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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Single-Molecule Tracking Measurements Reveal the Detailed Mechanisms of Molecular Diffusion in Solvent Mixtures under Nanoconfinement

Understanding mass transport mechanisms in nanopores is important for developing advanced materials for chemical separations, chemical sensing, and energy storage. This paper reports a novel imaging platform that is employed for the first time to investigate the detailed diffusion dynamics of single rhodamine B (RhB) dye molecules confined within solution-filled cylindrical anodic aluminum oxide (AAO) nanopores. The imaging platform relies on illumination of horizontally-oriented AAO nanopores in a highly inclined and laminated optical (HILO) light sheet microscopy geometry. The method was used to investigate the translational and orientational dynamics of single rhodamine B (RhB) molecules within horizontally-oriented 5- and 10-nm diameter AAO nanopores filled with water–ethanol mixtures. The established platform enabled the observation of one-dimensional motion along the pore axis involving occasional short- or long-term immobilization at the single-molecule level. Analysis of cumulative squared-displacement distributions revealed fast (5 – 30 µm²/s), intermediate (1 – 5 µm²/s), and slow (< 1 µm²/s) diffusion components. From the effects of mixture composition and pore size on the contributions of these three components, we inferred that the fast, intermediate, and slow components could be assigned to desorption-mediated hopping, crawling, and wiggling motions, respectively. The platform based on the horizontally-oriented AAO nanopores also permitted single-molecule emission polarization measurements that revealed the negligible steric confinement of individual diffusing RhB molecules within the AAO nanopores. The imaging platform based on AAO membranes and HILO microscopy provided a unique means to investigate how solvation-mediated surface interactions and nanoconfinement govern molecular transport in nanoporous environments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Modulation of seismic noise near the San Jacinto fault in southern California: origin and observations of the cyclical time dependence and associated crustal properties

SUMMARY We examine the cyclic amplitude variation of seismic noise recorded by continuous three-component broad-band seismic data with durations spanning 91–713 d (2008–2011) from three different networks: Anza seismic network, IDA network and the transportable seismic array. These stations surround the San Jacinto Fault Zone (SJFZ) in southern California. We find the seismic noise amplitudes exhibit a cyclical variation between 0.3 and 7.2 Hz. The high-frequency (≥0.9 Hz) noise variations can be linked to human activity and are not a concern. Our primary interest is signals in the low frequencies (0.3–0.9 Hz), where the seismic noise is modulated by semi-diurnal tidal mode M2. These long-period (low-frequency) variations of seismic noise can be attributed to a temporal change of the ocean waves breaking at the shoreline, driven by ocean tidal loading. We focus on the M2 variation of seismic noise at f = 0.6 Hz, travelling distances of ∼92 km through the crust from offshore California to the inland Anza, California, region. Relative to the shoreline station, data from the inland stations show a phase lag of ∼ –12°, which we attribute to the cyclic change in M2 that can alter crustal seismic attenuation. We also find that for mode M2 at 0.6 Hz, the amplitude variations of the seismic quality factor (Q) depend on azimuth and varies from 0.22 per cent (southeast to northwest) to 1.28 per cent (northeast to southwest) with Q = 25 for Rayleigh waves. We propose the direction dependence of the Q variation at 0.6 Hz reflects the preferred orientation of subfaults parallel to the main faulting defined by the primarily N45°W strike of the SJFZ.

Geochemistry & Geophysics↗
DOE OSTI2024

Microgrid Integration with High Performance Computing Systems for Microreactor Operation

Multiple nuclear microreactor concepts are currently being developed across several sizes and fuel types with high performance computing (HPC) systems anticipated to be end-users of the power. Nuclear microreactors are small in size, portable, produce less than 10 MW electric, operate autonomously, and have a refueling interval of as many as 10 years. However, their load-follow is also generally limited to 10%/minute or worse whereas the power variance in HPC systems easily exceeds this constraint under normal operations. This study explores an approach that requires no load-follow from the microreactor but integrates the HPC system with a microgrid built from commercial-off-the-shelf components. Three typical HPC architectures are explored in the context of microgrid operation in this study. Components of power quality and transient response are empirically measured for five different HPC load-follow response levels using a self-contained mobile datacenter connected to the microgrid capable of integration with a nuclear microreactor.

