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DOE OSTI2023

Walking the ‘design–build–test–learn’ cycle: flux analysis and genetic engineering reveal the pliability of plant central metabolism

Oilseeds are of great economic importance for food and animal feed and their contribution to renewable energy production. Soybean seeds (Glycine max (L.) Merr.) contain c. 40% protein, 20% oil, and 30% carbohydrate (Song et al., 2023). Due to the massive scale of soybean production worldwide, even small improvements in seed protein and oil content make economic sense (Song et al., 2023). Successful manipulation of seed composition largely depends on a thorough understanding of the processes and pathways involved in the biosynthesis of fatty acids and amino acids, which are the building blocks of lipids and proteins. Rational engineering of the synthesis of storage reserves, that is, the rerouting of metabolic flux in central metabolism, is difficult to accomplish due to the complexity of the central metabolic network, the intricate regulation of its enzymes at multiple levels, and the often-unpredictable effects of genetic manipulation (Sweetlove et al., 2017). Therefore, the advancement of our understanding of central metabolism and its control of carbon partitioning requires following an iterative ‘design–build–test–learn’ (DBTL) cycle (Lin & Eudes, 2020) where metabolic flux analysis and hypothesis testing by transgenic approaches are important components. Previous metabolic studies on soybeans using isotopic tracers and metabolic flux analysis have provided insight into how lipid and protein biosynthesis occurs simultaneously during seed development (Allen et al., 2009; Allen & Young, 2013; Kambhampati et al., 2021). In an article published in this issue of New Phytologist, Morley et al. (2023; 1834–1851) put the insights they have gained into the delivery of metabolic precursors and energy cofactors to oil synthesis to the test and arrive at a successful metabolic engineering design. They show that an increase in seed oil content in soybeans can be achieved by overexpression of malic enzyme (ME) during seed development. Malic enzyme refers to a class of decarboxylating malate dehydrogenase enzymes that oxidize malate with NAD + or NADP + as redox cofactor while generating pyruvate and CO 2 . Like higher plants in general, soybean has distinct NADH- or NADPH-producing ME isoforms localized to the cytosol, plastid, or mitochondria (Gerrard Wheeler et al., 2016). As Morley et al. show, an increase in seed oil can be achieved in particular when a NADP+-dependent enzyme isoform (EC 1.1.1.40) is overexpressed in the plastid. Given the complex compartmentalization of pyruvate, malate, and redox metabolism (Fig. 1), increased oil production appears to depend on additional pyruvate and reducing equivalents being produced in the same compartment where de novo fatty acid biosynthesis occurs: the plastid.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Integration of Data Analytics with Plant System Health Program

This report summarizes the R&D activities of the Plant Health Management (PHM) project during fiscal year 2020 (FY20). This project focuses on the development of methods that integrate component health data and propagate such information at the system level to evaluate system sources of risk. This project development lives in cooperation with the Risk Informed Asset Management (RIAM) project. The RIAM project, in fact, uses the reliability models and data generated by the PHM project to optimize plant operations (e.g., maintenance/replacement schedule, optimal maintenance posture). This year’s activities for the PHM project focused mainly on the development of two classes of models. The first one includes a series of component reliability models which include aging, testing and maintenance. The second class includes a series of system reliability models which focus on the secondary side of exiting U.S. reactors. These models are based on fault tree logic structures such that they can be used by existing plant PRA software. We also started to focus on the management of health data and we tackled this issue in two directions. The first one focuses on the integration of monitor data with simulation models to assess component health. This approach is moving from a classical data based to a model+data based approach with the goal of improving higher component health information. The second direction focuses on linking equipment reliability data (e.g., maintenance/failure reports, component monitoring data) directly to system reliability models using a safety margin based language rather than a probability based language. The main advantage of a safety margin based language is that it can provide to system engineers more tangible information on system/component health and how it propagates to the system level.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Accelerated Aging and Evaluation of Hose-In-Hose Transfer Lines in the Hanford Waste Transfer System - 20312

