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DOE OSTI2022

Factors linked to participant attrition in a longitudinal occupational health surveillance program

For occupational medical screening programs focused on long-term health surveillance, participant attrition is a significant barrier to success. Here we investigate demographic, medical history, and clinical data from National Supplemental Screening Program (NSSP) examinees for association with likelihood of return for a second exam (rescreening). A total of 15,733 individuals completed at least one NSSP exam before December 31, 2016; of those, 4832 also completed a second exam on or before December 31, 2019. Stepwise logistic regression models were used to identify variables associated with whether a participant was rescreened in the NSSP. Individuals were less likely to return for rescreening if they had a history of any cancer; cardiovascular problems; diabetes or kidney disease; or if they used insulin. Age at time of first exam and job site category significantly influenced likelihood of return. Workers categorized as “guests” were more likely to return. Participants were less likely to return if they had an abnormal urinalysis, abnormal pulmonary function, pneumoconiosis, aortic atherosclerosis, or hearing loss at their initial exam. Participants who received a chest X-ray at their initial screening were more likely to return. The presence of health problems is strongly linked to screening program attrition. Participants who are older at the time of their initial screening exam are less likely to return. The discovery of several strong demographic, medical, and job associations reveals the importance for medical screening programs to understand and address factors that influence participant retention and, consequently, the effectiveness of long-term health surveillance activities.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

Optimization of concentrator photovoltaic solar cell performance through photonic engineering

The goal of this program was to incorporate two new and innovative design concepts into the design and production of CPV cells that have near zero added cost, yet significantly increase the operational efficiency of CPV modules. The program focused developing luminescent coupling effects and radiative cooling layers to increase efficiency and suppress CPV module power losses due to spectral variations and heating. The major results of the program were: 1) The optics of three commercial refractive (Fresnel) concentrators were characterized and prevent application of radiative cooling concepts due to strong mid-IR absorption (4-12µm) required to effectively radiate blackbody radiation from the cells and provide cooling. Investigation of alternative materials for the concentrator lenses produced only undesirable options—materials with reasonable mid-IR transmission for cooling only had about 30-40 visible transmission, thus reducing incident sunlight by >50%. While our investigation was somewhat limited, our work suggests that the only viable concentrator system that can incorporate radiative cooling utilizes reflective optics. 2) With limited ability to test high concentration CPV cells (requires outdoor testing), we acquired both semi-crystalline and crystalline Si cells and tested them in our outdoor facility and demonstrated 4°C cooling using a simple silica layer coating on the cells. 3) Characterizing Si cells in the IR associated with radiative cooling, we observed very significant near-IR absorption that increases the cell operating temperature by a similar amount, 4-5°C. By appropriate surface layer design, one can produce a layer that is highly reflective in the near-IR (1.5-4µm) and highly emissive in the mid-IR (5-15µm), thus reducing cell operational temperature by 10°C and increasing efficiency by ~1% absolute. The radiative cooling effect in c-Si solar cells might be further improved by providing a higher thermal conductive elastomer for securing the cover glass on top of the AR-coating. Since it was never imagined that the front surface would provide any cooling for solar cells, thermal conductivity of this elastomer was never a design consideration, but, improving the conductivity could decrease cell temperature by another 3-4°C. The combined effect could be an ~1.5% absolute increase in cell and module efficiency, a very significant improvement. 4) Developed a numerical model to explore dependence of luminescent coupling efficiency over a broad range of operating conditions. We developed a novel method and facility to experimentally measure the luminescent coupling that can be used to confirm the dependence of luminescent coupling on multi-junction cell design parameters.

14 SOLAR ENERGY↗

DOE OSTI2023

Accelerating Manufacturing of Powder-Processed Strong, Lightweight and Thermally Stable Bulk Nanocrystalline Al Alloys via Engineered Interface States