microgrids↗
DOE OSTI2020

Reactions during conversion of simplified low-activity waste glass feeds

The mechanisms that affect the incorporation of 99Tc, a volatile radioactive component of concern, into glass melt during vitrification of low-activity waste (LAW) are being investigated to develop the method to increase the retention of 99Tc in glass waste form. Previous studies with simulated LAW glass feeds (slurry mixture of liquid waste and chemical/mineral additives) demonstrated that the early stage feed-to-glass conversion reactions below 800°C are critical for the Re (used as a nonradioactive surrogate of 99Tc) retention in glass. To examine the effect of feed composition on the feed-to-glass conversion reactions, simplified systems containing major LAW components (NaNO3 and NaOH) and representative additive components (SiO2 and H3BO3) were designed and tested. The ratio of H3BO3 to NaNO3 was varied in three-component system without NaOH and that of NaOH to NaNO3 was varied in the four-component system at a fixed H3BO3 to NaNO3 ratio. As a first step of testing with simplified feeds, this study applied thermal analyses and phase characterization of the reacting feeds, which were performed without the addition of Re, to investigate the evolution of salt phases during slurry drying process and upon heating of dried feeds.

Jin, Tongan↗
DOE OSTI2026

Upward band gap bowing and negative mixing enthalpy in multi-component cubic halide perovskite alloys

Physical properties intermediate between constituents of alloys can be achieved as downward convex positive bowing, upward concave negative bowing, or zero bowing. Such bowing effects are essential for band gap engineering in semiconductor alloys. Upward band gap bowing effects are rather rare, hindering the exploration on half of the available physical property space of alloys. Part of this being a rare event is related to the need to stabilize an alloy with low mixing enthalpy, so it does not phase separate. Here, in this paper, we find via density functional theory that one can satisfy the simultaneous conditions of negative mixing enthalpy and upward band gap bowing in four-component AB⁢X 3 halide perovskite alloys in the cubic perovskite structure. Such perovskite alloys have the B-site occupied by a mixture of group IVB and IIB elements that have the IVB-𝑠 and IIB-s states in the valence bands and conduction bands, respectively, leaving the delocalized 𝑠 states to strongly repel each other. This 𝑠−𝑠 repulsion leads to the upward band gap bowing and negative mixing enthalpies simultaneously. Remarkably, we identify a perovskite alloy that has a band gap much larger than all its components. Analogous trends of upward band gap bowing and negative mixing enthalpy also appear in the corresponding three-component and two-component AB⁢X 3 halide perovskite alloys. These observations of upward band gap bowing and negative mixing enthalpy will significantly accelerate the design of stable upward band gap bowing alloys in a broad range of material families.

14 SOLAR ENERGY↗
DOE OSTI2020

The use of seismic spatial gradients in a single layer neural network for seismic source discrimination: proof of concept

This report describes a proof-of-concept method of seismic source discrimination using seismic gradiometry and a common machine learning technique. The tests described here are purely numerical, using synthetic seismic data and well understood mathematical techniques. The primary innovation described here is the application of a richer seismic data set derived from seismic gradiometry. Seismic gradiometry is a method to estimate the time variable spatial gradient of the wavefield to compute various wavefield attributes such as slowness, dynamic strain, and rotational motions. With the addition of these wavefield attributes, we are afforded up to twenty "compo- nents" of time series data measured at a single point on, or in, the Earth. This is in direct contrast to conventional three-component seismic data collected at several locations using a seismic network. Using the gradiometrically-derived wavefield components directly in a single-layer neural network, I show that it is possible to discriminate between three common seismic source types (earthquakes, explosions, and opening fractures) for various noise conditions and gradiometry configurations.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2023

