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At least 217 records · Page 12

Recycling and Reuse of Tungsten-Rhenium Refractory Alloy Powder for Additive Manufacturing (Quarterly Progress Report - 01 April 2023-30 June 2023)

Savannah River National Laboratory in partnership with 6K Inc is working on demonstrating laser and electron-beam powder bed additive manufacturing processes of W-24Re alloy and developing powder reconditioning (deoxidation) technology via plasma spheroidization and investigating the properties and performance of additively manufactured W-24Re components produced using both virgin and recycled powders.

36 MATERIALS SCIENCE↗

Progress Report on Alloy 709 Base Metal Code Case Testing at ORNL in FY 2023

A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being carried out at Oak Ridge National Laboratory (ORNL), Idaho National Laboratory (INL) and Argonne National Laboratory (Argonne). In FY 2023, ORNL has continued to conduct a subset of the Code Case testing for tensile, creep rupture, fatigue and creep-fatigue on Alloy 709. This report also updates the key Code Case testing status and results on the first two commercial heats and the preliminary results on the third commercial heat of Alloy 709. The three commercial heats of Alloy 709 are all in plate product form.

36 MATERIALS SCIENCE↗

FY23 Progress Report on Viscosity and Thermal Conductivity Measurements of Molten Salts

As presented in this report, thermal conductivity and viscosity measurements were performed on key chloride pseudo-binary molten salt systems of relevance to molten salt reactor developers. Thermal conductivity measurements were conducted with a variable gap technique, in which a known heat flux is driven across a molten salt specimen and the temperature difference is measured, allowing calculation of the thermal conductivity. This is achieved by establishing a small gap between the bottom of a cylindrical inner containment, which houses electrical heating elements, and an outer containment, which houses cooling channels; the gap size can be varied by compression of a formed bellows. A new calibration scheme was developed herein, involving a correction factor to the heat flux based on He measurements at various temperatures. Furthermore, the data processing methodology was improved to minimize the impact of radiative heat transfer in the calculation of salt specimen thermal conductivity from the temperature difference measurements. Viscosity measurements were conducted with a rolling ball viscometer, in which a ball rolls some known distance in an angled tubular crucible, and the terminal velocity can be used to calculate the viscosity of the salt. The measurement can be performed in a quartz crucible, with which a standard camera can be used to track the ball, or in a metal crucible, with which x-ray radiography is required to track the ball. A new custom x-ray system was made and dedicated to the rolling ball viscometer to enable high throughput automated measurements with salts which require containment with metal. Both systems have been integrated with a ventilation stack which allows for off-gassing of radioactive material, enabling future measurements with U-bearing salts. The thermal conductivity measurements performed herein were with NaCl-KCl (44 mol% NaCl). This salt system was measured in the previous fiscal year, however the thermal conductivity values obtained were comparatively low, and so the system was remeasured with the aforementioned calibration scheme and improved post-processing techniques. The newly obtained thermal conductivity values for NaCl-KCl (44 mol% NaCl) indicate good agreement with kinetic theory and ab-initio models (within 5–10 %). The viscosity measurements performed herein were with three different compositions of NaCl-KCl: 75, 50, and 25 mol% NaCl; a new calibration scheme was applied to account for variable flow effects in the laminar regime. The results show reasonable agreement with literature (5–20 %, depending on the temperature, composition, and study); however, literature values are likely higher than true values based on pure end-member measurements performed in the comparative studies. The measurements conducted herein do show a trend such that viscosity increases with increasing NaCl concentration, which agrees well with one of two comparative studies. In general, the measurements conducted herein gives confidence in the capability to use these systems to accurately measure thermal conductivity and viscosity of actinide-bearing salts within the next fiscal year.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Progress Report of Alloy 709 Performance in Liquid Sodium

