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DOE OSTI2024

Seeing in with X-rays: 4D Strain and Thermometry Measurements for Thermal-Mechanical Testing

Understanding temperature-dependent material decomposition and structural deformation induced by combined thermal-mechanical environments is critical for safety qualification of hardware under accident scenarios. Seeing in with X-rays elucidated the physics necessary to develop X-ray strain and thermometry diagnostics for use in optically opaque environments. Two parallel thermometry schemes were explored: X-ray fluorescence and X-ray diffraction of inorganic doped ceramics– colloquially known as thermographic phosphors. Two parallel surface strain techniques–Path-Integrated Digital Image Correlation and Frequency Multiplexed Digital Image Correlation–were demonstrated. Finally, preliminary demonstration of time-resolved digital volume correlation was performed by taking advantage of limited view reconstruction techniques. Additionally, research into blended ceramic-metal coatings was critical to generating intrinsic thermographic patterns for the future combination of X-ray strain and thermometry measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Designing Resilient Communities: Hardware demonstration of resilience nodes concept

As part of the project “Designing Resilient Communities (DRC): A Consequence-Based Approach for Grid Investment,” funded by the United States (US) Department of Energy’s (DOE) Grid Modernization Laboratory Consortium (GMLC), Sandia National Laboratories (Sandia) is partnering with a variety of government, industry, and university participants to develop and test a framework for community resilience planning focused on modernization of the electric grid. This report provides a summary of the section of the project focused on hardware demonstration of “resilience nodes” concept.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

LEED: A Lightwave Energy-Efficient Datacenter

The Lightwave Energy-Efficient Datacenter (LEED) program is a disruptive “green-field” approach that provides a quantum leap in the energy efficiency of datacenters. LEED’s fundamental value proposition is that a novel and re-architected optical network—RotorNet— can deliver “more bandwidth per buck” as well as unique system-level attributes that significantly improve overall datacenter energy efficiency and performance. LEED has developed three system-level testbeds. The first testbed uses calibrated hardware and software power measurements to determine server energy efficiency as a function of network bandwidth and workload. These measurements have shown that increasing network communications bandwidth dramatically increases server energy efficiency providing a realistic path to the overall ENLITENED program goal of doubling the number of transactions per joule. The second testbed demonstrates key hardware: a prototype low-loss, high-port count optical “selector switch”. This switch was fabricated, racked, and tested. Measured switch characteristics include loss, bandwidth, crosstalk, switch time, system-level switch time (including the transceivers), and bit error rate. The third testbed demonstrates a fully working and manufactured pinwheel design which dramatically lowers the cost of design, while delivering high switch radix and low reconfiguration times. The LEED project has tied these three novel photonic switch prototypes together with production servers and software through the development of a novel FPGA-based NIC platform called Corundum. Corundum ensures that the packet-switched protocols supported by commodity operating systems and devices can interface with the Rotor switch design. The LEED group has used this combined hardware and software prototype to characterize applications running at a commercially relevant scale. The project has used a combination of enhanced optical modulation amplitude (OMA) modulators, broadband multiplexers and demultiplexers, avalanche photodiodes, and a novel burst-mode receivers to enable the insertion of LEED-developed optical switches without the need for expensive optical amplification. Our modeling has shown that measured LEED-developed device characteristics can achieve link characteristics of 2 pJ/bit including both transceivers and the Rotor switch. In summary, the LEED program has demonstrated a credible and practical path, through novel hardware and software, to realize the program objectives of ENLITENED. The net result will ensure that the United States maintains its strength in the crucial sector of Information Technology, which is vital to both our economic security and our national security.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Distributed Wind Monitoring Best Practices

