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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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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Rock weathering controls the potential for soil carbon storage at a continental scale

Abstract As rock-derived primary minerals weather to form soil, they create reactive, poorly crystalline minerals that bind and store organic carbon. By implication, the abundance of primary minerals in soil might influence the abundance of poorly crystalline minerals, and hence soil organic carbon storage. However, the link between primary mineral weathering, poorly crystalline minerals, and soil carbon has not been fully tested, particularly at large spatial scales. To close this knowledge gap, we designed a model that links primary mineral weathering rates to the geographic distribution of poorly crystalline minerals across the USA, and then used this model to evaluate the effect of rock weathering on soil organic carbon. We found that poorly crystalline minerals are most abundant and most strongly correlated with organic carbon in geographically limited zones that sustain enhanced weathering rates, where humid climate and abundant primary minerals co-occur. This finding confirms that rock weathering alters soil mineralogy to enhance soil organic carbon storage at continental scales, but also indicates that the influence of active weathering on soil carbon storage is limited by low weathering rates across vast areas.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

In-situ X-ray and visual observation of foam morphology and behavior at the batch-melt interface during melting of simulated waste glass

We report to attain a basic understanding of the primary foam structure and behavior, which affects the heat and mass transfer and the efficiency of the glass melting process, we investigated the primary foam layer under the glass batch floating on molten glass. The primary foam affects mass transfer during batch melting, in turn affecting the melting process. The recently performed direct in-situ three-dimensional X-ray computed tomography of the batch melting in a laboratory-scale melter vessel allowed us to visualize the features of the reacting batch layer and the foam that develops at its bottom, though with an insufficient resolution of images. In this study, we obtained better temporal and spatial resolution using the two-dimensional X-ray radiography and visual observation of the structure and behavior of transient primary foam as it formed and decayed. As soon as the batch was charged onto the melt surface, foam bubbles began to evolve, grow, and coalesce, forming a primary foam layer, 5-10 mm thick, within tens of seconds. This foam layer was sustained by ongoing gas evolving reactions counterbalanced by bubble coalescence into cavities that moved sideways and escaped to the atmosphere. Eventually, the entire remaining batch turned into foam that gradually decayed at the melt surface. The decay rate agreed with literature observations of surface foam produced by secondary foaming.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fossil energy deployment through midcentury consistent with 2°C climate stabilization

Energy system transformation scenarios satisfying particular climate stabilization objectives, such as 2°C, suggest that a wide range of fossil energy outcomes could be consistent with such objectives. The underlying drivers of variability in these outcomes cannot, however, be easily separated. This paper attempts to shed light on such drivers using a single, state-of-the-art global integrated assessment model (GCAM) to evaluate the energy system implications of climate stabilization near 2°C. We focus specifically on the role of fossil primary energy through midcentury under different assumptions about carbon capture and storage (CCS) and bioenergy supply. In our scenarios, coal and natural gas primary energy are most sensitive to the availability of CCS, with bioenergy supply having a secondary impact on these sources. Looking across primary energy sources, we find that primary energy from coal declines by midcentury relative to 2015 in all GCAM mitigation scenarios considered here, whereas primary energy from natural gas and oil increases by midcentury relative to 2015 in most of the scenarios in which CCS is available. We explain these results in terms of fundamental energy-economic relationships and discuss the implications of these findings for broader energy policy and planning.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Exosomes derived from hypoxic bone marrow mesenchymal stem cells rescue OGD-induced injury in neural cells by suppressing NLRP3 inflammasome-mediated pyroptosis

