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DOE OSTI2023

FY23 Status Report on MOOSE-Based Approaches to Modeling Core Bowing in Fast Reactors

Under the U.S. Department of Energy Office of Nuclear Energy’s Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism whereby increased power (which leads to temperature and flux gradients) influences the core to bow into less reactive configurations when the restraint system is properly designed. The phenomenon includes a complex interplay of radiation transport, duct temperature calculations involving fluid flow and heat transfer, and thermo-mechanical responses to the induced temperature and flux gradients. Structural material properties are also important to determining inelastic response to longer term flux gradients which cause irradiation creep and swelling. While core bowing provides a strong negative reactivity feedback when the restraint system is designed properly, it also results in additional forces between assemblies which increase the loads required to extricate them during refueling or control rod movement. Therefore, the restraint system must be designed with these tradeoffs in mind. The first stage of the work, which commenced in FY21 and continues through FY23, assesses thermo-mechanical modeling tools for producing core bowing predictions consistent with conventional tools. The Multiphysics Object Oriented Simulation Environment (MOOSE) Tensor Mechanics and Contact Modules are employed. This status report describes work on additional thermo-mechanical benchmark verification problems with increased complexity from the examples demonstrated in FY21 and FY22. Several benchmark verification examples were selected from the IAEA verification and validation report with increased number of ducts and more complex contact interaction behavior. These examples involve a full symmetric sector with restraint rings at multiple load pad locations to simulate a limited free-bow restraint system concept, as well as irradiation induced swelling and creep effects in a sector. In addition, improvements to the contact module sideset assignment were assessed and compared with previous MOOSE results to verify the contact behavior. The MOOSE-based results were compared to IAEA benchmark participants’ results. In every case, the MOOSE results agreed with other simulations results for estimating bowing behavior, providing additional verification basis of the tools for this particular physics application. Estimation of contact forces were mostly in agreement, with a few outlier results. A plan was suggested for dealing with the discrepancies with estimating contact force values. In addition, a 1-way coupling demonstration was performed using subchannel analysis code Pronghorn-SC and MOOSE on an ABR-1000-design sodium-cooled fast reactor assembly to evaluate coolant and duct wall temperatures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Strength, toughness, and reliability of a porous glass/biopolymer composite scaffold

Abstract Development of bioactive glass and ceramic scaffolds intended for the reconstruction of large segmental bone defects remains a challenge for materials science due to the complexities involved in clinical implantation, bone–implant reaction, implant degradation and the multiple loading modes the implants subjected to. A comprehensive evaluation of the mechanical properties of inorganic scaffolds and exploration of new ways to toughen brittle constructs are critical prior to their successful application in loaded sites. A simple and widely adopted approach involves the coating of an inorganic scaffold with a polymeric material. In this work, a systematic evaluation of the influence of a biopolymer, polycaprolactone (PCL), coating on the mechanical performance of bioactive glass scaffolds was carried out. Results from this work indicate that a biopolymer PCL coating was more effective in increasing the compressive strength and reliability of the glass scaffold under compression, but less effective in improving its flexural strength or fracture toughness. This is the first report that reveals the limited successfulness of a polymer coating in improving the toughness of strong scaffolds, suggesting that new and novel ways of toughening inorganic scaffolds should be future research directions for scaffolds applied in loaded sites. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 106B: 1209–1217, 2018.

Fu, Qiang↗

DOE OSTI2016

Determining heterogeneous slip activity on multiple slip systems from single crystal orientation pole figures

A new experimental method to determine heterogeneity of shear strains associated with crystallographic slip in the bulk of ductile, crystalline materials is outlined. The method quantifies the time resolved evolution of misorientation within plastically deforming crystals using single crystal orientation pole figures (SCPFs) measured in-situ with X-ray diffraction. A multiplicative decomposition of the crystal kinematics is used to interpret the distributions of lattice plane orientation observed on the SCPFs in terms of heterogeneous slip activity (shear strains) on multiple slip systems. Here, to show the method’s utility, the evolution of heterogeneous slip is quantified in a silicon single crystal plastically deformed at high temperature at multiple load steps, with slip activity in sub-volumes of the crystal analyzed simultaneously.