Accessible performance and operational data have been identified as a key enabler for distributed wind energy industry advancement. While utility-scale wind turbines benefit from reliable and continuous supervisory control and data acquisition (SCADA)-based monitoring platforms, monitoring of the U.S. fleet of distributed wind (DW) turbines has been more inconsistent, unreliable, and sometime difficult to access. Without fleet monitoring data, the industry will never understand and thus work to improve turbine under-performance and reliability issues. For the DW industry to scale up, attract investors, and boost credibility, fleetwide monitoring must be robust and reliable, select data must be made accessible to stakeholders, and the data must be in a format useful to users. To help move the industry toward a more standardized, accessible stream of monitoring data, this distributed wind monitoring best practices report attempts to cover topics including key monitoring channels, hardware, communication strategies, and accessibility. Strategic engagement with DW original equipment manufacturers (OEMs), service providers, lab and university researchers, testing organization, certification bodies, end users and solar photovoltaic (PV) monitoring experts has enabled a better understanding of the current state-of-the-art of monitoring and aided in articulating this set of best practices that will guide OEMs toward harmonized monitoring strategies, aimed at a future goal of achieving accessible performance and operational data for the entire fleet of U.S. distributed wind turbines.

17 WIND ENERGY↗

DOE OSTI2021

An Active Detection Scheme for Sensor Spoofing in Grid-tied PV Systems

In this paper an active detection scheme for sensor spoofing (manipulated externally via a cyber attack) in grid-tied PV systems is discussed. The core of the proposed active detection scheme is to introduce a private (secret) watermarking signal into the control inputs of the DC-DC converter and DC-AC inverter stages to detect any malicious spoofing (manipulation) of voltage/current sensor measurements controlling both the DC-DC converter maximum power point tracking (MPPT) stage and the DC-AC inverter of the grid-tied PV system. Several types of possible spoofing mechanisms (attack models) are discussed. The proposed sensor spoofing attack detector system consists of injecting a small magnitude of digital watermarking signal (DWS) and conduct three statistical watermark tests on the reported sensor measurements to determine if a) the proposed system is healthy and operating as expected b) if sensor signals were spoofed (manipulated) externally or c) if a particular sensor is malfunctioning due to a faulty hardware. It is shown via extensive simulations that the proposed DWS approach is robust in detecting malicious external manipulation of sensors controlling the grid tied PV system. A testing platform is currently under development and the experimental results will be discussed in the conference presentation.

Ibrahim, Hasan↗

DOE OSTI2026

Modeling and Power-Hardware-in-the-Loop Validation of Synchronous Machine Governor

This paper introduces the development of a high-fidelity gas turbine governor model using a programmable logic controller for power-hardware-in-the-loop (PHIL) validation. The governor model is integrated with the National Renewable Energy Laboratory's (NREL) PHIL test bed, featuring a 2-MVA synchronous machine and a 2.5-MW variable-speed drive, to emulate NG-driven HRSGs and CTs under various operational scenarios. The primary objective of this research is to study the grid-connected and islanding operations of conventional generation sources, with representative startup sequences including turbine purge, ignition, speed ramp-up, synchronization, and breaker closure. Preliminary results of the generator governor model on NREL PHIL platform, particularly using the 2.5-MW dynamometer system, offered significant insights into the modeling techniques, hardware integration, scaling, and real-world simulation dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Status Report on Development of MARCH Module Designs

The Transient Reactor Test (TREAT) facility was constructed in the late 1950’s, provided thousands of transient irradiations before being placed in standby in 1994, and was restarted in 2017 in order to resume its crucial role in nuclear heated safety research. Advances in modern computational capabilities and a resurgence of interest in novel reactor technology have created an opportunity for emphasizing modern science-based and separate effects test capabilities at TREAT. An innovative approach to this type of testing leverages the relatively low radioisotope accumulation during brief TREAT irradiations by arranging small fresh fuel specimens in low activation hardware “modules” so that they can be easily extracted and shipped for examination within weeks. The concept was termed the Minimal Activation Retrievable Capsule Holder (MARCH) irradiation vehicle system, and its maturation began under a Lab Directed Research and Development (LDRD) project starting in fiscal year 2017. Within the first year of this project, enough design and predictive modeling had been performed to prove the principle and ascertain support from major direct-funded DOE fuel development programs including the Accident Tolerant Fuels (ATF) program that sponsored the first modern fueled test to be performed in TREAT using the MARCH system. Since the design was modular in nature, it was straightforward for other sources to adopt and mature viable test modules while the LDRD project continued concurrently for two more years in conceptualizing and demonstrating the viability of other innovative modules. Many of these modules were adopted for continued development and irradiation under the Advanced Fuels Campaign and other direct sources. This report summarizes the MARCH modules that were conceptualized, designed, and deployed to date with the primary aim of providing reference information to future experiment designers.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