The overarching goal of this program is to develop an integrated materials by design framework enabling a simple, scalable, and efficient manufacturing route for thermally stable nanocrystalline Al-based alloys with high specific strength over a range of service temperatures. The central scientific principle underpinning this program is the elucidation, and ultimately implementation in novel alloy design, of unique interfacial structures and chemistries driven by segregation in multi-component systems that give rise to unprecedented processability and properties. This program targeted nanocrystalline Al-based ternary alloys produced by mechanical alloying of powders followed by compaction and sintering with hot pressing, which are inherently scalable and inexpensive manufacturing routes, but when applied to nanocrystalline alloys are usually plagued by low density and/or poor retention of the intended nanostructures during processing. This program successfully demonstrated manufacturing of a bulk (>1 cm 3 ) nanocrystalline Al-based alloy with a combination of thermal stability, high temperature strength retention, and specific strength that exceeds the current-state-of-the-art of Al alloys. It is anticipated that the greatest technological impact will occur by demonstration of rapid and scalable manufacturing of bulk nanocrystalline Al alloys with exceptional thermal stability and mechanical performance, thus enabling increased energy efficiency in high performance power generation systems via: (i) replacement of existing components with lightweight Al-based alloys and (ii) increasing operating temperatures with property retention. The program focused on the development of a simple and efficient manufacturing route for thermally stable nanocrystalline Al-based alloys with high specific strength over a range of service temperatures. The program is expected to have direct impact on scalable and economic manufacturing of bulk nanocrystalline alloys. This program profited from the recent discovery by the project team of segregation-driven amorphous intergranular films in nanocrystalline metallic alloys that can be kinetically frozen-in at sub-solidus temperatures. These interfacial states (also known as amorphous complexions) comprise a large fraction of the total material in nanocrystalline alloys and are responsible for two beneficial characteristics that anchor the proposed work: (1) activated sintering leading to high density and (2) retained nanostructures leading to high strengths that approach a substantial fraction of the theoretical limit. More specifically, these engineered interfaces led to a three-fold benefit: (i) high-throughput materials processing with low energy budget and cost, (ii) exceptional thermal stability, and (iii) high specific strength at both room temperature and intermediate temperatures experienced during service.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Development of a Half-Meter Scale Traveling-Wave (TW) SRF Cavity

While a demonstration of TW resonance excitation in the 3-cell structure in 2K liquid helium had been prepared and carried out at Fermilab in collaboration with Euclid Techlabs, the RF design process of 0.5~1 meter scale TW cavity was begun at Fermilab as the next step of TW development towards an accelerator-scale one. Considering the physical dimensions of existing SRF facilities (for fabrication, processing, and cryogenic testing), Fermilab has proposed a half-meter scale TW RF design consisting of a 7-cell structure and a power feedback waveguide (WG) loop. The WG loop design includes the new RF configurations for TW resonance control during a high-power operation. 1-year US-Japan collaboration program focused on EBW optimization for the TW shape iris joint within the narrow gap was awarded and the efforts has been made by Fermilab, Jlab, and KEK. 1-year LDRD program of Fermilab is awarded recently to fabricate a low-cost mockup of the WG loop with new RF configurations and validate them. Here we will present a preliminary 7-cell TW RF design and will report the progress and challenges through the programs awarded.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

High Temperature Materials Program Overview

The ART advanced materials program focuses on the application of materials and design methods to support advanced reactors deployment in the near and mid-term Covering materials, design, construction, licensing and operations. These slides speak to present and future Materials focus.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

An application of the Analytic Hierarchy Process for prioritizing user preferences in the design of a Home Energy Management System

Most demand response programs focus primarily on commercial and industrial loads. The sheer number of decision-influencing variables combined with a lack of a comprehensive understanding of human behavior make it difficult to develop response programs that encourage greater residential consumer participation. This paper presents a multi-criteria decision making approach using actual survey data for identifying user preferences. The novelty of the work is in considering functionality, cost, and carbon emissions for a given set of home appliances toward energy management. The paper explains the design methodologies used to prioritize the preferences from 1023 survey participants. Furthermore, the results are expected to inform the design of Home Energy Management Systems (HEMS) for participating in demand response programs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Morphophysiological Plant Phenotyping for the Development of Plant Breeding Under Drought and Heat Conditions: A Practical Approach

ABSTRACT Currently, the breeding programs focus their efforts on identifying and developing tolerant genotypes to adverse conditions, such as drought and high temperatures. In this context, the physiological approach, which involves phenotyping several traits, is useful for breeding programs. Leaf photosynthetic traits have become one of the main objectives to be evaluated for breeders due to their relationship with improving grain yield and biomass production. Gas exchange ( Ge ) and chlorophyll “a” fluorescence ( Chf ) are the main tools to characterize the photosynthetic activity in real time at the leaf level. Consequently, several association studies using proximal and nonproximal sensing (e.g., RGB, thermography) have been developed. However, for the correct application of this breeding approach, it is essential to have a basic knowledge of both the physiological principles involved in the readings and the limitations of phenotyping due to the characteristics of the devices available on the market. This revision also covers other traits, such as the morphological and anatomical characteristics of leaves and roots, and the use of isotopes complementing Ge and Chf measurements.

