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Demonstrate new plasticity models for doped UO 2 that capture dislocation mechanisms

In light water reactors, fuel vendors are investigating the use of dopants to modify the properties of UO 2 pellets, with the goal of improving pellet-cladding mechanical interactions during operation. Dopants are expected to ‘soften’ the pellets; that is, the doped pellets have higher plastic deformation than conventional UO 2 . This leads to a reduction in the severity of mechanical pellet-cladding interactions, helping to reduce the hoop strain on the cladding. By minimizing the strain exerted by the pellet on the cladding, it is anticipated that cladding performance under accident conditions can be enhanced (i.e., lowering the risk of burst during a LOCA). Dopants such as chromium (Cr) promote grain growth during pellet fabrication, leading to larger grains; therefore, understanding the link between chemistry, microstructure and mechanical deformation (enhanced creep rates) behavior of UO 2 is critical to helping operators further substantiate the benefits of doping UO 2 . Historically, the nuclear energy industry has relied on empirical models to make assessments of performance. Compared to empirical models, mechanistic physics-based models provide benefits, such as, fewer data points for validation and better extrapolation where experimental data is scarce or non-existent. In this report, Bayesian inference techniques have been applied to a previously developed lower length-scale-informed diffusional creep model. The objective is to i) infer lower-length-scale parameter distributions from available experiment and then ii) determine the uncertainties in the measurable quantity (in this case creep rates) after propagating the inferred lower length scale parameter uncertainties. The approach requires many evaluations of the model, which becomes computationally insurmountable; therefore, a neural-network model is trained to data obtained by sampling the full model over the most important parameters. This neural-network is then used in the Bayesian inference approach to determine probability distributions in the parameter values that represent the uncertainty in the model given what is known from the experiments (posterior). A significant reduction compared to conservative initial (prior) uncertainties is achieved through inference against the experimental data, demonstrating the efficacy of this approach. Furthermore, by accounting for uncertainties in the experimental conditions and sample non-stoichiometry, it is possible to resolve apparent discrepancies in experimental measurements within a self-consistent grain boundary (Coble) creep model that is sensitive to chemistry. This work has been written up and submitted to Nuclear Technology for a special issue on accelerated fuel qualification (AFQ). This uncertainty quantification (UQ) work not only improves the diffusional model, while accounting for uncertainty, but also establishes a framework which can readily be applied to the mechanistic models of dislocation deformation developed in this study. The most likely values from the Bayesian analysis are incorporated into our UO 2 diffusional creep model and a lower length scale-informed irradiation UO 2 creep mechanistic model to generate a dataset. This dataset has been provided to our INL collaborators for training an artificial neural network surrogate model, which will be implemented in the BISON fuel performance code to assess how the results differ from those currently obtained using a fully empirical model and that of using the nominal (uncalibrated) atomic scale parameters in our mechanistic model. Plastic deformation (creep and glide) in UO 2 is a complex phenomenon, governed by multiple underlying processes such as local defect concentrations, applied stresses, and microstructural characteristics. Consequently, there is a need for a meso-scale model with polycrystalline resolution capable of extrapolating to large grain sizes applicable to doped UO 2 , where data is limited and the model can help bridge the knowledge gap. By integrating atomistic data into the polycrystal LApx code, it becomes possible to predict dislocation climb and glide plasticity that simple analytical models cannot accurately represent. The application of atomic-scale data within LApx demonstrated the importance of climb and glide mechanisms in reproducing high-stress UO 2 behavior. Behaviors such as this are crucial to capture and implement in BISON, as parts of the fuel pellet can reach temperatures where glide can occur before pellet cracking. This model which captures dislocation based mechanisms for UO 2 is then used to stand up the doped model accounting for larger grain sizes. It was found that larger grain sizes can lead to enhanced deformation rates in the glide regime, and therefore can help with the pellet cladding mechanical interaction. Therefore if the fuel pellet reaches conditions (stress/temperature) where glide is active, the enhanced creep rates for larger grains in the glide regime (doped UO 2 ) can help with pellet cladding mechanical interactions. Plastic deformation in UO 2 involves multiple mechanisms, including diffusional creep, dislocation climb, and glide. This milestone contains two parts: (1) UQ of a pre-existing lower length scale informed mechanistic diffusional creep model, and (2) development of a new LApx based model for dislocation-mediated creep mechanisms in UO 2 , with application to large-grain doped UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Pyrochem Catalyst Company [Abstract]

