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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.

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DOE OSTI2021

Analytical modeling for redox flow battery design

Deeper market penetration of redox flow batteries requires optimization of the cell performance. Though important for optimization, detailed analytical solutions have not been developed for electrolyte flow, mass and charge transport, and reaction kinetics within redox flow batteries. To this end, here we present analytical solutions to active species concentration and over-potential based on advection-diffusion transport for ions and Bulter-Volmer model for interface reaction kinetics. The solutions were validated with results from a finite element model. These solutions were then applied to investigate the relationship between over-potential and state of charge, current density, reaction rate constant, flow velocity, diffusivity, total active species concentration, and electrode structure. Explicit formulas were identified for minimum activation over-potential and limiting current density as well as their dependence on electrolyte properties, operation conditions, and electrode structure. With our new mathematical formulas, this work provides a theoretical framework for flow battery design.

25 ENERGY STORAGE↗
DOE OSTI2021

A Cooperative Game Theory-based Approach to Under-frequency Load Shedding Control

This paper proposes a cooperative game theory-based under-frequency load shedding (UFLS) approach for frequency stability and control in power systems. UFLS is a crucial factor for frequency stability and control especially in power grids with high penetration of renewable energy sources and restructured power systems. Conventional UFLS methods, most of which are off-line, usually shed fixed amounts of predetermined loads based on a predetermined schedule which can lead to over or under curtailment of load. This paper presents a co-operative game theory-based two-stage strategy to effectively and precisely determine locations and amounts of loads to be shed for UFLS control. In the first stage, the total amount of loads to be shed, also referred to as deficit in generation or the disturbance power, is computed using the initial rate of change of frequency (ROCOF) referred to the equivalent inertial center. In the second stage, the Shapley value, one of the solution concepts of cooperative game theory, is used to determine load shedding amounts and locations. The proposed method is implemented on the reduced 9-bus 3-machine Western Electricity Coordinating Council (WECC) system and simulated on Real-time Digital Simulators (RTDS). The results show that the proposed UFLS approach can effectively return the system to normal state after disturbances.

42 ENGINEERING↗
DOE OSTI2023

Quantification of Energy Savings and Demand Reduction for a Heat Pump Integrated with Thermal Energy Storage (Final Report)

To mitigate the variation in demand on the electric grid, thermal energy storage (TES) is an alternative to electric batteries or installing new peaking power plants. Stakeholders and policy makers across the United States have expressed interests in promoting TES, as demonstrated by the US Department of Energy’s Grid-Interactive Efficient Buildings program and the efforts of various state legislatures. However, the cost value provided by TES are unclear. If reliable cost benefits were determined, stakeholders would have a clearer picture of the financial returns that can be gained from their investment in TES. The study in this report is conducted by ORNL with collaboration with Emerson the Helix Innovation Center. In the first part of this report, EnergyPlus was used to perform whole-building simulations for two residential buildings in Indianapolis and Atlanta. The HVAC system in both buildings were equipped with phase change material TES. The TES tank was charged in off-peak hours and discharged in peak hours to perform load shifting. First, the economic value implied by existing time-of-use (TOU) rates offered by utility companies was analyzed via whole-building simulation. Second, existing demand reduction (DR) incentives sourced from 3 different electrical grid administrators (i.e., California, Texas, and New England region) were surveyed to determine their implied value. The study suggests that the traditional value analysis that focuses on ROI for the building owner significantly undervalues TES technology making economic viability difficult. A more comprehensive value analysis that includes peak demand management and deferred capital for peaking power plants shows that TES should be economically viable but here the value is greater for the utility and requires large market penetration and aggregation to fully realize the benefits. Therefore, to facilitate commercialization, new business models are needed that include a broader range of stakeholders and distribute the value of TES proportionally. In the 2 nd part of this project, the benefits of a novel phase change material (PCM) integrated heat pump configuration were evaluated via detailed component based simulation. A one-dimensional PCM heat exchanger model which discretizes the PCM tank and refrigerant tubes into small control volumes is developed. Each control volume can have different PCM temperatures, PCM properties, and heat transfer coefficients. The PCM tank is charged by a wrapped tank condenser and discharged by an internal refrigerant coil. The PCM heat exchanger model is integrated into DOE/ORNL Heat Pump Design Model for heat pump system simulation. To demonstrate the performance of the PCM integrated heat pump, a case study in Chicago was performed. A Time-of-Use utility structure-based control strategy is implemented to schedule the PCM tank charging and discharging mode switching. Compared with a conventional electric heat pump, the PCM integrated heat pump shows superior performance on load shifting and utility cost reduction. As a result, the proposed system demonstrates 24.6% utility saving for cooling application and 25.8% utility saving for heating application.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Shifts in hydropower operation to balance wind and solar will modify effects on aquatic biota

