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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 OSTI2024

Advanced Manufactured Home Case Study: A Collaboration for High-Efficiency, Affordable Housing

The introduction of Zero Energy Ready Home Manufactured Homes (ZERH MH) qualification for manufactured homes has generated significant attention and interest in the industry to employ advanced manufacturing techniques. VEIC engaged with Titan Homes to create an advanced manufactured home design that employs ZERH standards, other client-driven above-code standards, and manufacturing processes improvements. This case study identifies specific energy-efficient and quality improvement measures that were implemented to achieve certification and take advantage of incentives for home manufacturers.

14 SOLAR ENERGY↗
DOE OSTI2024

Conceptual Design of a Tension Leg Platform With 22.3 MW Vertical Axis Turbine

Here, this paper presents the conceptual design of a tension leg platform (TLP) for the ARCUS “towerless” vertical-axis wind turbine (VAWT). VAWTs are ideal for floating offshore sites and have several advantages over horizontal-axis wind turbines (HAWT) including reduced top mass, lower center of gravity, increased energy capture, and in turn lower cost. The towerless ARCUS VAWT drives these advantages further through increased structural efficiency and by enabling more optimized TLP designs with simplified installation procedures. For hull sizing, we have studied three turbine sizes with corresponding power ratings of 5.1 MW, 10.4 MW and 22.3 MW. The largest turbine was identified as having the greatest potential to reduce the levelized cost of energy (LCOE) and is the reference size used for the further detailed design process. The conceptual design of the VAWT TLP has been awarded with an ABS Approval in Principle Certificate. This paper contains brief analysis results and design findings for a TLP designed to house a VAWT, including the following topics: • Applicable Design Codes • Metocean Conditions • ARCUS Turbine Loads • Design Load Cases and Requirements - Pre-service TLP Stability - In-place TLP Global Performance • Platform Configurations, Hull Structure Scantling Design, Weight and CG Estimation, and General Arrangement Drawings • Hull Ballast Plan for both Pre-service and In-place Conditions • Pre-service Quayside Integration, Transportation and Wet Tow Stability Analysis • Global Performance Analysis for Motions and Tendon tensions • Summary of cost components and system levelized cost of energy

17 WIND ENERGY↗
DOE OSTI2023

Supplemental Structural Analyses Used in Support of Certification of the Defense Programs Package 3

The Defense Programs Package (DPP)-3 is to be certified by the National Nuclear Security Administration (NNSA) Packaging and Transportation Division (PTD). Certification is based on successful physical testing of the package, and six certification test units (CTUs) have been subjected to the normal conditions of transport (NCT) and hypothetical accident conditions (HAC) outlined in Title 10 of the Code of Federal Regulations Part 71 (10 CFR 71). During regulatory testing of one of the CTUs, the drum lid closure bolt closest to the impact surface failed during the HAC 30-ft side drop. One of the testing goals for this CTU was to minimize the thermal pathway from the drum exterior shell to the containment vessel (CV) flange and O-rings, leading to the maximum damage scenario in preparation for thermal testing at 1475 °F. Therefore, the puncture bar impact proceeded as originally planned by striking the side wall of the package exterior closest to the location of the CV flange. This puncture bar impact did not attempt to exploit the region of the failed drum lid closure bolt to potentially cause more damage to the package. After the conclusion of regulatory testing, the DPP-3 package finite element model was used to numerically evaluate the effects of puncture bar impacts to the drum exterior in the vicinity of the failed drum lid closure bolt to further demonstrate the robustness of the DPP-3 design. Three alternate puncture bar impact locations and orientations were evaluated to demonstrate that these puncture bar impacts would not substantially reduce the effectiveness of the DPP-3 packaging. This paper describes the supplemental finite element models performed and structural analysis results that demonstrate the alternate HAC 40-in. puncture bar impact tests would have no deleterious effect on the performance of the DPP-3.

