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Wyandotte Integrated Renewable Energy Strategy (WIRES 2) (Final Technical Report)

Wyandotte Municipal Services (WMS), a Michigan Municipal Utility offering electric generation, transmission & distribution, water filtration & distribution and Broadband/Video sought to deploy a set of renewable energy projects for their Electric Utility that contributed to reducing the City’s environmental and energy impact, provided examples that would encourage businesses and citizens to adopt cleaner energy practices and help WMS meet the required renewable energy standards of the State of Michigan (10% in 2015, 15% in 2021). WMS generates and delivers roughly 280,000 megawatt hours (MWh) of electricity annually to more than 10,000 homes and 1,000 businesses within the City of Wyandotte. The Wyandotte Integrated Renewable Energy Strategy – WIRES 2 resulted in deployment of a set of community-scale micro-wind turbines, evaluation and installation of energy-efficient and low-maintenance light-emitting diode (LED) street lights and park lights in highly visible locations in the City and expansion of the geothermal heating and cooling district that already included residential geothermal systems, to include larger scale business/institutional systems at the Utility’s largest electric customer and at the City Library. Finally, WMS identified the need for job training in energy efficiency and renewable energy technologies to further develop a local skilled workforce in these areas. Partially funded by the grant, the wind turbine project provides a benchmark for WMS, local businesses and residents in the evaluation of utility-scale wind v. micro-wind in an urban environment as a renewable energy strategy. Also partially funded by the grant, the LED project benefited the City of Wyandotte by reducing load on the electric system for the public utility but also reduced City costs for streetlighting, parking lot lighting and park lighting without a compromise in security. The project also resulted in a visual success that has led to additional approvals for non-Grant related LED lighting installations resulting in further reduction in the electric load in the City. Commercial Geothermal installations resulted in the Utility being able to eliminate steam customers who formerly utilized the byproduct of steam from WMS electric production. Due to the reduction in natural gas prices and the overall reduction in market purchased power, it was no longer feasible for WMS to operate its Power Plant as a base load plant and to only operate on a market dispatch philosophy when market prices dictated that WMS could produce electricity cheaper than the market purchase price. This has resulted in fewer operating days for the WMS Power Plant, resulting in less environmental impact. WMS has now completely exited the steam business and the ability to offer a geothermal option to two (2) former steam customers (BASF-Wyandotte and the Bacon Memorial Library) allowed for that. In addition, peak loads have been shaved for these two (2) large customers due to the consistent temperature offered by geothermal heating and cooling, reducing the swings associated with thermostat changes caused by outside temperature changes during extreme high and low temperatures. Finally, energy efficiency and renewable energy college-level classes at Wayne County Community College allowed a group of interested students to pursue studies in those technologies through grant provided tuition, books and course materials. This effort provided a foundation of potential future employees not only for WMS but other energy efficiency/renewable energy employers such as Franklin Energy, a partner with WMS in energy optimization efforts with Wyandotte businesses.

17 WIND ENERGY↗

Final Report for Tech-X Corporations’s contribution to Enhancing Understanding of High Energy Density Plasmas from Wire Array and Solid Liner Implosions Using Fluid Modeling with Kinetic Closures

Recent results from experiments and simulation of magnetically driven pulsed power liners have explored the role of the early-time electrothermal instability in the evolution of the magneto-Rayleigh-Taylor instability. Our focus will be on understanding the development of such instabilities and the potential stabilization mechanisms via electron thermal conduction, viscosity, and large magnetic fields which we expect could play a significant role in supporting the success of the MagLIF program. Experiments have shown that studies of high-energy density plasmas from wire-array implosions require physics modeling that goes well beyond simple models such as ideal magnetohydrodynamics. The goal of this work is to provide increased understanding of these experiments by employing simulations with a multi-fluid extended-MHD model which uses kinetic closures for thermal conduction, resistivity and viscosity. We will use codes easily available to the wider research community, including university students, with a secondary goal of providing the community with well-benchmarked tools capable of advanced modeling of high-energy-density plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Development of Multi-Filament Textured-Powder Bi-2212/Ag Wire with Enhanced Local Area Ratio (Final Technical Report)

ATC has successfully developed a new method for making high-performance Bi-2212/Ag su-perconducting wire with a favorable local area ratio (LAR)=Ag:Bi-2212. The method begins by texturing a fine powder of Bi-2212: the powder is loaded uniformly into an open-sided silver foil channel, the flaps of foil are folded over the powder filling, and the package is hydraulically com-pressed in a die set to form a textured-powder (TP) bar. XRD analysis of the interior powder in a compressed bar shows a texture of 80% after 200 MPa compression.