Exosomes have been shown to have therapeutic potential for cerebral ischemic diseases. In this study, we investigated the neuroprotective effects of normoxic and hypoxic bone marrow mesenchymal stromal cells-derived exosomes (N-BM-MSCs-Exo and H-BM-MSCs-Exo, respectively) on oxygen-glucose deprivation (OGD) injury in mouse neuroblastoma N2a cells and rat primary cortical neurons. The proportions of dead cells in N2a and primary cortical neurons after OGD injury were significantly increased, and N-BM-MSCs-Exo (40 μg/ml) could reduce the ratios, noteworthily, the protective effects of H-BM-MSCs-Exo (40 μg/ml) were more potent. Western blotting analysis indicated that N-BM-MSCs-Exo decreased the expression of NLRP3, ASC, Caspase-1, GSDMD-N, cleaved IL-1β and IL-18 in N2a cells. However, H-BM-MSCs-Exo (40 μg/ml) was more powerful in inhibiting the expression of these proteins in comparison with N-BM-MSCs-Exo. Similar results were obtained in primary cortical neurons. Immunofluorescence assays showed that after N-BM-MSCs-Exo and H-BM-MSCs-Exo treatment, the co-localization of NLRP3, ASC, Caspase-1 and the GSDMD translocation from the nucleus to the cytoplasm and membrane after OGD injury were reduced in N2a cells and primary cortical neurons, and H-BM-MSCs-Exo had a more obvious effect. In addition, N-BM-MSCs-Exo and H-BM-MSCs-Exo significantly reduced lactate dehydrogenase (LDH) release and the IL-18 levels in cell culture medium in N2a cells and primary cortical neurons. Once again H-BM-MSCs-Exo induced these effects more potently than N-BM-MSCs-Exo. All of these results demonstrated that N-BM-MSCs-Exo and H-BM-MSCs-Exo have significant neuroprotective effects against NLRP3 inflammasome-mediated pyroptosis. H-BM-MSCs-Exo has a more pronounced protective effect than N-BM-MSCs-Exo and may be used to ameliorate the progression of cerebral ischemia and hypoxia injury in patients.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Experimental and computational study of particle formation kinetics in UF6 hydrolysis

The formation and growth of UO 2 F 2 particles by gas-phase UF 6 hydrolysis remains of interest to actinide chemistry researchers. The total number concentration of the UO 2 F 2 aerosol particles that can be produced in the reaction is regulated primarily by the availability of water molecules under our reactor conditions. An increase in water molecule concentration corresponds with a higher amount and larger size of UO 2 F 2 aerosol particles produced. The growth rates of aerosol particles appear to approach a single number in the range of [0.05 ± 0.03–0.08 ± 0.04] (nm s -1 ), as the molar ratio of water to UF 6 decreases below 1. The size of primary particles produced from the UF 6 hydrolysis under water-deprived conditions was estimated to be 3.6 ± 0.4 nm. As the molar ratio became greater than 1.7, the size of primary particles increased with increased availability of water molecules. The primary particle model developed in this work predicted a size range for the UO 2 F 2 primary particles similar to that estimated based on the data from gas-phase UF 6 hydrolysis experiments. This result suggests that the volume-driven coalescence process assumption used in the derivation of the primary particle model was reasonable. The ability to precisely control the availability of water molecules and reaction time could lead to the production of nearly monodispersed aerosol particles. This finding has significant implications in the engineering and manufacturing of fuel powder materials and possibly the future development and deployment of environmental sampling apparatus.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Effectiveness and nonlinear characterization of vibro-impact energy harvesting absorbers in controlling base-excited systems

In this study, model derivations are carried out of a dynamical system under base excitations with a piezoelectric energy harvesting absorber as the tuned-mass-damper. Additionally, amplitude stoppers are included to the absorber in order to create a broadband resonant response, increasing the window of operational use for energy harvesting and system's control. This study is unique in the fact that the energy harvester is coupled to the source of its excitation. A nonlinear reduced-order model is developed using Euler–Lagrange principle and the Galerkin method to accurately estimate the energy harvesting absorber's displacement, harvested power, and the oscillating response of the primary structure. The nonlinear interaction of the energy harvesting absorber and the amplitude stoppers are the focus of this study, where an in-depth investigation of bifurcation points of the primary structure and energy harvesting absorber responses is performed. Due to a transfer of energy between the primary structure and the absorber, it is shown that a soft stopper with stiffness $5 \times {10^3}\,{\text{N}}\;{{\text{m}}^{ - 1}}\,$ has great control of the primary structure with 60% of the uncontrolled amplitude being reduced, as well as an increase of the harvested energy. Medium stoppers with small initial gaps size and hard stoppers do not control the primary structure and show a decrease in the energy harvesting capabilities due to the activation of the nonlinear contact-impact interactions. Finally, these stoppers also generate aperiodic regions due to the possible presence of grazing bifurcations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Description of the multinucleon transfer mechanism for Ca 48 + Pu 244 and Kr 86 + Pt 198 reactions in a quantal transport approach

