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DOE OSTI2025

Polyethylene Upcycling to Liquid Alkanes in Molten Salts under Neat and External Hydrogen Source-Free Conditions

Development of facile approaches to convert plastic waste into liquid fuels under neat conditions is highly desired but challenging, particularly without noble metal catalysts and an external hydrogen source. Herein, highly efficient and selective polyethylene-to-gasoline oil (branched C 6 –C 12 alkanes) conversion was achieved under mild conditions (<170 °C) using commercially available AlCl 3 -containing molten salts as reaction media and to provide catalytic sites (no extra solvents, additives, or hydrogen feeding). The high catalytic efficiency and selectivity was ensured by the abundant active Al sites with strong Lewis acidity (comparable to the Al type in acidic zeolite) and highly ionic nature of the molten salts to stabilize the carbenium intermediates. Dynamic genesis of the Al sites was elucidated via time-resolved Al K-edge soft X-ray and 27 Al NMR, confirming the tricoordinated Al 3+ as active sites and its coordination with the as-generated alkene/aromatic intermediates. Further, the carbenium formation and polyethylene chain variation was illustrated by inelastic neutron scattering (INS) and an isotope-labeling experiment. Theoretical simulations further demonstrated the successive hydride abstraction, β-scission, isomerization, and internal hydrogen transfer reaction pathway with AlCl 3 as active sites. This facile catalytic system can further achieve the conversion of robust, densely assembled, and high molecular weight plastic model compounds to liquid alkane products in the diesel range.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Free-standing ultrathin lithium metal–graphene oxide host foils with controllable thickness for lithium batteries

Thin (≤20 μm) and free-standing Li metal foils would enable precise prelithiation of anode materials and high-energy-density Li batteries. Existing Li metal foils are too thick (typically 50 to 750 μm) or too mechanically fragile for these applications. Here, we developed a facile and scalable process for the synthesis of an ultrathin (0.5 to 20 μm), free-standing and mechanically robust Li metal foil within a graphene oxide host. In addition to low areal capacities of ~0.1 to 3.7 mAh cm –2 , this Li foil also has a much-improved mechanical strength over conventional pure Li metal foil. Our Li foil can improve the initial Coulombic efficiency of graphite (93%) and silicon (79.4%) anodes to around 100% without generating excessive Li residue, and increases the capacity of Li-ion full cells by 8%. In conclusion, the cycle life of Li metal full cells is prolonged by nine times using this thin Li composite anode.

25 ENERGY STORAGE↗

DOE OSTI2020

Foil backlighter development at the OMEGA laser facility for extended x-ray absorption fine structure experiments

Extended x-ray absorption fine structure (EXAFS) measurements require a bright and continuous x-ray source and a detection system with high spectral resolution to capture the modulations of the absorption coefficient above the material absorption edge. When performing EXAFS measurements under laser-driven dynamic compression, it is hence critical to optimize the backlighter x-ray emission. In this study, a series of experiments has been conducted at the OMEGA laser facility to characterize titanium (Z = 22), iron (Z = 26), germanium (Z = 32), molybdenum (Z = 42), silver (Z = 47), and gold (Z = 79) foil backlighters irradiated with 3 kJ–12 kJ of laser energy. The spectra have been recorded using a dual crystal spectrometer (DCS), a two-channel transmission spectrometer covering 11 keV–45 keV and 19 keV–90 keV energy bands. The DCS has been calibrated so that the spectral intensities can be compared between different campaigns.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Measurements of K-edge and L-edge extended x-ray absorption fine structure at the national ignition facility (invited)

High-energy-density laser facilities and advances in dynamic compression techniques have expanded access to material states in the Terapascal regime relevant to inertial confinement fusion, planetary science, and geophysics. However, experimentally determining the material temperature in these extreme conditions has remained a difficult challenge. Extended X-ray Absorption Fine Structure (EXAFS), referring to the modulations in x-ray absorption above an absorption edge from photoelectrons’ interactions with neighboring atoms, has proven to be a versatile and robust technique for probing material temperature and density for mid-to-high Z elements under dynamic compression. The current platform at the National Ignition Facility has developed six configurations for EXAFS measurements between 7 and 18 keV for different absorption edges (Fe K, Co K, Cu K, Ta L3, Pb L3, and Zr K) using a curved-crystal spectrometer and a bright, continuum foil x-ray source. Here, in this work, we describe the platform geometry, x-ray source performance, spectrometer resolution and throughput, design considerations, and data in ambient and dynamic-compression conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Three-colour digital holographic microscopy based on a Mach – Zender interferometer and a solid-state RGB laser