To avoid negative consequences to freshwater biota from climate change, society must complete the transition from fossil to renewable electricity sources. However, temporal patterns in hydropower generation (and flow releases that affect aquatic biota) may change with increased wind and solar penetration. We used power cost modeling to characterize current and future within-day and seasonal patterns in hydropower generation across the Eastern Interconnection in a wet and a dry year. Compared to the baseline, future hydropower generation across the grid decreased during the day and increased before dawn and after dusk. At a project level, such a pattern would suggest 'double peaking' operation (up- and down-ramping before dawn and after dusk, with lower releases midday). Variation in generation was higher in wet years than dry years, foreshadowing possible flow constraints on hydropower flexibility. At the grid scale, projected ramping rates were higher in all seasons. A review of the ecological literature suggests that these changes would shift the timing of invertebrate drift and elevate the risk of nest scouring during up-ramping and the risk of stranding or dewatering during down ramping. Thermal conditions may be moderated by increased ramping. Strategies for adapting to future shifts in the renewable portfolio range from re-regulation in reservoir cascades to providing flow refuge (structures and vegetation) below individual projects. Coordinated basin-scale operation can distribute peaking operation to maintain grid support while restricting local ramping at critical ecological times. In addition, research to design hybrid renewable systems that add battery storage is needed to understand how we can mitigate future risks to aquatic communities while promoting the use of renewable energy. This study, which is among the first to examine ecological side-effects of the shift to renewable energy in freshwater ecosystems, lays out a path toward understanding and navigating changes to flow regimes under the energy transition.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Batteries (2021 Annual Progress Report)

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2021 (FY 2021). In FY 2021, the DOE VTO battery R&D funding was approximately $\$$115 million. Its R&D focus was on the development of high-energy batteries for EVs as well as very high-power devices for hybrid vehicles. The electrochemical energy storage roadmap (which can be found at the EERE Roadmap web page2) describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability. VTO R&D has had considerable success, lowering the cost of EV battery packs to $\$$185/kWh in 2019 (representing more than 80% reduction since 2008) yet even further cost reduction is necessary for EVs to achieve head-to-head cost competitiveness with ICEs (without Federal subsidies). In addition, today’s batteries also need improvements in such areas as their ability to accept charging at a high rate, referred to as extreme fast charging (XFC) (15 minute charge) – to provide a “refueling” convenience similar to ICEs, and the ability to operate adequately at low temperatures. Research into “next-gen lithium-ion” batteries which would provide such functionalities is one of the R&D focus areas. VTO is funding research on both “next gen” chemistries (which employ an alloy anode and/or a high voltage cathode) and beyond lithium-ion (BLI) chemistries (which can, for example, employ a lithium metal anode).

25 ENERGY STORAGE↗
DOE OSTI2021

Isothermal Versus Sensible Cold Storage: A Model-Based Performance Comparison for Pumped Thermal Electricity Storage

Pumped-thermal energy storage (PTES) systems consume and produce electrical energy using thermal storage media as an intermediate stage. PTES lends itself to long-duration energy storage to facilitate high penetration of intermittent electricity generation. This study presents a model-based comparison of two thermal storage types within a PTES system: a conventional, single-phase, stratified water-glycol sensible storage system (SGS), and an ideal isothermal, two-phase heat exchanger that freezes a water reservoir (isothermal heat exchanger (IHEX)). The SGS thermal storage capacity is based on the liquid’s sensible heat change with temperature, whereas the capacity of the IHEX is based on the latent heat of isothermally freezing and melting water. The idealized IHEX modeled here undergoes steady-state melting and freezing (in contrast to transient rates, as observed with ice-on-coil storage). A computational model of a complete PTES system is presented and used to evaluate the PTES system-level performance with each type of cold storage. Compared to SGS-based PTES, under nominal operating conditions, the IHEX-based PTES increased electrical round-trip efficiency from 61% to 82% and increased energy density from 1.13 to 8.09 kWh/m 3 In conclusion, the performance of the PTES configured with IHEX storage was also analyzed under varying operating parameters.

