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DOE OSTI2022

Multi-technology building system retrofits for utility incentive programs: Savings, costs and baseline considerations

Utility incentive programs are an important channel to support the deployment of energy efficiency in buildings. To date, these programs have largely been limited to single-component strategies. However, many utilities are now motivated to identify and develop multi-component system retrofits to achieve deeper energy savings, which are essential to achieving broader energy and greenhouse gas reduction goals in the buildings sector. In this paper we present the energy savings, demand reductions, and cost-effectiveness of 16 systems retrofit packages in six utility regions in the United States. These results are being used by these utilities to inform and develop incentive programs for systems retrofits. Our analysis shows that packages with proven lighting and HVAC measures can provide 5–22% whole building annual energy savings, and 13–22% annual energy costs savings, using utility incentive program baselines (code and existing building). The packages are reasonably cost effective for replace-on-burnout but generally not for a retrofit scenario prior to end of equipment life. Demand response can increase both the energy savings and energy cost savings, further improving the cost effectiveness of these packages. We analyzed the impact of using existing building vs. code baselines for calculating savings, showing that the choice of baseline in developing utility incentive programs has a substantial impact on the attributable energy savings to a program, with significant implications for the overall viability of a program (generally savings against existing building condition are higher and improve project and program cost-effectiveness).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Assessment of Sandia's 2021 Pilot Program for Research Traineeships to Broaden and Diversify Fusion Energy Science: Development and Rapid Screening of Refractory Multi-Principal Elemental Composites for Plasma Facing Components

The Fusion Energy Sciences office supported “A Pilot Program for Research Traineeships to Broaden and Diversify Fusion Energy Sciences” at Sandia National Laboratories during the summer of 2021. This pilot project was motivated in part by the Fusion Energy Sciences Advisory Committee report observation that “The multidisciplinary workforce needed for fusion energy and plasma science requires that the community commit to the creation and maintenance of a healthy climate of diversity, equity, and inclusion, which will benefit the community as a whole and the mission of FES”. The pilot project was designed to work with North Carolina A&T (NCAT) University and leverage SNL efforts in FES to engage underrepresented students in developing and accessing advanced material solutions for plasma facing components in fusion systems. The intent was to create an environment conducive to the development of a sense of belonging amongst participants, foster a strong sense of physics identity among the participants, and provide financial support to enable students to advance academically while earning money. The purpose of this assessment is to review what worked well and lessons that can be learned. We reviewed implementation and execution of the pilot, describe successes and areas for improvement and propose a no-cost extension of the pilot project to apply these lessons and continue engagement activities in the summer of 2022.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗

DOE OSTI2023

Comparison of the Neutronic Performance of IRP-1 and IRP-2 at SNS

The Spallation Neutron Source (SNS) operated from start-up, in May 2006, through December, 2017 before replacing the Inner Reflector Plug (IRP). This component is the most costly and time-consuming “regular maintenance” replacement foreseen in the operation of the First Target Station (FTS). The IRP includes beryllium reflector blocks, steel and aluminum support structures, aluminum moderator vessels (which in turn include gadolinium and cadmium neutron poisons) and water coolant systems. The lifetime of this multi-million dollar component is driven by poison and decoupler burnup in moderator vessels. The moderators include these neutron poisons to best match neutron beam performance with scattering instrument needs. The burnup that comes with use changes the performance of the moderators until they no longer server their intended purpose. The reasonable desire to maximize the IRP lifetime means that the moderator performance at the Beginning Of Life (BOL) is significantly “over poisoned” and different from the performance at moderator End Of Life (EOL). Upon installation of the second IRP article, IRP-2, the SNS Neutronics team characterized the performance of the neutron beamlines in order to assess the differences between them, primarily by comparing the EOL performance of IRP-1 to the BOL performance of IRP-2. While IRP-2 was largely similar to IRP-1 in its conceptual design, there were some differences in the specific design of IRP-2 to support enhanced manufacturability, and the change from IPR-1 to IRP-2 coincided with the replacement of the light water in the IRP cooling loop with heavy water, as had been intended in the SNS design but not implemented during construction because of heavy water availability.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Surface chemistry and composition-induced variation of laser interference-based surface treatment of Al alloys