36 MATERIALS SCIENCE↗

Analysis of WIRE-21 SPND and Optical Fiber Sensor Measurements

The Wireless Instrumented RB Experiment 2021 (WIRE-21) was a highly instrumented experiment designed to test prototype wireless temperature and pressure sensors developed by Westinghouse Electric Corporation (WEC) in the High Flux Isotope Reactor (HFIR). In addition to these sensors, a suite of other sensors was also integrated into the experiment capsule, including various types of distributed optical fiber sensors and self-powered neutron detectors (SPNDs). This report presents an analysis of the data generated by the SPNDs and optical fiber sensors that were tested under the highest reported neutron flux. The distributed optical fiber sensor results demonstrate that F-doped optical fibers, particularly those inscribed with fs fiber Bragg gratings (FBGs), are capable of surviving fast neutron fluences on the order of 1021 n fast /cm 2 at temperatures relevant to light-water reactors (between 200 and 400°C). However, a significant blue-shift in the optical spectra of these sensors was observed over the course of irradiation which cannot be explained based on the current understanding of radiation-induced compaction in fused silica glass. A mechanistic understanding of this drift has not yet been developed and is proposed as future scope under the Advanced Sensors and Instrumentation program. Of the four SPNDs, only one appeared to operate normally during three cycles of irradiation. A radiation transport model of the experiment in HFIR was used to determine time-dependent neutron flux in this SPND and to calculate the neutron sensitivity of the device. Results showed a cycle averaged sensitivity of 1.5 ×10 -22 and 1.4 ×10 -22 A/nν for the first and third cycles of irradiation, respectively. Additional details pertaining to the optical fibers and SPNDs are included herein.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Production of Precursor Materials for the Development of Iron-Based Superconductor (IBS) Wire

The objective of the activities under this Annex is to address the extrinsic Jc limitations uncovered in pioneering work. In order to engineer the defects pinning landscape charged particle irradiations experiments on bulk samples with different doping and chemical additions will be performed at different National facilities (Test Beam Facility at Fermilab; Linac Isotope Producer at Brookhaven National Laboratory; Integrated Biology Laboratory at University of Wisconsin-Madison; Facility for Rare Isotope Beams at Michigan State University). The samples will be produced at TUAT by different synthesis techniques. Magnetization and advanced microscopy measures will be performed at Fermilab. After irradiation, depending on the level of radioactivity, the samples will be tested at Fermilab or where it is possible to measure radioactive materials as University of Wisconsin-Madison. In parallel, the precursor materials produced by TUAT will be used for IBS-wire fabrication at Fermi

43 PARTICLE ACCELERATORS↗

Methodology of the Extraction of Multi-Differential Cross Sections of Charged-Current $\nu_\mu$-Argon Interactions in MicroBooNE Using Wire-Cell $\nu_\mu$CC Selection

Neutrino physics experiments rely on accurate nuclear-interaction models that are in part guided by experimental observations. Multi-differential cross section measurements are particularly valuable for exploring the underlying physics described in these models, making them a significant step forward in the field. This note presents methodology in preparation to unfold neutrino flux-averaged double and triple-differential cross sections of the inclusive muon neutrino charged-current interaction on Argon. This work builds upon the existing framework and methodology presented in recent energy dependent cross section measurements at MicroBooNE using the Wire-Cell tomographic event reconstruction. The signal definition, choice of binning, and handling of estimated detector uncertainties are discussed, and the MicroBooNE simulation model is validated over the multi-dimensional phase space of muon momentum, muon polar angle, and visible hadronic energy.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Measurement of Charged-Current $ν_μ$ and $ν_e$ Interactions Towards a Search for Low-Energy $ν_Ε$ Excess Using Wire-Cell In Microboone

This technote summarizes the existing work in searching for $ν_e$ low-energy excess (eLEE) in MicroBooNE Booster Neutrino Beam (BNB) data stream based on the Wire-Cell event reconstruction paradigm. The charged-current $ν_μ$ and $ν_e$ events are selected from the 5.3e19 POT open data from the BNB beam, 6.37e20 POT far sideband from the BNB beam data, and 2.10e20 POT data from Neutrinos at the Main Injector (NuMI) beam. The charged-current $ν_e$ selection results from the BNB data that are sensitive to the eLEE search are not included. Various comparisons between data and Monte Carlo predictions are performed to validate the overall model and demonstrate the power of the analysis techniques. Physics sensitivities in terms of the exclusion and the discovery potential are presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Measurement of Neutral-Current $\pi^0$ Cross Section in MicroBooNE using Wire-Cell Reconstruction

This note presents the extraction of flux-averaged total and differential neutral-current $π^0$ cross section measurements, based on the Wiener-SVD unfolding method, using the MicroBooNE Liquid Argon Time Projection Chamber (LArTPC) and the Wire-Cell reconstruction paradigm. This measurement is critical for single-photon searches as neutral-current pion production represents one of the largest sources of background. We report the results for an exposure corresponding to 5.327 × 10 19 protons-on-target (POT).

