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Challenges and Solutions for Real-Time Phasor Modeling of Large-scale Distribution Network with High PV Penetration

The conversion process of a practical large-scale feeder data from a quasi-static time series (OpenDSS) model into a real-time phasor model (ePHASORSIM in Opal-RT) is discussed in the paper. The process is implemented using an open source Python software. Previous reported implementations for the conversion process lead to several errors when applied to a larger-scale system such as the one considered here. Hence in this work, we describe the common issues in this conversion and propose a customized solution to enhance the efficiency of the conversion and reduce the complexity in the process. A quantitative validation of the enhanced conversion process is presented in this work using an actual high PV penetration feeder model that consists of 2230 buses, and using actual load and PV profile data. After a detailed analysis, this customized conversion software will be made available as an open source tool and is expected to be helpful for researchers who want to pursue a similar conversion. Solutions to various observed issues such as identifying the lines due to islanded network, representation of full impedance model of transformer/lines as sequential models, complexity in the representation of single phase buses/lines as three phase buses/lines to make it compatible with the simulator platform are discussed. Comparison of power flow and time series simulation results obtained from both OpenDSS and ePHASORsim models show very low errors, validating the accuracy of the proposed conversion process.

14 SOLAR ENERGY↗

Uniform Field Electrode Generator

SAND2025-03788O Uniform Field Electrode Generator is a user-friendly tool designed to create uniform electric field electrodes, essential for high voltage applications. By generating electrodes with precise dimensions, it ensures a consistent electric field across their surfaces. This software is particularly beneficial for researchers and engineers working on projects like closing switches and studying power flow in advanced systems, such as the Z machine. Its unique approach simplifies the design process, making it accessible for users without technical expertise, while enhancing the efficiency and effectiveness of their electrical applications. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Mason, Tyler [Sandia National Lab. (SNL-CA), Liver↗

nnopf

SAND2026-19433O The nnopf tool addresses the optimal power flow (OPF) problem by optimizing electricity delivery from generating plants to consumers. At the same time, it minimizes costs and adheres to power grid constraints. While traditional methods for solving OPF can be computationally intensive, the tool mitigates this challenge by training neural networks on power grids to predict optimal solutions for the OPF problem. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy's National Nuclear Security Administration under contract DE-NA0003525.

Hart, William [Sandia National Lab. (SNL-CA), Live↗

Learning Distribution Grid Topologies: A Tutorial

Unveiling feeder topologies from data is of paramount importance to advance situational awareness and proper utilization of smart resources in power distribution grids. This tutorial summarizes, contrasts, and establishes useful links between recent works on topology identification and detection schemes that have been proposed for power distribution grids. The primary focus is to highlight methods that overcome the limited availability of measurement devices in distribution grids, while enhancing topology estimates using conservation laws of power-flow physics and structural properties of feeders. Grid data from phasor measurement units or smart meters can be collected either passively in the traditional way, or actively, upon actuating grid resources and measuring the feeder's voltage response. Analytical claims on feeder identifiability and detectability are reviewed under disparate meter placement scenarios. Such topology learning claims can be attained exactly or approximately so via algorithmic solutions with various levels of computational complexity, ranging from least-squares fits to convex optimization problems, and from polynomial-time searches over graphs to mixed-integer programs. Although the emphasis is on radial single-phase feeders, extensions to meshed and/or multiphase circuits are sometimes possible and discussed. Here this tutorial aspires to provide researchers and engineers with knowledge of the current state-of-the-art in tractable distribution grid learning and insights into future directions of work.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Data Analytics and Visualization of Energy Systems for Critical Infrastructure Insights