With improved high-temperature properties, Alloy 709 shows great potential for advanced reactor applications. To understand the effects of sodium on A709, small tensile specimens were machined from two commercial heats and subject to sodium exposure in two forced convection loops operated by Argonne. Thermal aging experiments were also conducted in parallel to isolate any sodium-specific effects. An increasing trend in yield strength and a decrease trend in ultimate tensile strength can be seen with the increasing exposure time, suggesting microstructural changes at these temperatures. Nonetheless, the thermally aged and sodium exposed samples behaved similarly, implying no sodium-specific effect at these temperatures. In contrast, 316H SS exposed to sodium at 650°C showed a strong sodium effect. The different responses of A709 and 316H SS to sodium exposure is of interest and requires additional effort to understand. The cold traps of the sodium loop were replaced early in FY23. During a maintenance operation, an unexpected sodium leak incident occurred at one of the sodium loops, triggering an emergency response. An investigation into the incident revealed that the leak happened at a VCR fitting on the recently replaced cold trap. The metal gasket of the leaked VCR fitting was not compressed sufficiently. A dimensional mismatch between the new component and old piping configuration was responsible for a significant misalignment. A new cold trap with improved design is in production. The new design provides additional flexibility and an access point for post-installation helium leak check and for venting of trapped gas. These design features will make the system more error-tolerant and the installation quality verifiable. A thermodynamic analysis was performed to understand the carburization-decarburization behavior of A709 in sodium environment. The equilibrium carbon activity in the alloy was evaluated with M 23 C 6 , TiC, and NbC. The carburization-decarburization boundary was calculated with different methods developed previously. The results suggests that A709 will be carburized in SMT-1 and SMT-2, and can be decarburized in low-carbon-activity environments such as EBR-II at temperatures above 620-650°C. Nonetheless, A709 should be less likely to be decarburized than 316H SS when exposed to the same low-carbon-activity environment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Energy-Efficient Maneuvering of Connected and Automated Vehicles (CAVs) with Situational Awareness at Intersections (Final Progress Report)

The increased development of Connected and Automated Vehicle (CAV) systems, currently used for safety and driver convenience, presents new opportunities to improve the energy efficiency of vehicles. Southwest Research Institute (SwRI) achieved a 20% energy consumption reduction in a 2017 Toyota Prius Prime plug-in hybrid by using connectivity (V2V, V2I, V2X) as part of the Next Generation Energy Technologies for Connected and Automated on-Road Vehicles (NEXTCAR) program. The energy consumption gains were achieved by a combination of vehicle dynamics and powertrain control algorithms with a focus on SAE L1 and L2 automated vehicles where a human is still responsible for safe operation. SwRI is now involved in NEXTCAR-II, focusing on energy-efficient control tech for SAE Level 4/5 automated vehicles, aiming for a 30% energy reduction compared to stock hybrids. The rise of Mobility as a Service (MaaS) is driving investments in L4 and L5 automated vehicles. A study by the University of Michigan shows these vehicles might increase energy use and emissions by 3-20%. Technology similar to NEXTCAR can enhance energy efficiency in highly automated vehicles, leveraging improved sensing and actuation capabilities. While the NEXTCAR programs targeted energy efficiency improvements for a single vehicle, this program adopts a more expansive approach. It places its focus on understanding and testing the cumulative effects within a region or corridor, aiming to assess how a subset of vehicles equipped with NEXTCAR-style technologies influence the overall energy consumption of all vehicles traveling within that area. Additionally, the program explores infrastructure-based mobility solutions to optimize efficiency, and seeks to understand and quantify public perception and likelihood of technology adoption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Industrial Assessment Center Program Final Progress Report

During September 1, 2016 to March 31, 2022 period, the University of Massachusetts’ Industrial Assessment Center completed 59 industrial assessments at plants across New England. Total annual sales for those plants, which employed 8,861 people, was close to $\$ 2.59$ billion. Our 317 recommendations amounted to potential savings of $\$ 6,866,009$, which represented 14.11% of the total energy costs these facilities incurred. By the time this report was prepared implementation information was available for all plants. A total of 132 recommendations, or 41.64%, were implemented, with annual savings totaling $\$ 1,856,921$, or 3.82% of total plant energy costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Electrification: 2023 Final Progress Report

This project proposes to develop a high-power density, high speed traction motor architecture called QMag, driven by a high-power density motor drive inverter using silicon carbide semiconductor devices. This new architecture will achieve the efficiency and power density targets by means of innovative winding and rotor structures, high bandwidth controls, and advanced thermal management solutions. The project team will pursue the goals of the project systematically, through Finite Element Analysis for machine design, through simulation and co-simulation techniques for power electronics and controls evaluation, and finally system design, fabrication, testing and evaluation. If this project successfully achieves and demonstrates the DOE targets for power density, cost, and reliability, the technology has the potential to become a core enabler of the flagship higher power product portfolio in commercial traction businesses, which has so far been confined to DC, induction, Brush Less DC (BLDC), Permanent Magnet AC (PMAC), and reluctance machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