Nonmetallic materials are used in the United States Department of Energy's Hanford Site Tank Farm waste transfer system. These materials include the inner primary hoses in the hose-in-hose transfer lines (HIHTLs), Garlock{sup R} gaskets, ethylene propylene diene monomer (EPDM) O-rings, and other nonmetallic materials. These nonmetallic materials are exposed to β and γ radiation, caustic solutions as well as high temperature and pressure stressors. How the nonmetallic components react to each of these stressors individually has been well established. However, simultaneous exposure of these stressors has not been evaluated and is of great concern to Hanford Site engineers. Florida International University's Applied Research Center engineers worked closely with key Hanford's Washington River Protection Solutions personnel to develop an experimental test plan that determines how these nonmetallic components react to various simultaneous stressor exposures. In this paper, research on the experimental testing of the hose-in-hose transfer lines used in the Hanford tank farm waste transfer system under simultaneous stressor exposures is presented. The stressor exposure experiments consisted of various combinations of simultaneous stressor exposure of caustic solution, high temperature and high pressure stressors. Research efforts focused on evaluating the aging behavior of EPDM by exposing samples of HIHTLs as well as EPDM dog bone shaped specimens to a 25% NaOH solution at (38 deg. C), operating (54 deg. C) and design temperatures (77 deg. C) for 6 months and 12 months. In addition, HIHTL and the EPDM dog-bone specimens were exposed to only hot water at 77 deg. C for a duration of one year. The mechanical and material properties of the samples were characterized and compared with those of the unexposed samples (baseline). Evaluations included burst pressure tests of the EPDM hose-in-hose transfer lines and material tensile strength test of EPDM dog-bone coupons. Both the tensile strength of the EPDM material dog bones and the burst pressure of the HIHTLs significantly decreased with the increasing temperature and increasing exposure time. When compared with the baseline samples, the burst pressure decreased by 28.75% for the sample aged at 77 deg. C after 12 months, in comparison to sample aged at 38 deg. C and 54 deg. C which had about 1.34% and 5.70% loss in burst pressures, respectively, after 12-month exposure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Southeast Carbon Sequestration Partnership (SECARB) Phase III Anthropogenic Test at Citronelle Field, Mobile Co., AL. Post-Injection Period Reservoir Modeling Report

The Southeast Carbon Sequestration Partnership (SECARB) Anthropogenic Test is a U.S. Department of Energy funded fully integrated carbon capture and storage initiative designed to demonstrate deep underground injection and containment of anthropogenic CO 2 sourced from Alabama Power’s Plant Barry. From August 20, 2012 to September 1, 2014, a total of 114,014 metric tonnes of CO 2 were transported via pipeline from Plant Barry and stored in a saline aquifer under a portion of the Citronelle Field operated by Denbury Onshore, LLC near Citronelle, Alabama. A major component of this project was to test and develop techniques to monitor, verify and account (MVA) for the CO 2 stored in the aquifer by the project. A suite of technologies were applied and developed to demonstrate non-endangerment of underground sources of drinking water (USDW’s) and to ensure that CO2 does not migrate out of intended zones within the subsurface. This involved several levels of monitoring: 1) Surface monitoring, 2) shallow groundwater monitoring, 3) deep reservoir monitoring and experimental MVA activities. Numerical models were developed to determine the project’s Area of Review (AoR) and to investigate the simulated advancement of the CO 2 plume through the subsurface aquifer for 30 years after the end of injection. An initial baseline area of review of 1,700 ft. was established. The key results demonstrating non-endangerment of USDW’s are presented.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Preliminary Procedures and Acceptance Criteria for in-situ Structural Materials Surveillance for MSR

This report describes the initial development of the technical basis for a materials surveillance technology that, when fully developed and validated, can be used by stakeholders to develop and implement a materials surveillance program to manage materials degradation during reactor operations. The procedures described in this report aim to bound the detrimental effects of the reactor environment on the creep-fatigue life of the reactor components through materials surveillance. Specifically, the report describes procedures for selecting critical locations within the reactor components for surrogate materials surveillance and the sizing and placements of passively-actuated materials surveillance test articles under development by the US Department of Energy, Advanced Reactor Technologies Program. These test articles apply cyclic thermomechanical load to a surrogate sample of the component structural material passively through thermal expansion mismatch within the articles, without requiring any penetrations in the reactor coolant boundary. The procedures can be used to size materials surveillance test articles so that they will fail before the corresponding structural component. These articles would be exposed to the component operating environment, located to experience a bounding radiation fluence and representative coolant exposure. They can be monitored during reactor operations to ensure that they have not failed under the combination of creep-fatigue damage and environmental degradation. The report describes the key technical decisions and the corresponding rational for using these procedures to provide advanced warning of any impending material failure. An appendix describes the technical basis and the procedure for sizing a family of passively-actuated test articles. Finally, the report describes future work needed to complete the technical basis underlying this materials surveillance technology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗

DOE OSTI2018

Baryonic Effects in Cosmic Shear Tomography: PCA Parameterization and the Importance of Extreme Baryonic Models

Baryonic effects are amongst the most severe systematics to the tomographic analysis of weak lensing data which is the principal probe in many future generations of cosmological surveys like LSST, Euclid etc.. Modeling or parameterizing these effects is essential in order to extract valuable constraints on cosmological parameters. In a recent paper, Eifler et al. (2015) suggested a reduction technique for baryonic effects by conducting a principal component analysis (PCA) and removing the largest baryonic eigenmodes from the data. In this article, we conducted the investigation further and addressed two critical aspects. Firstly, we performed the analysis by separating the simulations into training and test sets, computing a minimal set of principle components from the training set and examining the fits on the test set. We found that using only four parameters, corresponding to the four largest eigenmodes of the training set, the test sets can be fitted thoroughly with an RMS $\sim 0.0011$. Secondly, we explored the significance of outliers, the most exotic/extreme baryonic scenarios, in this method. We found that excluding the outliers from the training set results in a relatively bad fit and degraded the RMS by nearly a factor of 3. Therefore, for a direct employment of this method to the tomographic analysis of the weak lensing data, the principle components should be derived from a training set that comprises adequately exotic but reasonable models such that the reality is included inside the parameter domain sampled by the training set. The baryonic effects can be parameterized as the coefficients of these principle components and should be marginalized over the cosmological parameter space.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2016

Report on the Radiation Effects Testing of the Infrared and Optical Transition Radiation Camera Systems

Presented in this report are the results tests performed at Argonne National Lab in collaboration with Los Alamos National Lab to assess the reliability of the critical 99 Mo production facility beam monitoring diagnostics. The main components of the beam monitoring systems are two cameras that will be exposed to radiation during accelerator operation. The purpose of this test is to assess the reliability of the cameras and related optical components when exposed to operational radiation levels. Both X-ray and neutron radiation could potentially damage camera electronics as well as the optical components such as lenses and windows. This report covers results of the testing of component reliability when exposed to X-ray radiation. With the information from this study we provide recommendations for implementing protective measures for the camera systems in order to minimize the occurrence of radiation-induced failure within a ten month production run cycle.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Mu2e Production Target Thermal Test Project

The Mu2e experiment requires a production target that is capable of operating under extreme thermal conditions caused by an 8 GeV proton beam. This project’s objective supports the development of the Mu2e Pro- duction Target by testing the Stickman model’s thermal behavior. Angel Flores Luviano has assisted Jonathan Williams in progressing this project by contributing to the development of a Radiative Cooling Test Fixture (RCTF) that will be used to evaluate the thermal behavior of the new production target model. Engineering calculations were performed to an- alyze thermal performance and pressure drop within the cold well and wa- ter cooling circuit. These calculations also determined the optimal sizing for key components of the water system. An engineering note was made to document these calculations. CAD models of the water circuit piping, thermocouple mounting bars, and radiator chimney were developed, and prototype test rig components were fabricated using 3D printing. Future work will focus on continued RCTF development which includes control system integration, heater hardware design, and interfaces that can be scaled up to increase thermal capacity.