A catalytic converter is a key enabling technology for more advanced engine technologies to meet the more stringent fuel economy and emission standards of the future, particularly the requirement to treat emissions formed during a cold start (which account for between 60-80% of total emissions). As internal combustion engine technology is expected to remain a dominant force in the market, new and innovative catalyst technologies are needed with low temperature activity to reduce exhaust pollutants by 90% at temperatures as low as 150°C, with a performance lifetime that exceeds 150,000 miles of driving. Considering current catalyst technology only starts to convert pollutants at 200°C, the challenge is significant. Pyrochem Catalyst Company (PCC) has developed a promising PyroCatTM pyrochlore catalyst technology (that incorporates an NETL technology licensed by PCC), which has shown activity better than current state of the art and approaching the 150°C target. NETL and PCC will collaborate to transition PyroCatTM from lab-scale testing to commercialization through the generation of a commercially representative monolith catalyst that can be sent to automotive companies and catalyst manufacturers to validate in their reactor systems.

33 ADVANCED PROPULSION SYSTEMS↗

Precision Time Protocol Performance Testing Over Optical Transport Network

The US Department of Energy Office of Electricity has partnered with Oak Ridge National Laboratory (ORNL) to find alternative precision timing solutions for the nation’s power grid. This effort is in response to the vulnerabilities identified in the Global Navigation Satellite System (GNSS), of which the US Global Positioning System (GPS) platform is a part. Additionally, Executive Order 139055 has highlighted the need for alternative or backup timing solutions. ORNL has established a Timing Lab and has been testing various technologies and timing devices as part of this effort. Precision Time Protocol (PTP), and the off-the-shelf timing devices and network connections that support it, are among the alternatives being tested. This work reports the accuracy of PTP over an Optical Transport Network (OTN) and is part of a series published by the Center for Alternative Synchronization and Timing (CAST).