Multinucleon transfer (MNT) reactions involving heavy projectile and target combinations stand as a promising method for synthesizing new neutron-rich exotic nuclei, which may not be possible using hot or cold fusion reactions or fragmentation. Exploring the mechanisms behind MNT reactions is essential and it requires a comprehensive theoretical framework that can explain the physical observables in these reactions. This work aims to show that the quantal diffusion approach based on the stochastic mean-field (SMF) theory is capable of explaining the reaction dynamics observed in MNT reactions. Primary product mass distributions in 48 Ca + 244 Pu reaction at E c.m. = 203.2 MeV and 86 Kr + 198 Pt reaction at E c.m. = 324.2 MeV are calculated and compared with the available experimental data. In this work, we utilize the time-dependent Hartree-Fock (TDHF) calculations to analyze the mean-field reaction dynamics computationally in the reactions 48 Ca + 244 Pu and 86 Kr + 198 Pt for a broad range of initial angular momenta. Quantal transport description based on the SMF approach is used to calculate quantal diffusion coefficients and mass variances in 48 Ca + 244 Pu and 86 Kr + 198 Pt systems. The primary products arising from quasifission reactions are described by joint probability distribution in the SMF approach and those arising from fusion-fission are estimated by using the statistical deexcitation code gemini + +. Mean values of charge and mass numbers, scattering angles of the primary reaction products, and the total kinetic energies after the collision are calculated within the TDHF framework for a broad range of initial angular momenta. Throughout all the collisions, drift toward the mass symmetry and large mass dispersion associated with this drift are observed. Here, the calculated primary fragment and mass distributions using the SMF approach successfully explain experimental observations for the 48 Ca + 244 Pu and 86 Kr + 198 Pt systems. The primary mass distributions, mean values of binary products, and mass dispersions are determined and results are compared with the available experimental data. The observed agreement between the experimental data and SMF results highlights the effectiveness of the quantal diffusion mechanism based on the SMF approach, which does not include any adjustable parameters other than standard parameters of Skyrme energy density functional.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Transient Stability-Enhancing Method for Grid-Forming Inverters Under Current Limiting

The primary controller of a grid-forming (GFM) inverter governs the internal reference voltage and angle, which enables the inverter to naturally synchronize and share power with the connected grid; however, during disturbances on the grid caused by, e.g., line faults, overloading, or frequency and phase shifts, a GFM inverter can be pushed into a current-limited operation to protect the device against thermal damage. This can lead to a windup of the internal reference frequency generated by the primary controller and cause a total loss of synchronism with the grid. Here, to make the primary controller of GFM inverters more robust against transient instability, this paper proposes a method that manipulates the reference signals governed by the primary controller by introducing the concept of fictitious power. The fictitious power counteracts the integrator windup in the primary controller, which enables the current-limited inverter to conceive a stable operating point. This method is benchmarked against five state-of-the-art GFM inverter stabilization methods to evaluate its stability-enhancing performance. Full-order electromagnetic-transient simulations and experimental results of a hardware inverter test setup validate the benefits of the method to improve the transient stability of GFM inverters in the face of grid disturbances.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Viscosity of glass-forming melt at the bottom of high-level waste melter feed cold caps: Effects of temperature and incorporation of solid components

At the final stages of conversion of melter feed (glass batch) to molten glass, the transient glass-forming melt becomes a continuous liquid phase encapsulating dissolving solid particles and gas bubbles that produce primary foam at the bottom of the cold cap (the reacting melter feed in an electric glass melting furnace). The glass-forming melt viscosity plays a dominant role in primary foam formation, stability, and eventual collapse, thus affecting the rate of melting (the glass production rate per cold cap area). For several melter feeds designed for nuclear waste vitrification, we have traced the glass-forming melt viscosity during the final stages of feed-to-glass conversion as it changes in response to changing temperature and composition (resulting from dissolving solid particles). Starting with a relatively low values at the moment when the melt connects, melt viscosity reaches maximum within the primary foam layer and then decreases to its final melter-operating temperature value. We paid a particular attention to the cold-cap bottom—the boundary between the primary foam layer and the thermal boundary layer—where the melt viscosity affects the rate of melting predominantly through its effect on the temperature at which primary foam is collapsing.