Modernization of energy systems including transportation facilities provides opportunities for increased efficiency, expansion of commerce and meeting industry and federal goals. A significant increase in electrical demand is projected to meet these needs, which concentrates at facilities such as airports. For example, Xcel Energy working with two airports in their service area recently published information projecting an up to fivefold increase in electricity demand in the next 25 years [1]. Concurrently, the US Government Accountability Office (GAO) recently surveyed 30 commercial service airports identifying more than 300 outages of more than 5 minutes between 2015 and 2022 [2]. Power, reliability, and resilience planning becomes more important to safely maintain operations and the flow of commerce with fewer energy carriers providing necessary energy to safely move passengers and goods. NREL proposes to develop methodologies to allow owners, utilities, and federal agencies to dynamically analyze, forecast, and manage energy loads at airports, focused upon maintaining the flow of commerce in an efficient, sustainable, and resilient way. To address these energy challenges, a suite of technologies and methodologies can be leveraged to validate concepts, inform design, de-risk solutions and optimize energy management during deployment. These technologies include digitalization of energy systems, microgrid methodologies, and related energy technologies for building and vehicle loads. [1] Electrifying Airport Ecosystems - https://www.enterprisemobility.com/content/dam/enterpriseholdings/marketing/innovation-in-mobility/vehicle-innovation/airport-electrification-study-full-report-2024.pdf [2] Airport Infrastructure: Selected Airport's Efforts to Enhance Electrical Resilience https://www.gao.gov/products/gao-23-105203.

critcal infrastructure↗

Quantum Key Distribution Applicability to Smart Grid Cybersecurity Systems

To meet the increasing demand for electricity and to have a more reliable and resilient electric grid against conventional and extreme events, grid modernization is more crucial now than ever before. This will require the development and deployment of devices that provide advanced communication capabilities. The overall efficiency, reliability, and resilience of the smart grid will be inextricably linked to the exchange of information between these devices. Unfortunately, the increased information flow will increase the potential attack surface and introduce new vulnerabilities. While a smarter grid will depend critically on information flow, these benefits will be accrued only if that information can be protected. Nowadays, information is secured in smart grids primarily through cryptography. However, with the increasing number of sophisticated attacks as well as the increasing computational power, the security of the “classical” cryptographic algorithms is threatened. Quantum information science offers solutions to this problem, specifically quantum key distribution (QKD), which provides a means for the generation and secure distribution of symmetric cryptographic keys. The security of QKD stems ultimately from the very nature of quantum physics. In this paper, we investigate the applicability of QKD to the various smart grid sectors and specific use cases. We have identified 18 smart grid use cases of interest for QKD suitability together with 7 QKD factors used for the assessment of the various use cases. For each use case, the impact to security of the loss of confidentiality, integrity, and/or availability is specified. In addition, the suitability of QKD is assessed for each use case with respect to multiple factors.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A User’s Guide to the PLTEMP/ANL Code (V.4.3)

PLTEMP/ANL V4.3 is a program that obtains a steady-state flow and temperature solution for a nuclear reactor core, or for a single fuel assembly. It is based on an evolutionary sequence of codes originally used for plate temperatures, hence “PLTEMP”, developed at Argonne National Laboratory over several decades. Fueled and non-fueled regions are modeled. Each fuel assembly consists of one or more plates or tubes separated by coolant channels. The fuel plates may have one to five layers of different materials, each with heat generation. The width of a fuel plate may be divided into multiple longitudinal stripes, each with its own axial power shape. Depending upon the heat transfer method selected, the temperature solution is effectively 2-dimensional or 3-dimensional (Appendix XV). It should be noted that for a 3-dimensional solution the axial power shape is modeled without accounting for axial heat conduction. It begins with a solution across all coolant channels and fuel plates or tubes within a given fuel assembly, at the entrance to the assembly. The temperature solution is repeated for each axial node along the length of the fuel assembly. The geometry may be either slab or radial, corresponding to fuel assemblies made of a series of flat (or slightly curved) plates, or of nested tubes. A variety of thermal-hydraulic correlations are available to determine safety margins such as onset-of-nucleate boiling ratio(ONBR), departure from nucleate boiling ratio (DNBR), and onset of flow instability ratio (OFIR). Coolant properties for either light or heavy water are obtained from FORTRAN functions rather than from tables. The code is intended for thermal-hydraulic analysis of research reactor performance in the sub-cooled boiling regime. Both turbulent and laminar flow regimes can be modeled. Options to calculate both forced flow and natural circulation are available. A general search capability is available (Appendix XII) to greatly reduce the reactor analyst’s time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Using Machine Learning to Predict Future Temperature Outputs in Geothermal Systems

