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DOE OSTI2023

Interlocking metasurfaces

Abstract Interlocking metasurfaces (ILMs) are architected arrays of mating features that enable joining of two bodies. Complementary to traditional joining technologies such as bolts, adhesives, and welds, ILMs combine ease of assembly, removal, and reassembly with robust mechanical properties. Structural in nature, they act in a quasi-continuous manner across a surface and enable joining of complex surfaces, e.g., lattices. In this perspective, we define an ILM, begin exploring the design domain and illustrate its breath, and pragmatically evaluate mechanical performance and manufacturability. ILMs will find applications in various fields from aerospace to micro-robotics, civil engineering, and prosthetics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Isotopic Substitution Reveals the Importance of Aluminate Diffusion Dynamics in Gibbsite (Al(OH) 3 ) Crystallization from Alkaline Aqueous Solution

Understanding molecular-scale factors governing the precipitation of aluminum hydroxides, such as gibbsite, under alkaline conditions is important for the formation of laterite deposits, as well as aluminum processing. However, mechanisms enabling tetrahedral aluminate ions to assemble into octahedral sites of the gibbsite lattice remain unclear. Formation of oligomeric complexes has been hypothesized as a critical intermediate step. Here, we report a study of gibbsite solubility in highly alkaline solutions using deuterium substitution to probe equilibrium and kinetic factors that could affect oligomeric intermediate formation, including the reactivity and the diffusivity of aluminate ions. When substituting sodium hydroxide with sodium deuteroxide, solution analysis shows a nearly 40% and 50% increase in gibbsite solubility in 2.4 and 3.3 mol·kg –1 total sodium solutions, respectively. Raman spectroscopy indicated that monomeric aluminate ions are the predominant species in solution irrespective of deuteration. However, both 27 Al and 23 Na nuclear magnetic resonance (NMR) spectroscopy revealed significant differences in chemical shifts in deuterated solutions, and analysis of 1 H, 23 Na, and 27 Al diffusion coefficients with pulsed-field gradient, stimulated echo NMR spectroscopy shows a decrease in ion diffusivity with increasing total deuterium in solution, consistent with the notion of increasing strength in the hydrogen/deuterium bonding network. In conclusion, because the relative change in 1 H diffusion coefficients are commensurate with the difference in apparent solubility constants, there is evidence for an oligomeric intermediate whose steady-state concentration is maintained by the collision frequency of aluminate ions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Structural basis of colibactin activation by the ClbP peptidase

Abstract Colibactin, a DNA cross-linking agent produced by gut bacteria, is implicated in colorectal cancer. Its biosynthesis uses a prodrug resistance mechanism: a non-toxic precursor assembled in the cytoplasm is activated after export to the periplasm. This activation is mediated by ClbP, an inner-membrane peptidase with an N-terminal periplasmic catalytic domain and a C-terminal three-helix transmembrane domain. Although the transmembrane domain is required for colibactin activation, its role in catalysis is unclear. Our structure of full-length ClbP bound to a product analog reveals an interdomain interface important for substrate binding and enzyme stability and interactions that explain the selectivity of ClbP for the N -acyl- d -asparagine prodrug motif. Based on structural and biochemical evidence, we propose that ClbP dimerizes to form an extended substrate-binding site that can accommodate a pseudodimeric precolibactin with its two terminal prodrug motifs in the two ClbP active sites, thus enabling the coordinated activation of both electrophilic warheads.

Biochemistry & Molecular Biology↗

DOE OSTI2024

Metal-to-Ceramic Joining Methods to Support Development of Advanced Ceramic-Based CSP Components

The National Renewable Energy Laboratory, Missouri University of Science and Technology (MS&T), Massachusetts Institute of Technology (MIT), and Colorado School of Mines (CSM) collaborated to design, develop, and test a material concept at bench scale which will be used to achieve a ceramic-to-metal (C2M) joint between a selected metal HTF loop material and a selected ceramic material used by the Gen3 CSP technology pathway. The final joint assembly will need to possess sufficient mechanical properties to withstand static high-temperature (650 degrees-700 degrees C) and high-pressure (20 MPa) and thermal cycling (between 650 degrees C and 100 degrees C) conditions. The material concept consists of three key components: (1) a ceramic matrix composite (CMC) that serves as a compliant transition material aiming to mitigate the stresses due to the mismatch of coefficient of thermal expansion (CTE) from a direct ceramic-to-metal joint, (2) a metal-end joint utilizing a multi-principal element alloy (MPEA) with changing percentage of particle loading to bond the candidate metal to the CMC, and (3) a ceramic-end joint utilizing a glass ceramic to bond the candidate ceramic to the CMC.