Lee, Seung Min↗
DOE OSTI2025

Simulating evaporative wet and dry cycles in Gale crater, Mars using thermochemical modeling techniques

The aim of this work is to provide a model‐backed hypothesis for the formation of evaporites—sulfates, borates—in Gale crater using thermochemical modeling to determine constraints on their formation. We test the hypothesis that primary evaporites required multiple wet–dry cycles to form, akin to how evaporite assemblages form on Earth. Starting with a basalt‐equilibrated Mars fluid, Mars‐relevant concentrations of B and Li were added, and then equilibrated with Gale lacustrine bedrock. We simulated the cycles of evaporation followed by groundwater recharge/dilution to establish an approximate minimum number of wet–dry cycles required to form primary evaporites. We determine that a minimum of 250 wet–dry cycles may be required to start forming primary evaporites that consist of borates and Ca‐sulfates. We estimate that ~14,250 annual cycles (~25.6 k Earth years) of wet and dry periods may form primary borates and Ca‐sulfates in Gale crater. These primary evaporites could have been remobilized during secondary diagenesis to form the veins that the Curiosity rover observes in Gale crater. No Li salts form after 14,250 cycles modeled for the Gale‐relevant scenario (approximately 10 6 cycles would be needed) which implies Li may be leftover in a groundwater brine after the time of the lake. No major deposits of borates are observed to date in Gale crater which also implies that B may be leftover in the subsequent groundwater brine that formed after evaporites were remobilized into Ca‐sulfate veins.

58 GEOSCIENCES↗
DOE OSTI2024

An expedited screening platform for the discovery of anti-ageing compounds in vitro and in vivo

Background: Restraining or slowing ageing hallmarks at the cellular level have been proposed as a route to increased organismal lifespan and healthspan. Consequently, there is great interest in anti-ageing drug discovery. However, this currently requires laborious and lengthy longevity analysis. Here, we present a novel screening readout for the expedited discovery of compounds that restrain ageing of cell populations in vitro and enable extension of in vivo lifespan. Methods: Using Illumina methylation arrays, we monitored DNA methylation changes accompanying long-term passaging of adult primary human cells in culture. This enabled us to develop, test, and validate the CellPopAge Clock, an epigenetic clock with underlying algorithm, unique among existing epigenetic clocks for its design to detect anti-ageing compounds in vitro. Additionally, we measured markers of senescence and performed longevity experiments in vivo in Drosophila, to further validate our approach to discover novel anti-ageing compounds. Finally, we bench mark our epigenetic clock with other available epigenetic clocks to consolidate its usefulness and specialisation for primary cells in culture. Results: We developed a novel epigenetic clock, the CellPopAge Clock, to accurately monitor the age of a population of adult human primary cells. We find that the CellPopAge Clock can detect decelerated passage-based ageing of human primary cells treated with rapamycin or trametinib, well-established longevity drugs. We then utilise the CellPopAge Clock as a screening tool for the identification of compounds which decelerate ageing of cell populations, uncovering novel anti-ageing drugs, torin2 and dactolisib (BEZ-235). We demonstrate that delayed epigenetic ageing in human primary cells treated with anti-ageing compounds is accompanied by a reduction in senescence and ageing biomarkers. Finally, we extend our screening platform in vivo by taking advantage of a specially formulated holidic medium for increased drug bioavailability in Drosophila. We show that the novel anti-ageing drugs, torin2 and dactolisib (BEZ-235), increase longevity in vivo. Conclusions: Our method expands the scope of CpG methylation profiling to accurately and rapidly detecting anti-ageing potential of drugs using human cells in vitro, and in vivo, providing a novel accelerated discovery platform to test sought after anti-ageing compounds and geroprotectors.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Deciphering the PMI Surface Chemistry of Lithium-Based PFCs and its Effects on High Performance Plasmas in NSTX

The primary aims or objectives of the proposed work here focus on the dynamic measurement (Illinois PI Allain) and atomistic-based multi-scale computational atomistic simulations (UTK PI: Wirth) of: 1) lithium coatings with re-deposited hydrogenated carbon surfaces and high-Z substrates, 2) lithium coatings on boronized ATJ graphite surfaces and high-Z substrates and 3) lithium coatings on ATJ graphite and high-Z substrates with variation in temperature. Three main primary tasks are proposed to address each of the primary objectives listed above: 1) dynamic in-situ irradiation with D+, He+ species of lithium coatings with variation in interface substrate morphology (e.g. smooth vs rough, fuzz vs nanostructured); 2) validation and coupling with multi-scale computational simulations connecting the irradiated surface to the plasma edge; 3) extrapolation to long-pulse conditions (e.g. function of flux vs fluence studies). In primary objective #3, temperature-based effects will be studied to evaluate three primary mechanisms: a) D uptake and recycling, b) erosion, and c) surface melting and evaporation as a function of substrate morphology and chemistry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Criticality Control Overpack Fire Testing (Phase III)