Sakalaukus Jr., Peter J.↗
DOE OSTI2021

Universal Utility Data Exchange (UUDEX) – Security and Administration: Cybersecurity of Energy Delivery Systems (CEDS) Research and Development

A critical component of the Universal Utility Data Exchange (UUDEX) approach is the integrated security contained within its processing. This document describes how that security is designed and expected to be implemented by UUDEX Implementations (U-Implementations), including the UUDEX Server (U-Server) and UUDEX Clients (U-Clients). The UUDEX security hierarchy consists of three levels: 1. The UUDEX Instance (U-Instance) itself, which sits at the top of the hierarchy and contains the U-Server, the UUDEX Identity Authority (U-Identity Authority), and the UUDEX Administrator (U-Administrator) functions; 2. A group of one or more UUDEX Participants (U-Participants) that present “organizations” that participate in the U-Instance and contains the UUDEX Administrator Participant (U-U-Administrator Participant) function; 3. A group of one or more UUDEX Endpoints (U-Endpoints) that represent the individual UUDEX Publish Clients (U-Publish Client) responsible for supplying data to the U-Instance that is consumed by UUDEX Subscriber Clients (U-Subscriber Clients). U-Endpoints can be either autonomous devices that publish and subscribe data such as data exchange servers found in supervisory control and data acquisition and energy management systems, or they can be tied to users of applications that, for example, submit DOE OE-417 disturbance reports. U-Participants and U-Endpoints can be organized into UUDEX Groups (U-Groups). Any number of U-Participants or U-Endpoints can be members of a U-Group. A given U-Participant or U-Endpoint can be a member of multiple U-Groups, but a U-Group cannot contain other U-Groups. For example, a U-Group could be created to contain all U-Participant Transmission Operators within the purview of a Reliability Coordinator, and another U-Group could be created to contain all U-Participant Generator Operators within the purview of a Reliability Coordinator. U-Participants that are both Transmission Operators and Generator Operators would be members of both U-Groups. U-Participants, U-Endpoints, and U-Groups are used in the access control structures to provide access to individual UUDEX Subjects (U-Subjects). U-Groups are created by the U-Administrator and are managed by the U-Administrator or the designated U-Group Managers. U-Endpoints can be assigned UUDEX Roles (U-Roles) that can be used to further restrict access. U-Roles are assigned to individual U-Endpoints. For example, a U-Role of “Security Analyst” could be used to restrict which U-Endpoints can publish or subscribe security incident reports and vulnerability notifications, while a U-Role of “Transmission Planner” can be used to restrict which U-Endpoints can publish power system model updates. U-Role definitions are created by the U-Administrator, but the U-Roles are assigned to U-Endpoints by their respective UUDEX Participant Administrators (U-Participant Administrator). Because all information required to make security decisions is either included within the U-Endpoint’s X.509 digital certificate or stored in a datastore on the U-Server, all security decisions are performed and enforced within the U-Server. This reduces the complexity of the U-Client code and minimizes the chance for compromise of the integrity of the UUDEX security features.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

INL High-Performance and Sustainable Building Strategy

High-performance buildings are reliable, cost effective, and sustainable structures that minimize energy and water use, reduce solid waste and pollutant emissions, and limit the depletion of natural resources. High-performance buildings also provide a thermally and visually comfortable working environment that increases productivity for building occupants. As Idaho National Laboratory (INL) is the nation’s premier nuclear energy research laboratory, the physical infrastructure requires continual updating and repurposing to help accomplish that mission. INL’s infrastructure must incorporate high-performance sustainable design features to be fiscally responsible and reflect an image of innovation to the public and prospective employees. INL is a large consumer of energy with annual energy costs exceeding $16M. This High-Performance and Sustainable Building Strategy will help engineering and construction project teams design sustainable facilities, reduce life cycle operating costs, and support the INL net-zero plan while providing INL employees with a safe and healthy working environment. With these goals in mind, the recommendations described in this document are intended to form INL’s foundation for sustainable and high-performance building standards. This strategy incorporates the latest federal and Department of Energy (DOE) orders and directives, including DOE Order 436.1A, “Departmental Sustainability,” the DOE Sustainability Plan (SP), the INL Site Sustainability Plan (SSP), and Code of Federal Regulations (CFR). This document identifies the requirements of the “Guiding Principles for Sustainable Federal Buildings” (Guiding Principles) and briefly highlights the Leadership in Energy and Environmental Design (LEED) Gold certification. LEED Gold certification can be used to meet many of the requirements of the Guiding Principles.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