Characterizing the seismic response of a molten salt nuclear reactor

Abstract One Generation IV nuclear reactor, which uses a fluoride salt as a coolant, graphite reflector blocks as a moderator, and circulating buoyant TRISO pebbles as fuel is at an advanced stage of development. To characterize the seismic behavior of components of this reactor, validate numerical models for analysis, and develop recommendations for design, a set of earthquake‐simulator experiments on a scaled model of the reactor vessel and its internals was executed on a six‐degree‐of‐freedom earthquake simulator. The model was seismically isolated at its base using two types of spherical sliding bearings. The scaled model involved representations of the prototype reactor vessel, core barrel, reflector blocks, coolant, and spherical fuel pebbles. The material and geometric properties of different test components were selected based on a dynamic similitude scaling analysis and an approximate length scale of 0.4. Four sets of three‐component earthquake motions were used as inputs for testing. Instrumentation on the test specimen recorded the dynamic responses of the outer vessel, core barrel, and reflector‐block assembly, the hydrodynamic responses (sloshing and hydrodynamic pressure) of the liquid coolant, pebble consolidation under earthquake shaking, and the behavior of the isolation systems. This paper describes the design of the experiments and presents key results from the tests. The dynamic responses of the outer vessel, core barrel, and the reflector blocks revealed that the components responded as a unit for the intense shaking used in the experiments. The sloshing response of the fluid in a thin annulus near the perimeter of the vessel was heavily damped. The change in the packing fraction of the pebble bed under repeated, intense 3D earthquake shaking was less than 3%. Seismically isolating the vessel substantially reduced demands on its internal components.

Engineering↗
DOE OSTI2024

Patterning of multicomponent elastic shells by gaussian curvature

Recent findings suggest that shell protein distribution and the morphology of bacterial microcompartments regulate the chemical fluxes facilitating reactions which dictate their biological function. Here, we explore how the morphology and component patterning are coupled through the competition of mean and gaussian bending energies in multicomponent elastic shells that form three-component irregular polyhedra. We observe two softer components with lower bending rigidities allocated on the edges and vertices while the harder component occupies the faces. When subjected to a nonzero interfacial line tension, the two softer components further separate and pattern into subdomains that are mediated by the gaussian curvature. We find that this degree of fractionation is maximized when there is a weaker line tension and when the ratio of bending rigidities between the two softer domains ≈2. Our results reveal a patterning mechanism in multicomponent shells that can capture the observed morphologies of bacterial microcompartments, and moreover, can be realized in synthetic vesicles.

Monte Carlo methods↗
DOE OSTI2020

Internal structure of the San Jacinto fault zone at the Ramona Reservation, north of Anza, California, from dense array seismic data

SUMMARY We image the internal structure of the San Jacinto fault zone (SJFZ) near Anza, California, with seismic data recorded by two dense arrays (RA and RR) from ∼42 000 local and ∼180 teleseismic events occurring between 2012 and 2017. The RA linear array has short aperture (∼470 m long with 12 strong motion sensors) and recorded for the entire analysed time window, whereas the RR is a large three-component nodal array (97 geophones across a ∼2.4 km × 1.4 km area) that operated for about a month in September–October 2016. The SJFZ at the site contains three near-parallel surface traces F1, F2 and F3 from SW to NE that have accommodated several Mw > 6 earthquakes in the past 15 000 yr. Waveform changes in the fault normal direction indicate structural discontinuities that are consistent with the three fault surface traces. Relative slowness from local events and delay time analysis of teleseismic arrivals in the fault normal direction suggest a slower SW side than the NE with a core damage zone between F1 and F2. This core damage zone causes ∼0.05 s delay at stations RR26–31 in the teleseismic P arrivals compared with the SW-most station, and generates both P- and S-type fault zone trapped waves. Inversion of S trapped waves indicates the core damaged structure is ∼100 m wide, ∼4 km deep with a Q value of ∼20 and 40 per cent S-wave velocity reduction compared with bounding rocks. Fault zone head waves observed at stations SW of F3 indicate a local bimaterial interface that separates the locally faster NE block from the broad damage zone in the SW at shallow depth and merges with a deep interface that separates the regionally faster NE block from rocks to the SW with slower velocities at greater depth. The multiscale structural components observed at the site are related to the geological and earthquake rupture history at the site, and provide important information on the preferred NW propagation of earthquake ruptures on the San Jacinto fault.