14 SOLAR ENERGY↗

DOE OSTI2024

Three-dimensional nanoscale metal, metal oxide, and semiconductor frameworks through DNA-programmable assembly and templating

Controlling the three-dimensional (3D) nanoarchitecture of inorganic materials is imperative for enabling their novel mechanical, optical, and electronic properties. Here, by exploiting DNA-programmable assembly, we establish a general approach for realizing designed 3D ordered inorganic frameworks. Through inorganic templating of DNA frameworks by liquid- and vapor-phase infiltrations, we demonstrate successful nanofabrication of diverse classes of inorganic frameworks from metal, metal oxide and semiconductor materials, as well as their combinations, including zinc, aluminum, copper, molybdenum, tungsten, indium, tin, and platinum, and composites such as aluminum-doped zinc oxide, indium tin oxide, and platinum/aluminum-doped zinc oxide. The open 3D frameworks have features on the order of nanometers with architecture prescribed by the DNA frames and self-assembled lattice. Structural and spectroscopic studies reveal the composition and organization of diverse inorganic frameworks, as well as the optoelectronic properties of selected materials. The work paves the road toward establishing a 3D nanoscale lithography.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2021

Responsive Interfacial Assemblies Based on Charge‐Transfer Interactions

Abstract Charge transfer (CT) interactions have been widely used to construct supramolecular systems, such as functional nanostructures and gels. However, to date, there is no report on the generation of CT complexes at the liquid–liquid interface. Here, by using an electron‐deficient acceptor dissolved in water and an electron‐rich donor dissolved in oil, we present the in situ formation and assembly of CT complex surfactants (CTCSs) at the oil–water interface. With time, CTCSs can assemble into higher‐order nanofilms with exceptional mechanical properties, allowing the stabilization of liquids and offering the possibility to structure liquids into nonequilibrium shapes. Moreover, due to the redox‐responsiveness of the electron‐deficient acceptor, the association and dissociation of CTCSs can be reversibly manipulated in a redox process, leading to the switchable assembly and disassembly of the resultant constructs.

Sun, Shuyi↗

DOE OSTI2021

Responsive Interfacial Assemblies Based on Charge‐Transfer Interactions

Sun, Shuyi↗

DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Mechanical Characterization of Electrolyzer Membranes and Components Under Compression

Proton-exchange membrane (PEM) water electrolysis is a promising technology for producing clean hydrogen by electrochemically splitting water when paired with renewable energy sources. A major roadblock to improving electrolyzer durability is the mechanical degradation of the cell components, which requires an understanding of their mechanical response under device-relevant conditions. However, there is a lack of studies on the mechanical characterization of the PEM and other components, as well as and their interactions. This study aims to address this gap by using a custom-designed testing apparatus to investigate the mechanics of electrolyzer components in uniaxial compression at 25 and 80 °C. Findings show stress-strain response of components have a varying degree of nonlinearity owing to their distinct deformation mechanisms and morphologies, from porous structures to polymers. These results are used to develop an expression for compressive stress-strain response of Nafion membranes and then analyze the deformation of components under applied pressure by using a 1-D spring network model of cell assembly. This work provides a new understanding of mechanical responses of the electrolyzer membrane and cell components, which can help assess material design and cell assembly strategies for improved electrolyzer durability.

08 HYDROGEN↗

DOE OSTI2021

$\mathrm{REX}$: An analytical tool for reactor operating envelope expansion through fuel-clad thermo-mechanics

Here REX, an analytical reactor design tool for the identification and expansion of reactor operating envelopes, is introduced and detailed. Written in MATLAB, REX takes core geometries and axially discretized detector and depletion output from the Serpent neutron transport code and performs full-core, pin-specific thermal-hydraulic and thermo-mechanical calculations. REX identifies the operating envelopes of advanced, solid-fuel nuclear reactors on the basis of their fuel-cladding, fuel-gas, and coolant-cladding interfacial thermo-mechanics. It iteratively pushes coolant inlet temperatures and modifies fuel pin geometries to induce mechanical failure in their original cladding materials at the fullest extent of their fuel cycle lengths and permissible coolant inlet temperatures. It then attempts to expand their operating envelopes by determining the mechanical responses of alternative cladding materials under the same geometric conditions. The result of the REX calculation sequence is a set of 5-D variables describing the temperatures, pressures, geometries, and mechanics of the core as functions of assembly, fuel pin, axial zone, depletion step, and coolant inlet temperature for each candidate cladding material with the limiting fuel pin geometry for the original material.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Dynamic Transformation of High-Architectural Nanocrystal Superlattices upon Solvent Molecule Exposure