This report will describe the one test conducted during phase III of the Pipe Overpack Container (POC) test campaign, present preliminary results from these tests, and discuss implications for the Criticality Control Overpack (CCO). The goal of this test was to see if aerosol surrogate material inside the Criticality Control Container (CCC) gets released when the drum lid of the CCO comes off during a thirty-minute long, fully-engulfing, fire test. As expected from POC tests conducted in Phase I and II of this test campaign, the CCO drum lid is ejected about one minute after the drum is exposed to fully-engulfing flames. The remaining pressure inside the drum is high enough to eject the top plywood dunnage a considerable distance from the drum. Subsequently, most of the bottom plywood dunnage supporting the CCC burns off during and after the fire. High pressure buildup inside the CCC and inside two primary containers holding the surrogate powder also results in damage to the filter media of the CCC and the filter-house, thread attachment of the primary canisters. No discernable release of surrogate powder material was detected from the two primary containers when pre- and post-test average mass were compared. However, when the average masses are corrected to account for possible uncertainties in mass measurements, error overlap does not preclude the possibility that some surrogate powder mass may have been lost from these primary canisters. Still, post-test conditions of the secondary canisters enclosing these two primary canisters suggest it is very unlikely this mass loss would have escaped into the CCC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Thermal Hydraulic Experimental Test Article (FY2020 Status Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed. Since the FY19 THETA status report, the THETA primary system components have been assembled and tested using de-ionized water. Some results of this testing at select Richardson and Reynolds numbers are included herein. The custom THETA sodium flowmeter (permanent magnet submersible sodium flowmeter) has been built and calibrated using sodium in an auxiliary facility against a NIST traceable vortex shedder type flowmeter. The permanent magnet flowmeter showed excellent performance, following the theoretical equation for measured voltage quite well, with an error < 3.5% at flow rates ranging from 3-24 GPM at temperatures up to 400 °C. The secondary sodium system for heat rejection from intermediate heat exchanger has been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger have been procured.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Tritiated Sulfur Hexafluoride Disposition Strategies

Tritium (T 2 ) is a radioactive isotope of hydrogen that is produced in nuclear fission reactions and is often used in nuclear fusion reactions and accelerator-based applications for medical isotope production. As a hydrogen isotope, tritium can readily bind to hydroxyl radicals (OH), forming tritiated water (HTO or T 2 0), and to carbon atoms. Tritium decays to helium-3 ( 3 He) via beta-decay with max decay energy of 18.6 keV. While it is not an external radiation hazard, it can be an internal radiation hazard if tritium is inhaled, ingested, or absorbed through the skin. In applications where tritium is handled, tritium confinement is performed using different barriers to minimize releases to the environment. For gaseous (elemental), liquid (oxide), and metal (hydride) tritium, process piping and components provide the primary confinement function. Secondary tritium confinement is typically provided by inert (i.e. non-flammable gases such as nitrogen, argon, or helium) gloveboxes which are connected to a tritium stripper system. Primary tritium confinement barriers typically produce low volumes of high tritium concentrations of tritiated methane from carbon in steels or organic materials along with tritiated water/tritium oxide (e.g. HTO) and tritiated ammonia from reactions with oxygen and nitrogen. Tritium escaping primary confinement into secondary confinement atmospheres (e.g. gloveboxes) produce higher volumes of lower activity contamination than found in process piping. Tritium contamination also occurs by leaks or tritium permeation/diffusion through confinement materials. Tritium from inside primary confinement barriers will diffuse or leak out of the primary confinement barrier and usually into the air, if the system is inside an air hood or ventilated hot cell, or into the secondary confinement (e.g. glovebox) atmosphere which is either exhausted or stripped based on the function of the secondary confinement (glovebox) system. Accelerator based processes for medical isotope production represent an atypical tritium contamination challenge. In medical isotope production, deuterium supply gas is ionized and accelerated to a tritium gas target to produce neutrons that are then used to produce the medical isotopes through additional nuclear fission reactions. To create large voltage differentials for accelerator operations, an electrical insulation medium is needed to prevent or rapidly quench electric discharges. A common electrical insulation medium utilized in accelerator applications is sulfur hexafluoride (SF 6 ) gas. SF 6 has a high dielectric strength and allows for the construction of smaller accelerator systems compared to other electrical insulation mediums such as air or dry nitrogen. Due to tritium permeation/diffusion through accelerator process and confinement materials, there is the possibility that tritium can contaminate the electrical insulation medium of the accelerator. Tritium contaminated SF 6 creates a material without any obvious processes for managing the contamination, reuse, or disposal of the used SF 6 . This document will discuss possible management strategies for tritium contaminated SF 6 for accelerator-based processes for Molybdenum-99 (Mo-99) production.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Thermal Hydraulic Experimental Test Article (FY21 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time. Following installation of THETA into vessel #4, all data acquisition and control systems were brought online and commissioned at room temperature in the argon gas space of the empty vessel. The vessel zone 1 heaters were reinstalled and the flange was then insulated. The vessel 4 heaters were brought to a temperature of 100 °C and the THETA pump was jogged at 600 RPM to ensure it was functioning correctly. The secondary, AC Conduction based electromagnetic pump from CMI Novacast (product number CA-15) was ordered and will be delivered in late calendar year 2021. The custom designed permanent magnet based secondary flowmeter was designed, a drawing package and manufacturing specification created and quote requested from a machine shop. The intermediate heat exchanger design was completed and a drawing package is currently in progress. During the middle of calendar year 2021 the Building 308 sodium scrubber system was shut down in order to replaced some corroded piping and facilitate improvements on the system, thus requiring the sodium in METL to remain frozen. This has imposed a delay in filling vessel 4 with sodium to begin THETA testing. Sodium testing is expected to begin in early fiscal year 2022 as all THETA primary systems are operational.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Upcycling of Mixed Aluminum Alloy Shredder Scrap using Shear Processing

