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DOE OSTI2016

Graduate Student Program in Materials and Engineering Research and Development for Future Accelerators

The objective of the proposal was to develop graduate student training in materials and engineering research relevant to the development of particle accelerators. Many components used in today's accelerators or storage rings are at the limit of performance. The path forward in many cases requires the development of new materials or fabrication techniques, or a novel engineering approach. Often, accelerator-based laboratories find it difficult to get top-level engineers or materials experts with the motivation to work on these problems. The three years of funding provided by this grant was used to support development of accelerator components through a multidisciplinary approach that cut across the disciplinary boundaries of accelerator physics, materials science, and surface chemistry. The following results were achieved: (1) significant scientific results on fabrication of novel photocathodes, (2) application of surface science and superconducting materials expertise to accelerator problems through faculty involvement, (3) development of instrumentation for fabrication and characterization of materials for accelerator components, (4) student involvement with problems at the interface of material science and accelerator physics.

43 PARTICLE ACCELERATORS↗

DOE OSTI2016

Technique development for modulus, microcracking, hermeticity, and coating evaluation capability characterization of SiC/SiC tubes

Driven by the need to enlarge the safety margins of nuclear fission reactors in accident scenarios, research and development of accident-tolerant fuel has become an important topic in the nuclear engineering and materials community. A continuous-fiber SiC/SiC composite is under consideration as a replacement for traditional zirconium alloy cladding owing to its high-temperature stability, chemical inertness, and exceptional irradiation resistance. An important task is the development of characterization techniques for SiC/SiC cladding, since traditional work using rectangular bars or disks cannot directly provide useful information on the properties of SiC/SiC composite tubes for fuel cladding applications. At Oak Ridge National Laboratory, experimental capabilities are under development to characterize the modulus, microcracking, and hermeticity of as-fabricated, as-irradiated SiC/SiC composite tubes. Resonant ultrasound spectroscopy has been validated as a promising technique to evaluate the elastic properties of SiC/SiC composite tubes and microcracking within the material. A similar technique, impulse excitation, is efficient in determining the basic mechanical properties of SiC bars prepared by chemical vapor deposition; it also has potential for application in studying the mechanical properties of SiC/SiC composite tubes. Complete evaluation of the quality of the developed coatings, a major mitigation strategy against gas permeation and hydrothermal corrosion, requires the deployment of various experimental techniques, such as scratch indentation, tensile pulling-off tests, and scanning electron microscopy. In addition, a comprehensive permeation test station is being established to assess the hermeticity of SiC/SiC composite tubes and to determine the H/D/He permeability of SiC/SiC composites. This report summarizes the current status of the development of these experimental capabilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Distributed Resource Energy Analysis and Management System (DREAMS) Development for Real-time Grid Operations

This project supports development of the next generation, integrated energy management infrastructure (EMS) able to incorporate advance visualization of behind-the-meter distributed resource information and probabilistic renewable energy generation forecasts to inform real-time operational decisions. The project involves end-users and active feedback from an Utility Advisory Team (UAT) to help inform how information can be used to enhance operational functions (e.g. unit commitment, load forecasting, Automatic Generation Control (AGC) reserve monitoring, ramp alerts) within two major EMS platforms. Objectives include: Engaging utility operations personnel to develop user input on displays, set expectations, test and review; Developing ease of use and timeliness metrics for measuring enhancements; Developing prototype integrated capabilities within two operational EMS environments; Demonstrating an integrated decision analysis platform with real-time wind and solar forecasting information and timely distributed resource information; Seamlessly integrating new 4-dimensional information into operations without increasing workload and complexities; Developing sufficient analytics to inform and confidently transform and adopt new operating practices and procedures; Disseminating project lessons learned through industry sponsored workshops and conferences;Building on collaborative utility-vendor partnership and industry capabilities

14 SOLAR ENERGY↗

DOE OSTI2016

Development of Ultrafiltration Membrane-Separation Technology for Energy-Efficient Water Treatment and Desalination Process