Optimizing the power output, and economic value, of geothermal power plants over decades of operation is a major challenge in renewable energy. Optimizing the output requires the ability to predict the mass flow rates and the output temperatures of production wells based on the inputs of injection wells, as well as the time history of the system. Machine Learning (ML) that incorporates the known physics of geothermal systems is one possible solution to this challenge. In this work, we explore the ability of ML algorithms to predict future temperature outputs based on historical data. Considering the challenges with obtaining an empirical dataset from field data that is large enough to enable reliable ML, we propose an alternate approach: developing a high-fidelity reservoir model and using computational resources to build a dataset that enables ML. As a first step towards achieving this goal, we present preliminary results from applying ML to predict the temperature timeseries of simple modeled geothermal systems. We describe the application of relevant state-of-the-art ML approaches, such as the Long Short-Term Memory (LSTM) networks and Convolutional Neural Networks (CNN), to extract temporal structures in the model data. We assess the accuracy of the forecasts we obtain, compare the selected approaches, and share the lessons learned that would inform the process of training and utilizing ML algorithms for larger and more complex geothermal systems.

GEOTHERMAL ENERGY↗

Enhanced Control, Optimization, and Integration of Distributed Energy Applications (ECO-IDEA)

With support from the U.S. Department of Energy Solar Energy Technologies Office, the National Renewable Energy Laboratory (NREL) partnered with Xcel Energy, Schneider Electric, Varentec, and Electric Power Research Institute (EPRI) to meet the goals of the Enabling Extreme Real-Time Grid Integration of Solar Energy (ENERGISE) program. This project developed and validated an innovative data-enhanced hierarchical control architecture that enables the efficient, reliable, resilient, and secure operation of future distribution systems with a high penetration of distributed energy resources like solar energy. The architecture enables a hybrid control approach where a centralized control layer is complemented by distributed control algorithms for solar inverters and autonomous control of grid edge devices. It is fully interoperable and includes all the cybersecurity aspects necessary for reliable and secure system operation. The hybrid approach can seamlessly integrate multiple voltage-regulation technologies, both at central and grid-edge levels, which enables reliable and efficient system operation in the face of unpredictable conditions. The overarching goal of the Eco-Idea project is to develop, validate, and deploy a unique and innovative Data-Enhanced Hierarchical Control (DEHC) architecture that comprehensively addresses the formidable challenges associated with proliferation of high penetration of distributed PV such as reverse power flows, transients from variability of PV systems, feeder load balancing, and voltage stability. These issues are exposing the weaknesses of existing grid operations and controls - including, but not limited to, lack of grid situational awareness, heuristic and slow-acting control actions, latency of control for emergency situations, and points of failure in communications. The proposed architecture will comprehensively resolve the deficiencies of current operational settings - where monitoring and control solutions proposed across industry and academia may not be interoperable and may not coexist in the same system - and will enable an efficient, reliable, resilient, and secure operation of future distribution systems with penetration of solar energy well beyond current limits. The DEHC architecture was developed and validated rigorously through hardware-in-loop simulations in the laboratory environment and deployed on the field.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Resilient Operation of Networked Community Microgrids with High Solar Penetration