INL High-Performance and Sustainable Building Strategy

High-performance buildings are reliable, cost-effective, and sustainable structures that minimize energy and water use, reduce solid waste and pollutant emissions, and limit the depletion of natural resources while also providing a thermally and visually comfortable working environment that increases productivity for building occupants. As Idaho National Laboratory (INL) is the nation’s premier nuclear energy research laboratory, the physical infrastructure requires continual updating and re-purposing to help accomplish that mission. INL’s infrastructure must incorporate high-performance sustainable design features to be fiscally responsible and reflect an image of innovation to the public and prospective employees. INL is a large consumer of energy with annual energy costs exceeding $9M. In the current fiscal reality and with energy costs constantly increasing, this High-Performance and Sustainable Building Strategy will help engineering and construction project teams design facilities that are sustainable and will help to reduce life-cycle operating costs while providing INL employees with a safe and healthy working environment. With these goals in mind, the recommendations described in this document are intended to form INL’s foundation for sustainable and high-performance building standards. This strategy incorporates the latest federal and Department of Energy (DOE) orders and directives including Executive Order (EO) 13834, “Efficient Federal Operations” and its associated implementing instructions, DOE Order 436.1, “Departmental Sustainability,” the DOE Sustainability Report and Implementation Plan (SRIP), the INL Site Sustainability Plan (SSP), and Code of Federal Regulations (CFR). This document identifies the requirements of the Guiding Principles for Sustainable Federal Buildings (Guiding Principles) and briefly highlights the requirements of Leadership in Energy and Environmental Design (LEED®) Gold certification. LEED Gold certification, while optional, can be used to meet many of the requirements of the Guiding Principles.

13834↗
DOE OSTI2024

Nuclear Requalification of the ATR Core

The Advanced Test Reactor (ATR) creates a unique, high neutron flux materials testing environment that subsequently causes neutron embrittlement damage to its beryllium reflector. The reflector is eventually required to be replaced during a reactor Outage. Concurrently, a piece-for-piece core replacement is conducted to maintain reactor functionality called a core internals changeout (CIC). Once changeout is complete, ATR Reactor Engineering utilizes previous CIC data, notably 1977-1994 CIC data, to conduct predictive criticality analysis on the new, unirradiated core. However, CIC data has been inconsistently reported over the years making it difficult, and in some cases impossible, to utilize. These inconsistencies arise in various forms of not using correct units, inconsistent diagram usage, and not portraying the same kind of data similarly across the reports. To work around this inconsistency issue, Reactor Engineering is implementing the use of several new neutronic modeling codes that utilize modern computation speeds and methods to model the new core in different criticality environments. Further validation is then conducted by nuclear testing and bringing the reactor critical and conducting various irradiation tests. Upon completion and certification that the reactor passed all testing requirements, ATR can once again re-start normal operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

An infeasible-start framework for convex quadratic optimization, with application to constraint-reduced interior-point and other methods

A framework is proposed for solving general convex quadratic programs (CQPs) from an infeasible starting point by invoking an existing feasible-start algorithm tailored for inequality-constrained CQPs. The central tool is an exact penalty function scheme equipped with a penalty-parameter updating rule. The feasible-start algorithm merely has to satisfy certain general requirements, and so is the updating rule. Under mild assumptions, the framework is proved to converge on CQPs with both inequality and equality constraints and, at a negligible additional cost per iteration, produces an infeasibility certificate, together with a feasible point for an (approximately) ℓ 1 -least relaxed feasible problem, when the given problem does not have a feasible solution. The framework is applied to a feasible-start constraint-reduced interior-point algorithm previously proved to be highly performant on problems with many more inequality constraints than variables (“imbalanced”). Numerical comparison with popular codes (OSQP, qpOASES, MOSEK) is reported on both randomly generated problems and support-vector machine classifier training problems. The results show that the former typically outperforms the latter on imbalanced problems. Finally, application of the proposed infeasible-start framework to other feasible-start algorithms is briefly considered, and is tested on a simplex iteration.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Google/Makani Energy Kite Modeling (CRADA CRD-18-00569 Final Report)

In support of Makani’s energy kite development program, Makani engaged with NREL to develop, verify, and document a multiphysics engineering model of a megawatt-scale tethered energy kite (named KiteFAST). After the original development of KiteFAST was completed, Makani further engaged NREL to develop a software enhancement of KiteFAST to enable the dynamics modeling of an energy kite tethered to a floating offshore platform (named KiteFAST-OS). Before this project, the capability to model the aero-hydro-servo-elastic dynamics of an airborne wind energy (AWE) system with electricity generation on the flying device (fly gen) and crosswind flight operation did not exist. Such physics-based modeling capability is needed for loads analysis, structural design, and certification of energy kites. Throughout the project, an exclusive license kept KiteFAST and KiteFAST-OS available only to Makani, NREL, and its counterparts. With the ending of Makani, the KiteFAST and KiteFAST-OS software were merged into a single code base (named KiteFAST), the exclusive license was terminated, and the source code, documentation, and example models were released publicly.