25 ENERGY STORAGE↗
DOE OSTI2020

All Hands On Deck: Raising the Bar on Whole Building Performance-Based Code Compliance and Above-Code Programs

In 2019 a large-scale national effort was launched with support from U.S. Department of Energy, Pacific Northwest National Laboratory and Northwest Energy Efficiency Alliance (NEEA). The project aimed to develop a long-term vision and a roadmap for achieving a practical application of whole building performance-based code and above code program compliance in commercial buildings. The work was aided by engaging over 70 stakeholders across the country representing jurisdictions, above-code programs such as LEED and ENERGY STAR Multifamily Program, members of the ASHRAE Standard 90.1 and other Standard committees, IBPSA and software developers. The performance path requires whole building energy modeling and is gaining momentum. Many see it as the future of the commercial energy codes and the main pathway for achieving zero energy buildings. The paper describes the findings from a stakeholder survey funded by NEEA on the current state of performance-based path, its market penetration, trends, implementation practices and adoption challenges. It discusses the patterns revealed by experience of the states with decades-long history of performance-based compliance such as Florida and California and opportunities for taking advantage of the synergies between code and above-code programs. In addition, the paper provides an overview of the tools and resources developed as part of the effort including the compliance form for ASHRAE Standard 90.1 Section 11 and Appendix G, modeling submittal review manual, and modeler and reviewer qualification requirements. The tools and resources would help remove market barriers, deliver immediate benefits to jurisdictions and rating authorities, and achieve energy efficiency through whole-building performance path.

TSPR, Performance Based Complinace, Washington Sta↗
DOE OSTI2022

Micromobility Integrated Transit and Infrastructure for Efficiency (MITIE)

Nearly omnipresent in many cities of all sizes across the United States, micromobility vehicles-e-scooters, manual bicycles, e-bicycles, and larger seated electric scooters-are notably missing from SMART Mobility research. This project aims to expand the spectrum of modes currently being researched within SMART Mobility by exploring micromobility as an important tool toward meeting energy-efficient mobility goals. It expands on findings from SMART Mobility 1.0 that revealed preferences to reduce transportation-related expenses through use of a network of mobility-as-a-service (MaaS) and other shared mobility options, and builds on findings from a 2019 Vehicle Technology Analysis Program (VTAP) funded micromobility project conducted by our team. We will explore multiple facets of micromobility, including behavior and decision-making, the integration of micromobility within transportation infrastructure, energy estimates, and operations. Guiding research questions include: (1) What are the potential energy savings from low, medium, and high market penetration of micromobility (in passenger, multimodal, and freight domains)? (2) Which scenarios for micromobility use and related enablement of increased public transit use should be modeled/considered in the SMART 2.0 Workflow? (3) To what degree can micromobility supplement/complement transit system operations? (4) What are people's preferences towards micromobility? How do preferences vary across various sociodemographic segments? How can this knowledge inform operations? (5) What are optimal strategies to attain high user adoption and shift users toward more energy-efficient mode choices in terms of micromobility operation? How do these strategies affect energy savings, person-miles traveled, lifecycle energy use, and adoption rates? These questions will be addressed through applied research in five project emphasis areas: (1) Energy estimates of micromobility for Workflow scenarios: Expand and refine previous micromobility work to augment the Workflow approaches to modeling urban travel. (2) Multimodal connection with transit: Utilizing Mobility-Energy Productivity (MEP) tools to evaluate multimodal travel patterns enabled by micromobility, including assessing how to reduce barriers of inequity of access to mobility options and destinations. (3) Mode choice, induced demand, and infrastructure: Understanding the mode shift induced through micromobility to inform energy impact analysis. (4) Energy optimization of micromobility operations: Identification of micromobility operations parameters and development of operations scenarios to better understand present-day micromobility operations for integration into the Workflow, in partnership with BEAM and POLARIS modeling teams. (5) Micro-freight: Characterize the current state of micro-freight activities, including energy effects and geospatial analyses, to inform Workflow.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗
DOE OSTI2023