The growing scarcity of fresh water is a major political and economic challenge in the 21st century. Compared to thermal-based distillation technique of water production, pressure driven membrane-based water purification process, such as ultrafiltration (UF), nanofiltration (NF) and reverse osmosis (RO), can offer more energy-efficient and environmentally friendly solution to clean water production. Potential applications also include removal of hazardous chemicals (i.e., arsenic, pesticides, organics) from water. Although those membrane-separation technologies have been used to produce drinking water from seawater (desalination) and non-traditional water (i.e., municipal wastewater and brackish groundwater) over the last decades, they still have problems in order to be applied in large-scale operations. Currently, a major huddle of membrane-based water purification technology for large-scale commercialization is membrane fouling and its resulting increases in pressure and energy cost of filtration process. Membrane cleaning methods, which can restore the membrane properties to some degree, usually cause irreversible damage to the membranes. Considering that electricity for creating of pressure constitutes a majority of cost (~50%) in membrane-based water purification process, the development of new nano-porous membranes that are more resistant to degradation and less subject to fouling is highly desired. Styrene-ethylene/butylene-styrene (SEBS) block copolymer is one of the best known block copolymers that induces well defined morphologies. Due to the polarity difference of aromatic styrene unit and saturated ethylene/butylene unit, these two polymer chains self-assemble each other and form different phase-separated morphologies depending on the ratios of two polymer chain lengths. Because the surface of SEBS is hydrophobic which easily causes fouling of membrane, incorporation of ionic group (e,g, sulfonate) to the polymer is necessary to reduces fouling. Recently, sulfonated SEBS became commercially available and has been extensively explored for membrane-mediated water purification technology. The sulfonated block copolymer creates a well developed nano-sale phase-separated morphologies composed of hydrophilic domains (sulfonated polystyrene) and hydrophobic domains (polyethylene/polybutylene). The hydrophilic domains determines transport properties (water transport, salt and/or ion rejection, etc) and the hydrophobic domains provides mechanical stability of the membrane. Unfortunately, a high degree of sulfonation of SEBS induces excessive swelling and deterioration of mechanical stability of the membrane. In an effort to develop robust polymeric membrane materials for water purification technology, phosphonic acid-functionalized SEBS membranes are investigated during this report period. In compare to sulfonated polymers, the corresponding phosphonated polymers are known to swell less because of the formation of extensive hydrogen bonding networks between phosphonates. In addition to the expected better mechanical stability, phosphonated polymers has another advantage over sulfonated polymers for the use water purification membrane; each phosphonate can accommodate two ions while each sulfonate accommodates only one ion. Membrane properties (ion type, ionic density, etc) of new membranes will be studied and their separation performance will be evaluated in water purification and desalination process. Through systematic study of the relationship of chemical structure–surface property–membrane performance, we aim to better understand the nature of membrane fouling and develop more fouling-resistant water purification membranes. The basic understanding of this relationship will lead to the development of advanced membrane materials which can offer a solution to environmentally sustainable production of fresh water.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Development of Smart Ventilation Control Algorithms for Humidity Control in High-Performance Homes in Humid U.S. Climates

Past field research and simulation studies have shown that high performance homes experience elevated indoor humidity levels for substantial portions of the year in humid climates. This is largely the result of lower sensible cooling loads, which reduces the moisture removed by the cooling system. These elevated humidity levels lead to concerns about occupant comfort, health and building durability. Use of mechanical ventilation at rates specified in ASHRAE Standard 62.2-2013 are often cited as an additional contributor to humidity problems in these homes. Past research has explored solutions, including supplemental dehumidification, cooling system operational enhancements and ventilation system design (e.g., ERV, supply, exhaust, etc.). This project’s goal is to develop and demonstrate (through simulations) smart ventilation strategies that can contribute to humidity control in high performance homes. These strategies must maintain IAQ via equivalence with ASHRAE Standard 62.2-2013. To be acceptable they must not result in excessive energy use. Smart controls will be compared with dehumidifier energy and moisture performance. This work explores the development and performance of smart algorithms for control of mechanical ventilation systems, with the objective of reducing high humidity in modern high performance residences. Simulations of DOE Zero-Energy Ready homes were performed using the REGCAP simulation tool. Control strategies were developed and tested using the Residential Integrated Ventilation (RIVEC) controller, which tracks pollutant exposure in real-time and controls ventilation to provide an equivalent exposure on an annual basis to homes meeting ASHRAE 62.2-2013. RIVEC is used to increase or decrease the real-time ventilation rate to reduce moisture transport into the home or increase moisture removal. This approach was implemented for no-, one- and two-sensor strategies, paired with a variety of control approaches in six humid climates (Miami, Orlando, Houston, Charleston, Memphis and Baltimore). The control options were compared to a baseline system that supplies outdoor air to a central forced air cooling (and heating) system (CFIS) that is often used in hot humid climates. Simulations were performed with CFIS ventilation systems operating on a 33% duty-cycle, consistent with 62.2-2013. The CFIS outside airflow rates were set to 0%, 50% and 100% of 62.2-2013 requirements to explore effects of ventilation rate on indoor high humidity. These simulations were performed with and without a dehumidifier in the model. Ten control algorithms were developed and tested. Analysis of outdoor humidity patterns facilitated smart control development. It was found that outdoor humidity varies most strongly seasonally—by month of the year—and that all locations follow the similar pattern of much higher humidity during summer. Daily and hourly variations in outdoor humidity were found to be progressively smaller than the monthly seasonal variation. Patterns in hourly humidity are driven by diurnal daily patterns, so they were predictable but small, and were unlikely to provide much control benefit. Variation in outdoor humidity between days was larger, but unpredictable, except by much more complex climate models. We determined that no-sensor strategies might be able to take advantage of seasonal patterns in humidity, but that real-time smart controls were required to capture variation between days. Sensor-based approaches are also required to respond dynamically to indoor conditions and variations not considered in our analysis. All smart controls face trade-offs between sensor accuracy, cost, complexity and robustness.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Development and Implementation of CFD-Informed Models for the Advanced Subchannel Code CTF