5G Securely Energized and Resilient: Task 2 and 3 Progress Report

The 5G Securely Energized and Resilient project implemented at the National Renewable Energy Laboratory is sponsored by the Office of the Under Secretary of Defense and is designed to demonstrate the successful deployment of 5G-6G (FutureG) technologies in the context of electrical microgrid scenarios. Through implementation of this project, cybersecurity researchers were able to design a platform to better understand the fundamental system architecture, limitations, and benefits of 5G systems supporting energy system requirements. Although the work for this project was developed in the context of “FutureG Advanced Component Development & Prototypes,” which is a U.S. Department of Defense effort to ensure communications system resilience in the context of military deployments, the results can also apply to communications for electrical grids in general. Several key points were established in Tasks 2 and 3 of this project that are further expanded on in the body of this document.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Improving Fission Products at CARIBU: Near Field Detection (Q1/FY24 Quarterly Progress Report)

The article on “Direct Mass Measurements to Inform the Behavior for 128mSb in Nucleosynthesis Environments” by Daniel Hoff et al., recently published in Physical Review Letters. The results of the work are a combination of an extraordinary work on precision mass measurements performed with the Canadian Penning Trap at ANL (the most precise mass measurement of the ground state and the isomeric state in 128Sb performed to date), and an extensive nucleosynthesis theory calculation that include isomers performed by the theorists at LANL.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Quarterly Research Performance Progress Report (Q8)

As part of Task 1, we have started by testing our modeling capabilities by reproducing isothermal DFIT simulations presented in the literature. Once satisfied with the results we have started by targeting the modeling of the DFITs at conducted at well 58-32. We have a identified a specific test (cycle 4 in zone 2) as the most interesting to be model with GEOS hydraulic fracturing module. Thus, we have first produced results with an isothermal model and adjusted model parameters to get a satisfying match with field pressure data. The, we have added thermal effects and compared the modeling results with and without thermal effects to estimate how thermal effects may influence test interpretation. Models seem to suggest that, for small volumes of fluid, thermal effects are moderate. In Task 2, we have adapted GEOS phase-field formulation to be able to simulate near-wellbore hydraulic fracture nucleation and propagation. We have devised a novel formulation that, compared to other existing ones, incorporates rock strengths. We have submitted a journal publication about our work. We are currently employing this phase-field formulation to model the experiments taking place at U Pitt and help us understand the effect of various parameters. In Task 3, we have built a model of the region surround well 16A and have started modeling stage 3 stimulation because of its simpler planar geometry. After calibrating simulation parameters using known analytical solutions, we have simulated the stage 3 stimulation using our isothermal hydraulic fracturing module, varying the permeability field, the stress conditions including different physics to get a better understanding of the numerical challenges and of the effects of varying these parameters on the simulation results. In Task 4 laboratory experimentation, a set of specialized drilling and injection tools has been customized and constructed to accommodate an inclined well with an orientation of up to 30 degrees relative to material anisotropy or principal stress axes. These inclined samples have also undergone thermal stress and hydraulic fracturing at a temperature of 190 degrees Celsius. Furthermore, both vertical and deviated sampling testing setups enable an extended analysis of post-peak pressure behaviors, facilitating post-test pressure analyses such as the G-function, step rate, and fracture reopening measurements. Thus, the key components of in-situ stress estimation can be extracted and validated through our experiment, providing a solid foundation for validating existing in-situ stress estimation theories or proposing new ones. Simultaneously, we are integrating computer vision techniques with traditional experimental fracture observation methods such as multi-overcore/slicing and water-penetration fracture observation. This combination will prove beneficial in populating the hydraulic fracture patterns database, generated under challenging EGS conditions. This approach aims to deepen our understanding of the complexities in EGS reservoirs and pave the way for future data-driven investigations. Additionally, PITT has also equipped the ELE International compression machine, which is now prepared for conducting indirect tensile and fracture toughness tests. These tests will aid in characterizing how rock fabrics influence the resulting fracture patterns. Additionally, we have completed the required personnel training and gained access to Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) for conducting more detailed characterization and analysis of rock fabrics, as well as the examination of thermal and hydraulically induced fracture patterns. Thus, the PITT team has effectively demonstrated the capabilities of our experimental apparatuses in exploring the thermal effects, well deviation angles, material anisotropy, and operational choices (such as circulation rate, injection fluid viscosity, and injection rate) and their impact on pressure responses and fracture trajectories under the Utah FORGE conditions.