An SF 6 gas-insulated −500 kV DC conical insulator vacuum feedthrough

A test electrode was biased to −500 kV direct current (DC) by means of a novel SF 6 gas-insulated conical alumina insulator feedthrough. The design enables the extreme high vacuum conditions required by spin-polarized electron sources by reducing the photogun vacuum chamber volume compared to coaxial cylindrical insulators. In contrast to conventional inverted-insulator photogun designs that rely on solid dielectric interfaces for high-voltage terminations, the present design employs a pressurized SF 6 intervening volume between a conical alumina insulator and a modified commercial epoxy high-voltage cable receptacle. Here, this approach enables the use of commercially available cable hardware while extending the demonstrated operating voltage of solid feedthroughs. A maximum voltage of −500 kV was applied to a test electrode attached to the narrow end of the feedthrough inside a chamber filled with SF 6 at 170.3 kPa (10 psig) and later under vacuum to −259 kV, limited by field emission. The results demonstrate that a commercial high-voltage cable combined with a custom-designed SF 6 gas-insulated vacuum feedthrough can be used to bias photogun electrodes to −500 kV DC.

Palacios-Serrano, Gabriel [Thomas Jefferson Nation↗

DOE OSTI2025

Radio Frequency Field Programable Gate Array Implementation of Reflectometry Cable Monitoring

This document describes the development of a field programable gate array (FPGA) radio frequency system on a chip (RF SoC) adaptation and evaluation of the single-board device to perform both Frequency Domain Reflectometry (FDR) and Spread Spectrum Time Domain Reflectometry (SSTDR) for offline and online cable testing. The work builds on and leverages the work of Pacific Northwest National Laboratory (PNNL) in airport millimeter wave technology by using the same development hardware employed in that program. The work is performed under sponsorship from the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program and the task objective is to confirm and demonstrate feasibility to adapt FPGA technology for a cost-effective multiplexed single-board electronic module to perform cable tests that are equivalent to commercial and laboratory test instruments for FDR and SSTDR cable tests. The developed 2-channel (extendable to 7 channels) system was compared to dedicated and proven test instruments and shown to produce equivalent results on a range of cables and with a range of damage types. The FPGA reflectometry test board is one of several technologies that could facilitate implementation of online monitoring of safety critical cable systems.

42 ENGINEERING↗

DOE OSTI2018

Online Weld Quality Inspection System with Infrared Thermography

Today’s passenger vehicle on average contains 4,000 to 6,000 resistance spot welds (RSW). All US automakers perform destructive teardown evaluation to ensure the quality of the spot welds due to their criticality in crash resistance and performance of vehicles. The destructive teardown evaluation is labor intensive and costly. Sponsored by DOE VT Office, ORNL recently developed a prototype system (hardware and software) to non-destructively evaluate the quality of RSW based on infrared (IR) thermography. Highly cost competitive, ORNL’s system has been tested extensively in the laboratory with initial successful production environment validation. Ford, Honda, GM, Chrysler and major Tier One suppliers all have shown keen interest in this new technology. ORNL’s Technology Transfer Office licensed this technology to a small business (APLAIR Manufacturing Solutions) in TN. The licensee planned to develop a new hardware system based on ORNL’s IR NDE technology for real-time online weld inspection. In this CRADA project, ORNL was tasked to assist the licensee to transfer the technology and develop the new product suitable for automotive body-in-white production environment, making the technology ready for ‘real-world’ auto-body assembly line production environment.