The research described in this PhD thesis contributes to the development of efficient methods for utilization of high-fidelity models and codes to inform low-fidelity models and codes in the area of nuclear reactor core thermal-hydraulics. The objective is to increase the accuracy of predictions of quantities of interests using high-fidelity CFD models while preserving the efficiency of low-fidelity subchannel core calculations. An original methodology named Physics- based Approach for High-to-Low Model Information has been further developed and tested. The overall physical phenomena and corresponding localized effects, which are introduced by the presence of spacer grids in light water reactor (LWR) cores, are dissected in corresponding four building basic processes, and corresponding models are informed using high-fidelity CFD codes. These models are a spacer grid-directed cross-flow model, a grid-enhanced turbulent mixing model, a heat transfer enhancement model, and a spacer grid pressure loss model. The localized CFD-models are developed and tested using the CFD code STAR-CCM+, and the corresponding global model development and testing in sub-channel formulation is performed in the thermal- hydraulic subchannel code CTF. The improved CTF simulations utilize data-files derived from CFD STAR-CCM+ simulation results covering the spacer grid design desired for inclusion in the CTF calculation. The current implementation of these models is examined and possibilities for improvement and further development are suggested. The validation experimental database is extended by including the OECD/NRC PSBT benchmark data. The outcome is an enhanced accuracy of CTF predictions while preserving the computational efficiency of a low-fidelity subchannel code.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

Air Products carried out a scope of work under DOE Award No. DE-FE0012065 “Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications” with subcontractors Ceramatec, Penn State, and WorleyParsons. The scope of work under this award was aimed at furthering the development of the Ion Transport Membrane (ITM) Oxygen production process toward a demonstration-scale facility known as the Oxygen Development Facility (ODF). Specific activities will help to enable design and construction of the ODF through advancement of a number of challenging technical elements that are required to manage risk in the initial deployment of ITM technology. Major objectives of the work included developing ITM Oxygen ceramic membrane materials with improved performance and reliability, optimizing ceramic module geometry and fabrication methods, testing module performance, trialing the improved fabrication process at commercial scale in the Ceramic Membrane Module Fabrication Facility (CerFab), and advancing engineering development of the ITM oxygen production process, including vessel design and contaminant control measures to prepare for deployment of the ODF. The comprehensive report that follows details the team’s work, which includes several notable accomplishments: 1) compressive creep, a likely limiter of ceramic module lifetime in service, was demonstrated to be retarded by an order of magnitude by changes in material formulation, module joining dimensions, and internal wafer geometry; 2) two promising new materials were shown to be superior to the incumbent ITM material in a key material parameter related to oxygen flux; 3) module degradation mechanisms were identified following operation in large pilot-scale equipment; 4) options for utilizing ITM in a coal-to-liquids (CTL) facility to enable liquids production with carbon capture were identified and studied; and 5) the benefits of potential improvements to the technology were assessed for their cost impact on ITM Oxygen applications to clean power, fuels, and other applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Development of ITM Oxygen Technology for Low-cost and Low-emission Gasification and Other Industrial Applications