Geochemistry & Geophysics↗
DOE OSTI2020

Addressing Human and Organizational Factors in Nuclear Industry Modernization: An Operationally Focused Approach to Process and Methodology

Utility owners and operators of commercial nuclear power plants in the United States (U.S.) are and will be modernizing their nuclear power plants by performing a digital transformation involving design of an integrated set of systems that together enable a technology centric operating plant. The Plant Modernization Pathway of the U.S. Department of Energy Light Water Reactor Sustainability Program has a strategic action plan that lays the groundwork for a digital transformation of the nuclear industry. The model for this transformation is an advanced concept of operations, with an end point vision, “To achieve the maximum aggregate benefit enabled by this digital transformation.” To achieve this, the digital infrastructure for a nuclear plant must be designed as an integrated set of systems that together enable a technology centric operating model. The digital transformation process obviously needs to involve technology considerations and systems engineering, but it also needs to include human and organizational expertise. Thus, human and organizational factors, including sociotechnical systems methods and techniques (e.g., Cognitive Systems Engineering, Systems Theoretic Accident Modeling and Processes, human systems integration, and Macroergonomics) need to be considered for digital transformation projects in order to effectively integrate human and organizational expertise efforts into the new work system that results from nuclear power plant digital modernization. That is, the work system is the basic unit of sociotechnical systems analysis and contains three components: personnel, technical, and organization and management. These components should be jointly optimized with respect to the interdependence of systems performance criteria of effectiveness, efficiency and safety. Joint optimization can be achieved through the application of three human and organization functions: knowledge representation, knowledge elicitation, and cross-functional integration. This report provides a strategic framework for effective integration of human and organizational expertise within nuclear power plant digital modernization efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Mid–height seismic isolation of equipment in nuclear power plants

An innovative seismic isolation solution for designers of safety-class equipment in advanced nuclear power plants is introduced. The test specimen was a tall, slender, carbon steel vessel that could represent a reactor vessel, steam generator, or a heat exchanger in a nuclear power plant: 240 inches tall, outer diameter of 60 inches, and wall thickness of 1 inch. The vessel was supported by three radial mounts at its mid-height, near its center of gravity, on a steel frame. The vessel was subjected to three-component ground motions using a 6DOF earthquake simulator. The specimen was filled with water for testing to indirectly account for the fluid and internal equipment present inside a prototype vessel. Three configurations were tested: non-isolated, isolated using single Friction Pendulum (SFP) bearings, and isolated using triple Friction Pendulum (TFP) bearings. The test results demonstrate that mid-height seismic isolation is practical and enables a significant reduction in horizontal spectral accelerations. Furthermore, these outcomes are not specific to the spherical sliding bearings used in the experiments but are broadly applicable to mid-height, seismically isolated equipment.

42 ENGINEERING↗
DOE OSTI2020

Time-Lapse Vertical Seismic Profiling (VSP) for CO 2 Storage in a Depleted Oil Field in Northern Michigan