The cluster-based body-centered-cubic superlattice (cBCC SL) represents one of the most complicated structures among reported nanocrystal assemblies, comprised of 72 truncated tetrahedral quantum dots per unit cell. Our previous report revealed that truncated tetrahedral quantum dots within cBCC SLs possessed highly controlled translational and orientational order owing to an unusual energetic landscape based on the balancing of entropic and enthalpic contributions during the assembly process. However, the cBCC SL’s structural transformability and mechanical properties, uniquely originating from such complicated nanostructures, have yet to be investigated. Herein, we report that cBCC SLs can undergo dynamic transformation to face-centered-cubic SLs in response to post-assembly molecular exposure. We monitored the dynamic transformation process using in situ synchrotron-based small-angle X-ray scattering, revealing a dynamic transformation involving multiple steps underpinned by interactions between incoming molecules and TTQDs’ surface ligands. Furthermore, our mechanistic study demonstrated that the precise configuration of TTQDs’ ligand molecules in cBCC SLs was key to their high structural transformability and unique jelly-like soft mechanical properties. While ligand molecular configurations in nanocrystal SLs are often considered minor features, our findings emphasize their significance in controlling weak van der Waals interactions between nanocrystals within assembled SLs, leading to previously unremarked superstructural transformability and unique mechanical properties. Finally, our findings promote a facile route toward further creation of soft materials, nanorobotics, and out-of-equilibrium assemblies based on nanocrystal building blocks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Design of a Loss of Coolant Blowdown Capsule for Remote Assembly with High Burnup Fuel

The Transient Water Irradiation System is an enhanced capability capsule type irradiation vehicle designed to support fuel safety research for light water reactor specimens in the Transient Reactor Test Facility and is designed to simulate loss of coolant and reactivity-initiated accidents. The capsule was designed, deployed, and commissioned with fresh fuel specimens to validate instrumentation and prepare for previously irradiated high burnup specimens. The irradiation system features an extensive in-situ instrumentation package to detect phenomena typical to light water reactor fuels. To accommodate the assembly with high burnup specimens inside the Hot Fuel Examination Facility, and to ensure instrumentation integrity is maintained throughout assembly, the design was updated to support remote handling. The updated design features a hinge mechanism which allows for remote pre-irradiated specimen loading and assembly while protecting sensitive instrumentation by relocating during loading. Fixtures and equipment have been developed to handle the experiment capsule and components in cell, and to support remote assembly. The experiment module also includes radiation shielding and contamination control to support operations after removal from the hot cell.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

The Mu2e Calorimeter

The EM CsI crystals and SiPM readout calorimeter of the Mu2e experiment is fully assembled, with all components completed and tested; the mechanical structure is fully built, with a complete integration and test of all the analog sensors and electronics. The digital electronics is being produced and installed. We summarise the Calorimeter characteristics and the assembly status, as well as the move, installation and commissioning plans of the final disks in the Mu2e hall.

Borrel, L. [Caltech]↗

DOE OSTI2020

An epigenetic gene silencing pathway selectively acting on transgenic DNA in the green alga Chlamydomonas

Abstract Silencing of exogenous DNA can make transgene expression very inefficient. Genetic screens in the model alga Chlamydomonas have demonstrated that transgene silencing can be overcome by mutations in unknown gene(s), thus producing algal strains that stably express foreign genes to high levels. Here, we show that the silencing mechanism specifically acts on transgenic DNA. Once a permissive chromatin structure has assembled, transgene expression can persist even in the absence of mutations disrupting the silencing pathway. We have identified the gene conferring the silencing and show it to encode a sirtuin-type histone deacetylase. Loss of gene function does not appreciably affect endogenous gene expression. Our data suggest that transgenic DNA is recognized and then quickly inactivated by the assembly of a repressive chromatin structure composed of deacetylated histones. We propose that this mechanism may have evolved to provide protection from potentially harmful types of environmental DNA.

Neupert, Juliane↗

DOE OSTI2021

SIR Glass Test Vehicle Designed to Characterize Process Materials

The exposure to harsh environments can result in reliability issues on highly dense electronic packages and circuit assemblies. One area of concern is electrochemical failure mechanisms caused by electrolytic corrosion, electrochemical migration (dendrites), and leakage currents under humid conditions. These no-fault and no-trouble found failure points are challenging to detect and to perform process control during the assembly process. The focus of this research centers on metallizing glass surface insulation resistance test vehicles to characterize materials on electronic packages and components that exhibit the highest risk of failure due to material interactions and process residues. Glass test vehicles provide a visual representation of materials when they are exposed to moisture content in the air. Harsh environments can cause material interactions resulting in morphology changes, opening, and release of active components. A transparent test vehicle is highly functional for environmental stress testing under temperature, humidity, and bias. The designed experiment will evaluate the effects of material and process residues that can undergo changes in behavior during application, which leads to local failures.