36 MATERIALS SCIENCE↗

DOE OSTI2020

3D Experimental Measurements of Evolution of Force Chains in Natural Silica Sand

The mechanisms of force transmission in granular materials is a classic physics problem that has been addressed since the 19th century, when Heinrich Rudolf Hertz investigated the interaction between two similar objects that were in contact under compression. However, the study of force transmission mechanisms in assemblies of more particles has proven to be a formidable problem due to the complex nature of granular materials. In recent years, synchrotron microcomputed tomography (SMT) and three-dimensional X-ray diffraction microscopy (3DXRD) have been employed to study the mechanics of granular materials experimentally. Combining SMT and 3DXRD offers unique three-dimensional (3D) experimental measurements of the internal structure, kinematics (such as rotation and translation), and lattice strains of individual sand particles. In this paper, in situ SMT and 3DXRD scans were acquired at multiple load steps for a specimen composed of 2,705 natural Ottawa sand particles that were subjected to one-dimensional (1D) confined compression. An algorithm was developed to combine SMT images and 3DXRD lattice strain measurements and used to characterize the constitutive behavior of sand particles. The results were used to identify the crystal structure and the evolution of the stresses and lattice strains of individual sand particles. Another algorithm was developed to characterize the force structures within the specimen. Force structures were identified, and their properties (such as length) and evolution through the experiment were examined. The contact number of particles is a particle-scale property that affects the mechanics of granular materials. The effect of the contact number of the sand particles on the onset and evolution of the force structures was also investigated and discussed.

3D x-ray diffraction microscopy↗

DOE OSTI2021

Comparison of Candidate Designs and Performance Optimization for an Electric Traction Motor Targeting 50 kW/L Power Density

The continued expansion of the global electric vehicle fleet is accompanied by an unprecedented demand for high power density electric traction motors. With the ambitious U.S. DRIVE 2025 target of 50 kW/L power density and an equally aggressive cost reduction goal, innovative approaches have to be utilized in terms of both the design and manufacturing of electric traction motors. In this paper, six motor options are compared and the best design is picked for each option to investigate the drive and excitation requirements and the weighted power efficiency over multiple load points, with necessary mechanical stress and demagnetization checks. State-of-the-art winding technologies, including high slot fill die compressed windings and hairpin windings, and rotors both with permanent magnet (PM) and PM-free are incorporated. The design of high flux density and low harmonic content magnetic field is also demonstrated.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

A Study of Imbalance Levels Attributed to Photovoltaic Penetration in Distribution Systems

Abstract— The number of renewable sources, namely photovoltaics (PV), continues to grow within distribution systems. How placements impact a system’s performance remains a concern within both the research and the utility communities. Beyond system node voltages and real power losses, this work looks to industry standard imbalance metrics and the changes experienced on these values with varied levels of PV. Specifically, four imbalance metrics are presented and studied for an actual 906-bus distribution system. Multiple loading conditions and photovoltaic placement schemes are explored to compare the changes seen on these metrics across a variety of scenarios experienced by the network.

14 SOLAR ENERGY↗

DOE OSTI2018

Prediction of Cyclic Variability and Knock-Limited Spark Advance (KLSA) in Spark-Ignition (SI) Engine