The Midwest Regional Carbon Sequestration Partnership (MRCSP) was founded in 2003 as part of the U.S. Department of Energy’s (DOE’s) Regional Carbon Sequestration Partnership initiative. Since its founding, MRCSP has made significant strides toward making CCUS a viable option for states in the region. The public/private consortium, funded through the DOE Regional Carbon Sequestration Initiative, brings together nearly 40 industry partners and 10 states. Battelle, as the project lead, oversees research, development and operations and coordinates activities among the partners. The incremental, phased approach has built a valuable knowledge base for the industry and paved the way for commercial-scale adoption of CCUS technologies. From 2008 to 2020, MRCSP Phase III focused on the development of large-scale injection projects. This report is part of a series of reports prepared under the Midwestern Regional Carbon Sequestration Partnership (MRCSP) Phase III (Development Phase). These reports summarize and detail the findings of the work conducted under the Phase III project. This report describes the Dover 33 VSP study to test the effectiveness of time-lapse Vertical Seismic Profile (VSP) for detecting and delineating a plume of more than 271,000 tonnes of CO2 injected into the Brown Niagaran and A-1 Carbonate formations within the Dover 33 reef between March 2013 and September 2016. Five 2D walkaway VSP (WVSP) source lines were acquired by SIGMA3 in September 2016 to investigate the possible time-lapse response in both P-wave and PS-wave seismic data. The data was compared to the same survey geometry acquired in March 2013 by SR2020. The seismic energy was recorded into an 80-level, three-component geophone array deployed into the Dover 1-33 well and placed just above the reef. P-wave and PS-wave reflection images were produced for each of the three source lines from both the 2013 baseline and 2016 monitor surveys. The images were then compared to look for changes in the reflectivity at and around the injection location that might indicate how the CO 2 has moved over this time period. This technique revealed several localized areas with sizable impedance differences inside the reef where CO 2 would be expected; however, a large number of similar impedance “hotspots” were also detected outside the reef in areas where injected CO 2 would not be expected. Therefore, a second analysis that involved calculating P-wave and S-wave travel time differences between the 2013 and 2016 VSPs was conducted to look for a change that could be caused by the CO 2 plume.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Real space iterative reconstruction for vector tomography (RESIRE-V)

Tomography has had an important impact on the physical, biological, and medical sciences. To date, most tomographic applications have been focused on 3D scalar reconstructions. However, in some crucial applications, vector tomography is required to reconstruct 3D vector fields such as the electric and magnetic fields. Over the years, several vector tomography methods have been developed. Here, we present the mathematical foundation and algorithmic implementation of REal Space Iterative REconstruction for Vector tomography, termed RESIRE-V. RESIRE-V uses multiple tilt series of projections and iterates between the projections and a 3D reconstruction. Each iteration consists of a forward step using the Radon transform and a backward step using its transpose, then updates the object via gradient descent. Incorporating with a 3D support constraint, the algorithm iteratively minimizes an error metric, defined as the difference between the measured and calculated projections. The algorithm can also be used to refine the tilt angles and further improve the 3D reconstruction. To validate RESIRE-V, we first apply it to a simulated data set of the 3D magnetization vector field, consisting of two orthogonal tilt series, each with a missing wedge. Our quantitative analysis shows that the three components of the reconstructed magnetization vector field agree well with the ground-truth counterparts. We then use RESIRE-V to reconstruct the 3D magnetization vector field of a ferromagnetic meta-lattice consisting of three tilt series. Our 3D vector reconstruction reveals the existence of topological magnetic defects with positive and negative charges. We expect that RESIRE-V can be incorporated into different imaging modalities as a general vector tomography method. To make the algorithm accessible to a broad user community, we have made our RESIRE-V MATLAB source codes and the data freely available at https://github.com/minhpham0309/RESIRE-V.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Using Bayesian Methodology to Estimate Liquefied Natural Gas Leak Frequencies

This analysis provides estimates on the leak frequencies of nine components found in liquefied natural gas (LNG) facilities. Data was taken from a variety of sources, with 25 different data sets included in the analysis. A hierarchical Bayesian model was used that assumes that the log leak frequency follows a normal distribution and the logarithm of the mean of this normal distribution is a linear function of the logarithm of the fractional leak area. This type of model uses uninformed prior distributions that are updated with applicable data. Separate models are fit for each component listed. Five order-of-magnitude fractional leak areas are considered, based on the flow area of the component. Three types of supporting analyses were performed: sensitivity of the model to the data set used, sensitivity of the leak frequency estimates to differences in the model structure or prior distributions, and sufficiency of sample sized used for convergence. Recommended leak frequency distributions for all component types and leak sizes are given. These leak frequency predictions can be used for quantitative risk assessments in the future.

