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DOE OSTI2026

Joint Sample Analyses of Nuclear Forensic Materials Provided by the Republic of Kazakhstan: U. S. Laboratory Results

This document serves as an interim report to summarize sample analyses performed by Lawrence Livermore National Laboratory (LLNL) and Los Alamos National Laboratory (LANL) on a series of five nuclear forensics samples provided by the Institute of Nuclear Physics (INP) in the Republic of Kazakhstan. The sample set contains four uranium oxide powders and one low-enriched uranium fuel pellet. The samples were provided as part of a broader collaboration that involved a set of joint sample analyses conducted by INP and the US National Laboratories. The joint analyses are being conducted using well-developed analytical plans. These activities are designed to support the advancement of nuclear forensic science and capacity building in all three institutes in both countries. This report builds upon an earlier preliminary summary of the joint interactions and will be augmented by a final report. The final report will summarize the results and value of all sample analyses performed at the three institutes (INP, LLNL, and LANL). The final report will also provide an intercomparison of the results, analytical methods and best practices employed, as well as outline future collaborative nuclear forensics activities that are being developed in the Kazakhstan region.

and nuclear chemistry↗

DOE OSTI2026

The BUTTON-30 detector at Boulby

The BUTTON-30 detector is a 30-tonne technology demonstrator designed to evaluate the potential of hybrid event detection, simultaneously exploiting both Cherenkov and scintillation light to detect particles produced in neutrino interactions. The detector is installed at a depth of 1.1 km in the Boulby Underground Laboratory allowing to test the performance of this new technology underground in a low background environment. This paper describes the design and construction of the experiment.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Towards Predictive Plasma Science and Engineering through Revolutionary Multi-Scale Algorithms and Models (Final Report)

This report describes the high-level accomplishments from the Plasma Science and Engineering Grand Challenge LDRD at Sandia National Laboratories. The Laboratory has a need to demonstrate predictive capabilities to model plasma phenomena in order to rapidly accelerate engineering development in several mission areas. The purpose of this Grand Challenge LDRD was to advance the fundamental models, methods, and algorithms along with supporting electrode science foundation to enable a revolutionary shift towards predictive plasma engineering design principles. This project integrated the SNL knowledge base in computer science, plasma physics, materials science, applied mathematics, and relevant application engineering to establish new cross-laboratory collaborations on these topics. As an initial exemplar, this project focused efforts on improving multi-scale modeling capabilities that are utilized to predict the electrical power delivery on large-scale pulsed power accelerators. Specifically, this LDRD was structured into three primary research thrusts that, when integrated, enable complex simulations of these devices: (1) the exploration of multi-scale models describing the desorption of contaminants from pulsed power electrodes, (2) the development of improved algorithms and code technologies to treat the multi-physics phenomena required to predict device performance, and (3) the creation of a rigorous verification and validation infrastructure to evaluate the codes and models across a range of challenge problems. These components were integrated into initial demonstrations of the largest simulations of multi-level vacuum power flow completed to-date, executed on the leading HPC computing machines available in the NNSA complex today. These preliminary studies indicate relevant pulsed power engineering design simulations can now be completed in (of order) several days, a significant improvement over pre-LDRD levels of performance.

42 ENGINEERING↗

DOE OSTI2022

The field of human building interaction for convergent research and innovation for intelligent built environments

Human-Building Interaction (HBI) is a convergent field that represents the growing complexities of the dynamic interplay between human experience and intelligence within built environments. This paper provides core definitions, research dimensions, and an overall vision for the future of HBI as developed through consensus among 25 interdisciplinary experts in a series of facilitated workshops. Three primary areas contribute to and require attention in HBI research: humans (human experiences, performance, and well-being), buildings (building design and operations), and technologies (sensing, inference, and awareness). Three critical interdisciplinary research domains intersect these areas: control systems and decision making, trust and collaboration, and modeling and simulation. Finally, at the core, it is vital for HBI research to center on and support equity, privacy, and sustainability. Compelling research questions are posed for each primary area, research domain, and core principle. State-of-the-art methods used in HBI studies are discussed, and examples of original research are offered to illustrate opportunities for the advancement of HBI research.