Engine knock remains one of the major barriers to further improve thermal efficiency of Spark Ignition (SI) engines. Knock can be suppressed by lowering the compression ratio, or retarding the spark ignition timing, however, at an expense of efficiency penalty. SI engine is usually operated at knock-limited spark advance (KLSA) to achieve possibly maximum efficiency with given engine hardware and fuel properties, such as Research Octane Number (RON), Motor Octane Number (MON), and heat of vaporization, etc. Co-optimization of engine design and fuel properties is promising to improve the engine efficiency and predictive CFD models can be used to facilitate this optimization process. However, difficulties exist in predicting KLSA in CFD simulations. First, cyclic variability of SI engine demands that multi-cycle results are required to capture the extreme conditions. Secondly, Mach Courant-Friedrichs-Lewy (CFL) number of 1 is desired to accurately predict the knock intensity (KI), resulting in unaffordable computational cost, especially for multi-cycle simulations. In this study, a new approach to numerically predict KLSA using large Mach CFL number of 50 is proposed. This approach is validated against experimental data for a boosted Direct Injection Spark Ignition (DISI) engine at multiple loads and spark timings. G-equation combustion model coupled with well-mixed chemical kinetic model are used to predict the turbulent flame propagation and end-gas auto-ignition, respectively. Simulations run for 10 consecutive engine cycles at each condition. The results show good agreement between model predictions and experiments in terms of cylinder pressure, combustion phasing and cyclic variation. Engine knock is predicted with early spark ignition timing, indicated by significant pressure wave oscillation and end-gas heat release. Maximum Amplitude of Pressure Oscillation (MAPO) analysis is performed to quantify the KI, and the slope change point in KI extrema is used to indicate the KLSA accurately. Using a smaller Mach CFL number of 5 also results in the same conclusions thus demonstrating that this approach is insensitive to the Mach CFL number. The use of large Mach CFL number allows us to achieve fast turn-around time for multi-cycle engine CFD simulations.

Yue, Zongyu↗

DOE OSTI2020

Transient voltage-reversal in transformers with multiple secondary coils

By using a transformer with multiple secondary coils, a single unipolar power source can drive multiple loads that have different steady-state operating-voltage requirements. We show that, during initial turn-on, a transient voltage that is opposite in sign to the operating voltage can be induced in one or more of the secondary coils. This is because the surging currents in the coils during turn-on produce a strong inductive interaction between all the coils. In a particular secondary coil, the voltage induced by a neighboring secondary can be larger, and opposite in sign to, the voltage directly induced by the primary coil. The effect is transient because, when the secondary circuits reach their steady-state operating currents, they no longer couple inductively to each other. We also show that, during the turn-on period, the voltage induced in a secondary coil can be significantly larger than its steady-state voltage. These transient effects are controlled by the values of the "coil-coupling" parameters, which are functions of the transformer geometry and of the magnetic permeability and electrical resistivity of the materials used. The results are derived from the circuit equations, and verified using PSpice simulations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Report on High-Fidelity Dynamic Modeling of a Coal-Fired Steam Power Plant

As a result of the growth of renewables including solar and wind energy with fluctuating production, fossil fuel power plants are being required to cycle between high and low power production. This cycling is both at a greater frequency and over a wider range than in the past. In many cases, power plants are not designed for this type of cycling operation but can nonetheless endure these challenging operation requirements under the right conditions. In this project, optimal solution for enhanced flexible operations are being investigated using model based estimation and control techniques. To support the development of model-based estimator and model-based controls at GE Global Research, GE Steam Power configured a dynamic model using a reference steam plant design including the boiler, turbine, and water/steam conditioning systems as well as the controls needed for plant cycling with stability and reliability. The dynamic model was built using the APROS® software from VTT, and then calibrated to multiple load conditions from full load (100%TMCR) to partial loads (75%TMCR, 50%TMCR and 25%TMCR) based on internally developed steady state heat balance models at the unit level. These internal heat balance models are based on first principles and extensive engineering experiences from GE Steam Power as an OEM and a services provider. This topical report presents the structure of the unit level dynamic model, the tuning process, and representative simulation results from typical load cycling simulations using the dynamic model.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

Measurements of Mode I Interlaminar Properties of Carbon Fiber Reinforced Polymers Using Digital Image Correlation