We have developed a facility for recording colour digital holograms involving a Mach – Zender interferometer and a pulsed solid-state RGB laser, which radiates simultaneously at three wavelengths: 451, 532, and 634 nm. These wavelengths are obtained in the conversion of the radiation of a pulsed Nd{sup 3+} : YAG laser (1064 nm), which operates in the regime of intracavity parametric oscillation at a wavelength of 1570 nm, with the subsequent conversion of its frequencies to the red, green, and blue spectral regions in nonlinear KTP-crystal elements. The combination of this three-wavelength pulsed light source with the Mach – Zender interferometer provides the simultaneous recording of three spectral digital holograms with one matrix RGB radiation detector. Pulsed three-colour digital holography shows promise for the analysis of fast processes and rapidly varying colour phase objects. (paper)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Roadmap on cosmic EUV and x-ray spectroscopy

Cosmic EUV/x-ray spectroscopists, including both solar and astrophysical analysts, have a wide range of high-resolution and high-sensitivity tools in use and a number of new facilities in development for launch. As this bandpass requires placing the spectrometer beyond the Earth’s atmosphere, each mission represents a major investment by a national space agency such as NASA, ESA, or JAXA, and more typically a collaboration between two or three. In general justifying new mission requires an improvement in capabilities of at least an order of magnitude, but the sensitivity of these existing missions are already taxing existing atomic data quantity and accuracy. This roadmap reviews the existing missions, showing how in a number of areas atomic data limits the science that can be performed. The missions that will be launched in the coming Decade will without doubt require both more and improved measurements of wavelengths and rates, along with theoretical calculations of collisional and radiative cross sections for a wide range of processes.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Methods to Account for CAP-88 PC-Omitted Nuclides in Radioactive Air Emissions From DOE Facilities

Routine research and development activities at US Department of Energy facilities can result in the release of radioactive emissions, potentially exposing the public and the environment. Such emissions are subject to certain Clean Air Act regulations, specifically those outlined in 40 CFR Part 61, Subpart H, which are enforced by the US Environmental Protection Agency. Compliance is determined in part with a dose standard. Doses to members of the public from most US Department of Energy facility airborne emissions are modeled using CAP-88 PC software, the latest version of which contains more than 1,200 radionuclides. Radioactive effluents from US Department of Energy facilities may contain radioisotopes that are not available in CAP-88 PC, and those radioisotopes must still be evaluated to determine whether doses to members of the public are below established limits. CAP-88 PC-omitted radionuclides can be accounted for using alternate methods, including the use of surrogate radionuclides. Here, this paper elucidates the process of accounting for CAP-88 PC-omitted radionuclides by providing criteria and rationale for surrogate selection, a compilation of surrogate radionuclides used in the past by US Department of Energy facilities, a discussion of alternate methods used to account for CAP-88 PC-omitted radionuclides and a comparison of methods and impacts on receptor doses. Ultimately, this paper aims to aid in the process of surrogate selection and consequently to simplify and expedite compliance with Clean Air Act regulations.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2023

Autonomy Loops for Monitoring, Operational Data Analytics, Feedback, and Response in HPC Operations

Many High Performance Computing (HPC) facilities have developed and deployed frameworks in support of continuous monitoring and operational data analytics (MODA) to help improve efficiency and throughput. Because of the complexity and scale of systems and workflows and the need for low-latency response to address dynamic circumstances, automated feedback and response have the potential to be more effective than current human-in-the-loop approaches which are laborious and error prone. Progress has been limited, however, by factors such as the lack of infrastructure and feedback hooks, and successful deployment is often site- and case-specific. In this position paper we report on the outcomes and plans from a recent Dagstuhl Seminar, seeking to carve a path for community progress in the development of autonomous feedback loops for MODA, based on the established formalism of similar (MAPE-K) loops in autonomous computing and self-adaptive systems. By defining and developing such loops for significant cases experienced across HPC sites, we seek to extract commonalities and develop conventions that will facilitate interoperability and interchangeability with system hardware, software, and applications across different sites, and will motivate vendors and others to provide telemetry interfaces and feedback hooks to enable community development and pervasive deployment of MODA autonomy loops.