Micromobility Integrated Transit and Infrastructure for Efficiency (MITIE)

Nearly omnipresent in many cities of all sizes across the United States, micromobility vehicles-e-scooters, manual bicycles, e-bicycles, and larger seated electric scooters-are notably missing from SMART Mobility research. This project aims to expand the spectrum of modes currently being researched within SMART Mobility by exploring micromobility as an important tool toward meeting energy-efficient mobility goals. It expands on findings from SMART Mobility 1.0 that revealed preferences to reduce transportation-related expenses through use of a network of mobility-as-a-service (MaaS) and other shared mobility options, and builds on findings from a 2019 Vehicle Technology Analysis Program (VTAP) funded micromobility project conducted by our team. We will explore multiple facets of micromobility, including behavior and decision-making, the integration of micromobility within transportation infrastructure, energy estimates, and operations. Guiding research questions include: 1) what are the potential energy savings from low, medium, and high market penetration of micromobility (in passenger, multimodal, and freight domains)? 2) which scenarios for micromobility use and related enablement of increased public transit use should be modeled/considered in the SMART 2.0 Workflow? 3) to what degree can micromobility supplement/complement transit system operations? 4) what are people's preferences towards micromobility? How do preferences vary across various sociodemographic segments? How can this knowledge inform operations? 5) what are optimal strategies to attain high user adoption and shift users toward more energy-efficient mode choices in terms of micromobility operation? How do these strategies affect energy savings, person-miles traveled, lifecycle energy use, and adoption rates? These questions will be addressed through applied research in five project emphasis areas: 1) energy estimates of micromobility for Workflow scenarios: Expand and refine previous micromobility work to augment the Workflow approaches to modeling urban travel; 2) multimodal connection with transit: Utilizing Mobility-Energy Productivity (MEP) tools to evaluate multimodal travel patterns enabled by micromobility, including assessing how to reduce barriers of inequity of access to mobility options and destinations; 3) mode choice, induced demand, and infrastructure: Understanding the mode shift induced through micromobility to inform energy impact analysis; 4) energy optimization of micromobility operations: Identification of micromobility operations parameters and development of operations scenarios to better understand present-day micromobility operations for integration into the Workflow, in partnership with BEAM and POLARIS modeling teams; 5) micro-freight: Characterize the current state of micro-freight activities, including energy effects and geospatial analyses, to inform Workflow.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

WE-Validate: An Open-Source Framework For Wind Power Validation

Grid operators rely on historical weather time series at existing and planned wind power plants to make informed decisions when planning for a future power grid with very high penetration of renewable power. While synthetic wind power time series have been developed based on historical weather models, their validation with actual power production data remains complex due to variations in modeling practices and methodologies. This paper introduces the WE-Validate framework, originally designed for wind speed validation and now enhanced for wind power validation with a graphical user interface to support users with minimal programming experience. Validation of wind power with WE-Validate is based on robust metrics consisting of RMSE, centered RMSE, average bias, average percent bias, mean absolute error, mean absolute percent error, cross correlation, and calculation of ramping magnitude, rate, and duration. This paper showcases WE-Validate with validation of synthetically derived power for a wind plant in Washington state for one month in 2018. Validation of the synthetic power from two comparison data sets compared with observations shows both comparison series have strong correlation with observed across weekly and monthly aggregations while suffering from persistent negative bias. The suite of metrics within WE-Validate facilitates immediate insight into the utility of the comparison data sets through compression across multiple axes. This user-friendly, open-source tool can be extended beyond wind power, making it a valuable resource for system planners and operators in different domains.