24 POWER TRANSMISSION AND DISTRIBUTION↗

Findings on Subtask 3.1 - Bakken Rich Gas Enhanced Oil Recovery Project

Total in-place oil for the Bakken petroleum system (BPS) (which includes the Bakken and Three Forks Formations) has been estimated to be 600 billion barrels (bbl). However, BPS wells have decline rates as high as 85% over the first 3 years of their lives, and primary recovery factors typically range from 3% to 10% of original oil in place. Given the low initial recovery rates, even small incremental productivity improvements could dramatically increase technically recoverable oil in the BPS. One potential solution is enhanced oil recovery (EOR) using gas injection, such as carbon dioxide (CO2) or hydrocarbon (HC) gases. While commonly used in conventional reservoirs, CO2 EOR in unconventional tight oil reservoirs has been limited to pilot tests. EOR using rich gas (mixture of methane, ethane, and propane) has also been employed in numerous pilots in several unconventional plays and has recently been successfully applied in the Eagle Ford play. If successful, large-scale gas-based EOR in the BPS could dramatically increase oil productivity and recovery factors and extend the life of the play for decades. While CO2 may be a technically suitable working fluid for EOR in the BPS, supplies are limited and costs for using CO2 in EOR pilots are prohibitively high. Meanwhile, produced gas flaring has presented challenges for BPS operators in North Dakota. Analysis conducted by the North Dakota Pipeline Authority indicates that the current gas-gathering infrastructure in North Dakota is insufficient to accommodate all of the associated gas that is produced from the BPS. The geographically isolated location of North Dakota relative to large natural gas markets, combined with suppressed natural gas prices, has made it economically challenging for industry to invest capital in expanding gas-gathering infrastructure in the state. These circumstances led to a research program conducted by the Energy & Environmental Research Center (EERC) in partnership with Liberty Resources Management Company LLC (LR) to examine the potential to use rich gas injection for EOR and mitigate flaring. A rich gas EOR pilot test was designed and executed by LR at its Stomping Horse development area in Williams County, North Dakota. From July 2018 through May 2019, a total of 160 million standard cubic feet (MMscf) of rich produced gas was injected into the BPS using five different wells in a sequential injection strategy. LR’s Leon–Gohrick drill spacing unit (DSU) was used as the test site. Regulatory oversight was provided by the North Dakota Industrial Commission (NDIC). Technical support was provided by the EERC through a series of laboratory, modeling, and field-based activities, and additional post-pilot research activities incorporated learnings from the test, developed new laboratory data, improved fracture modeling methods, and developed machine learning and big data analytics. The results from the Stomping Horse rich gas EOR pilot activities indicate that developing an effective, economical EOR approach for the BPS will require more field tests. Another key lesson learned from the Stomping Horse tests is that detailed pre- and posttest data on reservoir conditions and fluids production are essential. Robust reservoir characterization provides information that is crucial to creating realistic geomodels and conducting valid dynamic simulations of potential EOR scenarios. A detailed understanding of the completions and production history of offset wells is also necessary for valid test result interpretations. This knowledge is essential to designing the operational parameters of injectivity tests and interpreting the results. A conformance control strategy is also essential to success. Laboratory-based examinations of rich gas interactions with reservoir fluids and rocks were conducted, with an emphasis on determining the ability to mobilize oil in the tight reservoir rocks and shales of the BPS. Injection fluid composition was shown to have a positive impact on reducing reservoir oil minimum miscibility pressure (MMP), reducing interfacial tension (IFT), and altering wettability. IFT and contact angle measurements demonstrated that wettability can be altered in the presence of rich gas, suggesting the potential to improve oil recovery. Iterative modeling of surface infrastructure and reservoir performance using data generated by the various project activities was conducted. A geologic model of the Stomping Horse area was built; history-matched oil, gas, and water production was used in simulations of various EOR scenarios. Early programmatic modeling results were used to support LR’s design and operation of the EOR pilot and to provide insight regarding optimization of future commercial-scale BPS EOR design and operations. Post-pilot modeling focused on alternative methods of understanding complex fracture networks and accelerating simulation time. These led to improved simulation run times and provide excellent history-matching results. Several of these iterative models were used as the bases for developing algorithms into machine learning and big data analytics. History matching in reservoir simulation is time-consuming and computer processing-intensive. Machine learning algorithms were created, and an automated history-matching tool was developed. A large set of synthetic reservoir simulations were created to generate well responses (oil, gas, and water production, well bottomhole pressure [BHP], and tracer or propane breakthrough) for a set of EOR operating parameters that included offset well status (open or closed), injectate (rich gas or propane), injection rate, and injection well BHP. A user interface was developed to provide real-time visualization. Machine learning-based models were developed to provide rapid forecasting of well performance given a set of user-defined EOR operating parameters. These predictive models allow the user to modify the offset well status, injection rate, and injection well BHP and rapidly forecast future production performance. The combination of real-time visualization tools with real-time forecasting tools provides a framework for real-time control—operational changes that the EOR site operator can enact (e.g., changing gas injection rates) to affect the observed performance and potentially improve the EOR outcome. There is great reason to be optimistic about the future of EOR in the Bakken. The results of the laboratory studies suggest significant potential for high rates of oil mobilization using produced field gas injection under the right conditions. The results of the lab studies, combined with rigorous statistical analysis of well production data and associated modeling efforts, confirm the notion that fluid mobility within the reservoir is controlled by fractures. As more knowledge is gained about the nature and distribution of fracture networks in the Bakken, the industry will be in a better position to predict and, ultimately, influence fluid mobility. New field tests are necessary to develop a more complete understanding of those conditions. Thoughtful and creatively engineered field tests within a well-characterized geologic setting will yield the fundamental knowledge needed to take Bakken oil production to the next level. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission’s Oil and Gas Research Program and Computer Modelling Group.

04 OIL SHALES AND TAR SANDS↗

Garnet/PVDF-HFP Hybrid Membranes for Li-Metal Batteries: Cooperative Research and Development Final Report, CRADA Number CRD-19-00807

Hazen Research, Inc., in collaboration with University of Colorado, Boulder (CU-B) and National Renewable Energy Laboratory (NREL), will develop and demonstrate a ceramic-polymer hybrid membrane based on garnet (Li7La3Zr2O12) and PVDF (Poly Vinylidene Fluoride)-HFP (Hexafluoropropylene) adaptable to Li-metal anodes. Under this CRADA, NREL will test the developed membranes providing feedback and advice to demonstrate hybrid membranes with Li-ion conductivity >10-4 S/cm at room temperature that are stable with Li-metal, followed by demonstration of full cells with Li-metal anode.