A key limitation for the use of aluminum alloys in multi-material structural components is effective surface cleaning and texturing techniques to improve the quality of structural joints. In this study, the surface and sub-surface chemistries are investigated for a novel surface treatment method using laser interferometry produced by two beams of a pulsed Nd:YAG laser. Surfaces of AA 5128 aluminum alloy were treated using a two-beam laser interference setup, enabling the structuring of the surface at length scales much less than that of the laser beam. Periodic and patterned surface structures were created by the interference power profile through ablation of deposits and debris and melting and re-solidification of the near-surface region during laser-treatment. Chemical changes to the Al alloy surface induced by laser treatment were examined in detail in this study using both x-ray photoelectron spectroscopy (XPS) and scanning Auger microanalysis (SAM) as a function of number of interfering laser shots. XPS surface analysis indicates that this laser technique is effective at cleaning aluminum surfaces. Furthermore, SAM data indicated that there is a compositional-induced variation of Mg due to laser-interference as Mg-rich areas were found in periodic interference-structured ridges.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Revealing Soil Organic Matter-mineral Associations with Advanced Chemical Imaging Methods

Although macro-scale in nature, most biogeochemical processes are driven by interactions at the microand nano-scale. Therefore, precise characterization of both organic and inorganic system components requires multi-scale, often multi-capability approaches. In this work, we present the state-of-the-art characterization of organic matter-mineral associations by high-resolution correlated chemical imaging.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Quantifying Dam-Induced Fluctuations in Streamflow Frequencies Across the Colorado River Basin

Periodic fluctuations in natural streamflow are a major driver of river ecosystem dynamics and water resource management. However, most U.S. rivers are impacted both by long-term hydroclimatic trends and dams that alter flow variability. Despite these impacts, it remains largely unexplored how dams affect the dominant frequencies of natural streamflow over a highly regulated river network. We investigated the entire Colorado River Basin (CRB) to understand how the annual (10–14 months) and multi-annual (24–60 months) frequencies in natural flow regimes have been progressively altered by dams. Given the significant alteration over the CRB, we captured changes in streamflow frequencies between naturalized and observed monthly flows via wavelet analysis. Based on the similarity of changes in streamflow frequencies (annual and multi-annual) over the last 30 years, sections of the riverine network were classified into four groups. The annual frequency was relatively well preserved downstream of Hoover Dam, while showing a systematic trend of alteration downstream of Glen Canyon Dam until Hoover Dam. Meanwhile, the multi-annual frequency component was highly altered for the entire Lower Colorado main stem (i.e., downstream of Glen Canyon). We also identified dams with significant impacts on streamflow frequency by comparing wavelet coherence estimates. This study advances the notion that dams fundamentally alter river flow regimes across multiple frequencies and with varying amplitudes over time and space, with alteration propagating – or being dampened – by both hydroclimatic fluctuations and water resource management.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

A Statistical Framework for Evaluating Rain Microphysics in Model Simulations and Disdrometer Observations

Abstract Statistical analyses of a large disdrometer data set and a diverse set of model simulations for convection using the Regional Atmospheric Modeling System were conducted, with the mutual goal of providing insights into precipitation formation and microphysical processes. We demonstrate that a two‐moment bulk microphysical model successfully captures the dominant observed modes of variability in rainfall related to rainfall intensity and raindrop size distributions. The model reproduced the general distribution of observed precipitation groups (PGs) derived from Principal Component Analysis. The multi‐variable analysis also uncovered some shortcomings in the model as well as limitations of the disdrometer data. The model solutions were constrained in their predicted drop size distributions (DSDs) due to the fixed DSD parameters assumed in a two‐moment microphysics scheme. A case study from the Mid‐latitude Continental Clouds and Convection Experiment field project demonstrated how model results can be used to contextualize the disdrometer observations which are limited in sample size, spatial coherence, and detection of small drops and low drop concentrations. The case study also showed that the spatial patterns of the statistically derived PGs revealed by the model are consistent with the hypothesized microphysical processes that determine surface rain DSDs. This work demonstrates how leveraging the strengths of observations and models together can improve our understanding and representation of rain microphysical processes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Quantitative analysis of cost savings and occupants’ preferences in grid-interactive smart home operation