Moncheur de Rieudotte, Malcolm P.↗
DOE OSTI2024

Feasible Actuator Range Modifier (FARM), a Tool Aiding the Solution of Unit Dispatch Problems for Advanced Energy Systems

Integrated energy systems (IESs) seek to minimize power generating costs in future power grids through the coupling of different energy technologies. To accommodate fluctuations in load demand due to the penetration of renewable energy sources, flexible operation capabilities must be fully exploited, and even power plants that are traditionally considered as base-load units need to be operated according to unconventional paradigms. Thermomechanical loads induced by frequent power adjustments can accelerate the wear and tear. If a unit is flexibly operated without respecting limits on materials, the risk of failures of expensive components will eventually increase, nullifying the additional profits ensured by flexible operation. In addition to the bounds on power variations (explicit constraints),the solution of the unit dispatch problem needs to meet the limits on the variation of key process variables, including temperature, pressure and flow rate (implicit constraints).The FARM (Feasible Actuator Range Modifier) module was developed to enable existing optimization algorithms to identify solutions to the unit dispatch problem that are both economically favorable and technologically sustainable. Thanks to the iterative dispatcher–validator scheme, FARM permits addressing all the imposed constraints without excessively increasing the computational costs. In this work, the algorithms constituting the module are described, and the performance was assessed by solving the unit dispatch problem for an IES composed of three units, i.e., balance of plant, gas turbine, and high-temperature steam electrolysis. Finally, the FARM module provides dedicated tools for visualizing the response of the constrained variables of interest during operational transients and a tool aiding the operator at making decisions. These techniques might represent the first step towards the deployment of an ecological interface design (EID) for IES units.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

The effect of aspect ratio on the mechanical behavior of Li metal in solid-state cells

The Li metal anode is necessary for solid-state batteries to dramatically exceed the energy density of state-of-the-art conventional Li-ion batteries. To enable the Li metal anode, the mechanical properties of Li metal under compression in a commercially relevant cell configuration must be determined. This work examines the compression creep behavior of Li metal coupled with a relevant model solid-state electrolyte (Li 6.5 La 3 Ta 0.5 Zr 1.5 O 12 ) and current collector (Ni) as a function of applied stress (1–10 MPa) and Li foil thickness (100–700 μm). At 1 MPa applied stress, the strain rate of all Li foil thicknesses under compression was almost four orders of magnitude lower than what is predicted from tensile creep tests. Steady-state creep behavior was observed for Li foil ≥350 μm at 5 MPa and ≥250 μm at 10 MPa. Conversely, sustained creep deformation was not observed for 100 and 150 μm Li foils at any applied stress. It is suggested that friction at the Li/LLZO and Li/Ni interfaces leads to the formation of hydrostatic stress that controls Li deformation at low aspect ratios. Finally, these results have implications for battery pack stack pressure requirements, particularly relating to void formation during stripping and Li metal filament penetration during plating.

25 ENERGY STORAGE↗
DOE OSTI2022

Predicted performance of a tangential viewing hard x-ray camera for the DIII-D high field side lower hybrid current drive experiment

High field side launch of lower hybrid current drive (LHCD) has improved accessibility and penetration over low field side launch on DIII-D. Simulations predict single pass absorption under a wide range of plasma conditions. Hard x-ray (HXR) measurement of LHCD generated fast electron bremsstrahlung (50–250 keV) will validate wave propagation and absorption. Emissivity profiles are recovered from one-dimensional inversion of HXR brightness to determine LH damping location, fast electron slowing down time, and some indication of the fast electron energy. The camera will be implemented by populating 32 tangential sightlines of the existing Gamma Ray Imager with Kromek SPEARTM Cadmium Zinc Telluride (CZT) detectors sensitive to 10–1000 keV photons with 10 keV energy resolution. Expected count rates allow for <0.5 ms time resolution. Pulses are processed using 50 ns shaping time Cremat CR-200 Gaussian shaping modules and are digitized by 25 MHz D-TACQ ACQ216 digitizers. The performance of the HXR camera is evaluated by comparing predicted fast electron density profiles and inverted synthetic brightnesses obtained from the ray-tracing/Fokker–Planck codes GENRAY/CQL3D. Inversions closely matched predicted fast electron profiles for a range of experimental parameters.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Density pedestal prediction model for tokamak plasmas

