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At least 55 records · Page 3

Near Repository Unsaturated Alluvium Disposal Modeling with Improved Geological Realism

The Disposal Research and Development (R&D) Program of the US Department of Energy (DOE) office of Nuclear Energy (NE-8) Spent Fuel and Waste Science and Technology (SFWST) Campaign is to conduct R&D on disposal of spent nuclear fuel (SNF) and high-level waste (HLW). The goal of the Geologic Disposal Safety Assessment (GDSA) within this project is to develop a disposal system modeling and analysis capability that supports the integrated modeling of coupled processes controlling disposal system performance of deep geologic repositories, including uncertainty. This report describes a specific activity in the Fiscal Year 2024 (FY24) associated with the GDSA Repository Systems Analysis (RSA) work package in collaboration with the GDSA Geologic Modeling work package at Los Alamos National Laboratory (LANL). The overall objective of the GDSA RSA work package is to develop generic deep geologic repository concepts and repository system performance models in crystalline, argillite, salt, and unsaturated alluvium potential host-rock environments, and to simulate and analyze these generic repository concepts and models using GDSA Framework toolkit, and other tools as needed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Shaker Table Test

This report describes the Shaker Table Test conducted on September 12, 2018, at the Dynamic Certification Laboratories (DCL) in Sparks, Nevada. This report satisfies Milestone M3SF-19SN010202021 Shaker Table Test, Sandia National Laboratories (SNL) Work Package (Parent WBS # 1.08.01.02.02; Work Package #SF-19SN01020202). The Shaker Table Test is related to the Multi-Modal Transportation Test (MMTT) conducted in 2017. During the MMTT, accelerations and strains were measured on the transportation platform, ENsa UNiversal (ENUN) 32P dual-purpose rail cask, cradle, basket, and three surrogate 17x17 pressurized water reactor (PWR) assemblies (one from SNL, one from Spain and one from Korea).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Support for Advanced Fuel Fabrication MC&A Approaches

This report summarizes the key activities of the Material Protection, Accounting, and Control Technologies (MPACT) program’s safeguards training work package for FY25. The work focused on two main areas: domestic safeguards training and the development of new technologies for nuclear material accounting and control (NMAC). A key development during this FY was the delivery of NMAC statistics for US Nuclear Regulatory Commission requirements refresher course. The course objective was to assist industry in meeting the MC&A program requirements for fuel cycle facilities; this training focused on front-end bulk fuel cycle processes. At the same time, a report was prepared on the research output of an effort that focused on the benefits of commercial fuel debundling for NMAC and waste management. The MPACT team evaluated various technologies and proposed a fuel debundling detector that integrates gamma spectroscopy and neutron detection as the most practical solution. The scope of activities under this work package for FY26 focuses on developing a fundamental nuclear material control plan, also known as MC&A plan, for tristructural isotropic (TRISO) fuel fabrication facilities. This plan will address the various NMAC requirements for facilities that handle Category II.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Status of the US Space Station ECLSS and internal TCS