Many utility companies in the United States have introduced time-of-use (TOU) rates for homeowners with the goal of regulating electricity consumption during peak hours. The electrical appliances in homes include various thermostatically controlled devices, such as air conditioners (AC) for thermal comfort, and nonthermostatically controlled devices such as clothes washers. As a result, homeowners face the complicated challenge of economically operating multiple electrical appliances in their homes while maintaining comfort and convenience. This is usually due to the lack of an explicit understanding of the correlation between cost saving and the users’ comfort. To understand the correlation, this article is designed to construct a framework by integrating three major components: a multi-objective optimization method accommodating multiple competing goals with different weights, a learning-based system modeling approach describing the dynamics and thermal coupling effects of appliances, and a novel comfort index method differentiating preferred and acceptable thermal comfort. Our proposed framework can allow the indoor air temperature to fall into the "preferred" range with a marginal cost increase. Furthermore, the simulation result shows that an additional 8 h for the preferred thermal comfort can be achieved with a cost increase of only 1.77%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

A new stabilizing regime of tearing mode entrainment in the presence of a static error field

Uncorrected static error fields in axisymmetric fusion devices are one of few remaining serious obstacles for advancing the present tokamak-based approach to practical reactors. The disruption due to magnetohydrodynamic tearing mode locking is one of them. Recently, a hypothesis has been proposed that there may exist a self-healing stabilized regime in which the static resonant error field is effectively shielded by forcing the mode slowly to rotate inductively by the applied non-axisymmetric field, that has been developed based on non-linear, resistive, reduced MHD simulation with cylindrical single helicity model. Proof-of-principle experiments in the DIII-D device showed that the magnetic mode structure on the plasma surface is qualitatively consistent with the simulation prediction. However, radial mode profiles revealed qualitatively different behavior. This finding led to a revised hypothesis that in actual non-circular toroidal devices, a tearing layer in forced rotation induces the shielding-out process at other rational surfaces when we take into account of multi-resonant Fourier components. The time evolution of the radial penetration was supportive of this hypothesis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2018

Hybrid Multi-Material Endoskeleton Overmolded Structure for Automotive Powertrain

Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) worked with American Axle and Manufacturing (AAM) to demonstrate additive manufacturing’s (AM) applicability to multi-material endoskeleton driveline mechanisms. The goal of this phase one technical collaboration project was to significantly reduce mass, improve efficiency, and improve power torque density of the driveline mechanism through applied research analysis of a multi-material solution. The focus of the effort explored the impact of multi-material endoskeleton components on reducing the weight of a typical drivetrain component using a blend of metal additive manufacturing with overmolding. For this study, a conventional rear driveline power transfer unit housing was selected. The component was geometrically optimized for additive manufacturing and to ensure proper lubrication of the gears. Therefore, traditional weight reduction techniques were invalid because AM enables weight reduction far beyond what is capable with traditional manufacturing. The hypothesis was that an inner aluminum structure could be optimized with respect to strength and weight reduction. An outer composite surface was overmolded to the aluminum AM part to satisfy the part’s geometric constraints and to provide embodiment for oil encapsulation. The original component weighed 11.3 lb whereas the topologically optimized structure was 6.96 lbs, which is a 4.34 lb difference. When the missing aluminum material was replaced with a composite material, the part weighed approximately 8.66 lbs resulting in a 2.64 lb or 23% weight reduction from the traditionally manufactured part. These first phase efforts are deemed a success. A proposed second phase will explore the material and design requirements necessary to ensure a viable mechanical interface between the AM component and overmolding.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Novel Algae Technology to Utilize CO 2 for Value Added Products

The Helios-NRG technology for converting coal-based flue CO 2 into valuable products has been successfully validated through a series of rigorous test programs. The key component, the MSC (Multi Stage Continuous System), played a pivotal role in this process. The MSC's various stages were seamlessly integrated and controlled by a second-generation automated system, surpassing project goals in terms of both algal productivity and capture efficiency. Notably, the MSC's operational duration improved while maintaining healthy cultures. The integrated system was rigorously tested under real outdoor conditions with varying sunlight levels and template flue gas. The final MSC test, conducted at the NCCC, successfully met project objectives.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Security component with fiber Bragg grating

A fiber Bragg grating (FBG) security component for single-party and multi-party monitoring is provided. The security component includes an optical fiber having a plurality of Bragg gratings. The Bragg gratings provide a spectral response that is randomized based on the manufacture of the security component. For single-party use, the spectral response provides a reproducible spectral signature when interrogated with an optical signal. For multi-party use, each party applies a known optical interrogation signal to the security component and applies an external stress known only to the respective monitoring party. The resulting shift in the spectral signature is unique to each monitoring party, making it extremely difficult to successfully counterfeit the security component's response for all such parties.