Abstract A model for the pedestal density prediction based on neutral penetration combined with pedestal transport is presented. The model is tested against a pedestal database of JET-ILW Type I ELMy H-modes showing good agreement over a wide range of parameters both in standalone modelling (using the experimental temperature profile) and in full Europed modelling that predicts both density and temperature pedestals simultaneously. The model is further tested for ASDEX Upgrade and MAST-U Type I ELMy H-modes and both are found to agree with the same model parameters as for JET-ILW. The JET-ILW experiment where the isotope of the main ion is varied in a D/T scan at constant gas rate and constant β N is successfully modelled as long as the separatrix density ( n e,sep ) and pedestal transport coefficient ratio ( D / χ ) are varied in accordance with the experimentally observed variation of n e,sep and the isotope dependence of D / χ found in gyrokinetic simulations. The predictions are found to be sensitive to n e,sep which is why the model is combined with an n e,sep model to predict the pedestal for the STEP fusion reactor.

Physics↗
DOE OSTI2024

Oxygen Storage Incorporated Into Net Power and the Allam–Fetvedt Oxy-Fuel sCO2 Power Cycle—Techno-Economic Analysis

Abstract With the planned future reliance on variable renewable energy, the ability to store energy for prolonged time periods will be required to reduce the disruption of market fluctuations. This paper presents a method to analyze a hybrid liquid-oxygen (LOx) storage/direct-fired supercritical carbon dioxide (sCO2) power cycle and optimize the economic performance over a diverse range of scenarios. The system utilizes a modified version of the NET Power process to produce energy when energy demand exceeds the supply while displacing much of the cost of the air separation unit (ASU) energy requirements through cryogenic storage of oxygen. The model uses marginal cost of energy data to determine the optimal times to charge and discharge the system over a given scenario. The model then applies ramp rates and other time-dependent factors to generate an economic model for the system without storage considerations. The size of the storage system is then applied to create a realistic model of the plant operation. From the real plant operation model, the amount of energy charged and discharged, the capital expenditures (CAPEX) of each system, energy costs and revenue and other parameters can be calculated. The economic parameters are then combined to calculate the net present value (NPV) of the system for the given scenario. The model was then run through the SMPSO genetic algorithm in Python for a variety of geographic regions and large-scale scenarios (high solar penetration) to maximize the NPV based on multiple parameters for each subsystem. The LOx storage requirements will also be discussed.

Engineering↗
DOE OSTI2022

Long term performance of vacuum insulation panels integrated into building components

Vacuum insulation panels provide much greater resistance to heat transfer than conventional insulation materials, making them ideal for building applications, especially where space is a constraint. Of particular interest is energy retrofits where high insulation values are required with very little or no modifications to existing building envelope elements such as fenestrations and service penetrations. To facilitate the use of vacuum insulation panels (VIPs) in residential and commercial construction, this study investigates the performance of VIPs integrated into polyisocyanurate foam board and vinyl siding after several years of service. Vacuum insulation panels integrated with polyisocyanurate boards were studied in mixed humid and cold climates. The integration of VIPs with vinyl siding was investigated in a mixed humid climate. Periods of service were between two and five years. In all cases, the integrated building components outperformed conventional materials by almost 40 percent during heating and cooling periods. However, the percent reduction in heat gains and losses of the integrated building components decreased with time at a rate between approximately 4% and 10% per year during the service period. In some cases, the rate seems to converge to a steady -state value. Measurements are ongoing to determine if a steady-state value is attained or the panel's insulation value continues to decrease with time. This study is critical in addressing the service life and durability of the building envelope with VIP integrated building components. The effect of these changes will be reviewed in the context of an exterior retrofit.