Conservation of critical materials is an increasing area of focus in the Unites States. In 2023, aluminum was added to the US Department of Energy Final Critical Materials List which has spurred public and private research into sustainable management of these resources. Additionally, efficiency in manufacturing and conservation of natural resources are growing concerns with targets to lower global carbon emissions, as primary aluminum alloy production is energy intensive, requiring 14 MWh of electricity plus 0.4 tonnes of CO2 per tonne of Al. Due to these factors, is essential that more sustainable manufacturing methods for aluminum alloys are developed going forward. To this end, much research is ongoing on the topic of more efficient utilization and recovery. However, most of this research still requires primary aluminum in the production process. Here, it will be attempted to bypass the use of primary aluminum and produce useful material recycled from 100% post-consumer scrap. Even considering recent developments in recycling of Al scrap, there is still a large amount of post-consumer scrap that is underutilized due to high impurity content, and that amount will increase significantly as more and more aluminum alloys are utilized in vehicles. This “scrap wave” is expected to cover 80% of the demand for automotive aluminum alloys by 2050 . A challenge to be addressed before the coming scrap wave can be fully utilized is that the tolerance of manufacturing techniques to impurities or off-spec alloy compositions must be increased. Particularly, in 5000-and 6000-series alloys (the most common wrought alloys in durable products), excess iron, copper, and silicon create brittle intermetallics during casting that remain in the extruded microstructure which limit the formability, ductility, and corrosion resistance of the alloy. Concerningly, many of the highest-volume post-consumer aluminum scrap streams such as automotive shredder scrap contain a mix of alloys including both wrought and cast alloys. Their compositions can vary widely depending on geography and the time of year. Because they are mixed, they often contain high content of multiple alloying elements such as Si and Cu in higher concentrations than are found in typical wrought alloys. They may also be contaminated with non-Al alloys from fasteners that get mixed in and often have high content of unwanted elements such as Fe. As a method for utilizing these underused scrap streams that are high in tramp elements, an emerging extrusion technology is being developed at the Pacific Northwest National Laboratory (PNNL) that aims to upcycle 100% post-consumer aluminum scrap directly into extruded components without the addition of primary aluminum . This new technology, called Shear Assisted Processing and Extrusion (ShAPE), is enabling a shift away from today’s recycling paradigm by reaching deeper into lower-value scrap streams, using shredder scrap as the extrusion billet material. Sometimes referred to as Twitch or Tweak, these scrap streams result from shredding and sorting of automobiles, building materials, appliances, and consumer goods. ShAPE combines the linear axis of conventional extrusion with a rotating extrusion die. This rotating die applies large strain to the material during extrusion, which breaks up large impurity-containing intermetallic particles, reducing their deleterious effects. This has been demonstrated for 6063 machining scrap spiked with excess Fe, and Twitch scrap high in Fe, Si and Cu where strength and ductility were retained for both feedstock compositions. Additionally, the extreme plastic deformation during ShAPE enables extrusion of billets with high Si that are too brittle for processing by conventional extrusion. By using 100% post-consumer shedder scrap as feedstock, ShAPE has the potential to slash embodied energy and carbon in extruded components by >80% compared to conventional extrusion of primary aluminum alloys.

Milligan, Brian K.↗