42 ENGINEERING↗

DOE OSTI2017

Report on the FY17 Development of Computer Program for ASME Section III, Division 5, Subsection HB, Subpart B Rules

One of the objectives of the high temperature design methodology activities is to develop and validate both improvements and the basic features of ASME Boiler and Pressure Vessel Code, Section III, Rules for Construction of Nuclear Facility Components, Division 5, High Temperature Reactors, Subsection HB, Subpart B (HBB). The overall scope of this task is to develop a computer program to aid assessment procedures of components under specified loading conditions in accordance with the elevated temperature design requirements for Division 5 Class A components. There are many features and alternative paths of varying complexity in HBB. The initial focus of this computer program is a basic path through the various options for a single reference material, 316H stainless steel. However, the computer program is being structured for eventual incorporation all of the features and permitted materials of HBB. This report will first provide a description of the overall computer program, particular challenges in developing numerical procedures for the assessment, and an overall approach to computer program development. This is followed by a more comprehensive appendix, which is the draft computer program manual for the program development. The strain limits rules have been implemented in the computer program. The evaluation of creep-fatigue damage will be implemented in future work scope.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE), has completed the project “Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development” under U.S. Department of Energy (DOE) Award Number DE-FE0024076. This project was part of DOE’s Novel Crosscutting Research and Development to Support Advanced Energy Systems program. AUSC Tube Membrane Panel Development was a two and one half year project to develop and verify the manufacturability and serviceability of welded tube membrane panels made from high performance materials suitable for the AUSC steam cycles, defined as high pressure steam turbine inlet conditions of 700-760°C (1292-1400°F) and 24.5-35MPa (3500-5000psi). The difficulty of this challenge lies in the fact that the membrane-welded construction imposes demands on the materials that are unlike any that exist in other parts of the boiler. Tube membrane panels have been designed, fabricated, and installed in boilers for over 50 years with relatively favorable experience when fabricated from carbon and Cr-Mo low alloy steels. The AUSC steam cycle requires membrane tube panels fabricated from materials that have not been used in a weldment with metal temperatures in the range of 582-610°C (1080-1130°F). Fabrication materials chosen for the tubing were Grade 92 and HR6W. Grade 92 is a creep strength enhanced ferritic Cr-Mo alloy and HR6W is a high nickel alloy. Once the materials were chosen, GE performed the engineering design of the panels, prepared shop manufacturing drawings, and developed manufacturing and inspection plans. After the materials were purchased, GE manufactured and inspected the tube membrane panels, determined if post fabrication heat treatment of the tube membrane panels was needed, performed pre- and post-weld heat treatment on the Grade 92 panels, conducted final nondestructive inspection of any heat treated tube membrane panels, conducted destructive inspection of the completed tube membrane panels,and performed simulated shop repairs on the panel fabricated using Grade 92. GE executed the program as the prime contractor under the direction of Principal Investigator Mr. James Pschirer. Other participants in this project included GE Boiler Engineering, GE Chattanooga Manufacturing, GE Materials Technology Center, GE Rocky Mountain Service Center, and a Technical Consultant from Electric Power Research Institute (EPRI).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

User input verification and test driven development in the NJOY21 nuclear data processing code

Before physically-meaningful data can be used in nuclear simulation codes, the data must be interpreted and manipulated by a nuclear data processing code so as to extract the relevant quantities (e.g. cross sections and angular distributions). Perhaps the most popular and widely-trusted of these processing codes is NJOY, which has been developed and improved over the course of 10 major releases since its creation at Los Alamos National Laboratory in the mid-1970’s. The current phase of NJOY development is the creation of NJOY21, which will be a vast improvement from its predecessor, NJOY2016. Designed to be fast, intuitive, accessible, and capable of handling both established and modern formats of nuclear data, NJOY21 will address many issues that many NJOY users face, while remaining functional for those who prefer the existing format. Although early in its development, NJOY21 is quickly providing input validation to check user input. By providing rapid and helpful responses to users while writing input files, NJOY21 will prove to be more intuitive and easy to use than any of its predecessors. Furthermore, during its development, NJOY21 is subject to regular testing, such that its test coverage must strictly increase with the addition of any production code. This thorough testing will allow developers and NJOY users to establish confidence in NJOY21 as it gains functionality. This document serves as a discussion regarding the current state input checking and testing practices of NJOY21.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