Estrada, Félix [Instituto de Investigaciones Agrop↗

DOE OSTI2025

Development of a Robust Reference Electrode in Aggressive Chemical and Radiation Environments in the Hanford Waste Tanks

The Hanford site stores more than 200 million liters of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground carbon-steel storage tanks, separated between 149 single shell tanks (SSTs) and 28 double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The tanks will need to remain in-service far beyond the initial 40-year design life, and effective corrosion control practices must remain in force to extend the tanks’ lifespans. This effort includes direct measurements of corrosion rate (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements and open circuit potential measurements). The Hanford site began monitoring the corrosion potential in select DSTs in 2008. Of the 45 reference electrodes that have been installed, 29 have failed and 6 others provided unreliable results. DOE-EM is supporting a 3-year program to develop a chemical and radiation resistant reference electrode for application in the Hanford tanks. The first year of the program focused on understanding the failure mechanism for the reference electrodes and identification of candidate construction materials that would mitigate degradation of the electrodes in the waste environment. During the second year of the program, the objectives were to: 1) test candidate materials under simulated waste conditions, 2) design components that will extend the service life of the electrode, 3) fabricate materials for prototype reference electrodes, and 4) assemble prototype reference electrodes for accelerated testing. The reference electrode is constructed of four principal parts: 1) junction, 2) casing, 3) inner chamber backfill materials, and 4) the sensing wire. Principally, improvements of the junction, casing, and inner chamber backfill materials are being pursued. The junction material at the interface between the waste and the inner chamber of the reference electrode was identified as a critical component in the failure of the reference electrodes. Nine candidate replacement junction materials were tested under simulated waste conditions to evaluate permeation rate. These materials included a variety of polymeric and ceramic materials, some of which were 3-D printed. Thus far, porous polyvinylidene fluoride materials have performed satisfactorily and are being considered for prototype development. The commercial electrode casing materials in general have performed well. Additionally, 3-D printing of chemically and mechanically stable materials is being investigated as a means for further improvement in fabrication consistency. SRNL has also investigated altering the reference electrode design to extend the service life. The new design of the interior of the reference electrode casing creates a longer, more tortuous path between the junction material and the electrode sensing wire. A finite element model was used to optimize the design without adversely impacting the circuit resistance of the electrode during the measurements, thus preserving the measurement accuracy while enhancing the service life. The inner chamber back fill materials are also critical to the performance of the reference electrode. Materials that are resistant to intruding tank waste and provide a conductive path to the sensing wire were investigated. Gel and powder materials that are interspersed with a conductive chloride bearing material were tested for their influence on diffusion and electrode resistance. All the investigated materials and components will be assembled, with collaboration from commercial vendors, to fabricate the initial prototypes. Accelerated testing of the prototypes will be initiated in Year 2 of the program and will be completed in Year 3. A recommendation on the materials of construction and the design of the new robust reference electrode will be presented to the Hanford tank farm facility.

Sykes, Kiana [Savannah River National Laboratory (↗

DOE OSTI2020

Status Update on the SCIP-IV Program in 2020

Phase 1 of the Studsvik Cladding Integrity Project (SCIP) was launched in 2004. It was a 5-year Organisation for Economic Co-operation and Development (OECD) / Nuclear Energy Agency (NEA) joint project operated by Studsvik with about 30 participating organizations, including regulatory bodies, research institutions, utilities, and fuel suppliers from 13 different countries. The initial SCIP program focus was directed toward studying basic phenomena of fuel rod failures driven by pellet cladding mechanical interaction to get a better understanding of fundamental failure mechanisms. SCIP IV is a continuation of the SCIP programs and is planned to be another five-year project that started in July 2019. It is organized and managed in a manner similar to the earlier SCIP programs, including both a technical group and a management board. The work of SCIP-IV includes significant research into issues related to the back end of the fuel cycle, including spent nuclear fuel (SNF) storage and transportation issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Experimental Procedure and Results for Contact Thermal Conductance Measurements performed during FY 2021