47 OTHER INSTRUMENTATION↗

DOE OSTI2015

RF low-level control for the Linac4 H{sup −} source

The H{sup −} source for the Linac4 accelerator at CERN uses an RF driven plasma for the production of H{sup −}. The RF is supplied by a 2 MHz RF tube amplifier with a maximum power output of 100 kW and a pulse duration of up to 2 ms. The low-level RF signal generation and measurement system has been developed using standard CERN controls electronics in the VME form factor. The RF frequency and amplitude reference signals are generated using separate arbitrary waveform generator channels. The frequency and amplitude are both freely programmable over the duration of the RF pulse, which allows fine-tuning of the excitation. Measurements of the forward and reverse RF power signals are performed via directional couplers using high-speed digitizers, and permit the estimation of the plasma impedance and deposited power via an equivalent circuit model. The low-level RF hardware and software implementations are described, and experimental results obtained with the Linac4 ion sources in the test stand are presented.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

IOTA Run 2 Beam Dynamics Studies in Nonlinear Integrable Systems

Nonlinear integrable optics is a promising design approach for suppressing fast collective instabilities. To study it experimentally, a new storage ring, the Integrable Optics Test Accelerator (IOTA), was built at Fermilab. IOTA has recently completed its second scientific run, incorporating many hardware and instrumentation improvements. This report presents the results of the two integrable optics experiments - the quasi-integrable Henon-Heiles octupole system and the fully integrable Danilov-Nagaitsev system. We demonstrate tune spread and dynamic aperture in agreement with tracking simulations, and a stable crossing of the integer resonance. Based on recovered single-particle phase space dynamics, we show improved invariant jitter consistent with intended effective Hamiltonian. We conclude by outlining future plans and efforts towards proton studies and larger designs.

43 PARTICLE ACCELERATORS↗

DOE OSTI2017

OLED Lighting Substrate and Encapsulation System for Breakthrough Cost Reductions

OLED lighting is predicted to contribute a significant part of the US energy savings that will result from the implementation of Solid-State Lighting (SSL). OLED lighting adoption is predicted to reach approximately 5% of the lighting market by 2020. The primary purpose of this study was to address a barrier in OLED lighting adoption, this being OLED production costs. This project enabled the elimination of the anode patterning steps, by physically insulating the cathode contact area from the blanket coated ITO anode. Furthermore, this technology eliminates the need to change shadow masks between the organic materials and the cathode, making the OLED deposition machines simpler, lower cost, and less prone to particle generation. Finally, the process developed here permits the creation of a perfectly hermetic seal thereby eliminating the cost of desiccant materials. In this project, we successfully developed an ultrasonic soldering process to create a perfectly hermetic metal-on-glass bond. This required the evaluation of many ultrasonic solder materials, soldering parameters, and solder hardware configurations. In addition, methods to evaluate the hermeticity of the solder seal were developed and successfully tested. Our work demonstrated the ability to make a hermetic solder seal between a device glass and a cover glass using a Cerasolzer 155 ultrasonic solder. The resulting process could be leveraged to almost any OLED configuration. As we did not have the opportunity to produce a significant quantity of OLED devices for environmental testing, hermeticity was verified by measuring helium leakage rates through the seal. A second facet of this project required the development of a patterned glass frit insulating barrier over surface of the anode. To accomplish this, the appropriate insulator formulation and geometry needed to be established. In addition, this insulator needed to be robust enough to hold up to the ultrasonic soldering process previously mentioned. Given the aggressive nature of the ultrasonic soldering process, it was a significant challenge to develop an insulator which would withstand the resulting solder cavitation. The frit material and firing process turned out to be quite expensive and time consuming which was a major contributor to the higher than anticipated cost of this technology. In the end, it was found that a Vanadium Phosphate glass frit provided the most reliable insulator over the ITO.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