42 ENGINEERING↗

DOE OSTI2020

Development of a Versatile, Full-featured Search Functionality for Indico

Indico, CERN’s popular open-source tool for event management, is in widespread use among facilities that make up the HEP community. It is extensible through a robust plugin architecture that provides features such as search and video conferencing integration. In 2018, Indico version 2 was released with many notable improvements, but without a full-featured search functionality that could be implemented easily outside of CERN. At both Fermi and Brookhaven National Laboratories, the user community viewed the lack of this popular feature as a significant impediment to deployment of the new software. In the meantime, CERN embarked upon a major redesign of their core search service, one that would also necessitate a rewrite of the Indico search interface. Seeing this pressing need, the two US labs decided to collaborate, with assistance from the CERN development team, on a project to develop the requisite search functionality for the larger user community. The resulting design exploits the simplified schema defined in the new CERN Search micro-service, based on Invenio and Elasticsearch, while still providing a flexible path to implementation for alternative backend search services. It is intended to provide a software package that can be installed easily and used out of the box, by anyone at any site. This paper will discuss the design choices and architectural challenges, and provide an overview of the deployment and use of these new plugins.

Constanta, Penelope↗

DOE OSTI2022

2021 Annual Site Environmental Report

This report provides the U.S. Department of Energy (DOE) and the public with information on the level of radioactive and non-radioactive pollutants (if any) that are added to the environment as a result of Princeton Plasma Physics Laboratory’s (PPPL) operations. The results of PPPL’s 2021 environmental surveillance and monitoring program are presented and discussed. The report also summarizes environmental initiatives, assessments, and community involvement programs that were undertaken in 2021. PPPL’s on-site operations were significantly curtailed in 2021 due to the global coronavirus pandemic. PPPL has engaged in fusion energy research since 1951. The Laboratory’s mission is to develop the scientific knowledge and advanced engineering to enable fusion to power the U.S. and the world, and to developing the understanding of plasmas from the nano- to the astrophysical scale. PPPL’s primary experiment, the National Spherical Torus Experiment-Upgrade (NSTX-U) is a collaboration among national laboratories, universities, and national and international research institutions and is a major element in the US Fusion Energy Sciences Program. Its design tests the physics principles of spherical torus (ST) plasmas, playing an important role in the development of smaller, more economical fusion reactors. Due to previous operational issues, NSTX-U did not operate in 2021. PPPL is engaged in a project to replace key NSTX-U components and systems to enable operation of this international fusion user facility. In 2021, PPPL’s radiological environmental monitoring program measured tritium in the air at the NSTX-U Stack and at onsite sampling stations. Using highly sensitive air monitors, PPPL is capable of detecting small changes in the ambient levels of tritium. The operation of an in-stack monitor located on D-site is used to demonstrate compliance with the National Emission Standard for Hazardous Air Pollutants (NESHAPs) regulations. Also included in PPPL’s radiological environmental monitoring program, are water monitoring – ground, surface, and waste waters. PPPL’s radiological monitoring program characterized the background levels of tritium in the environment and those data are presented in this report. Ground water monitoring continued under New Jersey Department of Environmental Protection’s (NJDEP) Site Remediation Program regulations. PPPL monitored for non-radiological contaminants, mainly volatile organic compounds (components of common degreasing solvents). In 2021, PPPL complied with permit limits for surface and sanitary discharges. PPPL was honored with awards for EPEAT-certified electronics purchasing and use of peracetic acid as an alternative water treatment chemical in its non-potable process water systems an NJDEP recycling award.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