Weapons Test Engineering groups at LANL are responsible for testing and simulating weapon assemblies and subassemblies in support of qualification and certification of nuclear weapon systems. The complex nature of the assemblies themselves coupled with the loading environments, gives rise to low confidence and high uncertainties in the interpretation of both experimental and simulated results. In an effort to reduce these uncertainties, a project was started at LANL to perform focused and systematic experiments combined with simulations to increase confidence in both arenas. A key goal of the work performed under the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests TRUST program, focuses on identifying and minimizing sources of uncertainty associated with experimental and computational techniques. Specifically, with the above as motivation, a measurement procedure was developed by MST-8 to perform thermal conductivity measurements on cylinders of both similar and dissimilar metallic systems as a function of loading conditions and varying material interface morphologies between these components.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Electron optics for 4 MeV ultrafast electron microscope - Final Report

Calabazas Creek Research, Inc. (CCR), in collaboration with Northern Illinois University (NIU), proposed to leverage CCR’s experience in electron beam generation and focusing and NIU’s experience in electron microscopy to develop a 4 MeV UEM with sub-ns temporal resolution and 0.3 nm spatial resolution with a relative energy spread of 10-5. Important design tools for the program were CCR’s 3D, finite element code Beam Optics Analyzer (BOA) and the photocathode design code PHOTOQE. However, early in the program it became clear that information necessary to use PHOTOQE was not available, and the program focused on the modifying to BOA to provide the required functionality.

beam optics simulation↗

DOE OSTI2025

Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024

In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.

16 TIDAL AND WAVE POWER↗

DOE OSTI2016

Development and Demonstration of Large-Scale Metal Additive Manufacturing for Military Vehicle Applications (Final Report)

Additive Manufacturing (AM) is a process by which complex parts can be manufactured directly from a basic feedstock without the need for tooling. From a defense perspective, this will enable direct manufacture of parts for legacy equipment. However, current AM technologies are limited to small part sizes (approximately 1 cubic foot), slow production rates (approximately 1 cubic inch per hour) and expensive feedstocks (approximately $100/lb). The objective of this project was to explore the impact large-scale, high production rate additive manufacturing can have on military applications. First, the program explored the use of existing composite large-scale (Big Area Additive Manufacturing – BAAM) systems for both tooling and direct part replacement with the use of the Army’s Low Velocity Airdrop Delivery (LVAD) system and Willy’s Jeep. We report on the cost and time required for the development of both tooling and parts. Second, the program focused on expanding the BAAM technology to directly manufacture aluminum and steel components. A robotic welding system was developed, test articles manufactured and with a final deliverable of a steel bumper manufactured and installed on the Jeep. This report covers the results of the program and describes follow-on efforts to commercialize the technology.

36 MATERIALS SCIENCE↗

DOE OSTI2023

The Low-Yield Nuclear Monitoring (LYNM) Experimental Science Plan

The Low-Yield Nuclear Monitoring (LYNM) Program is a long-term NNSA research and development effort designed to improve the United States’ explosion monitoring capabilities, particularly with respect to low-yield and potentially evasive underground nuclear testing. The LYNM Program focuses on researching, discovering, and exploiting unique and useful signatures, from all available technologies and sensors (e.g., seismic, acoustic, electromagnetic, gases, and particulates (both stable and radioactive)). Four Department of Energy laboratories participate in LYNM and together are referred to as the ‘quad-lab’. The R&D program execution is performed under NNSA defined structures known as “ventures”. Four science ventures were established: 1) Explosion Source Functions; 2) Containment of Low-Yield Underground Tests; 3) Local Signatures; 4) Dynamic Monitoring Networks. To organize and execute the large field scale experiment a fifth venture was established: 5) Physics Experiment One (PE-1). As part of the LYNM Program, a series of experiments are planned at various scales and levels of venture involvement. These vary from those that involve a subset of labs and/or LYNM ventures (e.g., small experiments), to full quad-lab LYNM Program field-scale integrated experiments. Such experiments may involve chemical explosions with tracer materials or other means of simulating the expected signals from a nuclear explosion. The LYNM Program does not conduct actual nuclear explosions. Since 1992, the U.S. has observed a moratorium on underground nuclear explosions. This document is intended to provide the underlying scientific basis for the LYNM planned experimental work. Each specific LYNM experiment will develop a goals, objectives, and requirements (GOR) plan following the guidance in this document. The LYNM technical staff will define the numbers and types of experiments required over the course of the Program based on technical needs and within funding constraints. As with any scientific experiment series, the number and types of experiments may change based upon the experimental results obtained. An experiment that agrees with models/codes/software signature predictions may need fewer repetitions/variations, depending upon the level of statistical rigor desired, as compared to one in which the predictions and experimental data do not match. The large LYNM field-scale integrated experiments require the longest lead-time for planning, and these are discussed in more detail near the end of this document.

