Search NASA⌕ Search

SEARCH · Search NASA

Results for “Milestones”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗
DOE OSTI2020

Support CEED-enabled ECP applications in their preparation for Aurora/Frontier

The goal of this milestone was to help CEED-enabled ECP applications (particularly ExaSMR, MARBL, ExaAM, ExaWind and E3SM) in their preparations for the Aurora and Frontier architectures. This work included collaboration with ECP vendors and porting and optimization of CEED’s benchmarks and miniapps to early access hardware. As part of this milestone, we also made the best bake-off problems and bake-off kernel implementation from Nek, MFEM, libParanumal and the external community available in the latest libCEED release, libCEED-0.7. During the milestone period we also organized, in virtual form, the fourth CEED Annual meeting (CEED4AM) which included representatives from ECP applications, vendors and software technology projects. The specific tasks addressed in this milestone were to: (1) Work with vendors to port and run CEED benchmarks on early access systems for Aurora and Frontier; (2) Make the best BP/BK implementations from Nek, MFEM, libParanumal and external community available in libCEED; (3) Organize the next CEED Annual meeting (CEED4AM); and (4) Optimize CEED applications and miniapps for Aurora and Frontier architectures. The artifacts delivered include the next libCEED release, libCEED-0.7, and a number of developments integrated within applications to improve their GPU performance and capabilities. See the CEED website, http://ceed.exascaleproject.org and the CEED GitHub organization, http://github.com/ceed for more details.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Experiences of Member States in Building a Nuclear Security Infrastructure for New Nuclear Power Programmes

A nuclear power programme has many benefits, but it is a major undertaking that requires careful planning and preparation as well as a substantial investment in time. It also necessitates the establishment of a sustainable national infrastructure with committed and sustained financial and human resources. While nuclear power is not unique in this respect, it is different from other sources of energy because of the risks associated with the use of nuclear material, as well as the need for compliance with international legal instruments, internationally accepted nuclear safety standards, nuclear security guidance, and safeguards requirements. The IAEA’s Milestones in the Development of a National Infrastructure for Nuclear Power, IAEA Nuclear Energy Series No. NG-G-3.1 (Rev. 1), defines a phased approach that identifies 19 infrastructure issues that should be addressed in each of the three phases of the development of a nuclear infrastructure for a nuclear power programme. The publication Evaluation of the Status of National Nuclear Infrastructure Development IAEA Nuclear Energy Series NG-T-3.2 (Rev. 2) provides a methodology to determine the status of the infrastructure conditions covering all 19 issues identified in the Milestones Approach. A companion IAEA Implementing Guide, Establishing the Nuclear Security Infrastructure for a Nuclear Power Programme, IAEA Nuclear Security Series No. 19, provides guidance on the recommended actions to be taken by a State to establish an effective national nuclear security infrastructure for a nuclear power programme using the Milestones Approach. This publication is intended to provide guidance based on the experiences and good practices of Member States with embarking nuclear power programmes as well as Member States that are expanding their nuclear power programmes. The guidance is in the form of case studies, which highlight challenges, issues, and solutions identified by Member States as lessons learned for new nuclear power programmes. This TECDOC is designed to present the experiences of Member States to assist other Member States in developing a nuclear security programme. It addresses the key actions necessary to establish an effective national nuclear security infrastructure for a nuclear power programme consistent with the three phases of the IAEA Milestones Approach. The Member States that provided case studies in this document are at different stages in the development of a nuclear power programme.

42 ENGINEERING↗
DOE OSTI2026

TDCOSMO XXIII. Measurement of the Hubble constant from the doubly lensed quasar HE 1104−1805

Time-delay cosmography leverages strongly lensed quasars to measure the Universe’s current expansion rate, H 0 , independently from other methods. The latest TDCOSMO milestone measurement primarily used quadruply lensed quasars for their mass profile constraints. However, doubly lensed quasars, being more abundant and offering precise time delays, could expand the sample by a factor of 5, significantly advancing towards a 1% precision measurement of H 0 . We present the first TDCOSMO analysis of a doubly imaged source, HE 1104−1805, including the measurement of the four necessary ingredients. First, by combining 17 years of data from the SMARTS, Euler, and WFI telescopes, we measured a time delay of 176.3 +11.4 −10.3 days. Second, using MUSE data, we extracted stellar velocity dispersion measurements in three radial bins with 5% to 13% precision. Third, employing F160W HST imaging for lens modelling and marginalising over various modelling choices, we measured the Fermat potential difference between the images. Fourth, using wide-field imaging, we measured the convergence added by objects not included in the lens modelling. By combining these four ingredients, we measured the time delay distance and the angular diameter distance to the deflector, favouring a power-law mass model over a baryonic and dark matter composite model. The measurement was performed blindly to prevent experimenter bias and resulted in a Hubble constant of H 0 = +5.8 −5.0 × λ int km s −1 Mpc −1 , where λ int is the internal mass sheet degeneracy parameter. This is in agreement with the TDCOSMO-2025 milestone and its precision for λ int = 1 is comparable to that obtained with the best-observed quadruply lensed quasars (4–6%). This work is a stepping stone towards a precise measurement of H 0 using a large sample of doubly lensed quasars, supplementing the current sample. The next TDCOSMO milestone paper will include this system in its hierarchical analysis, constraining λ int and H 0 jointly with multiple lenses.