17 WIND ENERGY↗
DOE OSTI2020

Cask RT-100 Type B(U) Self-Certification for DOT 7A, Type A Nuclear Waste Transportation - 20098

The purpose of this Type A certification is to diversify the use of the RT-100 cask by allowing the end user to transport either Type A or Type B radioactive waste in accordance with the handling procedures for each waste category. The project's scope included the development of a matrix that contains all applicable requirements for a Type A package from the Code of Federal Regulations (CFR), Title 49 for the Department of Transportation (DOT) with a justification for each requirement. Moreover, the scope included the writing of conditions and restrictions list for the transportation of Type A nuclear waste, the writing of a compliance statement, and the design and fabrication of a Type A placard to be permanently placed on the RT-100 cask. Type A packages are self-certified by the end user using one of three methods as permitted by 49 CFR 173.461, either by performance of tests with prototypes or samples of the specimens representing the packaging, or reference to a previous satisfactory demonstration of compliance of a sufficiently similar nature, or calculations or reasoned evaluation using reliable and conservative procedures and parameters. Since the RT-100 cask was licensed by the Nuclear Regulatory Commission (NRC) as a Type B cask, Robatel relied on the method of reference to a previous satisfactory demonstration of compliance of a sufficiently similar nature for Type A certification. This method was determined to be acceptable, since Type B packages are evaluated for more demanding transport conditions than those required for Type A packages. This paper presents Robatel's process for certifying the RT-100 cask for Type A shipments, an overview of the DOT regulations related to Type A packages, and the documents that were generated for the end user. This paper is concluded with a discussion on the advantages of having the option to transport both Type A and Type B nuclear waste, and possible future projects to further improve the operation of the cask when making Type A shipments. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Unique safety features and licensing requirements of the NuScale small modular reactor

Small modular reactors (SMR) offer a novel approach to the construction and operation of nuclear power plants. The NuScale VOYGR™ plant uses a simplified SMR design that is based on proven light-water reactor technology with substantial improvements in nuclear safety. It consists of a 250 MWt reactor core housed with other primary system components in an integral reactor pressure vessel surrounded by a steel containment vessel, all of which is immersed in a large pool of water that also serves as the ultimate heat sink. At the core of the NuScale safety case are three primary safety systems: the decay heat removal system, the emergency core cooling system, and the containment. The ability of the NuScale Power Module (NPM) passive safety systems to remove core decay heat for an unlimited duration is demonstrated through analysis of a beyond-design-basis extended loss of AC power with no replenishment of water to the ultimate heat sink or operator actions. The NuScale methodology to evaluate an indefinite loss of AC power uses the proprietary NRELAP5 systems analysis computer code. Analysis results show that the reactor coolant system liquid level above the core is maintained and that containment pressure remains below the vessel design pressure. Once full passive air cooling is established, containment pressure and temperature will decrease over time with decreasing core decay heat. NuScale received standard design approval in September 2020 and design certification in January 2023 for its 50 MWe NPM configured as a 12 module plant. NuScale is currently seeking standard design approval to increase its core power to 250 MWt, nominally 77 MWe per module, in a 6-module plant (VOYGR™-6) configuration. The high-level safety of NuScale’s SMR technology is foundational to a new standard of nuclear power plant resilience.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Dynamic System Scaling Applied to Zr-4 Cladding under RIA Conditions

The research and development lifecycle for new fuel designs currently has an ideal 20-25 year timeline. Efforts are currrently underway to accelerate fuel design and development using high performance fuel modeling codes and reduced scale experiments with new instrumentation techniques. However current tools available require a full scale prototype to be designed and tested for fuel qualification. The thermal-hydraulics community has leveraged scaling methodologies to use reduced scale integral effect test facilities (Westinghouse AP600/1000, NuScale Power Module) in lieu of building full scale prototypes for reactor design certification. Dynamic System Scaling (DSS) is a recent development to scaling methodologies that enable the tracking and quantification of dynamic scaling distortions experienced throughout a transient. Recent TREAT experiments performed reactivity initiated accident (RIA) pulses on UO2 fuel rodlets in Zr-4 cladding and were accompanied by BISON predictions for the cladding temperature. DSS is applied to pyrometer data of outer cladding temperatures and two BISON predictions after peak cladding temperature has been reached. One BISON case uses a constant gap conductance value between the fuel and cladding and the other using a conventional gap conductance model. Results from the DSS analysis show that there is good agreement between both BISON predictions and the experimental data and that there is not a significant distortion seen between using either gap conductance model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Zero Energy Ready Out of the Box