autonomy loops↗

DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗

DOE OSTI2024

Manufacturing Cathodes via Dry-Processing for Lithium-Ion Batteries

Conventional lithium-ion battery (LIB) electrodes are prepared through a wet slurry process with n-methyl pyrrolidone solvent, especially for cathodes. The wet slurry process encounters several disadvantages such as binder migration, electrode cracking in thick electrodes, energy intense heat-dry NMP solvent removal, and costly NMP recovery. The cost and energy consumption of coating and drying of electrode are about 11.5 % and > 46 % in LIB manufacturing, respectively. Thereby, it is essential to develop a facile roll-to-roll solvent-free LIB electrode processing for reducing the cost and energy consumption. Recently, the Maxwell-type dry processing (DP) shines new lights on LIB manufacturing, which mainly bases on dry mixing (DM) of electrode component powder followed by calendering into electrode films and laminating onto current collectors, realizing the rapid manufacturing of LIB electrodes in a powder-to-film manner for industries. This report shares some recent progress on the DP from our group. We aim to further advance the manufacturing science of DP by correlating the processing conditions with electrode properties and performance. Particularly, we investigate the effect of DM, and compression on the polytetrafluoroethylene (PTFE) binder fiberization, porosity, mechanical properties, electrical conductivity and electrochemical behaviors of electrodes. The DM study suggests that PTFE fiberization heavily relies on the degree of DM. Insufficient DM results in poor PTFE fiberization while outrageous DM damages the formed PTFE fibers. Both negatively affect the mechanical behaviors of the electrodes and their rate capability. However, moderate DM is highly beneficial. In addition, our study of the porosity impact reveals that LiNi0.8Mn0.1Co0.1O2 (NMC) secondary particles can be broken into primary particles due to compression, especially at low porosity. Those fractured NMC secondary particles exhibit lower modulus. We propose that a moderate porosity of around 32% favors the electronic conductivity, charge transfer impedance and rate capability. The study of the cathodic electrolyte interphase layer of PTFE-based DPed electrode confirms that side reactions of PTFE binder due to the formation of LiF in LiClO4-based electrolyte.

Tao, Runming↗

DOE OSTI2022

Specimen Size and Geometry Effects on the Master Curve Fracture Toughness Measurements of EUROFER97 and F82H Steels

EUROFER97 and F82H are two leading reduced-activation ferritic-martensitic (RAFM) steels for fusion blanket applications. Exposure to the harsh environment of fusion reactors can result in severe degradation of materials fracture toughness (FT). Thus, the post-irradiation evaluation of FT is critical to understanding the material behavior. Due to the space constraint of irradiation facilities, the development of small specimen test techniques (SSTT) is necessary to evaluate the performance of irradiated materials. In this study, we evaluated the specimen size and geometry effects on the ductile-to-brittle transition FT of EUROFER97 batch-3 and F82H-BA12 steels. The specimen thicknesses ranged from 1.65 to 12.7 mm and the geometries included 1.65 mm bend bar, 4 mm mini-compact tension (miniCT), and 0.5T compact tension (CT) specimens. Fracture toughness testing and evaluations were performed using the Master Curve method in the ASTM E1921-19 standard. After size correction to 1T size using the Master Curve method, no specimen size effect was observed between the 4 mm miniCT and 0.5T CT specimens for the Master Curve reference temperature T0Q, while the bend bars yielded a higher T0Q. A strong effect of fatigue precrack front straightness on T0Q for 0.5T CT specimens was observed. The minimum number of specimens needed for each specimen geometry has been determined.