Capen, Bill↗

DOE OSTI2022

Observation of an Orientational Glass in a Superlattice of Elliptically-Faceted CdSe Nanocrystals

Extensive prior work has shown that colloidal inorganic nanocrystals coated with organic ligand shells can behave as artificial atoms and, as such, form superlattices with different crystal structures and packing densities. Although ordered superlattices present a high degree of long-range positional order, the relative crystallographic orientation of the inorganic nanocrystals with respect to each other tends to be random. Recent works have shown that superlattices can achieve orientational alignment through combinations of nanocrystal faceting and ligand modification, as well as selective metal particle attachment to particular facets. These studies have focused on the assembly of high-symmetry nanocrystals, such as cubes and cuboctahedra. In this work, we study the assembly of elliptically faceted CdSe/CdS core/shell nanocrystals with one distinctive crystallographic orientation along the major elliptical axis. We show that the nanocrystals form an unexpectedly well-ordered translational superlattice, with a degree of order comparable to that achieved with higher-symmetry nanocrystals. Additionally, we show that, due to the particles' faceted shape, the superlattice is characterized by an orientational glass phase in which only certain orientations are possible due to entropically frustrated crystallization. In this phase, the nanocrystals do not exhibit a local orientational ordering but rather have distinct orientations that emerge at different locations within the same domain. The distinct orientations are a result of a facet-to-facet lock-in mechanism that occurs during the self-assembly process. These facet-to-facet alignments force the nanocrystals to tilt on different lattice planes forming different projections that we termed apparent polydispersity. Our experimental realization of an orientational glass phase for multifaceted semiconducting nanocrystals can be used to investigate how this phase is formed and how it can be utilized for potential optical, electrical, and thermal transport applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Gear Test Assembly – Experimental Testing and Gear Analysis (FY2021 Year End Report)

The Gear Test Assembly (GTA) is an experimental apparatus designed to test mechanical components used in fuel handling systems of liquid-sodium cooled fast-spectrum nuclear reactors. The performance and lifetime of gears, bearings, and dynamic seals are the primary focus of study. Three experimental campaigns have been completed since the start of operation in 2019, and the GTA is currently assembled and ready to begin the fourth experimental campaign. Sodium operations at the Mechanisms Engineering Test Loop (METL) have been paused while repairs are made to the Building 308 Alkali Metal Scrubber. This work is nearly complete, and once METL is brought back into operation the GTA will begin sodium testing immediately.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

AN ESTIMATE OF SPENT NUCLEAR FUEL MECHANICAL LOADS IN THE GENERAL 30 CM PACKAGE DROP SCENARIO

The US Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is performing research to determine the mechanical loading conditions applied to spent nuclear fuel (SNF) during normal conditions of transport to inform mechanical tests of SNF and close an important knowledge gap related to the practical disposition of SNF in the US. Researchers at Pacific Northwest National Laboratory (PNNL) have completed an extensive finite element study to characterize and estimate the potential mechanical loads on SNF during a hypothetical 30 cm drop of an SNF transportation package. This modeling study is validated with test data collected by the SFWST program during a physical test campaign that included one-third scale package drop tests and full-scale single fuel assembly drop tests. The test campaign was led by Sandia National Laboratories (SNL) and included international collaboration with Equipos Nucleares S.A, S.M.E (ENSA) and Bundesanstalt für Materialforschung und -prüfung (BAM). The key contribution of the modeling study is to go beyond the limitations of the limited number of physical tests to estimate the impact response to variations in impact angle, initial gap conditions, fuel assembly design, burnup and other parameters that affect the mechanical loads. The methodology of this study included a classic parametric study to calculate the impact response of highly detailed fuel assemblies over many combinations of parameters. Models of a 17x17 pressurized water reactor fuel assembly and a generic 10x10 boiling water reactor fuel assembly were both used in this study to cover the major fuel assembly types in the US inventory. Over 2,000 impact responses were calculated. The results of the parametric study were evaluated using traditional methods and basic statistics. The results were also used to construct a damage model using multiple nonlinear regression techniques to predict the mechanical loads over the full range of all input parameters. The damage model was found to work very well for all impact angle cases where the cask came to rest on its side. It was concluded that end drop cases where the cask remained vertical (instead of tipping over onto its side) were not sufficiently characterized by the current set of parametric study cases to include in the damage model, but it was not a priority to fully investigate that range because the highest mechanical loads were observed in the broader range of side impact cases. This modeling work provides sufficient insight into the mechanical loads on SNF during a hypothetical 30 cm package drop that, when considered along with the physical test data collected by the SNL-led team, the SFSWT program can consider the knowledge gap closed.

Klymyshyn, Nicholas A.↗