03 NATURAL GAS↗
DOE OSTI2021

A Frequency-Domain-Based Algorithm for Detecting Microseismicity Using Dense Surface Seismic Arrays

We propose a new frequency-domain-based algorithm for detecting small-magnitude seismic events using dense surface seismic arrays. Our proposed method takes advantage of the high energy carried by S waves, and approximate known source locations, which are used to rotate the horizontal components to obtain the maximum amplitude. By surrounding the known source area with surface geophones, we achieve a favorable geometry for locating the detected seismic events with the backprojection method. To test our new detection method, we used a dense circular array, consisting of 151 5 Hz three-component geophones, over a 5 km aperture that was in operation at the Utah Frontier Observatory for Research in Geothermal Energy (FORGE) in southcentral Utah. We apply the new detection method during a small-scale test injection phase at FORGE, and during an aftershock sequence of an Mw 4.1 earthquake located ~30 km north of the geophone array, within the Black Rock volcanic field. We are able to detect and locate microseismic events (Mw<0) during injections, despite the high level of anthropogenic activity, and several aftershocks that are missing from the regional catalog. By comparing our method with known algorithms that operate both in the time and frequency domain, we show that our proposed method performs better in the case of the FORGE injection monitoring, and equally well for the off-array aftershock sequence. Our new method has the potential to improve microseismic event detections even in extremely noisy environments, and the proposed location scheme serves as a direct discriminant between true and false detections.

Geochemistry & Geophysics↗
DOE OSTI2021

ARMADA. I. Triple Companions Detected in B-type Binaries α Del and ν Gem

Ground-based optical long-baseline interferometry has the power to measure the orbits of close binary systems at ∼10 μas precision. This precision makes it possible to detect “wobbles” in the binary motion due to the gravitational pull from additional short-period companions. We started the ARrangement for Micro-Arcsecond Differential Astrometry (ARMADA) survey with the Michigan Infra-Red Combiner (MIRC)/MIRC-X instrument at the Center for High Angular Resoloution Astronomy (CHARA) array for the purpose of detecting giant planets and stellar companions orbiting individual stars in binary systems. We describe our observations for the survey, and introduce the wavelength calibration scheme that delivers precision at the tens of microarcseconds level for <02 binaries. We test our instrument performance on a known triple system, κ Peg, and show that our survey is delivering a factor of 10 better precision than previous similar surveys. We present astrometric detections of tertiary components to two B-type binaries: a 30 day companion to α Del, and a 50 day companion to ν Gem. We also collected radial velocity data for α Del with the Tennessee State University Automated Spectroscopic Telescope at Fairborn Observatory. We are able to measure the orbits and masses of all three components in these systems. We find that the previously published radial velocity orbit for the inner pair of ν Gem is not consistent with our visual orbit. The precision achieved for these orbits suggests that our ARMADA survey will be successful at discovering new compact triple systems to A/B-type binary systems, leading to better statistics of hierarchical system architectures and formation history.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Low-Cost Preform and Molding Processes