cosmological parameters↗
DOE OSTI2026

New thermal-relic targets for sub-GeV dark matter direct detection

Dark matter direct detection experiments involving electron recoils are beginning to test highly predictive, thermal-relic milestones for sub-GeV dark matter models. Due to the Lee-Weinberg bound, thermal dark matter candidates in this mass range necessarily require comparably light mediator particles to achieve a suitably large annihilation cross section. Here we present new thermal-relic milestones for sub-GeV dark matter candidates that couple to vector mediators. In these models, the mediators are massive gauge bosons of anomaly-free Abelian extensions to the Standard Model, including the dark photon, gauged L i - L j , B - L , and B - 3 L i models, where B is the baryon number, L is the lepton number, and i , j index the lepton families. Since the same interactions that govern cosmological production also govern electron scattering, the targets we present are firmly predictive and allow for these models to be robustly discovered or falsified. Furthermore, since the mediators we study exhaust the minimal anomaly-free U(1) extensions to the Standard Model, our results offer a complete list of predictive milestones for sub-GeV dark matter coupled to vector mediators.

Han, Xu [Chicago U.] (ORCID:0009000821607836)↗
DOE OSTI2020

Stability of zirconium hydride

This reports complete Milestone M2.2.1 Stability of zirconium hydride: Experimental investigation of the hydrogen concentration of encapsulated zirconium hydride before and after joining. In this milestone, we first report the successful fabrication of crack-free bulk zirconium hydride by using the ORNL static hydriding system. The fabricated hydride was characterized by using X-ray diffraction (XRD) and X-ray computed tomography (XCT). XRD results showed that the δ-phase zirconium hydride, α-zirconium, and ε-phase hydride were present. XCT confirmed the absence of the internal cracking. The hydrogen concentration was determined by the weight change before and after hydrogen loading, given the fact that the oxide phase was not found during XRD analysis. Two metallic cladding materials, i.e., molybdenum and FeCrAl, were selected to encapsulate the fabricated zirconium hydride pellets. Demonstration capsules were designed and machined. Mo crucible was successfully sealed by using a combination of electron beam welding and gas tungsten arc welding. Due to the undesired neutronics property of Mo, further investigation of this cladding material was not pursued. Electron beam welding and laser beam welding were employed to seal the FeCrAl capsules. XRD were performed on the zirconium hydride before and after the sealing. The results showed that the welding process has negligible impact on the hydrogen content in the FeCrAl-canned zirconium hydride. The presented work fulfilled the proposed work under this milestone and paves a pathway to fabricate single-phase zirconium hydride and to develop robust cladding materials to can bulk zirconium hydride.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Opacity Table Generation

Radiation opacity is a key property of material systems which describes the absorption and scattering of photons. Such processes are an important part of energy transport, diagnostics, and astrophysical phenomena. Recent experiments in iron opacity and continuum lowering have sparked renewed interest in and careful vetting of opacity models. Even within the local thermodynamic equilibrium approximation, opacity varies over a large parameter space: material, temperature, density, and energy. Opacity tables that span wide regimes of this parameter space are of prime importance to radiation-hydrodynamics codes. Accurate opacity calculations cannot be achieved inline during a radiation hydrodynamics simulation since they involve accounting for all possible electron transitions of all important atomic states of a thermal ensemble. Livermore’s current framework utilizes precalculated tables at many densities, temperatures, and energies. Last year, the opacity theory team completed an L2 milestone concerning the development of a new code, Opus, which served the dual purpose of creating a modern code infrastructure and version control as well as the basis for training new members of that team, a critical need as key members near or are passed retirement. For the current L2 milestone, we exercised and validated Opus on three elements: boron, carbon, and nitrogen, which have few enough electrons to allow a careful convergence study over many input parameters. Here, we report on the production of new tables, show their convergence with respect to important parameters, state some of their limitations, and document a mostly automated production process. In this section, we address the milestone completion criteria, found on the title page and the subsection headings. In section 2, we validate Opus against Tycho and compare with TabOp and Atomic. Section 3 details some of the physics implemented in Opus and relevant to this report. We then cover details of the density-temperature grid in section 4 and do a spectral comparison between different parameter settings and different codes in section 5. After summarizing these results in section 6, we give instructions how to run the opacity table scripts in appendix A and document the scripts and input/output files in appendix B.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Integrated System and Application Continuous Performance Monitoring and Analysis Capability

