevant scales. Collectively, these studies charted a logical pathway: small-scale work built scientific confidence, medium-scale work highlighted opportunities and challenges, and large-scale work proved industrial impact. The overarching conclusion of this report is that AM + PM-HIP should not be seen as a replacement for forging but as a complementary pathway that provides the US with flexibility, resilience, and new options for manufacturing nuclear-grade components. Looking ahead, several directions emerge as critical to sustaining progress. Predictive modeling must become faster, more accessible, and more accurate, with digital twins and machine learning reducing reliance on trial and error. Powders and alloys must be optimized for HIP, with improved cleanliness, reduced oxides, and tailored chemistries that enhance creep, fatigue, and irradiation resistance. Interfaces between AM and HIP regions must be better engineered through coatings, machining strategies, and surface treatments to mitigate oxide formation and ensure reliable bonding to explore opportunities for HIP of targeted compositional parts, as well as multimaterial HIP cladding applications. Monitoring and nondestructive evaluation need to expand, incorporating multimodal sensors, x-ray computed tomography, and real-time data integration through platforms such as Pelican. At the same time, the pathway to industrial adoption requires techno-economic analysis, machinability studies, and qualification frameworks aligned with industry and regulatory standards. Finally, workforce and academic engagement must be strengthened. Programs that train technicians and engineers for US Navy and US Department of Energy manufacturing challenges should be paired with academic partnerships to support fundamental research, with open sharing of non-export-controlled data to accelerate innovation and build the next generation of experts. In conclusion, this report demonstrates that hybrid AM + PM-HIP is scientifically viable and strategically important. By combining the design agility of AM with the consolidation strength of HIP and embedding modeling, monitoring, and workforce development, this approach provided a transformative new capability for US manufacturing. The path forward is clear: hybrid AM + PM-HIP is not just a promising research direction but is also potentially an industrially relevant pathway that can reshape how nuclear-grade components are designed, qualified, and deployed.

36 MATERIALS SCIENCE↗