This project, funded by the US Department of Energy’s Solar Energy Technologies Office (SETO), focused on the operation of microgrids as a coordinated network. The primary objective, which was successfully achieved, was to develop both control strategies and hardware solutions to support the resilient and efficient operation of networked microgrids with high solar penetration. The work was structured around the following four main tasks: • Development of distributed and scalable optimization algorithms for AC-coupled networked microgrids. • Design and implementation of a novel DC interconnection hardware to enable precise power exchange between microgrids. • Laboratory operational validation of the developed technologies using 480 V testbeds and commercially available hardware. • Field operational validation of the complete solution in Adjuntas, Puerto Rico, interconnecting two kW-scale, split-phase microgrids of Casa Pueblo’s microgrids. This project addressed multiple technical challenges across the domains of optimization, control, hardware interconnection, and protection. One of its key contributions was delivering tangible, real-world solutions for networking microgrids. In contrast to purely theoretical or simulation-based work, this project included full-scale hardware operational validation both in the lab and in the field. The work conducted as part of this project—in collaboration with the University of Puerto Rico; the University of Tennessee, Knoxville; the University of Central Florida; and Casa Pueblo—has advanced the state of the art in networked microgrids. Key contributions include the development of distributed control strategies, practical solutions for real-world implementation challenges, and the introduction of a novel DC interlink approach for microgrid interconnection. The project featured both laboratory and field validation using commercial off-the-shelf components. The field deployment successfully validated that a group of microgrids can operate in a coordinated manner, enabling precise power flow between systems and mutual support during extreme events. This project resulted in 15 journal publications and 15 conference papers; 5 graduate students and 15 undergraduate students were supported. The codes of distributed optimization and forecasting were made open-source through OSTI.gov for distributed optimization and forecasting. All the publications are available in the ORNL-hosted project landing page. The DC interlink with state-of-charge balancing control was operationally validated in Adjuntas by interconnecting two real-world, 240 V split-phase microgrids. To the best knowledge of the team, this represents the first operational validation of AC microgrids interconnected via DC-interlinks. As a culmination of this project, a follow-on grant was awarded to support the technology transfer of the distributed optimization framework to a commercial microgrid controller, Stellar Edge, developed by the California-based company New Sun Road.

14 SOLAR ENERGY↗

Supporting ARPA-E Power Grid Optimization (Final Report)

Pacific Northwest National Laboratory (PNNL), Arizona State University (ASU), Georgia Institute of Technology (Georgia Tech), Los Alamos National Laboratory (LANL), National Renewable Energy Laboratory (NREL), Texas A&M University (TAMU), The University of Texas at Austin (UT), and the University of Wisconsin-Madison (UW-M) supported the ARPA-E Grid Optimization (GO) Competition by providing a common problem formulation, data format, datasets, evaluation mechanism, scoring, rules, and results that resulted in the awarding of $\$9.24$ million dollars to teams from academia, industry, and national labs for solving three sets of increasingly difficult non-linear, security- constrained AC Optimal Powerflow (AC-OPF) optimization problems in order to increase the efficiency of the US Electric Grid. It is estimated that a 1% increase in efficiency can save $\$1$ billion. Current industry practices typically use a linear DC model (DC-OPF) in order solve the OPF problem within the time constraints of the operation schedule. The GO Competition challenges the best power engineers, mathematicians, and computer scientists to make possible operational decisions based on accurate physical models. To accomplish this, the GO Competition created a series of Challenges and funded teams to produce the best solver. Challenge 1 was to solve the security constrained Alternating Current Optimal Power Flow (ACOPF) problem. Challenge 2 extended that to by adding adjustable transformer tap ratios, phase shifting transformers, switchable shunts, price-responsive demand, ramp rate constrained generators and loads, and fast-start unit commitment (UC). Furthermore, Challenge 2 was a maximization problem while Challenge 1 was a minimization problem. While Challenge 3 was being developed, the entrants were invited to find better solutions to the Challenge 2 synthetic datasets with no restrictions on time, hardware, or algorithms. The Challenge 2 solutions turned out to be very good. Challenge 3 expanded the Challenge 2 problem further by using multiperiod dynamic markets, including advisory models for extreme weather events, day-ahead markets, and the real-time markets with an extended look-ahead. These problems included active bid-in demand and topology optimization. Together the Challenges used nearly 30 million CPU hours. Since each team was working on the same problem, using the same data, and running on the same hardware, fair comparisons could be drawn as to the best solver. The datasets were varied enough, however, that the best solver for one dataset was not necessarily the best at another, so cumulative scores were used. The process was managed by the PNNL maintained website https://GOCompetition.energy.gov, where Entrants could find information about the problem, the data, the rules, submit their solver for evaluation, and see the scores of all the competing teams on a Leaderboard. Interest was world-wide but only American teams were eligible for prizes. The Competition has produced 34 journal articles 115 papers and been cited over 500 times in the literature, including 12 dissertations (4 from foreign countries; Columbia (2), Germany, and Italy) and 3 from the DOE ExaScale project. Software developed by Pearl Street Technologies for Challenges 1 and 2 is now deployed by Southwest Power Pool (SPP) and Midcontinent Independent Service Operator (MISO). Other teams have received inquiries from venture capitalists. Google DeepMind has thanked the Competition for making the datasets developed for the Competition public. They are using it to train machine learning models. The larger datasets have billions of unknowns to be solved for, but only a small percent matter in the final solution. Knowing what unknowns are important can dramatically speedup the solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗

A User’s Guide to the PLTEMP/ANL Code

PLTEMP/ANL V4.3 is a program that obtains a steady-state flow and temperature solution for a nuclear reactor core, or for a single fuel assembly. It is based on an evolutionary sequence of codes originally used for plate temperatures, hence “PLTEMP”, developed at Argonne National Laboratory over several decades. Fueled and non-fueled regions are modeled. Each fuel assembly consists of one or more plates or tubes separated by coolant channels. The fuel plates may have one to five layers of different materials, each with heat generation. The width of a fuel plate may be divided into multiple longitudinal stripes, each with its own axial power shape. Depending upon the heat transfer method selected, the temperature solution is effectively 2-dimensional or 3-dimensional (Appendix XV). It begins with a solution across all coolant channels and fuel plates or tubes within a given fuel assembly, at the entrance to the assembly. The temperature solution is repeated for each axial node along the length of the fuel assembly. The geometry may be either slab or radial, corresponding to fuel assemblies made of a series of flat (or slightly curved) plates, or of nested tubes. A variety of thermal-hydraulic correlations are available to determine safety margins such as onset-of-nucleate boiling ratio(ONBR), departure from nucleate boiling ratio (DNBR), and onset of flow instability ratio (OFIR). Coolant properties for either light or heavy water are obtained from FORTRAN functions rather than from tables. The code is intended for thermal-hydraulic analysis of research reactor performance in the sub-cooled boiling regime. Both turbulent and laminar flow regimes can be modeled. Options to calculate both forced flow and natural circulation are available. A general search capability is available (Appendix XII) to greatly reduce the reactor analyst’s time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Optimal Microgrid Networking for Maximal Load Delivery in Phase Unbalanced Distribution Grids: A Declarative Modeling Approach

Over the last several years, microgrids have increasingly become a part of the discussion about technologies that can improve the resilience of modern electrical grids. During extreme situations, microgrids have the capability to provide electrical service to customers within their boundaries when they would otherwise experience disruptions, and, when networked together, provide services to additional customers outside the microgrid boundaries. As a result, these technologies have motivated the community to develop new approaches for leveraging networked microgrid capabilities that utilize increasing levels of modeling sophistication. This has yielded a new challenge, where it has becoming increasingly difficult to fully quantify and evaluate the contribution of such detail. Here, the primary innovation presented in this paper is a method to standardize the approach to quantifying and evaluating these contributions via a declarative modeling approach that supports seamless mix-and-match of representations to ease comparison of modeling approaches and develop comprehensive understandings of how new contributions improve solutions to this problem.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Bi-fidelity approximation for uncertainty quantification and sensitivity analysis of irradiated particle-laden turbulence