33 ADVANCED PROPULSION SYSTEMS↗

Performance of Quantum Dot Coatings for Luminescent Solar Concentrating Windows: Cooperative Research and Development Final Report, CRADA Number CRD-16-00640

The two major outcomes from this DOE supported collaboration between UbiQD and NREL were: 1) an expert analysis/modeling of the expected performance and cost of luminescent solar concentrating windows with quantum dot coatings, and 2) critical R&D characterization of materials and device performance analysis using equipment and processes that are too expensive for UbiQD to perform in-house. The latter also included third-party validation of the device performance with an NREL-certified conversion efficiency that was ultimately published. (see ACS Energy Lett. 2018 and recently ACS Appl. Energy Mater. 2020).

14 SOLAR ENERGY↗

H2@Scale - Validating an Electrolysis System with High Output Pressure: Cooperative Research and Development Final Report, CRADA Number CRD-18-00741

Electrolysis has been a commercially available product for a while and electrolyzers have been a proven capability to provide additional benefits (e.g. controllable load for grid services) in addition to production of hydrogen. The hydrogen output is typically compressed for storage and dispensing. Compression adds cost and decreases system reliability. Honda’s electrolyzer systems have been developed to include electrochemical compression to leverage the production system itself for at least partial compression. In this project, the team will evaluate Honda’s PEM based electrochemical compression system. The system is capable of compressing hydrogen up to 70 MPa electrochemically. Validation testing is the next step to accelerate this technology into the marketplace, as the validation will provide needed data under a variety of operation conditions and controls. These operating conditions and controls are based on over a decade of NLR research and development with low-temperature electrolysis. The validation testing will include preparing NLR’s site for third party evaluation, benchmark testing of Honda’s stack and system, and simulating operation connected to renewables or in a grid service profile. NLR’s Energy System Integration Lab will be the location for the electrolyzer validation research and integrated into the Hydrogen Infrastructure Test & Research Facility (HITRF). This will build into the existing retail style hydrogen fueling station for a fully integrated experimental setup.

08 HYDROGEN↗

Conquering Data Chaos: Research Data Management with Kubernetes

Managing massive volumes of data and effectively making it accessible to researchers poses significant challenges and is a barrier to scientific discovery. In many cases, critical data is locked up in unwieldy file formats or one-off databases and is too large to effectively process on a single machine. This talk explores the role of Kubernetes, an open-source container orchestration platform, in addressing research data management challenges. I will discuss how we are using a set of publicly available open-source and home-grown tools in the National Renewable Energy Lab (NREL) Data, Analysis, and Visualization (DAV) group to help researchers overcome data-related bottlenecks. The talk will begin by providing an overview of the data challenges faced in research data management, including data storage, processing, and analysis. I will highlight Kubernetes' ability to handle large-scale data by leveraging containerization and distributed computing, including distributed storage. Kubernetes allows researchers to encapsulate data processing infrastructure and workflows into portable containers, enabling reproducibility and ease of deployment. Kubernetes can then schedule and manage the resource allocation of these containers to enable efficient utilization of limited computing resources, leading to more efficient data processing and analysis. I will discuss some limitations of traditional, siloed approaches to dealing with data and emphasize the need for solutions which foster collaboration. I will highlight how we are using Kubernetes at NREL to facilitate data sharing and cooperation among research teams. Kubernetes' flexible architecture enables the deployment of shared computing environments, such as Apache Superset, where researchers can seamlessly access and analyze shared datasets. Providing the ability to have one research team easily consume data generated by another, utilizing Kubernetes' as a central data platform, is one of the major wins we've encountered by adopting the platform. Finally, I will showcase real-world use cases from NREL where we have used Kubernetes to solve some persistent data challenges involving large volumes of sensor and monitoring data. I will discuss the challenges we encountered when creating our cluster and making it available as a production-ready resource. I will also discuss the specific suite of tools, including Postgres and Apache Druid for columnar and timeseries data, and Redpanda Kafka for streaming data we have deployed in our infrastructure, and the process that went into the selection of these tools.

collaborative environment↗

CRADA Number NFE-18-07313 with Nth Cycle, Inc. (CRADA Final Report)

Cooperative Research and Development Agreement (CRADA) NFE-18-07313 between Oak Ridge National Laboratory (ORNL) and Nth Cycle Inc. focused on developing a technology for sustainable recycling of rare earth and specialty metals (e.g., Y, Co, Li; RESE), as well as bulk and precious metals from industrial manufacturing and waste streams through the use of electrochemical carbon nanotube-enabled filters. The project outcome was expected to be a stronger mechanistic understanding of the electrochemical recovery of metals from real manufacturing process streams and e-waste streams, and the development of an optimized high-throughput pilot-scale device ready for commercialization. Testing, design, and development of a v1 prototype to prove the technology was unsuccessful (we were not able to reach the go/no-go outlined in Objective 1) and we were unable to continue our redesign due to COVID-19 lockdown and no access to lab from March 2020 – until our graduation from the program.