Numerical models based on cohesive zones are usually used to model and simulate the mechanical behavior of laminated carbon fiber reinforced polymers (CFRP) in automotive and aerospace applications and require different interlaminar properties. This work focuses on determining the interlaminar fracture toughness (G IC ) under Mode I loading of a double cantilever beam (DCB) specimen of unidirectional CFRP, serving as prototypical material. The novelty of this investigation is the improvement of the testing methodology by introducing digital image correlation (DIC) as an extensometer and this tool allows for crack growth measurement, phenomenological visualization and quantification of various material responses to Mode I loading. Multiple methodologies from different international standards and other common techniques are compared for the determination of the evolution of G IC as crack resistance curves (R-curves). The primarily metrological sources of uncertainty, in contrast to material specific related uncertainties, are discussed through a simple sensitivity analysis. Additionally, the current work offers a detailed insight into the constraints and assumptions to allow exploration of different methods for the determination of material properties using the DIC measured data. The main aim is an improvement of the measurement technique and an increase in the reliability of measured data during static testing, in advance of future rate dependent testing for crashworthiness simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2016

MC{sup 2}-3/DIF3D Analysis of the ZPPR-15 Axial Expansion Experiments

The Zero Power Physics Reactor (ZPPR) fast critical facility at the Argonne National Laboratory-West (ANLW) site in Idaho was built in 1969 to obtain neutron physics information necessary for the design of fast breeder reactors. The ZPPR-15 phases A through D were part of a series of cores intended to model a 330 MWt Integral Fast Reactor (IFR) concept. The ZPPR-15 assembly consisted of an inner core zone, an outer core zone of higher fissile content, a thin radial blanket and a thick steel reflector. The inner and outer core zones were of approximately equal volumes. The core zones simulated a sodium-cooled, metal-fueled fast reactor with approximately 10 wt.% zirconium in the target fuel composition. Phases A and B simulated an equilibrium cycle UPu-Zr fuel core where plutonium created in the blankets was sufficient to negate the need for enriched {sup 235}U feedstock. Phase D simulated a beginning of life U-Zr fuel core with enriched uranium fuel although approximately 10% of the fuel in the outer zone of the Phase D core was plutonium because {sup 240}Pu was required to provide a neutron source for the modified source multiplication technique used for many reactivity worth measurements such as sodium void worth in ZPPR. Phase C simulated the intermediate state between beginning of life and equilibrium cycle conditions with 50% enriched uranium fuel and 50% plutonium fuel in the inner and outer core zones. These configurations represent the various stages of reactor operating conditions. Phase A did not contain zirconium (metal fuel is typically alloyed with Zr) while Phases B, C and D did contain zirconium although the limited plate inventory restricted the zirconium zone to the inner core zone. This set of experiments was performed between April 1985 and July 1986 and focused on validation of both the concept and modeling. In each phase, there were multiple loadings for sub-critical, critical, and with regard to this manuscript, axial expansion worth measurements. Combined, these cores can be used to assess the accuracy of physics codes and evaluated cross section data for IFR concept reactors. This paper presents a recent effort that was made on retrieving validation data from the ZPPR-15 experiments and on deterministic modeling and analysis using MC{sup 2}-3/DIF3D for code validation. Axial expansion experiments and ZPPR-15D loading 206 were selected for this analysis. An explicit modeling of the axial expansion (introduction of gaps between sections of drawer) of ZPPR-15D loading 206 yielded a 32% over-prediction in the worth of the axial expansion with the MC2-3/DIF3D models. This indicates a consistent bias between ZPPR-15B and ZPPR-15D with regard to the deterministic modeling of the experiments. As part of future work, we intend on investigating whether the cross section processing or homogenization model is to blame, but we note with such small changes in k-effective in a large model, it is rather difficult to obtain zero errors as is typical for other worth measurements. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Cooperative Load Scheduling for Multiple Aggregators Using Hierarchical ADMM