Scientific applications run on high-performance computing (HPC) systems are critical for many national security missions within Sandia and the NNSA complex. However, these applications often face performance degradation and even failures that are challenging to diagnose. To provide unprecedented insight into these issues, the HPC Development, HPC Systems, Computational Science, and Plasma Theory & Simulation departments at Sandia crafted and completed their FY21 ASC Level 2 milestone entitled "Integrated System and Application Continuous Performance Monitoring and Analysis Capability." The milestone created a novel integrated HPC system and application monitoring and analysis capability by extending Sandia's Kokkos application portability framework, Lightweight Distributed Metric Service (LDMS) monitoring tool, and scalable storage, analysis, and visualization pipeline. The extensions to Kokkos and LDMS enable collection and storage of application data during run time, as it is generated, with negligible overhead. This data is combined with HPC system data within the extended analysis pipeline to present relevant visualizations of derived system and application metrics that can be viewed at run time or post run. This new capability was evaluated using several week-long, 290-node runs of Sandia's ElectroMagnetic Plasma In Realistic Environments ( EMPIRE ) modeling and design tool and resulted in 1TB of application data and 50TB of system data. EMPIRE developers remarked this capability was incredibly helpful for quickly assessing application health and performance alongside system state. In short, this milestone work built the foundation for expansive HPC system and application data collection, storage, analysis, visualization, and feedback framework that will increase total scientific output of Sandia's HPC users.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Integrated System and Application Continuous Performance Monitoring and Analysis Capability (Final)

Scientific applications run on high-performance computing (HPC) systems are critical for many national security missions within Sandia and the NNSA complex. However, these applications often face performance degradation and even failures that are challenging to diagnose. To provide unprecedented insight into these issues, the HPC Development, HPC Systems, Computational Science, and Plasma Theory & Simulation departments at Sandia crafted and completed their FY21 ASC Level 2 milestone entitled "Integrated System and Application Continuous Performance Monitoring and Analysis Capability." The milestone created a novel integrated HPC system and application monitoring and analysis capability by extending Sandia’s Kokkos application portability framework, Lightweight Distributed Metric Service (LDMS) monitoring tool, and scalable storage, analysis, and visualization pipeline. The extensions to Kokkos and LDMS enable collection and storage of application data during run time, as it is generated, with negligible overhead. This data is combined with HPC system data within the extended analysis pipeline to present relevant visualizations of derived system and application metrics that can be viewed at run time or post run. This new capability was evaluated using several week-long, 290-node runs of Sandia’s ElectroMagnetic Plasma In Realistic Environments (EMPIRE) modeling and design tool and resulted in 1TB of application data and 50TB of system data. EMPIRE developers remarked this capability was incredibly helpful for quickly assessing application health and performance alongside system state. In short, this milestone work built the foundation for expansive HPC system and application data collection, storage, analysis, visualization, and feedback framework that will increase total scientific output of Sandia’s HPC users.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

FY2020 Annual Report on Subcontract B631779 with UC Berkeley: Reactive Precursors Additive Manufacturing Report

This work succeeded in reaching each of the stated milestones for developing, printing, reacting, and characterizing the uranium carbide final products. Leveraging experience gained from creating magnesium oxide inks (milestone #1) and prior reactive precursor work with boron carbide (milestone #2) a uranium carbide reactive precursor ink was developed. The chosen composition of ink utilized a mixture of wax, petrolatum, and stearic acid as the binder. The reactive precursor portion of the ink was comprised of uranium oxide and nano particle activated carbon for production of uranium carbide via carbothermal reduction. Following an in-air burnout of the binder at 160C the printed samples were reacted and sintered at 1750C in an argon environment induction furnace. The resulting product has an open porosity dense, foam-like internal structure with a calculated density of 89% in the solid fraction.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2021