Ziock, Klaus-Peter↗

DOE OSTI2022

Searching for Exotic Signals with the NOvA Experiment

Two highly segmented NOvA scintillation detectors, separated by 810 km and located in the pathof the NuMI neutrino beam produced at Fermilab, are optimized to study the neutrino oscillationphenomenon. At the same time, the larger Far Detector with 4,000 m2 surface area is capable to search for the low-mass magnetic monopoles, and to monitor the flux of the high-multiplicitycosmic ray showers. The smaller Near Detector, located 100 m underground at Fermilab, is ableto search for the presence of possible elusive Dark Matter particles in the high-intensity NuMIneutrino beam, and to study the seasonal variations of multi-muon cosmic flux component. BothNOvA detectors serve in combination as a powerful supernova neutrino detector, and allow forthe multi-messenger signal searches in coincidence with LIGO/Virgo gravitational wave events.A survey of the most recent NOvA results on these topics is presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Searches for decays of new particles in the DUNE Multi-Purpose near Detector

One proposed component of the upcoming Deep Underground Neutrino Experiment (DUNE) near detector complex is a multi-purpose, magnetized, gaseous argon time projection chamber: the Multi-Purpose Detector (MPD). We explore the new-physics potential of the MPD, focusing on scenarios in which the MPD is significantly more sensitive to new physics than a liquid argon detector, specifically searches for semi-long-lived particles that are produced in/near the beam target and decay in the MPD. The specific physics possibilities studied are searches for dark vector bosons mixing kinetically with the Standard Model hypercharge group, leptophilic vector bosons, dark scalars mixing with the Standard Model Higgs boson, and heavy neutral leptons that mix with the Standard Model neutrinos. We demonstrate that the MPD can extend existing bounds in most of these scenarios. We illustrate how the ability of the MPD to measure the momentum and charge of the final state particles leads to these bounds.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

High-Resolution Large-Eddy Simulations of Historical U.S. Gulf Coast Hurricanes

This dataset provides coupled mesoscale and microscale (large-eddy simulation; LES) atmospheric simulations of five historical U.S. Gulf Coast hurricanes. Meso-microscale coupled simulations of Hurricanes Harvey (2017), Nate (2017), Michael (2018), Laura (2020), and Delta (2020) were performed with the Weather Research and Forecasting (WRF) model v4.1.5. The mesoscale component captures the multi-day evolution of each storm's track, intensity, and large-scale structure across the Gulf of Mexico, while the LES component explicitly resolves the dominant turbulent eddies in the hurricane boundary layer at a horizontal grid spacing of 33.33 m. Together, these simulations characterize tropical cyclone wind fields across atmospheric scales ranging from ~100 km down to ~100 m, spanning storm intensities from Category 2 through Category 4 on the Saffir–Simpson scale. This dataset contains the Large-Eddy simulations. The data will be divided according to the storm intensity level at the simulation time. Category 2: Harvey, Nate Category 3: Michael, Delta Category 4: Michael, Laura

17 WIND ENERGY↗

DOE OSTI2026

High-Resolution Mesoscale Simulations of Historical U.S. Gulf Coast Hurricanes

17 WIND ENERGY↗

DOE OSTI2022

Multiphysics Analyses of the Bottom Components of the 3D Printed Transformational Challenge Reactor

This research presents multi-physics analyses on the bottom components of the Transformational Challenge Reactor (TCR) facility. These components include the bottom axial reflector and the steel exit cone. The bottom axial reflector is made of pure silicon carbide elements hosting helium cooling channels These elements are 3D printed and therefore can host any arbitrary shape of the helium cooling channels. The design of the bottom reflector considers the neutronics and thermo-fluid dynamics performances as well as the manufacturing process optimization. More precisely, the best design of the bottom reflector reduces neutron leakage by avoiding straight cylindrical helium channels that facilitate neutron leakage, minimizes the helium flow pressure drop, and reduces the number of 3D printed silicon carbide pieces. The exit cone steel structure collects the hot helium from the bottom fuel assemblies and channels the cold helium to the top of the fuel assemblies. The steel simultaneous contact with hot and cold helium flows sets a large thermal gradient. Different designs of the exit cone are proposed to reduce the steel equivalent stress from the helium thermal load. The multi-physics analyses have been performed using Ansys Fluent, Ansys Mechanical, STAR-CCM+, and Serpent computer programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