The U.S. Space Station includes many elements and systems. Responsibility for these have been delegated to four NASA centers via a work packaging concept. Marshall Space Flight Center (MSFC) is responsible for work package one (WPOI) which includes the habitation, laboratory modules, the logistic carrier elements, as well as the environmental control and life support system (ECLSS), the internal thermal control system (ITCS), and the internal audio and video systems. Current status of the ECLSS and internal thermal are the subjects of this paper. The ECLSS is composed of six subsystem groups: the temperature humidity control, the atmosphere control and supply, the air revitalization, water reclamation and management, fecal waste management, and the fire detection and suppression subsystems. The internal TCS consists of all WP01 elements of passive and active thermal measures. The ECLSS and ITCS provide services for the permanently orbiting pressurized modules as well as the pressurized and unpressurized logistics carriers. The logistics carriers are used as ground-to-station ferries for both resupply and initial delivery of selected new equipment and later replacement items. Equipment, which cannot be subjected to the rigors of the space environment, will be carried in the pressurized logistic carrier; while an unpressurized carrier is used to resupply other commodities, such as external fluid consumables. The laboratory module houses the equipment for both payloads and subsystem maintenance and repair. The habitation module is dedicated to providing living and sleeping quarters including a galley, sleeping provisions, hygiene facilities, medical services as well as services for exercise and relaxation. The four nodes that join the two modules at their ends also house electronics as well as work stations and outside viewing cupolas. The airlocks, one providing an emergency hyperbaric chamber capability, are also attached. This assembly constitutes the U.S. provided portion of the initial station. Additional international modules and docking provisions for future attached pressurized payload as well as dual logistic module and growth capabilities are also provided. The primary heat rejection mechanism is achieved via a central set of radiators provided by another work package. The interface with the central TCS at the module heat exchangers defines the active control interface boundary of the ITCS with the central TCS. All internal cooling of the permanent orbital elements are provided via internal active fluid loops within the elements utilizing water as the transport media. Cabin and equipment cooling are provided by forced air flow and cold plate heat sinks. A special active cooling loop is provided in the laboratory module to accommodate experiments and other payloads. Coatings and insulation are used in conjunction with the active components to passively limit heat losses/gains. The most challenging ECLSS new technology issues relate to oxygen and water recovery. Closure of the oxygen loop requires the use of new regenerative CO 2 removal and concentration techniques, CO 2 reduction to convert the CO 2 to water with a waste by-product, and the electrolysis of water to produce breathing oxygen for water recovery. For water recovery three separate loops are currently planned. One loop provides potable water by utilizing a combination of recovered condensate and CO 2 reduction water. A second loop purifies hygiene water from waste from the showers, clothes washer, hygiene/hand wash stations and a dishwasher. The third loop provides hygiene water by the reclamation and purification of urine water. This paper outlines the basic services provided by the ECLSS and ITCS and describes the ECLSS functional distribution throughout the pressurized assembly.

R. Humphries↗

An underwater work systems package

A modular unit which is adaptable to several existing deep sea submersibles was developed to extend their working abilities and acquire knowledge of components and techniques for working in the deep sea environment. This work systems package is composed of an aluminum pipe structure on which are mounted two six-function grabber arms, a seven function manipulator, tool suit, 1,000/lb. capacity winch, electrohydraulic power supply, electronics housing, lights, and television. The unit is designed to be operated by itself either remotely or with divers, attached to manned submersibles, or mounted on unmanned cable-controlled submersibles.

Estabrook, N. B.↗

AAM Project: High Density Vertiplex (HDV) Research and Capabilities

NASA is currently engaged in dedicated research into vertiports through its Advanced Air Mobility Project, housed within the Airspace Operations Safety Program (AOSP), through a Sub-Project referred to as High Density Vertiplex, or simply HDV. This effort’s mission is to develop a reference automation architecture for vertiports that will enable operations to scale to the density levels envisioned for future environments. Through the development of the HDV Concept of Operations and accompanying architecture documents a research roadmap was developed as part of the effort's formulation process that laid the foundations for the work and schedule to be completed as part of the HDV scope and technical challenge. This presentation provides the background of the HDV Sub-Project and outlines the concept and capabilities as it has developed to date. Summaries of the completed work package and status of current work package will be provided with details on specific capabilities and supporting integration developments.

vertiport↗

Q-Fibre Quarterly Performance Progress Report

The project titled Quantitative Strain Monitoring for Well and Seal Integrity through Wellbore Fiber Optic Cable s, or Q-Fibre in short, is a multi-national collaborative project under the Clean Energy Transitional Partnership (CETP) program. The lead organization of the project is the Norwegian Geotechnical Institute (NGI), and the LLNL team joins as a beneficiary member. The LLNL team receives the funding from the U.S. Department of Energy with the amount of $\$$1 million across three years, and the budget is primarily allocated to Work Package 3 (WP3) of the project, which focuses on Numerical Modeling of Fiber Optic Cable Data . Figure 1 presents all work packages involved in the project and corresponding lead organization for each work package. The LLNL team leads WP3.