Scoping study to expedite development of a field deployable and portable instrument for UF6 enrichment assay

The primary objective of the present study is to identity the most promising, viable technologies that are likely to culminate in an expedited development of the next-generation, field-deployable instrument for providing rapid, accurate, and precise enrichment assay of uranium hexafluoride (UF6). UF6 is typically involved, and is arguably the most important uranium compound, in uranium enrichment processes. As the first line of defense against proliferation, accurate analytical techniques to determine the uranium isotopic distribution in UF6 are critical for materials verification, accounting, and safeguards at enrichment plants. As nuclear fuel cycle technology becomes more prevalent around the world, international nuclear safeguards and interest in UF6 enrichment assay has been growing. At present, laboratory-based mass spectrometry (MS), which offers the highest attainable analytical accuracy and precision, is the technique of choice for the analysis of stable and long-lived isotopes. Currently, the International Atomic Energy Agency (IAEA) monitors the production of enriched UF6 at declared facilities by collecting a small amount (between 1 to 10 g) of gaseous UF6 into a sample bottle, which is then shipped under chain of custody to a central laboratory (IAEA’s Nuclear Materials Analysis Laboratory) for high-precision isotopic assay by MS. The logistics are cumbersome and new shipping regulations are making it more difficult to transport UF6. Furthermore, the analysis is costly, and results are not available for some time after sample collection. Hence, the IAEA is challenged to develop effective safeguards approaches at enrichment plants. In-field isotopic analysis of UF6 has the potential to substantially reduce the time, logistics and expense of sample handling. However, current laboratory-based MS techniques require too much infrastructure and operator expertise for field deployment and operation. As outlined in the IAEA Department of Safeguards Long-Term R&D Plan, 2012–2023, one of the IAEA long-term R&D needs is to “develop tools and techniques to enable timely, potentially real-time, detection of HEU (Highly Enriched Uranium) production in LEU (Lowly Enriched Uranium) enrichment facilities” (Milestone 5.2). Because it is common that the next generation of analytical instruments is driven by technologies that are either currently available or just now emerging, one reasonable and practical approach to project the next generation of chemical instrumentation is to track the recent trends and to extrapolate them. This study adopted a similar approach, and an extensive literature review on existing and emerging technologies for UF6 enrichment assay was performed. The competitive advantages and current limitations of different analytical techniques for in-field UF6 enrichment assay were then compared, and the main gaps between needs and capabilities for their field use were examined. Subsequently, based on these results, technologies for the next-generation field-deployable instrument for UF6 enrichment assay were recommended. The study was organized in a way that a suite of assessment metric was first identified. Criteria used in this evaluation are presented in Section 1 of this report, and the most important ones are described briefly in the next few paragraphs. Because one driving force for in-field UF6 enrichment assay is related to the demanding transportation regulation for gaseous UF6, Section 2 contains a review of solid sorbents that convert and immobilized gaseous UF6 to a solid state, which is regarded as more transportation friendly and is less regulated. Furthermore, candidate solid sorbents, which show promise in mating with existing and emerging assay technologies, also factor into technology recommendations. Extensive literature reviews on existing and emerging technologies for UF6 enrichment assay, covering their scientific principles, instrument options, and current limitations are detailed in Sections 3 and 4, respectively. In Section 5, the technological gaps as well as start-of-the-art and commercial off-the-shelf components that can be adopted to expedite the development of a fieldable or portable UF6 enrichment-assay instrument are identified and discussed. Finally, based on the results of the review, requirements and recommendations for developing the next-generation field-deployable instrument for UF6 enrichment assay are presented in Section 6.