The entry cost for prototyping a composite component for manufacture using automated, high rate processes is prohibitively expensive in many cases, especially for small business, where tooling costs may be several $100k. Discussions with industry also indicate that many small companies, tier 1 and 2 suppliers, have an interest to mold composite parts but do not want to deal with the capital cost, material handling issues, and labor associated with dry fiber preforming operations. While the molders may locate near the end user for logistics reasons, it may be more cost effective for the performer to remain regional and invest in capital equipment to support preform automation, thus keeping costs to a minimum. This project was designed to explore and demonstrate several options to meet these industry needs. Dry fiber preforming approaches were evaluated which allow for low pressure resin infusion, single sided tooling options such a vacuum assisted resin transfer molding (VARTM) or low pressure resin transfer molding (RTM-light). Unlike sheet molding compound, SMC compression molding where typical molding pressures of 1000 psi are required to push material into the desired location; positioning of a dry fiber preform into the desired location on the tool allows for low molding pressures of 10-50 psi. Lower molding pressures allow for use of low cost, additive fabrication of polymeric tooling. Polymeric tooling is suitable for rapid part prototyping and limited production. Dry fiber preforming approaches evaluated included use of commercial chopped strand mat, robotic chopper gun deposition, and continuous fiber preform augmentation using tailored fiber placement (TFP). Use of chopped strand mat does not require a robotic deposition method, however a cutting table is generally required and there is typically 20-30% scrap generation. While various fiber areal weights are available, the preform is not readily optimized for minimal fiber use or weight savings. In contrast, a robotic chopper gun approach allows for localized deposition where fiber is required to meet structural requirements. The robotic method is highly automated and minimizes fiber scrap, however the capital cost of the equipment and engineering labor for programming can result in higher preform cost compared to chopped strand mat in certain cases depending on preform complexity. Dry fiber preforming using the robotic chopper gun method allows for creation of three dimensional forms. This approach may be ideal for molding in-house, or if the preforms stack together densely to allow for efficient shipping. Applications evaluated for this program considered trade-off between fabrication of a fully 3D preform versus production of a flat preform which is designed to readily drape into the final desired shape. Such a preform design greatly simplifies robotic programming and requires no specialized tooling. The flat preforms are easily stacked and shipped to the final molding location. Flat preforms are much easier to augment with TFP continuous fiber to provide local reinforcement. The demonstration and evaluation of these preforming and tooling methods were completed on three component applications. The first application was a battery box cover for an electric vehicle which was highly three dimensional. The second demonstrator article was comprised of complex contours and was used to demonstrate the use of TFP and RTM-light molding process. The third demonstration article was the roof of an operator’s cab for large construction equipment. The roof is relatively flat however it is comprised of complex changes in thickness which clearly demonstrate the advantage of robotic chopper gun approach as compared to using numerous preform layers of chopped strand mat. The cost trades for the various preforming methods are summarized to help guide the reader as to preforming method considerations. Finally, these demonstrations all used glass fiber roving. A fourth, exploratory task was added to evaluate the ability to make preforms using Zoltek’s carbon fiber split tow roving. We were able to adapt the chopper gun to make flat preforms for laminate testing, but further development effort would be required to make suitable preforms.

36 MATERIALS SCIENCE↗
DOE OSTI2024

ASME Design Code Rule Changes for Nuclear Graphite

The American Society of Mechanical Engineers Boiler Pressure and Vessel Code (ASME BPVC) Section III, Division 5, Article HHA-3000 outlines graphite core component and graphite core assembly design guidelines. Graphite core components are defined as ?components manufactured from graphite that are installed to form a graphite core assembly within the reactor pressure vessel of a high temperature, graphite moderated fission reactor.? (p. 413) Graphites? inherent defect distributions do not allow for deterministic material reliability. Rather, graphite has variable strength distributions which change by grade. Article HHA-3000 outlines two semi-probabilistic methods, the full and simplified assessments, which set design load limit targets for each of three component structural reliability classes. The Design Task Group was officially recognized as a specialized task group within ASME November of 2023, though we?ve been collaborating since 2022. The purpose of the Design Task Group is to correct, clarify, and make HHA-3000 function as intended. The Design Task Group will sunset once we?ve achieved our objectives. The Design Task Group was specifically told to not write new Code. While there may be more precise and more accurate methods to determine reliability targets, the current methods are conservative, relatively simple to implement, and have thus far been considered satisfactory for setting design reliability targets. Much of the ground-work to write proposal files and background documents for records to make the changes needed to achieve our objective have been completed. The Design Task Group has documented much of their work through papers, presentations, and memorandums. Three memorandums in which INL team members had substantial contributions are found in the Appendices: FEA Modeling for the Baseline Program, Evaluating the Effects on Margin of Updating the Threshold and Shape Parameters in the Full Assessment, and Interpretations of the Full and Simplified Assessments in ASME BPVC. Most of the on-going work to achieve the Design Task Group?s objective will be addressing comments on existing records and moving records through the balloting process. The Design Task Group met bi-weekly mostly through the end of FY2023. Since February 2024, the Design Task Group has mostly been completed with solving and documenting the technical issues associated with the assessments. Unless new tasks are identified, the remaining work of the Design Task Group will be political and editorial.

97 MATHEMATICS AND COMPUTING↗