42 ENGINEERING↗

Use of control umbilicals as a deployment mode for free flying telerobotic work systems

Work to date on telerobotic work systems for use in space generally consider two deployment modes, free flying, or fixed within a limited work envelope. Control tethers may be employed to obtain a number of operational advantages and added flexibility in the basing and deployment of telerobotic work systems. Use of a tether allows the work system to be separated into two major modules, the remote work package and the control module. The Remote Work Package (RWP) comprises the free flying portion of the work system while the Control Module (CM) remains at the work system base. The chief advantage of this configuration is that only the components required for completion of the work task must be located at the work site. Reaction mass used in free flight is stored at the Control module and supplied to the RWP through the tether, eliminating the need for the RWP to carry it. The RWP can be made less massive than a self contained free flying work system. As a result, reaction mass required for free flight is lower than for a self contained free flyer.

Kuehn, J. S.↗

Fission Product Volatility and Off-Gas Systems for Molten Salt Reactors

The overall objective of the Department of Energy investigation into off-gas technology for molten salt reactors (MSR)s is to develop a list of functional requirements for an effective and reliable system. In collaboration with other elements of the Advanced Reactor Campaign ( denoted in italics ), the off-gas work package will address the following questions: 1. What is the composition of the gas stream going to the off-gas system ( chemistry and source term work package )? 2. What is the function of each off-gas treatment component, and how do they work? How efficient are they at removing or delaying fission and activation products? 3. What are the maintenance requirements of the off-gas system? 4. Is the system able to effectively detect and respond to off-normal events ( off-gas, source term, and simulation work packages )? 5. What measurement capabilities are possible now? What are the gaps? The objective of the off-gas project in fiscal year 2019 was to address the second, fourth, and fifth questions above. Thus, project has proceeded along two fronts: one focused on scrubber development at Oak Ridge National Laboratory and the other focused on spectroscopic detection of simulant fission product iodine at Pacific Northwest National Laboratory. A molten hydroxide scrubber was proposed for removal of both acidic gases, entrained mists, and particulates from a sparged molten salt off-gas. Hydroxide solutions are well known for their scrubbing ability and have been used in the off-gas systems of salt processing facilities. For the current project, a NaOH–KOH eutectic is being evaluated as a gettering medium. A laboratory-scale prototype glass scrubber was designed and built for the removal of aerosol simulants. The glass allows visualization of the scrubber operation, which is important for designing the stainless-steel housing for the NaOH–KOH eutectic. In parallel, Pacific Northwest National Laboratory has been developing optical sensors for detecting fission products and aerosol or mist species that could be entrained in the off-gas flow of an MSR. Efforts include Raman spectroscopy to identify and quantify iodine species such as I2 and ICl and laser-induced breakdown spectroscopy and laser-induced fluorescence for mists. Next year, these optical methods will be added to the hydroxide scrubber instrumentation to determine its effectiveness against airborne vapors and mists of concern.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Additive Manufacturing of Fe-based Alloys for Nuclear Reactor Environments

This report is a Milestone 2 deliverable in FY2025, under work package MT-25AN090211 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program. It provides an update on the work done on the laser based additive manufacturing of steels for nuclear applications, conducted collaboratively by Argonne National Laboratory and Pacific Northwestern National Laboratory. Building upon FY23 and FY24 efforts, the focus of FY25 includes continued optimization of process parameters for the alloys: A709 & G92. The work package also includes fabricating test samples to conduct a thorough microstructural analysis and perform preliminary mechanical testing. The major accomplishments of this work package are summarized below, applicable to both Laser Powder Bed Fusion (LPBF) processes conducted at Argonne National Laboratory and Laser Powder Directed Energy Deposition (LP-DED) processes conducted at Pacific Northwest National Laboratory.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Establishing New Capability of High Temperature Electrochemical Impedance Spectroscopy Techniques for Equilibrium and Kinetic Experiments