Particle-laden turbulent flows subject to radiative heating are relevant in many applications, for example concentrated solar power receivers. Efficient and accurate simulations provide valuable insights and enable optimization of such systems. However, as there are many uncertainties inherent in such flows, uncertainty quantification is fundamental to improve the predictive capabilities of the numerical simulations. For large-scale, multi-physics problems exhibiting high-dimensional uncertainty, characterizing the stochastic solution presents a significant computational challenge as most strategies require a large number of high-fidelity solves. This requirement might result in an infeasible number of simulations when a typical converged high-fidelity simulation requires intensive computational resources. To reduce the cost of quantifying high-dimensional uncertainties, we investigate the application of a non-intrusive, bi-fidelity approximation to estimate statistics of quantities of interest associated with an irradiated particle-laden turbulent flow. This method exploits the low-rank structure of the solution to accelerate the stochastic sampling and approximation processes by means of cheaper-to-run, lower fidelity representations. Here, the application of this bi-fidelity approximation results in accurate estimates of the quantities of interest statistics, while requiring a small number of high-fidelity model evaluations.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Throughput Optimization of Molybdenum Carbide Nanoparticle Catalysts in a Continuous Flow Reactor Using Design of Experiments

Transition metal carbides (TMCs) have attracted significant attention because of their applications toward a wide range of catalytic transformations. However, the practicality of their synthesis is still limited because of the harsh conditions in which most TMCs are prepared. Recently, a solution-phase synthesis of phase-pure a-MoC1-x nanoparticles was presented. While this synthetic route yielded nanoparticles with exceptional catalytic performance, the reaction parameter space was not explored, and catalyst throughput was not optimized for scale-up. Continuous flow platforms coupled with statistical design of experiments (DoE) can provide a powerful method for understanding the reaction parameter space for optimizations. Here, we demonstrate the use of statistical DoE in tandem with response surface methodology for a parametric screening analysis to optimize the throughput of a MoC1-x nanoparticle synthesis utilizing a millifluidic flow reactor. A full factorial design was implemented to evaluate four input variables (reaction temperature, flow rate, solvent fraction of oleylamine, and precursor concentration) that carry statistically significant effects on three responses (throughput, residence time, and isolated yield). A Doehlert matrix was implemented to investigate each significant variable at a higher number of levels to optimize throughput. Our results give a nonintuitive set of experimental conditions that resulted in an optimized throughput of 2.2 g h-1. This translates to a 50-fold increase in throughput compared to the previously reported batch method. The catalytic performance of the MoC1-x nanoparticles produced under optimized throughput was demonstrated in the CO2 hydrogenation reaction. This DoE screening analysis and throughput optimization of MoC1-x synthesis open the door to an increased feasibility for scale-up.

design of experiments↗

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9, 435, 011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

99 GENERAL AND MISCELLANEOUS↗

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9,435,011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

36 MATERIALS SCIENCE↗

Physics-Informed Deep Learning-Based Proof-of-Concept Study of a Novel Elastohydrodynamic Seal for Supercritical CO 2 Turbomachinery

Supercritical carbon dioxide (sCO 2 ) power cycles show promising potential of higher plant efficiencies and power densities for a wide range of power generation applications such as fossil fuel power plants, nuclear power production, solar power, and geothermal power generation. sCO 2 leakage through the turbomachinery has been one of the main concerns in such applications. To offer a potential solution, we propose an elastohydrodynamic (EHD) seal that can work at elevated pressures and temperatures with low leakage and minimal wear. The EHD seal has a very simple, sleeve-like structure, wrapping on the rotor with minimal initial clearance at micron levels. Here, in this work, a proof-of-concept study for the proposed EHD seal was presented by using the simplified Reynolds equation and Lame’s formula for the fluid flow in the clearance and for seal deformation, respectively. The set of nonlinear equations was solved by using both the conventional Prediction–Correction (PC) method and modern Physics-Informed Neural Network (PINN). It was shown that the physics-informed deep learning method provided good computational efficiency in resolving the steep pressure gradient in the clearance with good accuracy. The results showed that the leakage rates increased quadratically with working pressures and reached a steady-state at high-pressure values of 15~20 MPa, where Q = 300 g/s at 20 MPa for an initial seal clearance of 255 μm. This indicates that the EHD seal could be tailored to become a potential solution to minimize the sCO 2 discharge in power plants.

30 DIRECT ENERGY CONVERSION↗