FORCE-DISPATCHES Integration - Initial Demonstration

Integrated energy systems (IES) combine, in mutually beneficial ways, power from variable renewable energy sources and nuclear power plants (NPP) to improve economic viability under uncertain market and weather conditions. The open-source Framework for Optimization of Resources and Economics (FORCE) tool suite, developed at Idaho National Laboratory (INL), has enabled comprehensive modeling and simulation of IES. The capabilities within FORCE include grid portfolio optimization through the Holistic Energy Resource Optimization Network (HERON) and the transient process model analysis library HYBRID, among others. Continuous efforts and investments from the IES programs have been made to expand and improve the versatility of the FORCE toolset in fiscal year 2022. Code-coupling and cross-tool communication have been important methods for improving this versatility. This report focuses on an additional workflow in the HERON tool for capacity and dispatch stochastic optimization through integration with the external tool Design Integration and Synthesis Platform to Advance Tightly Coupled Hybrid Energy Systems (DISPATCHES). DISPATCHES was primarily developed by the National Energy Technology Laboratory, in collaboration with other national laboratories, which included INL, universities, and industry partners. It is coupled to a library of algebraic models for specific plant components, and to a framework for stochastic optimization different from that provided in the current Risk Analysis Virtual Environment (RAVEN)-running-RAVEN algorithm in HERON. HERON currently conducts stochastic optimization via an outer-inner loop: it optimizes over variable capacity on the outer loop, and at each step within the capacity parameter space, conducts an inner optimization over scenarios (of market signals, demand, and/or weather patterns) and hourly dispatch throughout a user-specified number of years. On the other hand, DISPATCHES conducts stochastic optimization via an “all-at-once” strategy in which capacity variables are optimized at the same level as dispatch variables, as all scenarios are considered at once. The latter method works especially well for projects of limited size and project length, as the necessary computational power and memory increases with the number of variables and scenarios. The new capability to use the DISPATCHES workflow in HERON enhances standalone simulations by leveraging FORCE tools—namely, the economic metrics from the Tool for Economic Analysis (TEAL) and reduced-order model (ROM) sampling from RAVEN. The initial demonstration of the DISPATCHES workflow simulates an existing nuclear-case flowsheet within the DISPATCHES repository—this models a NPP with a secondary revenue stream for hydrogen production. Electrical output from the plant is converted to hydrogen via a proton-exchange membrane (PEM) electrolyzer, hydrogen tanks are used for storage, and an additional turbine is added for hydrogen combustion. Continued work regarding this FORCE-DISPATCHES integration will include automatic generation of DISPATCHES models from HERON inputs, offering analysts the option of using either the RAVEN-runsRAVEN or DISPATCHES workflow to solve technoeconomic optimization problems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

2022 Annual Site Environment Report, Princeton Plasma Physics Laboratory

This report provides the U.S. Department of Energy (DOE) and the public with information on the level of radioactive and non-radioactive pollutants (if any) that are added to the environment as a result of Princeton Plasma Physics Laboratory’s (PPPL) operations. This report fulfills the annual public reporting requirements of DOE Order 231.1B. The results of PPPL’s 2022 environmental surveillance and monitoring program are presented and discussed. The report also summarizes environmental initiatives, assessments, and community involvement programs that were undertaken in 2022. PPPL’s on-site operations started to be restored in 2022, following curtailments in 2020 and 2021 for the global coronavirus (COVID-19) pandemic. PPPL has engaged in fusion energy research since 1951 and at its current locations since 1958. The Laboratory’s mission is to develop the scientific knowledge and advanced engineering to enable fusion to power the U.S. and the world, and to develop the understanding of plasmas from the nano- to the astrophysical scale. PPPL’s primary experiment, the National Spherical Torus Experiment-Upgrade (NSTX-U) is a collaboration among national laboratories, universities, and national and international research institutions and is a major element in the US Fusion Energy Sciences Program. Its design tests the physics principles of spherical torus (ST) plasmas, playing an important role in the development of smaller, more economical fusion reactors. Due to previous operational issues, NSTX-U did not operate in 2022. PPPL is engaged in a project to replace key NSTX-U components and systems to enable the operation of this international magnetic fusion user facility. In 2022, PPPL’s radiological environmental monitoring program measured tritium in the air at onsite sampling stations. Using highly sensitive air monitors, PPPL is capable of detecting small changes in the ambient levels of tritium. The operation of monitors located on D-site is used to demonstrate compliance with the National Emission Standard for Hazardous Air Pollutants (NESHAPs) regulations. Also included in PPPL’s radiological environmental monitoring program, are water monitoring – ground, surface, and waste waters. PPPL’s radiological monitoring program characterized the background levels of tritium in the environment and those data are presented in this report. Ground water monitoring continued under New Jersey Department of Environmental Protection’s (NJDEP) Site Remediation Program regulations. PPPL monitored for non-radiological contaminants, mainly volatile organic compounds (components of common degreasing solvents). In 2022, PPPL complied with permit limits for surface water and sanitary wastewater discharges. PPPL was honored with an award for EPEAT-certified electronics purchasing from the Global Electronics Council.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Towards Automated Design of Polymer Precursors for Rational Design of Porous Carbon-Materials [Slides]