In nuclear fuel and cladding materials, changes in structure and chemistry over the lifetime of the fuel can have a significant impact on fuel and reactor performance. Currently, chemical evolution over the lifetime of the fuel can only be inferred using post-irradiation examination. As an alternative to post-irradiation measurements, electrochemical impedance spectroscopy (EIS) can provide an in-pile measurement of changes in chemistry in oxides and hydrides coupling with modeling such as finite element (FE) and other material characterization techniques such as atom probe tomography (APT), Raman spectroscopy, in-situ Transmission Electron Microscopy (TEM), and synchrotron X-ray microscopy. The objective of this work package is to develop EIS techniques for the in-pile measurement of changes in solid state chemistry of fuels and materials in coupling with model simulation and material characterization. This work package will involve the initial development of electrochemical sensing technologies for measuring spatial- and time-resolved changes in fuel and cladding chemistry. Specific attention will be paid to monitoring changes in fuel stoichiometry, monitor cladding hydride formation and deformation, and cladding corrosion. This report summarized the FY17 achievements of this work package. A laboratory was begun to set up from scratch. The laboratory place was located; necessary equipment and materials were purchased and some were delivered; laboratory instruction (LI) for conducting experiments was drafted for review; radiation level of depleted UO2 that will be investigated as the potential testing sample was valued for safety issue; a testing plan for measuring changes in stoichiometry of oxide fuels has been made and roadblocks for making measurements at high temperature have been pinpointed; in addition, collaboration with Boise State University (BSU) and Massachusetts Institute of Technology (MIT) has been established. In short, the capability of applying EIS for in-pile measurement of changes of fuels and cladding materials was initiated to be established.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Modeling Activities Related to Waste Form Degradation: Progress Report

This report represents the milestone deliverable M4SF-21SN010309021 “Modeling Activities Related to Waste Form Degradation: Progress Report” that describes the progress of R&D activities of ongoing modeling investigations specifically on nuclear waste glass degradation, Density Functional Theory (DFT) studies on clarkeite structure and stability, and electrochemical modeling of spent nuclear fuel (SNF). These activities are part of the newly-created Waste form Testing, Modeling, and Performance work package at Sandia National Laboratories (SNL). This work package is part of the “Inventory and Waste Form Characteristics and Performance” control account that includes various experimental and modeling activities on nuclear waste degradation conducted at Oak Ridge National Laboratory (ORNL), SNL, Argonne National Laboratory (ANL), and Pacific Northwest National Laboratory (PNNL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Modeling Activities Related to Waste Form Degradation: Progress Report

This report represents the milestone deliverable M4SF-22SN010309092 “Modeling Activities Related to Waste Form Degradation: Progress Report” that describes the progress of R&D activities of ongoing modeling investigations specifically on nuclear waste glass degradation, Density Functional Theory (DFT) studies on clarkeite structure and stability, and electrochemical model development of spent nuclear fuel (SNF). These activities are part of the Waste Form Testing, Modeling, and Performance work package at Sandia National Laboratories (SNL). This work package is part of the “Inventory and Waste Form Characteristics and Performance” control account that includes various experimental and modeling activities on nuclear waste degradation conducted at Oak Ridge National Laboratory (ORNL), SNL, Argonne National Laboratory (ANL), and Pacific Northwest National Laboratory (PNNL).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluation of Engineered Barrier Systems in the Disposition of Spent Nuclear Fuel