Closing the Loop on Automotive Carbon Fiber Prepreg Manufacturing Scrap

The project demonstrated how to “close the loop” on carbon fiber by integrating industrial carbon fiber scrap into new functional components in an automotive lightweighting application. The project serves as a validation of discontinuous recycled carbon fiber in a commercial context, while generating comprehensive material data throughout the production chain. To this end, the project exhibited increasing complexity as material evaluation progressed from benchtop to commercial scale through full-scale part production, with key material properties thoroughly characterized throughout the process. Of particular focus was the form of the fiber that was fed into compounding, as recycled fiber has historically been problematic to feed at commercial-scale. Carbon fiber is energy-intensive to manufacture, so reuse of existing fiber material can reduce costs and increase sustainability. Additionally, by integrating recovered short fiber into a thermoplastic, regrind processes can be used to provide feedstock for later generations of product. While regrind plastics are not “infinitely recyclable”, reusing the manufacturing scrap over several generations of products can greatly increase material sustainability and lower the fractional embodied energy of each successive product. As such, this project supports the IACMI technical goals of (1) 25% lower carbon fiber-reinforced polymer (CFRP) cost, (2) 50% reduction in CFRP embodied energy, and (3) 80% composite recyclability into useful products. The initial stage of the project involved down selecting surface treatment (sizing) chemistries. Sizing evaluations were performed on Vartega’s chemically recycled intermediate modulus fiber along with standard modulus dry scrap which was oversized with sizing provided by Michelman. More dramatic improvements from sizing were found on the standard rather than the intermediate modulus fibers. The strength of the chemically recycled individual fibers were evaluated by Michelman and ORNL through single fiber testing and found to be comparable to similarly evaluated virgin fibers. UDRI’s mechanical testing on injection molded test specimens identified similar mechanical properties and fiber distribution relative to benchmark specimens. Additional surface chemistry tests and visualizations were performed by the Colorado School of Mines to confirm close conformance between the benchmark and recycled-fiber specimens. As the mechanical test results exceeded the 80% threshold established as the go/no-go(GNG), the project scale was increased to use commercial-scale equipment that would both better characterize the manufacturing utility of the target product format and allow qualitative assessment of a complex commercial part. An upscaled compounding evaluation was performed with a 27 mm twin-screw compounding extruding using oversized standard modulus fibers that were formatted to improve bulk solids transfer. The project team anticipated that milestone mechanical benchmarks could be achieved given the favorable performance of the sized standard modulus material identified in the initial micro-compounding trials. While the mechanical performance did meet the milestone target for that phase of the project, mechanical properties for this standard modulus-based compound were still less than those of the Ford specification. To compare the performance, the project team oversized intermediate modulus dry fibers and compounded them with the project resin at BASF using a 40 mm compounder. Test specimen mechanical performance exceeded the targets laid out in both the project milestone and the Ford specification. A series of prototype parts were successfully molded, albeit with instances of short shot components due to the high thermal conductivity of the carbon fiber compared to glass fiber for which the prototype tool was designed for. The project demonstrated that recycled carbon fiber is a viable option in fiber reinforced compound, providing greatly increased strength and modulus for applications that require them. The “agglomerated” format that facilitated effective bulk solids transfer of recovered fiber showed promise for industrial application.

36 MATERIALS SCIENCE↗
DOE OSTI2022

STNS01-44 BEE – FY22-1: Enhanced BEE Client [Slide]

BEE provides a portable, modular, HPC-focused workflow engine capable of managing containerized applications at scale. In FY22 BEE is completing enhancements and refinements that will complete the major development work of the workflow system. The first major milestone is the development of a graphical client. The second milestone will be the ability for BEE to automatically restart checkpointed tasks. The final milestone for FY22 will be the ability to launch and manage multiple simultaneous workflows.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Report on Initial Tribological Studies of Graphite in Dry Argon and Molten Salt Environment

This report documents completion of the Advanced Reactor Technologies (ART) Level 2 Milestone M2TG-24OR0501081: “Complete report on initial tribological studies within molten salt environment”, due January 31, 2024. This milestone is a carryover milestone from FY23 M2TG-23OR0501091. The report summarizes the initial studies on tribological characterization of the graphite–graphite sliding interface in a dry argon and molten FLiNaK salt environment. The experiments were conducted on a high-temperature multifunctional tribometer placed in a glovebox. This configuration enables probing the wear and friction properties at high temperatures in an inert environment. The worn surfaces were analyzed using high-resolution microscopy and white-light profilometry to determine the wear modes and wear rates. This report discusses the previous wear and friction studies on 316H stainless steel (SS) sliding against graphite in molten salt for different temperatures, sliding speeds, and salt amount. Moreover, key tribological parameters of pebble-on-pebble interaction in gas-cooled and molten salt reactors (MSRs) are analyzed and used to design an experimental test matrix for future studies. The outcomes of this project could provide key information about the tribological behavior of graphite pebbles in gas-cooled and MSRs, thereby contributing to safer operation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