SPC-2734 Chromalox Oil Heater System Procurement Specification

This specification will supply the necessary technical information to the vendor to allow them to provide the system we need for the Thermal Energy Delivery System (TEDS) construction. TEDS is being constructed within the dynamic energy transport and integration laboratory (DETAIL) facility to test heat transfer components, distribution systems, instruments, and controls that can be monitored and controlled for hybrid generation of electrical power and/or non-electrical products. TEDS is designed to operate as a part of an integrated system or independently to demonstrate component operations, to develop and validate thermal energy transport models and control systems, and to study thermal energy inertia and storage. Within the integrated system, TEDS will be connected to the INL Real Time Digital Simulator (RTDS) test platform to develop and demonstrate monitoring and control systems and to investigate real-time, hardware-in-the-loop response characteristics relative to grid operations. As the basis of the TEDS, Chromalox (the vendor) has been chosen to design and supply a heater, pump, storage tanks, and pressure vessel due to their experience with industrial-scale heat transfer oil systems.

25 ENERGY STORAGE↗

DOE OSTI2023

Modular, Multifunction, Multiport and Medium Voltage Utility Scale SiC PV Inverter (Final Report)

This project is to develop and demonstrate a Modular, Multi-function, Multiport and Medium Voltage utility scale SiC solar inverter (M4 Inverter). The M4 Inverter is a next generation utility scale PV + storage inverter that can substantially reduce the levelized cost of energy (LCOE) while providing grid friendly ancillary services. Conventional utility scale solar inverters includes three parts, a megawatt rated solar inverter, a low frequency transformer (LFT) and a medium voltage switch gear. The proposed M4 Inverter directly converts the DC output of solar panels to medium voltage AC, eliminating the bulky and costly LFT. The M4 Inverter also has a DC port to interface with an additional energy storage device. This plus its bidirectional power flow capability, allows multiple functions in addition to PV maximum power tracking be achieved. These additional functionalities include but not limited to reactive power support, peak shaving, fast frequency regulation and synthetic inertia. Predicted LCOE reductions with these added functionalities, improved efficiency and longer lifetime time are more than 30% compared with the 2017 utility scale solar LCOE. A 1MVA SiC M4 Inverter was developed and tested at high power level. The project has also advanced the state of the art in controller hardware in the loop simulation capability. Power electronic innovations introduced in the M4 Inverter includes 1700V SiC MOSFET application in 1500V PV system, soft switching three-port power converters and modular converter architecture.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Fast, Controllable, and Modular Solid-State Circuit Breaker Design for Battery Management Systems

Electric power grid is experiencing a growing number of distributed and inertia-free generation resources. To facilitate the growing generation and load demands, and ensure stable operation, energy storage systems, especially behind-themeter-storage (BTMS), have emerged as a potential candidate. BTMS plays a vital role in the grid storage sector and supports high power charging for EVs. However, the potential of thermal runaway and associated safety concerns in the batteries can hamper their widespread adoption. In this work, we provide a solution for a fast and controllable discharge of a cell that was identified as a stressful/faulty, in the battery pack, and fast circuit breaking leveraging the Solid-State Circuit Breaker (SSCB) technology which provides active control over the cell connection as opposed to conventional passive solutions. Testing on the simulation platform successfully validated the concept, demonstrating its efficacy. Controlled discharge testing with 20Ah LiFePO4 Lithium Iron Phosphate (LFP) cells from 1C-10C current rate on the hardware prototype corroborated simulation results, demonstrating design feasibility and providing essential data for its performance and thermal characteristics, while also revealing limitations that inform areas for further optimization.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

PACT Center: Perovskite PV Accelerator for Commercializing Technologies (Final Technical Report)