In this conference paper for the ASHRAE Buildings XV conference, December 2022, PNNL staff share key metrics for companies who are combining off site construction with certification to the U.S. Department of Energy’s Zero Energy Ready Home program to create homes that are both cost effective to construct and high performance to live in. Key performance metrics and measures for modular, panelized, and SIP homes are compared against all homes in the DOE Zero Energy Ready Home program and against new homes built to code. These metrics show that off-site construction homes got similar or better energy performance to site-built homes, and in the case of modular and panelized, at considerably lower average cost than site-built homes. The paper also highlights the experiences of two DOE Zero Energy Ready Home builders who employ offsite construction methods. One builder constructs production homes using pre-assembled panels. The other builder designs and ships kit homes all over the United States. The paper will focus on the optimum value engineering aspects of the panelized construction processes used by each builder to identify management and production practices employed by the builders to operate profitably while meeting high energy performance goals, despite a year marked by skyrocketing materials costs and supply chain and labor shortages. Cost and labor savings methods will be discussed in the context of these two unique business models.

U.S. Department of Energy Building Technologies Pr↗
DOE OSTI2024

Paths Forward: Approaches to Achieve Plug and Process Load Efficiency and Control in Commercial Buildings: Preprint

To accomplish net-zero carbon in the built environment by 2050, we must equitably decarbonize commercial buildings, which includes reducing plug and process loads (PPLs). PPLs are plug-in or hardwired electric and gas loads that are not directly associated with major building end uses like lighting and heating, ventilating, and air conditioning. PPLs account for a growing portion of U.S. commercial building energy consumption. Although commercial building PPL strategies and technologies are available today, they have not been adopted at a level sufficient to achieve significant savings and load flexibility across the building stock. In our "Pathways to Plug and Process Load Efficiency and Control" study, we investigated why these technologies and strategies have not seen widespread adoption and identified five behavior and technology pathways to increase PPL reduction in commercial buildings. In this paper, we expand beyond identifying the pathways and discuss approaches for achieving them. We discuss the importance of collecting and sharing data and case studies on PPL energy consumption and savings from control technology implementation, including code-required measures, for increasing adoption. Centralizing case studies and data, engaging industry organizations, and promoting awareness of PPL efficiency benefits to relevant groups are also key approaches. Additionally, funding, incentives, and rebate programs play important roles in driving PPL efficiency and control adoption. Finally, we discuss integrating PPL efficiency into broader company goals, such as environmental, social and governance (ESG) strategies and green building certifications, to further drive adoption.

adoption pathways↗
DOE OSTI2022

Challenges and Possible Solutions in Aeroelastic Modeling for the Distributed Wind Industry

Aeroelastic modeling (AM) is the primary methodology for structural and performance assessment of any wind turbine; it provides an understanding of the impact of design parameters on turbine loading and power response before witnessing it in the field. Despite these advantages, the use of AM in the distributed wind technology (DWT) sector is limited. This article represents a short summary of an in-depth assessment by the authors of the status of AM and its role within the distributed wind technology design standards. The research gathered input and feedback from a large number of U.S. and international stakeholders, reviewed technical strengths and weaknesses of the current edition of the design standards, analyzed the minutes from recent industry workshops and meetings, collected publicly available AM templates, and provided an evaluation of the existing AM codes. Several goals were achieved including providing strategies for the load assessment categorization of turbines based on rotor swept area and archetype, and guidance for AM verification and validation. Recommendations within this study will advance the value and the ease-of-use of AM, thereby allowing the industry to better capitalize this underutilized tool, resulting in a more efficient design process, an easier path to certification, and overall better and more reliable distributed wind technology products.