36 MATERIALS SCIENCE↗

Prokaryotic and eukaryotic cell-free systems for prototyping (CRADA Final Report)

CRADA FP00008491 between Berkeley Lab and Synvitrobio, Inc. (now Tierra Biosciences) validated the use of cell-free phenotyping to conduct functional genomics. Currently, most phenotyping work occurs using cellular fermentation methods and cellular techniques. This limits functional genomics throughput, which increasingly cannot handle the wealth of genetic information developed from next-generation sequencing technologies. De-risking a cell-free phenotyping approach has the advantage of increasing multiple-fold the throughput of genetic information that can be explored and expanding the $3B market for protein synthesis and characterization, leading to the accelerated development of human therapeutics and new biologically based materials.

59 BASIC BIOLOGICAL SCIENCES↗

Unified Software Architecture for Advanced Materials and Manufacturing Technologies Data Management and Processing: FY 2023 Multidimensional Data Correlation Platform

This report details the various digital manufacturing activities ongoing at ORNL as part of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is exploring a data-driven approach to demonstrate the use of AM for the fabrication of components for nuclear applications, with the goal of providing a greater understanding of manufacturing quality outcomes that would pave the way toward the development of standards for certification and qualification. The objective of this work package is to establish a digital manufacturing discipline common to all participants of the AMMT program to improve the performance, reliability, and lifetime of nuclear components. As part of this effort, we will develop a unified software architecture for AMMT data management and processing, deploy the digital platform across AMMT participants’ facilities, and generate pedigreed datasets in a common format across multiple labs and facilities. To this end, the MDDC work package has focused on three activities during FY23. First, the MDF Digital Tool was overhauled to better serve the needs of the AMMT program. Next, multiple laser powder bed fusion (L-PBF) systems at the MDF were upgraded to a common sensor package for collecting comparable in situ data across machines. Finally, various improvements relevant to the AMMT program were implemented in the ORNL-developed software tool, Peregrine. This report marks the completion of FY23 milestone M3CR-22OR0403051: Report Describing the Architecture of the Digital Platform to Support AMMT Activities.

36 MATERIALS SCIENCE↗

Ion-Electron Coupling-Driven Redox Behavior in Metal–Organic Frameworks

Redox-active metal–organic frameworks (MOFs) have long been proposed as electronic transport platforms, yet the microscopic origin of their conductivity remains debated. A theoretical demonstration reveals charge transport in a Zn(pyrazole–naphthalene diimide (NDI)) MOF arising not from delocalized band-like states but from redox hopping between discrete linker sites. Using ab initio molecular dynamics simulations combined with electronic structure analysis, we established a direct link among electron injection, structural reorganization, and transport. Electron accumulation proceeds sequentially and site-selectively from imide and carbonyl groups of the NDI core progressively involving pyrazole N atoms at higher reduction states, through a hierarchy of redox-active sites. In contrast, Zn nodes remain essentially redox-inactive, which confirms their structural role. Density-of-states analysis corroborates a transport regime dominated by linker-centered states with evolving p-character upon reduction, resulting in dynamically reconfigured conduction networks. Real-time trajectories reveal anisotropic linker-to-linker electron transfer modulated by counterion coordination. This cooperative ion–electron regime emerges from potential energy surface collapse into a single low-barrier transition (ΔG ‡ ≈ 45 meV), where ionic and electronic motions evolve adiabatically on the same free-energy landscape. Elucidating redox conductivity in Zn(pyrazole–NDI) MOFs provides a theoretical framework for use in neuromorphic computing and related technologies.