Demand response (DR) serves an important role in improving the efficiency and stability of power systems. In recent years, with advances in communication and smart device technologies, many aggregators have emerged to facilitate end customer participation in DR programs. These aggregators, equipped with customized optimal control algorithms, are capable of providing various grid services. Among them is load scheduling during DR events, namely following a load signal provided by the utility company while minimizing overall customer discomfort. However, as the number of aggregators keeps increasing, it becomes challenging for utility companies to conduct load scheduling for multiple aggregators and generate reference signals for each of them. This paper proposes an optimization framework using hierarchical alternating direction method of multipliers (H-ADMM) to optimally generate load following signals for multiple aggregators. Under this framework, utility and multiple aggregators work in a cooperative manner, aiming at minimizing an overall system cost from different levels of the power system hierarchy, while protecting user privacy. A case study has been conducted in a system with multiple aggregators, based on control of HVAC loads. Experimental results validate the effectiveness of the proposed algorithm.

ADMM↗

DOE OSTI2020

Cooperative Load Scheduling for Multiple Aggregators Using Hierarchical ADMM

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Cooperative Load Scheduling for Multiple Aggregators Using Hierarchical ADMM: Preprint

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Weather Sensitive High Spatio-Temporal Resolution Transportation Electric Load Profiles For Multiple Decarbonization Pathways

Electrification of transport compounded with climate change will transform hourly load profiles and their response to weather. We present a novel approach to generating hourly electric load profiles that considers charging strategies and evolving sensitivity to temperature. The approach consists of downscaling annual state-scale sectoral load projections from the multisectoral Global Change Analysis Model (GCAM) into hourly electric load profiles leveraging high resolution climate and population datasets. Profiles are developed and evaluated at the Balancing Authority scale, with a 5-year increment until 2050 over the Western U.S. Interconnect for multiple decarbonization pathways and climate scenarios. The datasets are readily available for production cost model analysis. Our open source approach is transferable to other regions.

Decarbonization, tranportation, Electric vehicle c↗

DOE OSTI2020

Impacts of Experimentally Obtained Harmonic Spectrums of Residential Appliances on Distribution Feeder

Owing to the increased use of power electronic based appliances and energy-efficient home equipment such as modern lighting loads, the percentage of nonlinear loads has increased in the distribution system, which can impact system performance, loss, and stability. Thus a comprehensive knowledge of their power quality and harmonic analysis is essential to improve the load models, voltage stability assessment, determination of possible interactions at harmonic frequencies, protection planning, and the effect of system impedance. This paper focuses on harmonic load flow analysis for multiple residential load types to determine the expected impacts on an modeled distribution secondary. For this study, the household appliances include lighting, power electronic, resistive, and motor loads with a nominal supply voltage of 120 V single-phase or 240 V split phase at a nominal frequency of 60 Hz. The harmonic spectrums, as obtained from the experimental evaluation of real loads, are used to inform the harmonic load flow for a detailed secondary network, including the distribution service transformer extracted from a real distribution feeder's model. Additionally, the impact of voltage harmonics on a three-phase test load is presented with experimental results. The harmonic data of the transformer terminal voltage, as obtained from the former load flow study, are scaled to generate the source voltage for the three-phase configuration of the grid simulator to make the test setup very similar to a typical secondary design in the U.S.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

DOE OSTI2016

Collectively loading programs in a multiple program multiple data environment

Techniques are disclosed for loading programs efficiently in a parallel computing system. In one embodiment, nodes of the parallel computing system receive a load description file which indicates, for each program of a multiple program multiple data (MPMD) job, nodes which are to load the program. The nodes determine, using collective operations, a total number of programs to load and a number of programs to load in parallel. The nodes further generate a class route for each program to be loaded in parallel, where the class route generated for a particular program includes only those nodes on which the program needs to be loaded. For each class route, a node is selected using a collective operation to be a load leader which accesses a file system to load the program associated with a class route and broadcasts the program via the class route to other nodes which require the program.

97 MATHEMATICS AND COMPUTING↗