17 WIND ENERGY↗
DOE OSTI2021

Safety Analysis Report For Packaging, Y-12 National Security Complex, Model ES-3100 Package with Bulk HEU Contents

This safety analysis report for packaging (SARP) presents the results of the safety analysis prepared in support of the Consolidated Nuclear Security, LLC (CNS) request for licensing of the Model ES-3100 package with bulk highly enriched uranium (HEU) contents and issuance of a Type B(U) Fissile Material Certificate of Compliance. This SARP, published in the format specified in the U.S. Nuclear Regulatory Commission (NRC) Regulatory Guide 7.9 and using information provided in UCID-21218 and NRC Regulatory Guide 7.10, demonstrates that the Y-12 National Security Complex (Y-12) ES-3100 package with bulk HEU contents meets the established NRC regulations for packaging, preparation for shipment, and transportation of radioactive materials given in Title 10, Part 71, of the Code of Federal Regulations (CFR) [10 CFR 71] as well as U.S. Department of Transportation (DOT) regulations for packaging and shipment of hazardous materials given in Title 49 CFR.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Aeroelastic Modeling for Distributed Wind Turbines: March 11, 2021 - November 10, 2021

Aeroelastic modeling (AM) is the primary methodology for structural and performance assessment of any wind turbine whereby providing an understanding of the impact of design parameters on its loading and power response before witnessing it in the field. Despite these advantages, the use of AM in the Distributed Wind Technology (DWT) sector is limited, especially within the less established manufacturers. This project represents an in-depth assessment of the status of AM and its role within the Standards for the DWT industry. The study gathered input and feedback from a large number of national and international stakeholders, reviewed technical strengths and weaknesses of the current edition of the design standards, analyzed recent industry workshops' and meetings' minutes, collected publicly available AM templates, and provided an evaluation of the existing AM codes. The study achieved several goals including providing strategies for the load assessment categorization of turbines based on rotor swept area and archetype, and guidance for AM verification and validation (V&V), which includes discussions of measurement requirements and a sample test-plan useful for future V&V campaigns and design standard development. This document summarizes the different tasks conducted in the course of the project and highlights the steps required to improve the AM adoption based on a multifaceted approach that encompasses: 1) augmenting AM software capabilities, 2) publishing AM best-practices and design-basis, 3) creating new model templates, 4) providing guidance for V&V of codes and specific turbine models leveraging field testing best-practice, and 5) addressing weaknesses in the current standards. Many of the future objectives identified in this study could leverage NREL's upcoming testing campaigns of three modern distributed wind turbines. Recommendations within this study will advance the value and the ease-of-use of AM, thereby allowing the industry to better capitalize this underutilized tool resulting in a more efficient design process, an easier path to certification, and overall better and more distributed reliable wind turbine products.

17 WIND ENERGY↗
DOE OSTI2019

Shortening the Design and Certification Cycle for Additively Manufactured Materials by Improved Mesoscale Simulations and Validation Experiments: Fiscal Year 2019 Status Report.

This report outlines the fiscal year (FY) 2019 status of an ongoing multi-year effort to develop a general, microstructurally-aware, continuum-level model for representing the dynamic response of material with complex microstructures. This work has focused on accurately representing the response of both conventionally wrought processed and additively manufactured (AM) 304L stainless steel (SS) as a test case. Additive manufacturing, or 3D printing, is an emerging technology capable of enabling shortened design and certification cycles for stockpile components through rapid prototyping. However, there is not an understanding of how the complex and unique microstructures of AM materials affect their mechanical response at high strain rates. To achieve our project goal, an upscaling technique was developed to bridge the gap between the microstructural and continuum scales to represent AM microstructures on a Finite Element (FE) mesh. This process involves the simulations of the additive process using the Sandia developed kinetic Monte Carlo (KMC) code SPPARKS. These SPPARKS microstructures are characterized using clustering algorithms from machine learning and used to populate the quadrature points of a FE mesh. Additionally, a spall kinetic model (SKM) was developed to more accurately represent the dynamic failure of AM materials. Validation experiments were performed using both pulsed power machines and projectile launchers. These experiments have provided equation of state (EOS) and flow strength measurements of both wrought and AM 304L SS to above Mbar pressures. In some experiments, multi-point interferometry was used to quantify the variation is observed material response of the AM 304L SS. Analysis of these experiments is ongoing, but preliminary comparisons of our upscaling technique and SKM to experimental data were performed as a validation exercise. Moving forward, this project will advance and further validate our computational framework, using advanced theory and additional high-fidelity experiments.

36 MATERIALS SCIENCE↗