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Measurement of charged-current $\nu_{\mu}$ and $\nu_e$ interactions with wire-cell in MicroBooNE towards a search for low-energy $\nu_e$ excess

This technote summarizes the existing work in searching for $\nu_e$ low-energy excess (eLEE) in MicroBooNE Booster Neutrino Beam (BNB) data stream based on the Wire-Cell event reconstruction paradigm. The charged-current $\nu_{\mu}$ and $\nu_e$ events are selected from the 5.3e19 POT data from the BNB beam and 2.06e20 POT data from Neutrinos at the Main Injector (NuMI) beam. The charged-current $\nu_e$ selection results from the BNB data that are sensitive to the eLEE search are not included. Various comparisons between data and Monte Carlo predictions are performed to validate the overall model and demonstrate the power of the analysis techniques.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Progress Towards an Investigation of the MiniBooNE Low Energy Excess Using Neutral-Current Delta-Like Single Photons in MicroBooNE with Wire-Cell 3D Reconstruction Algorithms

This note presents progress towards a Neutral-Current (NC) Delta-like single photon search in MicroBooNE using Wire-Cell 3D reconstruction and pattern recognition algorithms. This analysis will help address the question of the MiniBooNE Low Energy Excess (LEE) [1]. The selections are similar to the previously published Pandora-based single photon selections [2] in many ways, but here we use independent reconstruction and selection tools and examine a larger phase space (including charged pions and multiple protons). In the future, we will significantly reduce systematic uncertainties via the use of constraining sideband observations in order to statistically test specific models of the MiniBooNE LEE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Progress towards an investigation of the MiniBooNE Low Energy Excess using neutral-current Delta-like single photons in MicroBooNE with Wire-Cell 3D reconstruction algorithms

This note presents progress towards a Neutral-Current (NC) Delta-like single photon search in MicroBooNE using Wire-Cell 3D reconstruction and pattern recognition algorithms. This analysis will help address the question of the MiniBooNE Low Energy Excess (LEE). The selections are similar to the previously published Pandora-based single photon selections in many ways, but here we use independent reconstruction and selection tools and examine a larger phase space (including charged pions and multiple protons). In the future, we will significantly reduce systematic uncertainties via the use of constraining sideband observations in order to statistically test specific models of the MiniBooNE LEE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Multipole-based Cable Braid Magnetic Penetration Model for Conducting Wires

In this report, we investigate the effects of conductor losses in a multipole-based cable braid magnetic penetration model. Our multipole model uses a mesh of the actual cable geometry, which enables us to model more complicated structures. After summarizing the first principles model formulation, we consider a one-dimensional array of wires, for which an analytical solution is known in the lossless case. We extend this solution to the lossy case by using a complex-valued radius. We also model this structure analytically using a conformal-mapping solution. We then compare both the self-impedance and the transfer impedance results from our first principles cable braid electromagnetic penetration model to those obtained using the analytical solutions. An analysis for various frequencies (and skin depths) usually encountered in cable modeling is reported. These results are found in good agreement up to a radius to half spacing ratio of about 0.7, demonstrating a robustness needed for many commercial and non-commercial cables.

36 MATERIALS SCIENCE↗

Re-assembly and test of COMB dipole magnet with STAR® wires

Fermilab is developing the Conductor on Molded Barrel (COMB) magnet technology that works well with round REBCO conductors. COMB-STAR-1 magnet based on STAR wire by AMPeers was fabricated and tested in liquid nitrogen in 2023. The magnet demonstrated >90 Ic retention in the coils (before/after winding). Even though the magnet was not originally designed for operation at lower than 77 K temperatures, it was decided to test it in liquid helium to: - check the instrumentation and the DAQ system; - check the ability to detect resistive transitions or quenches and to protect the magnet; - gather the information on possible magnet design chances and upgrades of the test facility for future testing of HTS magnets. The magnet was re-assembled with a larger iron yoke and the axial supports and tested in liquid helium in 2024 at Fermilab s Vertical Magnet Test Facility (VMTF). It was the first HTS magnet test at that facility ever.

Kashikhin, Vadim↗

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

Preliminary Activation Wire Analysis for the POKER Experiment Flattop Irradiation

Activation foils, or in this case wires, are commonly deployed to critical experiments at the Na tional Criticality Experiments Research Center (NCERC) to provide additional neutron diagnostics and provide additional energy-dependent responses to tie back to neutronic and/or multi-physics simulations.

07 ISOTOPE AND RADIATION SOURCES↗