36 MATERIALS SCIENCE↗

DOE OSTI2017

PIPER: Performance Insight for Programmers and Exascale Runtimes: Guiding the Development of the Exascale Software Stack

The PIPER project set out to develop methodologies and software for measurement, analysis, attribution, and presentation of performance data for extreme-scale systems. Goals of the project were to support analysis of massive multi-scale parallelism, heterogeneous architectures, multi-faceted performance concerns, and to support both post-mortem performance analysis to identify program features that contribute to problematic performance and on-line performance analysis to drive adaptation. This final report summarizes the research and development activity at Rice University as part of the PIPER project. Producing a complete suite of performance tools for exascale platforms during the course of this project was impossible since both hardware and software for exascale systems is still a moving target. For that reason, the project focused broadly on the development of new techniques for measurement and analysis of performance on modern parallel architectures, enhancements to HPCToolkit’s software infrastructure to support our research goals or use on sophisticated applications, engaging developers of multithreaded runtimes to explore how support for tools should be integrated into their designs, engaging operating system developers with feature requests for enhanced monitoring support, engaging vendors with requests that they add hardware measure- ment capabilities and software interfaces needed by tools as they design new components of HPC platforms including processors, accelerators and networks, and finally collaborations with partners interested in using HPCToolkit to analyze and tune scalable parallel applications.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Biomass Pyrolysis to Hydrocarbon Fuels in the Petroleum Refining Context: Cooperative Research and Development Final Report, CRADA Number CRD-12-500

This work focuses on developing a thermochemical route to produce biofuels from agricultural wastes such as sugar cane bagasse, wood chips or corn stover; more specifically it intends to develop the biomass pyrolysis route, which produces bio-oils. Production of bio-oils by pyrolysis is a commercial technology. However, bio-oils are currently not being used for liquid fuels production. Although bio-oils can be produced by high-pressure liquefaction, pyrolysis is a less expensive technology. Nevertheless, bio-oils cannot be used directly as a transportation fuel without upgrading, since they are generally unstable, viscous, and acidic. Thus NREL and Petrobras intend to use their combined expertise to develop a two-step route to biofuels production: in the first step, a stable bio-oil is produced by NREL biomass pyrolysis technology, while in the second step it is upgraded by using two distinct catalytic processes under development by Petrobras. The first process converts bio-oil into gasoline, LPG, and fuel oil using the catalytic cracking process, while the second one, converts bio-oil into synthesis gas. Syngas gasification catalysts provided by both NREL and Petrobras will be tested. The work includes experiments at both sites to produce bio-oil and then biofuels, life-cycle analysis of each route, personnel training and development of analytical methods with a duration time of two years.

09 BIOMASS FUELS↗

DOE OSTI2017

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improve the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Advanced Ultrasupercritical (AUSC) Materials Thick-Walled Cycling Header Development for ComTest-AUSC (Final Report)

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE) recently completed “Advanced Ultrasupercritical (AUSC) Materials Thick-Walled Cycling Header Development for ComTest-AUSC” under Award No. DE-FE0026183 for the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). This project developed a design for testing of a high temperature nickel-based superalloy thick-walled header to simulate cycling and flexible plant operation in new and existing plants. The objective was to simulate the expected thermal stresses of a new AUSC plant or a retrofit header in an existing plant to improve flexible dynamic operation while maintaining component integrity and overall power plant reliability. The high performance superalloy materials that enable higher operating temperatures and pressures can support future transformational power technologies including new AUSC plants at 4250-5000 psi, 730°C/760°C or will serve as a replacement component in a repowered or retrofit USC coal powered cycling plant at 3600 psi, 600°C. These alloys can also enable supercritical CO2 cycles, nuclear power, solar power and more efficient natural gas combined cycle units as targeted by the U.S. DOE/NETL Cross-Cutting Research Technology Program Plan. Recently developed advanced nickel alloys such as Inconel 740H (740H) and Haynes 282 (H282) have been successfully tested on a pilot scale for fireside corrosion using steam loop tubing at AUSC temperatures of 760°C in actual operating coal fired boiler. These high strength materials have been demonstrated their adequacy for use in other high temperature boiler components such as superheater tubes. Thick-walled superheater outlet headers which operate at high temperatures and pressure under severe cycling condition are considered as one of the most critical component in the AUSC coal fired boiler. Over the design life of a plant, these headers are exposed to the most severe fatigue and creep damage accumulation and need to be properly designed for the expected cycling in an AUSC plant with flexible operation. These materials need to demonstrate adequate design life of 20 to 30 years for creep and fatigue conditions. The following tasks were performed: 1. A conceptual design was developed of a thick-walled component representative of typical headers with several tube connections and proper flow rates (~100,000 lbs/hr) suitable for Phase II test at 760°C operation. This was based on a process analysis of expected full scale new and component retrofit designs for AUSC; 2. A multi-physics flow and heat transfer computational fluid dynamics (CFD) analysis of the component for proper layout of the header configuration, number and geometry (size) of tubes required for bypass flow, flow rates through the tubing, and sectional pressure drops was performed. Steam to header metal heat transfer film coefficients in the header section and the tubes during the two stages (half load and full load) of the cycling operation were evaluated and used in the stress analysis; 3. Detailed analytical evaluation of the thick-walled pipe and tube connections for mechanical integrity under cycling conditions was performed. This included transient thermal stress analysis and fatigue usage estimation including the tube-to-pipe weld geometries and weld materials; 4. A layout and design of the thick-walled test component was developed and instrumentation required for a test was identified; 5. Continuum Damage Mechanics (CDM) creep prediction models were extended to 740H and H282 and validated with public data on 740H and H282 for use in creep analysis. In addition, detailed creep analyses were performed separately for the design life of the conceptual AUSC superheater outlet header using these General Electric (GE) creep constitutive models. GE was the prime contractor for the project, which was directed by Principal Investigator Robert Schrecengost and Lead Scientist Dr. B. Reddy Ganta. Other collaborative participants in this project included GE Global Research, GE Boiler Engineering, and a Technical Consultant from EPRI.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