Overview: Developed capability enables easy building of realistic polymer structures and a straightforward evaluation of polymer properties using different computational approaches. Topics of relevance to LANL mission: fundamental understanding of gas, vapor, ion, and liquid transport in polymer materials with applications in carbon capture, clean energy, hydrogen production (e.g., fuel cells and electrolyzes); Toxic element removal; Design of polymer binders in explosives. Workforce Development: Project provided a valuable opportunity to for a PI to manage a LANL research effort, expand collaborations (e.g., MPA division), and establish research topic that aligns with the LANL mission; The capability built was highlighted in the proposal "Versatile Polyolefins-Based Ionomer Platform for Next Generation Polymer Electrolyte Membrane and Hydrogen Production" lead by InnoSense LLC in collaboration with MPA-1 and T-1 as a response to DOE's call DE-FOA-0003003: Science Foundations for Energy Earthshots.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Manatee County Clear Sky Assessment Process: Prioritizing Solar + Storage for Resilient Facilities & Communities

The Clear Sky Tampa Bay project was a 15-month collaborative research effort to support solar + storage deployment for community resilience in Florida. The Clear Sky Decision Support Toolkit is a collection of resources designed to support users in conducting solar + storage prioritization and feasibility screening assessments at critical facilities. The Tampa Bay Regional Planning Council worked with four local governments in the region to test and apply the Toolkit. This case study series describes how each partner government used the Toolkit and highlights key insights and lessons learned that other users could follow to replicate the process. Manatee County applied the Clear Sky Decision Support Toolkit to two of the county's critical facilities: Nolan Middle School, which serves as a special needs emergency shelter, and its Public Safety Complex (PSC), which houses critical services including emergency management, communications, and medical services, traffic control, and more. The PSC serves as the Emergency Operations Center during activation events. The Clear Sky assessment process improved interagency communication and coordination and informed siting decisions for a potential solar + storage system for the Manatee County PSC.

14 SOLAR ENERGY↗

DOE OSTI2024

Pinellas County Clear Sky Assessment Process: Prioritizing Solar + Storage for Resilient Facilities & Communities

The Clear Sky Tampa Bay project was a 15-month collaborative research effort to support solar + storage deployment for community resilience in Florida. The Clear Sky Decision Support Toolkit is a collection of resources designed to support users in conducting solar + storage prioritization and feasibility screening assessments at critical facilities. The Tampa Bay Regional Planning Council worked with four local governments in the region to test and apply the Toolkit. This case study series describes how each partner government used the Toolkit and highlights key insights and lessons learned that other users could follow to replicate the process. Pinellas County applied the Clear Sky Decision Support Toolkit to improve interagency coordination and gather data to analyze solar + storage projects for its critical facilities. This case study examines energy resilience strategies for the Pinellas County Solid Waste-to-Energy Plant. The Toolkit's modular assessment process developed institutional capacity and knowledge within the county and will assist in the research and application of future solar energy projects.

14 SOLAR ENERGY↗

DOE OSTI2021

Hillsborough County Clear Sky Assessment Process: Prioritizing Solar + Storage for Resilient Facilities & Communities

The Clear Sky Tampa Bay project was a 15-month collaborative research effort to support solar + storage deployment for community resilience in Florida. The Clear Sky Decision Support Toolkit is a collection of resources designed to support users in conducting solar + storage prioritization and feasibility screening assessments at critical facilities. The Tampa Bay Regional Planning Council worked with four local governments in the region to test and apply the Toolkit. This case study series describes how each partner government used the Toolkit and highlights key insights and lessons learned that other users could follow to replicate the process. Hillsborough County used the Clear Sky Decision Support Toolkit to analyze solar + storage as an additional resiliency feature at its Brandon Support Operation Complex (BSOC). During normal operations, the BSOC houses water utility administration services and workspaces for water and wastewater engineers, facilities maintenance, and environmental management staff. During emergency management activation, the BSOC serves as an emergency hub for Emergency Support Function 3 (ESF-3), which includes public utilities, public works, and engineering staff support members. The BSOC is designated as a critical facility by the County.