This document is a summary of the R&D activities associated with the Engineered Barrier Systems Work Package. Multiple facets of Engineered Barrier Systems (EBS) research were examined in the course of FY18 activities. This report is focused on delivering an update on the status and progress of modelling tools and experimental methods, both of which are essential to understanding and predicting long-term repository performance as part of the safety case. Specifically, the work described herein aims to improve understanding of EBS component evolution and interactions. Utlimately, the EBS Work Package is working towards producing process models for distinct processes that can either be incorporated into performance assessment (PA), or provide critical information for implementing better constraints on barrier performance The main objective of this work is that the models being developed and refined will either be implemented directly into the Generic Disposal System Analysis platform (GDSA), or can otherwise be indirectly linked to the performance assessment by providing improved bounding conditions. In either the case, the expectation is that validated modelling tools will be developed that provide critical input to the safety case. This report covers a range of topics — modelling topics include: thermal-hydrologic-mechanical-chemical coupling (THMC) in buffer materials, comparisons of modelling approaches to optimize computational efficiency, thermal analysis for EBS/repository design, benchmarking of thermal analysis tools, and a preliminary study of buffer re-saturation processes. Experimental work reported, includes: chemical evolution and sorption behavior of clay-based buffer materials and high-pressure, high temperature studies of EBS material interactions. The work leverages international collaborations to ensure that the DOE program is active and abreast of the latest advances in nuclear waste disposal. This includes participation in the HotBENT Field Test, aimed at understanding near-field effects on EBS materials at temperatures above 100 °C, and the analysis of data and characterization of samples from the FEBEX Field Test. Both the FEBEX and HotBENT Field Tests utilize/utilized the Grimsel Test Site in Switzerland, which is situated in a granite host rock. These tests offer the opportunity to understand near field evolution of bentonite buffer at in situ conditions for either a relatively long timescale (18 years for FEBEX) or temperature above 100 °C (HotBENT). Overall, this report provides in depth descriptions of tools and capabilities to investigate nearfield performance of EBS materials (esp. bentonite buffer), as well as tools for drift-scale thermal and thermal-hydrologic analysis critical to EBS and repository design. For a more detailed description of work contained herein, please see Section 10 ("Conclusions") of this document.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluation of Engineered Barrier Systems (Mid-year Status Report)

This document is a summary of the R&D activities associated with the Engineered Barrier Systems Work Package. Multiple facets of Engineered Barrier Systems (EBS) research were examined in the course of FY19 activities. This report is focused on delivering an update on the status and progress of modelling tools and experimental methods, both of which are essential to understanding and predicting long-term repository performance as part of the safety case. Specifically, the work described herein aims to improve understanding of EBS component evolution and interactions. Ultimately, the EBS Work Package is working towards producing process models for distinct processes that can either be incorporated into performance assessment (PA), or provide critical information for implementing better constraints on barrier performance. The main objective of this work is that the models being developed and refined will either be implemented directly into the Geologic Disposal Safety Assessment (GDSA) platform, or can otherwise be indirectly linked to the performance assessment by providing improved bounding conditions. In either the case, the expectation is that validated modelling tools will be developed that provide critical input to the safety case.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluation of LPBF Steels for Nuclear Applications

This report provides an update on the prioritization of existing reactor materials for advanced manufacturing. This report is a Milestone 3 deliverable in FY2023, under work package CT-23AN130401 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program here at Argonne National Laboratory (ANL). The focus of FY23 for ANL included the determination of a decision criteria matrix for the prioritization of existing materials, the literature review of a select few Fe-based alloys, and working with vendors to obtain customized powders. The work package also includes fabricating test samples in a Renishaw AM400 Laser Powder Bed Fusion (LPBF) system and optimizing the process parameters. The major outcomes of this work package are: With collaborations from PNNL, ORNL, and INL, we were able to establish a decision criteria matrix containing a total of 6 categories and 31 different criteria. These will be used to downselect alloys for further evaluation; As part of that, 6 different Fe-based alloys were selected, 3 austenitic stainless steels (A709, D9, AFA) and 3 ferritic/martensitic steels (HT9, Grade 91, Grade 92). Customized powders were obtained from vendors in small quantities to fabricate initial prints to check printability of these specific alloys; A total of 72 single track experiments were performed on two alloy systems, 1 austenitic stainless steel (A709) and 1 ferritic/martensitic steel (Grade 91) in order to optimize the process parameters for the full 3d prints. The optimization led to the selection of 20 different processing conditions, 10 for each class of alloys; D9 and AFA alloys showed extensive cracking and porosity in the samples. This was due to less-than-ideal conditions present in the chamber during the deposition. A709 printed using the same process parameters showed almost fully dense samples with no noticeable porosity or any other defects. SEM and EBSD analysis revealed single phase FCC microstructure with cellular structure within the grains; HT9, Grade 91, Grade 92 alloys also showed no noticeable signs of cracking and ImageJ analysis showed porosity <0.5% in all conditions. While Grade 91 and Grade 92 showed single phase BCC microstructures, the presence of martensite laths was noted in HT9 alloy; Future work will include further characterization of these alloys to better understand the microstructural evolution during the 3d printing process.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