Chen, Xiang↗

DOE OSTI2020

Jitter-induced Max-of-N fluence distribution at the National Ignition Facility

Max-of-N fluence is the maximum peak fluence at a given location over N number of shots and is important for calculating fluence dependence for intrinsic laser-induced optic damage. Previously, we observed the Max-of-N effect on the National Ignition Facility and developed an ad-hoc model to calculate its effect. In this work, we attempt to understand the fundamental mechanism that causes this Max-of-N effect. We conclude that the primary fundamental mechanism responsible for this effect is dominated by the combination of fluence variations and pointing jitter of the laser. This discovery both strengthens our model for predicting optics longevity and gives us insight into how to mitigate this effect.

42 ENGINEERING↗

DOE OSTI2020

Acceptance Calculation and Study of Fault Scenarios in the PIP-II Linac

The Proton Improvement Plan (PIP)-II is a proposed high intensity proton facility being developed at the Fermilab. The PIP-II is primarily based on construction of a new superconducting radio frequency (SRF) linear accelerator (linac) that would deliver an average beam current of 2mA with output energy up to 800 MeV. The acceptance of an accelerator outlines its sensitivity against deviations from its nominal design parameters. Consequently, a higher acceptance minimizes possibility of the beam loss. This paper presents longitudinal and transverse acceptance of the PIP-II SRF linac. Furthermore, paper also discusses implications of fault scenarios, such as the cavity failure, on the beam optics and acceptances.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Spectroscopy of Resonances in the Astrophysical r p –Process Path. Final Technical report

This report describes the results of a project to study the spectrum of proton-resonances which determine the energy release and timescale for the astrophysical rp-process path. Steps to achieve successful experiments include the commissioning of a the in-flight radioactive-beam facility RESOLUT , development of instrumentation and analysis techniques for experiments performed with it. Radioactive-beam experiments performed in the context of the grant included the reactions 25 Al(d,n) 26 Si, 19 O(d,p) 20 O, 19 Ne(d,n) 20 Na and 17 F(d,n) 18 Ne. The experimental program developed experiments and methods to characterize aspects of proton-capture reactions with respect to the in the context of the astrophysical rp-process.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Welded and Hydrogen Charged Zircaloy-4 and Welded Stainless Steel 347 Property Data and Microstructures for the Target Solution Vessel and Support Lines of SHINE

SHINE Medical Technologies is developing a facility that will produce molybdenum-99 for medical isotope procedures. As part of this facility, a metal tank, called the target solution vessel (TSV), will hold a uranyl sulfite solution. The TSV must withstand neutron irradiation near room temperature and potential corrosion from the aqueous solution. The large cylindrical TSV will be fabricated by welding and will have numerous pipes and connections also attached via welding. The vessel and those pipes will have varying thicknesses so both gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW) will be necessary to fabricate different sections. The original material under consideration for the TSV was Zircaloy-4 (Zry-4), but it is known to form a hydride which can degrade its mechanical properties. Thus, some investigation here is focused on the effects of hydrogen uptake in the Zry-4. Additionally, the alternative material being considered is AISI 347, a stainless steel. Both materials have little existing data for their neutron irradiation behavior below 100°C, and both have open questions on the weld behavior under neutron irradiation. Testing has focused on characterizing their weld properties with tensile tests and performing neutron irradiation of samples in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL).

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2021

Status and prospects for the development of a Neutron Target Facility

Neutron-induced reactions are a topic of general interest, with scientific and technical impact ranging from nuclear energy and national security to the fundamental sciences. Details of the fission process are critically important for energy production and reactivity for applications, while transmutation reactions such as (n,γ) can contribute to application-specific diagnostic information as well as our understanding of stellar nucleosynthesis. As a result, there is a long history of global investment in the necessary facilities and scientific programs to study this important class of physics.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024

Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Electrochemical Compression for Ammonia Storage and Refrigeration System (Phase 2)

In this project, we studied the performance of the ammonia EC compressor under a variety of different conditions. We replicated preliminary data and using a small cell with 5 cm 2 of active area. We demonstrated the operation of larger cells with 100 cm 2 of active area. Further, we used a commercially available hydrogen EC compressor stack to analyze the scaled-up compressor performance. While previous experiments examined only the transient EC compressor performance, we developed test facilities that allowed the compressor to reach steady state.

25 ENERGY STORAGE↗