14 SOLAR ENERGY↗

DOE OSTI2025

Princeton Plasma Physics Laboratory Annual Site Environmental Report for Calendar Year 2024

This report provides the US Department of Energy (DOE) and the public with information on the level of radioactive and non-radioactive pollutants (if any) that are added to the environment as a result of Princeton Plasma Physics Laboratory’s (PPPL) operations. This report fulfills the annual public reporting requirements of DOE Order 231.1B. The results of PPPL’s 2024 environmental surveillance and monitoring program are presented and discussed. The report also summarizes environmental initiatives, assessments, and community involvement programs that were undertaken in 2024. PPPL has engaged in fusion energy research since 1951 and at its current locations since 1958. The Laboratory’s mission is to develop the scientific knowledge and advanced engineering to enable fusion to power the US and the world, and to develop the understanding of plasmas from the nano- to the astrophysical scale. PPPL’s primary experiment, the National Spherical Torus Experiment-Upgrade (NSTX-U) is a collaboration among national laboratories, universities, and national and international research institutions and is a major element in the US Fusion Energy Sciences Program. Its design tests the physics principles of spherical torus (ST) plasmas, playing an important role in the development of smaller, more economical fusion reactors. Due to previous operational issues, NSTX-U did not operate in 2024. PPPL is engaged in a project to replace key NSTX-U components and systems to enable the operation of this international magnetic fusion user facility. In 2024, PPPL’s radiological environmental monitoring program measured tritium in the air at onsite sampling stations. Using highly sensitive air monitors, PPPL is capable of detecting small changes in the ambient levels of tritium. The operation of monitors located on D-site is used to demonstrate compliance with the National Emission Standard for Hazardous Air Pollutants (NESHAPs) regulations. Also included in PPPL’s radiological environmental monitoring program, are water monitoring – ground, surface, and waste waters. PPPL’s radiological monitoring program characterized the background levels of tritium in the environment and those data are presented in this report. Ground water monitoring continued under New Jersey Department of Environmental Protection’s (NJDEP) Site Remediation Program regulations. PPPL monitored for nonradiological contaminants, mainly volatile organic compounds (components of common degreasing solvents). In 2024, PPPL complied with permit limits for surface water and sanitary wastewater discharges. PPPL was honored with an award for EPEAT-certified electronics purchasing from the Global Electronics Council on July 25, 2024.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Irradiation of Advanced Cladding Specimens in the High Flux Isotope Reactor: Capsule Designs and Test Matrix

The Advanced Fuels Campaign (AFC) has initiated the Advanced Reactor Cladding (ARC) irradiation campaign to generate irradiation performance data for candidate fuel cladding concepts. The campaign includes a diverse set of ferritic/martensitic steels, oxide dispersion strengthened (ODS) alloys, FeCrAlbased alloys, coated materials, and welded cladding specimens produced through multiple US Department of Energy (DOE) programs and international collaborations. Three complementary experimental thrusts comprise the campaign: tensile testing (ARC Tensile) to rapidly screen candidate alloys, fracture toughness testing (ARC Fracture) to evaluate irradiation effects on crack resistance, and tubular weld testing (ARC Weld) to quantify irradiation-induced changes in the mechanical performance of end cap welds. This report documents the irradiation campaign design, including the selected materials, specimen types, irradiation matrix, and capsule designs for irradiation within the High Flux Isotope Reactor (HFIR). A total of 14 irradiation capsules were developed to achieve target irradiation temperatures between 300°C and 600°C and doses up to 30 dpa. Thermal analyses were performed using finite element methods to establish capsule geometries capable of achieving the desired specimen temperatures while accommodating differences in specimen geometry and material properties. The resulting capsule designs provide the basis for irradiation of the AFC-ARC experimental matrix and subsequent post-irradiation examination to assess the effects of neutron irradiation on advanced cladding materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Building a Collaborative Relationship between Contractor and Oversight at SRPPF