Aldykiewicz Jr, Antonio↗
DOE OSTI2022

Quarterly Management Document – FY22, 1st Quarter, Multi-pass Hybrid Laser Arc Welding of Alloy 740H

This report summarizes the progress made on the project during the first quarter of FY22. The model for deep penetration laser welding continues to be developed to understand and mitigate cracking issues associated with laser welding Alloy 740H. The effects of laser wobble on laser welding of this alloy are also being developed. Additionally, the short-term creep behavior of welds made by various hybrid laser arc parameters has been obtained and the results indicate they are comparable to welds made by conventional gas tungsten arc welding which is a factor 2 slower than the hybrid welds. Additionally, the creep behavior of laser-only welds is also consistent with conventional gas tungsten arc welds as well as the hybrid laser arc welds made under this project. However, the creep rate of the laser-only welds is much higher than that observed in the hybrid laser arc welded specimens. This is most likely due to the narrower weld produced by laser-only welding compared to hybrid laser arc welding and, thus, the higher creep rate of laser-only welded creep specimens is likely a result of the increased fraction of base metal (which exhibits a higher creep rate than weld metal) contained within the gage section of the creep specimen. Creep rupture lifetimes were all about the same for both laser-only and hybrid laser arc welded specimens and consistent with the creep rupture lifetime of conventional gas tungsten arc welded creep specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Adhesion Capabilities of Permanent Foaming Fixatives

DOE-EM have identified an operational requirement for a fixative that can immobilize and/or encapsulate residual contamination in 3D void volumes (pipes, gloveboxes, waste containers, etc.) during D and D activities. Failure to safely and effectively immobilize residual contamination can: Put workers at risk; Contaminate the public and environment; Drive up costs. Commercial-off-the-shelf (COTS) polyurethane (PU) foams is one possible solution and is currently being investigated by Savannah River National Lab (SRNL). Adhesion testing will dictate how well PU foams will adhere and immobilize residual contamination onto a substrate. Results can provide a performance criteria for Section 5 of ASTM E3191: Standard Specification for Permanent Foaming Fixatives Used to Mitigate Spread of Radioactive Contamination. Initial mechanical testing showed intumescent rigid PU foams were best in class (tensile, compression, TGA/DSC) Application of intumescent rigid PU foam in pipe scenario with 'contamination' showed excellent adhesion capabilities as long as foam had contact with pipe. The foam, however, was not able to penetrate 'contamination' but created pockets where the contamination interacted with the substrate. Pretreatment options of pipe were considered to produce better immobilization capabilities. Pretreatment options included COTS products like baking spray, rubber cement, and soap. Foam was still able to immobilize on a global sense, but not a local sense. Essentially acted as a mechanical plug. A tensile tester (MTS Criterion Series 43) was utilized to evaluate the tensile adhesion strength of 6 COTS PU foams. ASTM D1623: Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics. Procedures: PU foams were cured between two smooth 2'' x 2'' 304 stainless steel coupons with hinges glued on plates for gripping support. Parameters Used: Pull rate of 0.1 in/min. Calculations: Tensile adhesion strength, elongation, and ImageJ analysis of how PU foam is left on substrate. Outcome: The PU foam with the best adhesion capabilities would be downselected for further evaluation to be used as a permanent foaming fixative. The rigid PU foams had the best adhesion capabilities with the R1 foam having a max load of 236 N. One of the I-R2 samples reached almost 450 N and another sample reached 2500 N before slipping. The other intumescent foam, I-F4, had the most coverage on the stainless steel coupon's surface from the ImageJ results (61.43% surface coverage). The intumescent foam, I-R2, will be the foam of choice for future testing due its fire retardant and adhesion capabilities. Future directions: Conduct the following experiment in a pipe scenario with the down-selected PU foam. Procedures: PU foam will be cured between in a 304 stainless steel pipe (ID: 4'', OD: 4.5'', Height: 4''). Parameters Used: Compression testing results will be referenced to determine if foam's adhesion strength would be greater its compression strength as its being compressed. Calculations: Compression strength, shear stress, total time elapsed. Conduct further adhesion testing with the down-selected PU foam (I-R2) to be treated as a permanent foaming fixative (PFF). Determine the minimum contact the PFF should have with the substrate for adequate results. Evaluate if PFF's adhesion capabilities is time dependent (3.1.5 of ASTM E3911). Subject PFF to seismic stressors addressed in Safety Basis of Interim Operation documents (SBIO) to further evaluate adhesion capabilities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