15 GEOTHERMAL ENERGY↗

Dual-Purpose Canister Filling Demonstration Project Progress Report at ORNL, 2023

The US DOE Office of Nuclear Energy is investigating the feasibility of direct disposal of dual-purpose canisters (DPCs) in a hypothetical geological repository to offset the potential requirement to repackage spent nuclear fuel (SNF) from existing DPCs into smaller, disposal-ready canisters. Oak Ridge National Laboratory (ORNL) is currently evaluating the feasibility of filling void space in loaded DPCs with an engineered material to prevent a criticality event caused by groundwater/moderator intrusion. Metal alloys are being investigated as a filler material because of their relatively low viscosities when molten, which may facilitate their injection via an existing drainpipe that runs almost the full length of the DPC. ORNL’s strategy for evaluating filler viability includes simulations and physical demonstrations of filling and casting behavior, as well as evaluations of materials for compatibility in the repository environment. Filling of DPCs in this manner is expected to mitigate the risk associated with a post-closure criticality event during the repository performance assessment time frame (10,000 years or greater). Efforts in this fiscal year focused on (1) destructive analysis of experimental filler castings made in FY 2022, (2) a report outlining a conceptual design of a DPC filling facility (Fortner et al., 2023, M3SF 23OR010305044/ ORNL/SPR-2023/2921, May 31, 2023), (3) a report on affected features, events, and processes (FEPs) due to DPC filling (Price et al., 2023, M3SF-23SN010305093, issuance pending), (4) developing and testing a more practical alloy filler based upon a Sn-Al eutectic, and (5) modeling the heating and cooling dynamics of a DPC subjected to molten metal filling. The preliminary results from each of these tasks support the feasibility of filling DPCs with metal as a strategy against the possibility of criticality in the repository. The FY 2022 casting was found to penetrate even very small orifices in the mold and internal structures. Preliminary testing of the Sn-Al eutectic indicate little interaction of the melt with Zircaloy cladding. Thermal modelling shows that a filled DPC will cool to manageable temperatures within 2-3 days, which is likely manageable in a facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Los Alamos National Laboratory Laboratory Directed Research and Development Program: FY23 Annual Progress Report- Compendium of Project Summaries

The project summaries are organized by Capability Pillar – Complex Natural and Engineered Systems, Information Science and Technology, Materials for the Future, Nuclear and Particle Futures, Science of Signatures, and Weapons Systems. Project summaries for continuing projects appear first, followed by project summaries and technical outcomes for projects that ended in FY23.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

Production of Astatine-211 for Translational Science in Radiotherapy (Research Performance Progress Report)

In this proposal we outline the methods to improve the isotope production of astatine-211 at the University of Pennsylvania Cyclotron Facility. Astatine-211 is an isotope that emits alpha- radiation and has high potential for treating otherwise untreatable cancers. The goal of this proposal is two fold, 1) Optimize current production of astatine-211 and maintain routine production and 2) develop new isotope production target systems and chemical isolation systems. By completing this proposal we will ensure that the University of Pennsylvania Cyclotron Facility continues to build it’s isotope program in an effort that unites under DOE isotope network supply initiatives with the overall goal of increasing the national supply of isotopes. The University of Pennsylvania is uniquely located in the northeast corridor of the United States of America and has access to dozens of institutions that could use astatine-211 in their research. With the support of the DOE we have the opportunity to provide additional momentum to this growing field of research and will be able to provide the foundation for economical development of astatine-211 research and application in medicine.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

Los Alamos National Laboratory Laboratory Directed Research and Development Program (FY22 Annual Progress Report)

Laboratory Directed Research and Development (LDRD) helps Los Alamos National Laboratory solve national security challenges through excellence in mission-focused science, technology, and engineering. The DOE Laboratory and Site-Directed Research and Development programs are among the most impactful sources of research and development for our Nation. The heart of the LDRD program is high-risk, high-reward research that creates innovative technical solutions for some of the Nation’s most difficult challenges. The LDRD programs follow strategic guidance derived from the missions of the U.S. Department of Energy, the National Nuclear Security Administration (NNSA), and the Laboratory.