RESIN: Responsible Innovation for Highly Recyclable Plastics - TASK 4: Risk Assessment Framework

This report covers the entirety of Task 4, but its main purpose is to deliver milestones ML4.4 and ML4.5, the last two SOPO milestones under Task 4. ML4.4 reports on the compatibility of polymer properties that affect both environmental performance and functional performance and the tradeoffs involved in turning these properties to the benefit of each. ML4.5 presents a complete set of information on the critical properties of benign target products, where benign products are defined as those with the shortest environmental lifetime which meet performance requirements. To support and provide context to the discussions of ML4.4 and ML4.5 and to provide a complete picture of Task 4, milestones 4.1-4.3 are briefly summarized at the beginning of the report. The discussion of ML4.4 introduces the notion of polymer persistence as a proxy for environmental risk. It then discusses the development and comparison of two machine leaning models explored for estimating polymer degradation rates, a random forest (RF) classifier and an RF regressor. Given the advantage of continuous outputs rather than simple classes, the RF regressor was incorporated in the Excel risk calculator, which to this point could implement the objectives of subtasks 4.1-4.3, estimating polymer release and redistribution. The ML4.4 discussion then addresses the effect of each of the three polymer features used by the RF regressor on polymer functional performance. These features are number molecular weight (Mn), glass transition temperature (T g ) and heat of fusion (H fus ). The discussion of ML4.5 reviews the conceptual framework of the risk model, which served as the foundation for developing the Excel risk calculator and describes the use of, and assumptions within, the calculator. Appendix A is further provided as a user’s guide for the calculator. To demonstrate how the calculator is intended to be used by developers in the design of low-risk polymers, an analysis of 27 hypothetical polymers defined by varying values for the three polymer features used by the RF regressor is presented. The range of parameter values selected produces estimates of polymer degradation rates and lifetimes that may be typical of various consumer products made from polyurethane polymers and shows how changes in polymer features affect lifetimes. The demonstration also predicts the final distribution of released polymer materials in environmental compartments as a function of consumer product mix and assumed leakage rates of end-of-life processes. Lastly, this report summarizes the achievement of Task 4 goals from original conception to final delivery and discusses how and to what degree to which each subtask goal was achieved.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Deployment of BISON models of fuel restructuring at high burnup and related fission gas behavior in UO 2

This milestone report details the advancements made in fiscal year 2024 under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to improve the modeling of fission gas behavior in high burnup UO 2 nuclear fuel in the BISON fuel performance code. As nuclear fuel is pushed to higher burnups, significant microstructural changes occur within the fuel, including the formation of a high burnup structure (HBS) on the pellet rim and a dark zone deeper within the pellet. These regions, characterized by subgrain formation and increased pore densities, have critical implications for fission gas behavior and release, which are not well understood. The modeling capabilities in BISON did not adequately predict these phenomena, leading to an underestimation of fuel restructuring and - potentially - of fission gas release. To address these gaps, this milestone focused on three key objectives: (1) reviewing and assessing Sifgrs's capabilities for low burnup fuel, on which high burnup capabilities rely, (2) validating and expanding HBS fission gas modeling capabilities, including investigating mechanisms for fission gas release from HBS, and (3) expanding Sifgrs to enable modeling of dark zone formation and its effects on fission gas behavior. These objectives were achieved and are described herein. The achievements of this NEAMS milestone are significant for the industry's goal of burnup extension. The improved predictive modeling capabilities for both low- and high-burnup conditions enhance our understanding of fuel performance under both normal operations and transient scenarios. Although goals were reached, future work is necessary to validate these models against experimental data and quantify their accuracy in different conditions. In parallel, mechanistic modeling efforts should continue to extend and refine these capabilities to increase accuracy while reducing reliance on empirical models. This will ensure robust performance across a broader range of conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Heated Test of Neutron Sensor in NRAD

This document is a short PowerPoint slide deck which illustrates completion of an FY21 milestone associated with the Advanced Sensor Initiative (ASI). These slides will be attached to a Department of Energy PICS entry claiming completion of the milestone. The milestone was to conduct high temperature irradiation testing of neutron flux sensors (M3CT-21IN0702024). The test was conducted 8/25/2021 and reached a temperature of 800C.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