Charge transfer↗

Assessing the cumulative effects of nearshore habitat restoration actions for multiple populations of juvenile salmon in Whidbey Basin, Washington: foundation and approach for synthesis and evaluation

Ecosystem restoration is a common tool for re-establishing ecosystem processes, structures, and functions to improve biodiversity and services in coastal and estuarine ecosystems. In the Salish Sea, salmon habitats have been fragmented, reduced in size, and diminished in quality, and the ecosystem processes that form and sustain these habitats have been degraded and disrupted as well. This loss is especially prevalent in estuaries, where up to 90% of former salmon habitat has been lost or compromised. Salmon species are integral to the identities and cultures of people in the Pacific Northwest, yet salmon abundances remain at historic lows, especially in urbanized areas. Recent investments in restoration are creating rearing habitat and repairing lost ecosystem function. However, restoration efforts in this region have largely proceeded at the site scale, with less attention to big-picture thinking regarding how restoration will effectively recover degraded or lost habitats for target species. As a result, no landscape-scale evaluation program exists, and the cumulative benefits of multiple interventions are unknown. We describe innovative methods for science synthesis related to the evaluation of cumulative effects of ecosystem restoration for Pacific salmon, using years of existing, but disparate data. Building from previous work on cumulative effects evaluation and incorporating a hierarchy of hypotheses approach, we propose using causal inference across numerous hypotheses in a framework to assess the cumulative benefits to Pacific salmon from multiple estuarine restoration projects. We present the framework as a method that can be used to address many complex questions and provide examples from the Salish Sea where the approach is being implemented. The framework draws on science synthesis from numerous fields and uses a hierarchy of hypotheses, causal analysis at multiple scales, and a new hierarchy of synthesis for assessing multiple lines of evidence documenting restoration effects on Pacific salmon. We propose causal inference to synthesize dissimilar data streams, in our case, to identify various manifestations of cumulative effects of restoration and benefits to salmon, and to further inform restoration and recovery planning. A unifying framework would allow for the detection of thresholds at which restoration provides measurable improvement and would greatly advance understanding of the effects of restoration on ecosystems.

59 BASIC BIOLOGICAL SCIENCES↗

Low Cost, High Volume, Carbon Fiber Precursor for Plasma Oxidation

Light weighting with carbon fiber is critical to improving the energy efficiency of wind turbines, airplanes, and automobiles, but the high cost of carbon fiber continues to limit market growth and applications. Half of this cost is in the raw materials. For the carbon fiber market to reach the next level of adoption, the cost of both the raw materials and conversion must be reduced. This project considered the combination of low-cost, textile-grade precursors combined with the increased efficiency of plasma oxidation to greatly reduce the cost of carbon fiber. The primary objective of this project was to make industrial-grade carbon fiber (550 ksi tensile strength, 35 Msi tensile modulus) from textile-grade PAN precursors, something that cannot be achieved with conventional oxidation and to date has not been achieved with any technology. To accomplish this, the project team iteratively optimized the process conditions in the plasma oxidation and carbonization stages to maximize the tensile properties of the resultant carbon fibers. This involved implementing experimental designs for both stages, whereby process conditions (e.g. temperature) were varied and correlated to fiber properties. Samples of oxidized PAN fibers (OPFs) were prepared using a small pilot-scale plasma oxidation oven at 4XTechnologies (4XT). The thermal, chemical, and physical properties of OPF samples were analyzed by the University of Tennessee (UTK) and Oak Ridge National Laboratory (ORNL). The OPF samples were then converted to carbon fiber by subsequent low- and high-temperature carbonization using a lab-scale furnace at ORNL. The resultant carbon fibers were tested for tensile strength also at ORNL, and the results were fed back into the experimental design. Of the hundreds of carbon fiber samples produced over the course of the project, the best sample had an average break strength of 479 ksi and modulus of 33 Msi. While the best tensile properties achieved fell short of the final project targets of 550 ksi for break strength and 35 Msi for modulus, the team demonstrated the potential to produce industrial-grade carbon fiber using textile-grade precursors. The best performing fiber samples had tensile properties that are 87% of the goal for tensile strength and 94% of the goal for tensile modulus. With additional optimization work, it is likely that the targets could be achieved, since only a fraction of the process parameter space was explored during this project. 4XT and its affiliate (4M) have already secured funding through private equity, and there is a CRADA (Cooperative Research and Development Agreement) project currently underway with the Carbon Fiber Technology Center (CFTF) at ORNL to continue this research. Additionally, while not an original goal of the project, the carbon fibers for most samples had diameters >8.5μm. This is considerably larger than commercially available carbon fiber products, which can impart unique properties to the composites (e.g. increased compressive strength) and decrease manufacturing costs even further. Moreover, these fibers were oxidized with plasma oxidation using residence times ranging <60mins, which would be considered fast for normal diameter fibers, but it is as much as 5x faster when factoring in the diameter of the fibers.