The Perovskite PV Accelerator for Commercializing Technologies (PACT) center was established in July 2021 as a national resource to accelerate the commercialization of perovskite photovoltaic (PV) technology in the United States. Since its inception, PACT has been led by Sandia National Laboratories (Sandia) in partnership with the National Laboratory of the Rockies (NLR), formerly known as NREL. From FY20-FY23, Los Alamos National Laboratory (LANL), CFV Labs, Black & Veatch (B&V), and the Electric Power Research Institute (EPRI) were part of the project team. LANL brought expertise in perovskite PV device designs and processing, CFV Labs (now GroundWork Renewables) provided initial indoor and outdoor measurement hardware technology, B&V led the initial effort on perovskite PV bankability, and EPRI worked on reviewing testing standards, identifying commercialization gaps, and helping to run PACT’s Industry Advisory Board, a group including representatives from commercial testing labs, independent engineering firms, insurance companies, state regulators, and electric utilities. To source perovskite PV module samples, PACT contracted with the University of North Carolina (UNC), the University of Toledo, the University of Washington, and SLAC/Stanford University to provide a steady stream of research-grade perovskite mini modules, enabling protocol development in advance of commercial module availability. The project period ran from July 1, 2021, through December 31, 2025, including a No Cost Extension. Starting in FY25, the project was continued as a Core Capability in the Lab Call portfolio and continues at a reduced budget with only Sandia and NLR as funded recipients. Notably, starting in FY25 PACT expanded its scope beyond MHP modules to accept all emerging PV mini module technologies for testing, including organic PV (OPV) and all-thin-film tandems, with the aim of supporting commercialization across the broader emerging PV ecosystem. With this change in scope the program was renamed the PV Accelerator for Commercializing Technologies, dropping perovskite from the name.

14 SOLAR ENERGY↗

DOE OSTI2022

Using Energy Storage-Based Grid Forming Inverters for Operational Reserve in Hybrid Diesel Microgrids

In remote arctic communities, where access to a bulk electrical grid interconnection is not available, the implementation of islanded microgrids has been the most viable way to produce and distribute electricity services to their inhabitants. Historically, these islanded grids have relied primarily on diesel generators or hydropower resources to supply the baseload. However, this practice can result in increased expense due to the high costs associated with fuel transportation and the significant amounts of on-site storage necessary when fuel transportation is unavailable during winter months. In order to mitigate this problem, arctic microgrids have started to transition to a hybrid-source operational mode by incorporating renewable energy sources that are inherently variable in nature, such as wind or solar. Due to their highly stochastic behavior, these hybrid-source islanded microgrids can pose potential issues related to power quality due to introduction of rapid net load fluctuations and inability of diesel generators to respond rapidly. In addition, non-firm stochastic sources can require significant idling diesel generator resources to serve as spinning reserves, which is inefficient and wasteful. This work studies the problems that may arise in the transient dynamics of a real-world hybrid diesel microgrid when subjected to a loss of wind generation. Moreover, this work proposes a transition from a diesel spinning reserve to a battery energy-storage system (BESS) operating reserve scheme. The study of the proposed transition is important in establishing the fundamental implication of transient dynamics and the potential benefits of integrating a BESS as a spinning reserve in terms of stability, frequency nadir, and transient voltage deviation. The methods to investigate and validate the transient dynamics relied on both electromagnetic simulation models of GFMIs and a commercially available GFMI in an experimental power hardware-in-the-loop setup. The simulation results showed that the proposed operating reserve scheme improves the power quality of the system in terms of voltage deviation and frequency nadir when the microgrid is subjected to a loss of wind generation scenario. Depending on the simulation cases, adding a GFMI reduced the frequency nadir between 65.3% and 86.7%. Moreover, the reductions in the voltage deviations improved between 3.6% and 23.0%. From these results it can be concluded that the integration of a GFMI can reduce the frequency nadir in a hybrid diesel microgrid, and in turn, reduce diesel consumption, which improves system reliability while reducing fuel expenses. Furthermore, the novelty of this work relies on the fact that the offline simulation results were validated using a power hardware-in-the-loop platform that incorporated a 100 kVA commercially available GFMI as the device under test.

Hernandez-Alvidrez, Javier↗