58 GEOSCIENCES↗

DOE OSTI2022

Energy Efficient Material Processing through Automated Process Monitoring and Controls

Smart manufacturing is bound to play a crucial role in reducing global energy consumption while accelerating economic development. This phenomenon is evident in advanced sensing technology developments, data analytics and machine learning/AI, automated controls, cloud computing, etc. The immediate opportunity for smart manufacturing is to improve the energy efficiency of manufacturing operations through innovations in processes and controls. The manufacturing industry still consumes about 30% of total global energy production, which is significant. This program focused on the recommendation of heterogeneous sensors to monitor the Chemical Vapor Infiltration (CVI) process parameters, states, and key performance indices and utilize cloud computing to sort and analyze the real-time data. Learning through data analytics helps guide the control parameters affecting energy usage. The target process in the program is the CVI process at the Honeywell South Bend facility, which is one of the most energy-intensive manufacturing industries.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Batteries 2018 Annual Progress Report

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2018 (FY 2018). In FY 2018, the DOE VTO battery R&D funding was approximately $101 million. Its R&D focus was on the development of high-energy batteries for PEVs and very high-power devices for hybrid vehicles. The electrochemical energy storage roadmap describes ongoing and planned efforts to develop electrochemical storage technologies for PEVs. To advance battery technology to improve the market penetration of PEVs and hybrid vehicles, the program focuses on overcoming specific technical barriers typically related to the battery’s cost, performance, life (both calendar life and cycle life), its tolerance to abusive conditions, and its recyclability/sustainability. Various battery chemistries are being investigated with that aim.

25 ENERGY STORAGE↗

DOE OSTI2023

Summary of Methodology for Mitigating Risks Associated with Licensing and Qualifying AM Nuclear Materials

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program focuses on accelerating the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Laser powder bed fusion (LPBF) is one of the most popular additive manufacturing (AM) processes for fabricating components with intrinsically complex geometries. LPBF was extensively explored for nuclear applications under the previous Transformational Challenge Reactor program. Additionally, Oak Ridge National Laboratory developed and licensed the Peregrine software and larger digital platform that couples machine learning and in situ data collection during AM to detect anomalies and any evolved defects. The digital platform will be critical to (1) the qualification of AM components for nuclear applications that link location-specific data to macroscopic properties and (2) predict final component performance. Current in situ process monitoring tools are valuable for observing the formation of stochastic flaws, but additional data are needed to predict the resulting microstructures and associated material performance. Rapid cooling rates and large thermal gradients have caused large heterogeneities in the microstructure, which cause anisotropy in mechanical performance. The AMMT program is evaluating the best approaches for addressing these heterogeneities and their effect on component performance using a combination of multiscale modeling, enhanced in situ process monitoring, and high throughput experimental testing. This report summarizes strategies for mitigating the risks associated with qualifying AM components, including developing new sensing capabilities for in situ process monitoring and characterizing melt pool solidification and residual stresses to inform multiscale modeling efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Computational Modeling of Atmospheric Processes at Texas Southern University

Texas Southern University (TSU) is strengthening its research program in atmospheric chemistry and physics with a climate science emphasis by leveraging partnerships with the U.S. Department of Energy’s Atmospheric Radiation Measurement (ARM) Facility, Brookhaven National Laboratory (BNL), and the Tracking Aerosol Convection Interactions ExpeRiment (TRACER). This RDPP-supported program focuses on secondary organic aerosols (SOAs) and reactive atmospheric species that influence cloud formation, precipitation processes, and radiative forcing. SOAs play a critical role in cloud microphysics and Earth’s energy balance, yet the chemical and physical mechanisms governing SOA–cloud interactions remain a significant source of uncertainty in predictive climate models. Through computational modeling, observational data analysis, and national laboratory collaboration, this program develops a skilled cohort of students trained in atmospheric science, environmental data analysis, and climate-relevant modeling. These research experiences build technical competencies that are transferable to careers in government laboratories, academia, and industry. By engaging students from historically underrepresented communities in high-impact climate research, TSU expands participation in the atmospheric sciences workforce while contributing meaningful scientific insights to DOE-supported ARM research activities. This partnership strengthens national capacity in climate science and supports the development of the next generation of atmospheric researchers.

54 ENVIRONMENTAL SCIENCES↗