Identifying Barriers and Pathways to Success for Renewable Energy Development on American Indian Lands

American Indian tribes possess lands rich with renewable energy (RE) resources. Tribes have great potential and need to develop these resources, yet face a host of barriers that continue to impede development. Understanding these challenges as well as the pathways that can be taken to overcome them may facilitate more economic development to meet community needs and better position tribes to play a role in securing a low-carbon energy future for the United States. This paper presents the results of an expert elicitation of 24 tribal energy experts from federal, tribal, academic, and private industry backgrounds to identify barriers and opportunities for federally recognized tribes in the lower 48 states. Experts identified a number of unique challenges facing tribes including financing and funding, infrastructure, tribal leadership and staff, state-level influence, and partnerships. Cultural factors were seen only to be of concern with large-scale development. Tribal sovereignty is a significant motivation for RE development and has yet to be fully realized. Cultural considerations are critical to the success of future projects; smaller residential and community-scale projects may be a better fit. Improving partnerships between tribes and the private sector can increase RE deployment and overcome historical distrust. States can have a double-ended influence on projects within tribal lands through taxation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2017

Research and Development Toward Massive Liquid Argon Time Projection Chambers for Neutrino Detection

Liquid argon (LAr) time projection chambers (TPC) have rapidly increased in importance as particle detectors throughout the past four decades. While much research has been completed, there are still many areas which require further development to build and operate the next generation LAr TPC experiment, such as the Deep Underground Neutrino Experiment (DUNE). These include high voltage breakdown, argon purification and purity monitoring, and vacuum ultraviolet (VUV) scintillation light measurement. Visual monitoring of high voltage breakdown is helpful in allowing assessment of the performance of high voltage component design. Thus, a system of cryogenic cameras, the first of its kind, was developed for use in a large LAr cryostat, without the need for additional electronics heating. The system functioned without problem for 50 days at cryogenic temperature, with some degradation of image quality, and provided a useful monitor for the DUNE 35-ton cryogenics systems. The system did not observe any high voltage breakdowns during the run. Further development of the concept is ongoing for future installation in other experiments. The monitoring of LAr purity using TPC data is a fundamental study for LAr TPC experiments. However, the study has not been performed for a large LAr TPC in the presence of high electronic noise. Custom software was developed and validated for the accurate reconstruction of signals in noisy TPC data. The results of the reconstruction were used to successfully measure the LAr electron lifetime with an uncertainty comparable to alternate methods of measurement. The electron lifetime of the 35-ton Phase II run is determined to be 4.12 ± 0.17 (stat.) ±0.40 (syst.) ms. For general purpose research and development of high purity LAr as a particle detection medium, a dedicated test stand was designed, constructed, and commissioned. The system is used to test the gaseous photomultiplier (GPM) performance at cryogenic temperatures. The GPM functions with photoelectron multiplication at 77 K, at a reduced gain. Further study is required to show the detector’s direct sensitivity to LAr VUV scintillation light.

Thiesse, Matthew↗