The success of Department of Energy (DOE) projects is dependent on a functional, healthy, and collaborative relationship between the contractor and the federal oversight. A healthy relationship marked by a collaborative mindset between these two groups, can facilitate better operational safety, operational efficiency, and regulatory compliance. This paper will explore aspects of such a relationship, the roles and responsibilities of the contractor and federal oversight, the present and historical relationships in the DOE complex, and best practices considered by the contractor and federal oversight used at the Savannah River Plutonium Processing Facility (SRPPF) at the Savannah River Site (SRS). Due to the current design phase of the SRPPF, the contractor and federal oversight have a unique opportunity to begin establishing a strong relationship early in the project’s life. As a result of this dynamic, the two groups have already demonstrated their ability to successfully respond to ongoing design issues. In general, a strong criticality safety program is beginning to mature for the SRPPF alongside a developing criticality safety federal oversight group. This paper will discuss the various factors that have brought about this collaborative relationship. Lastly, a case study will be incorporated into this paper demonstrating the ability of the SRPPF contractor and federal oversight to overcome challenges relating to the SRPPF project. This case study may guide groups around the DOE Complex to create better, more functional relationships between the two parties. The case study will provide a detailed description of the issue and parties involved, highlight the factors that allowed the group to overcome the challenge via effective collaboration, and the outcome of the event. Increasing collaboration may benefit the complex, as a whole, in order to meet the mission demands of the DOE.

collaboration↗

DOE OSTI2021

Design and Operation of Energy Systems with Large Amounts of Variable Generation: IEA Wind TCP Task 25 (Final Summary Report)

This report summarizes findings on wind integration from the 17 countries or sponsors participating in the International Energy Agency Wind Technology Collaboration Program (IEA Wind TCP) Task 25 from 2006-2020. Both real experience and studies are reported. Many wind integration studies incorporate solar energy, and most of the results discussed here are valid for other variable renewables in addition to wind. The national case studies address several impacts of wind power on electric power systems. In this report, they are grouped under long-term planning issues and short-term operational impacts. Long-term planning issues include grid planning and capacity adequacy. Short-term operational impacts include reliability, stability, reserves, and maximizing the value of wind in operational timescales (balancing related issues). The first section presents the variability and uncertainty of power system-wide wind power, and the last section presents recent studies toward 100% shares of renewables. The appendix provides a summary of ongoing research in the national projects contributing to Task 25 for 2021-2024. The design and operation of power and energy systems is an evolving field. As ambitious targets toward net-zero carbon energy systems are announced globally, many scenarios are being made regarding how to reach these future decarbonized energy systems, most of them involving large amounts of variable renewables, mainly wind and solar energy. The secure operation of power systems is increasingly challenging, and the impacts of variable renewables, new electrification loads together with increased distribution system resources will lead to somewhat different challenges for different systems. Tools and methods to study future power and energy systems also need to evolve, and both short-term operational aspects (such as power system stability) and long-term aspects (such as resource adequacy) will probably see new paradigms of operation and design. The experience of operating and planning systems with large amounts of variable generation is accumulating, and research to tackle the challenges of inverter-based, nonsynchronous generation is on the way. Energy transition and digitalization also bring new flexibility opportunities, both short and long term.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Managing technical debt across large-scale control systems

This presentation provides a comprehensive overview of technical debt in the context of control systems for large-scale physics facilities. We will explore its various forms, common causes, and potential consequences on system reliability, maintainability, and upgradability. Drawing on experiences from multiple projects, we will present a range of strategies for proactively managing technical debt, including best practices in design, development, testing, and documentation, as well as reactive approaches for identifying and mitigating existing issues. The presentation will also emphasize the importance of a collaborative approach and the use of modern tools, like fault tracking systems, to ensure the long-term health and success of control systems in our field.

Watts, Adam [Fermilab]↗