99 GENERAL AND MISCELLANEOUS↗

Data Science Enabled Enabled Discovery of Superconductors (Final Progress Report)

This Final Technical Report describes efforts by 4 PIs at the University of Florida (Peter Hirschfeld, Richard Hennig, Greg Stewart and James Hamlin), over the period September 2019-August 2023, to use data science and machine learning techniques to discover new conventional superconductors. The PIs constructed a discovery loop with two theorists and two experimentalists to: develop algorithms to machine learn descriptors correlating strongly with the critical temperature Tc (PI's Peter Hirschfeld, UF Physics and Richard Hennig, UF Materials Science and En), synthesize and measure properties of promising materials, and feed back the knowledge gained into the prediction algorithm. This work was motivated by the theoretical prediction and experimental discovery of high-pressure, high-pressure hydride superconductors, and to find ways to recreate the high critical temperatures in these systems at ambient pressure. Highlights from the grant include: 1) a new equation for Tc in terms of moments of the electron-phonon spectral function, improving on the so-called Allen-Dynes equation (1975); 2) study of the metastable A15 superconductor Nb3Si, formed under explosive compression at ~1000GPa to determine the kinetic barrier to the ground state structure; 3) the development of ultra-fast machine-learned atomic potentials for molecular dynamics, and 4) the discovery of superconductivity at 19K in WB2 arising from metastable defect structures in the crystal.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Annual IC Progress Report

The goal of this project is to computationally investigate the progenitors of astrophysical gamma-ray bursts (GRB), the most extreme explosions in the universe across length and time scales. We have developed a cutting-edge, code-bridging approach to exploring the physics behind these luminous events to test the hypothesis that GRBs with electromagnetic radio emission originate from massive star (MS) and black hole (BH) binary systems. Our multi-scale, multi-physics theoretical framework for GRBs is based on solving well-defined and testable hydrodynamics problems associated with the dynamical evolution of the system. We solve stages of the evolution in a tractable way with a suite of well-developed state-of-the-art computational tools that include the stellar evolution code MESA, the general relativistic magnetohydrodynamics (GRMHD) code Athena++, and the binary black hole (BBH) population synthesis code COSMIC, as well as a number of self-written python post-processing tools.

79 ASTRONOMY AND ASTROPHYSICS↗

Continued Development and Advanced Testing of DPC Filler Cements (on FY22 R&D and Demonstration Activities) (Progress Report)

Commercial generation of energy by nuclear power plants in the United States (U.S.) has produced thousands of metric tons of spent nuclear fuel (SNF), the disposal of which is the responsibility of the U.S. Department of Energy (DOE). Utilities typically utilize the practice of storing this SNF in dual-purpose canisters (DPCs). DPCs were designed, licensed, and loaded to meet Nuclear Regulatory Commission (NRC) requirements that preclude the possibility of a criticality event during SNF storage and transport, but were not designed or loaded to preclude the possibility of a criticality event during the regulated post-closure period following disposal, which could be up to 1,000,000 years (Price, 2019). There are several options being investigated that could facilitate the disposal of SNF stored in DPCs in a geologic repository (Hardin et al., 2015; SNL 2020b; SNL 2021b). These include: (1) repackage the SNF into canisters that are designed to prevent criticality during the regulated post-closure period following disposal, but with an increased disposal cost estimated at approximately $\$$20B in United States dollars (USD) (Freeze et al., 2019); (2) analysis of the probability and consequences of criticality from the direct disposal of DPCs during a 1,000,000-year post-closure period in several geologic disposal media (Price, 2019); and (3) filling the void space of a DPC with a material before its disposal that significantly limits the potential for criticality over the post-closure regulatory period. This report further investigates the third option, filling DPC already containing SNF with a material to limit the potential for criticality over the post-closure regulatory period.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