36 MATERIALS SCIENCE↗

Bat Impact Minimization Technology: An Improved Bat Deterrent for the Full Swept Rotor Area of Any Wind Turbine

The growth in the number of wind turbine generators has led to a significant number of fatal interactions with bat species. The need to reduce the number of bat fatalities while minimizing power losses is the greatest conservation challenge for wind energy development in parts of the country, according to the American Wind Wildlife Institute. Technological solutions that can also allow turbines to operate normally would generate the maximum electricity and avoid financial losses. Bats use echolocation to perceive their surroundings by listening to features of echoes from their high frequency vocal signals reflecting from targets. In this project, Frontier Wind built on previous research demonstrating that ultrasonic noise can mask echolocation and act as a repellent or deterrent to bat flight activity. Whereas the initial study only broadcast ultrasonic transmissions from the center of the turbine, the Strike Free™ system developed for this project extended the ultrasonic coverage to the entire area swept by the turbine blades. Frontier Wind designed the system components and their integration and then tested them in the lab and in the field at Pattern Energy’s Hatchet Ridge Wind Facility near Redding, California. The researchers used an acoustic model to determine the optimal configuration of transmitters along the blades to provide sound transmission coverage across the turbine rotor swept area volume. The custom ultrasonic transmitters were designed specifically for the echolocation frequencies of the four main bat species that have been shown to have died at Hatchet Ridge, although the transmitters can be customized for different frequencies as needed in other geographic locations. The Strike Free™ system shows promise for reducing bat fatalities, and the path to commercialization requires further testing to validate and optimize performance in the field.

17 WIND ENERGY↗

Low-Temperature Non-Oxidative Coupling of Methane on Atomically Dispersed Titanium–Aluminum–Boron Nanopowder

Nonoxidative coupling of methane represents a long-standing challenge in heterogeneous catalysis, as it requires activation of the carbon–hydrogen (C–H) bond, controlled carbon–carbon (C–C) bond formation, and effective hydrogen management without relying on oxidants. Here, we report a low-temperature C–H activation and nonoxidative C–C coupling of methane over atomically dispersed titanium–aluminum–boron nanopowder (Ti–Al–B NP) utilizing a catalytic microreactor coupled to synchrotron single-photon photoionization reflectron time-of-flight mass spectrometry. The soft-ionization, in situ probing method detects the nascent reaction products and radical intermediates under operando conditions, including methyl radical, C2 hydrocarbons, and molecular hydrogen. Methane activation is initiated at 800 K, approximately 700 K below the gas-phase decomposition threshold, leading predominantly to ethylene formation with selectivity reaching up to 78% among the C–C coupled products. Electronic structure calculations on model Ti–Al–B clusters elucidate a cooperative catalytic mechanism in which titanium enables methane adsorption and C–H activation, boron acts as a reversible hydrogen reservoir, and aluminum stabilizes methylene intermediates, thereby facilitating selective C–C coupling and dehydrogenation. These findings establish a distinct catalyst architecture for nonoxidative methane coupling based on earth abundant elements alternative to expensive platinum and other noble metal-containing conventional catalysts and provide molecular-level design principles for controlling dehydrogenation and subsequent C–C bond formation in challenging light alkane conversions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High-field superconducting halo in UTe 2

The heavy fermion material UTe 2 is a candidate topological superconductor that exhibits multiple magnetic field–induced superconducting phases. One such phase exists only at fields greater than 40 tesla, a considerable scale given its critical temperature of only 2 K. Here, in this work, we extend measurements of this state with fields outside of the bc crystallographic plane and reveal its core structure: The superconducting phase wraps around the b axis in a halo-like fashion and appears to be stabilized by a field component perpendicular to the magnetic easy axis. This angle dependence points to a multicomponent spin-triplet order parameter with a finite angular momentum of the Cooper pairs. The pairing mechanism remains enigmatic, and UTe 2 ’s specific magnetophilic superconducting tendencies seem incompatible with existing models for field-enhanced superconductivity.

Lewin, Sylvia K. [National Inst. of Standards and ↗

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