Flores Luviano, Angel Augusto [Unlisted, US]↗

DOE OSTI2021

Time Dependence of Methane Generation Rates from Saltstone

This report documents the tests performed to address the requirements listed in the Technical Request, which resulted in a Task Technical & Quality Assurance Plan (TTQAP) and a Run Plan to obtain the required information. The research expands previous scoping work to better understand methane generation in the Saltstone Disposal Facility (SDF). That scoping work demonstrated that methane is produced when sulfide-containing material is added to methylmercury (MeHg), which is found in the SDF Tank 50 feed waste. When Tank 50 waste is combined with grout premix solids dry feed ingredients of cement, slag cement, and fly ash, sulfides are released from the slag cement component of the premix. The prior testing results showed that while the concentration of total mercury was not affected in the pH 14 waste, the MeHg likely reacted with the sulfide contained in the slag. The scoping tests were performed in sealed reactors and thus, methane generation was not measured continuously; rather, it was measured after one hour and after 24 hours. After 24 hours, a large percentage of the MeHg was converted to methane, but after 1 hour only a small percentage of methane was released. It is noteworthy that the methane generation rate (MGR) was greater at the one-hour measurement. The data compiled from the scoping work needed to be expanded to better understand the generation of methane released from grout mixed with Tank 50 waste. This expanded study developed a more extensive knowledge of how and when methane is generated to inform the Documented Safety Analysis (DSA) of the SDF. As such, employing 8 sealed reactors, the methane generation time periods were extended to 2, 4, 6, 18, 30, 48, 72, and 96 hours (4 days). Results are documented herein to determine the capacity for MeHg, contained within Tank 50 salt solution (T50SS) simulant, to produce methane when mixed with saltstone dry feed ingredients, i.e., individual components (cement, slag, and fly ash) or a combination of those components.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Thermal Hydraulic Experimental Test Article (FY21 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA has been installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2 and Figure 3. Since the FY20 THETA status report, further water shakedown testing was performed, some final welding modifications were performed, all system components were sanitized, dry assembled, and commissioned. The THETA submersible electromagnetic flowmeter was welded closed to hermetically seal internal components from sodium followed by a helium leak check for the final time. Following installation of THETA into vessel #4, all data acquisition and control systems were brought online and commissioned at room temperature in the argon gas space of the empty vessel. The vessel zone 1 heaters were reinstalled and the flange was then insulated. The vessel 4 heaters were brought to a temperature of 100 °C and the THETA pump was jogged at 600 RPM to ensure it was functioning correctly. The secondary, AC Conduction based electromagnetic pump from CMI Novacast (product number CA-15) was ordered and will be delivered in late calendar year 2021. The custom designed permanent magnet based secondary flowmeter was designed, a drawing package and manufacturing specification created and quote requested from a machine shop. The intermediate heat exchanger design was completed and a drawing package is currently in progress. During the middle of calendar year 2021 the Building 308 sodium scrubber system was shut down in order to replaced some corroded piping and facilitate improvements on the system, thus requiring the sodium in METL to remain frozen. This has imposed a delay in filling vessel 4 with sodium to begin THETA testing. Sodium testing is expected to begin in early fiscal year 2022 as all THETA primary systems are operational.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Foam Fracturing Study for Stimulation Development of Enhanced Geothermal Systems

The large thermal gradients and high subsurface temperatures of the western region of the U.S. hold great potential for the implementation of enhanced geothermal systems (EGS). The development of these potential EGS resources requires stimulation of the reservoir to enhance permeability and it has been widely reported that a substantial amount of water will be required should conventional hydraulic stimulation be used. This presents a huge challenge and a high risk to the geothermal development because the water stress1 in these areas is already high or extremely high. The use of foam, a gas/liquid mixture predominantly composed of gas, in fracturing is considered and explored in this project as a potential approach to address water concerns with hydraulic stimulation in the development of EGS. This project, led by Oak Ridge National Laboratory (ORNL) in collaboration with Temple University, was awarded in an open lab call in 2018, and was part of the DOE GTO waterless stimulation initiative. The goal of the project was to demonstrate the feasibility of foam fracturing for EGS development through two primary tasks: Task 1: Laboratory study of the effectiveness of foam fracturing for representative geological materials, including cyclic pressurization using foam (led by ORNL) and Task 2: High temperature foam material selection and characterization (led by Temple University). In FY19, ORNL finished the critical review on serval issues associated with foam fracturing and the implementation of the proposed tasks in a lab study (Wang, et al., 2019), and completed the foam fracturing testing using cement as a model material (Wang, et al, 2020a). The work at ORNL was geared up to develop a brand-new foam testing system in FY20. The purchase of main components for the new system was finished in the first half of the FY20. The assembly of the foam testing system and foam fracturing testing were completed in the second half of the FY20 (Wang, et al., 2021a). Task 1 required the development of a test system which can be used to perform hydraulic fracturing of geological specimens with both water and foamed liquids at pressure up to 6,000 psi (41.4 MPa). The system possesses several capabilities that conventional injection systems lack for hydraulic fracturing. In addition to its ability to generate foam with controlled quality, it is capable of cycling pressure levels between specified values up to frequencies of 50 Hz. The latter capability was developed to evaluate the hypothesis that cyclic loading of samples would produce enhanced fracturing. The system consists of two sections: one for foam generation and another for foam injection. The foam is generated through separate control and pressurization of liquid and gas phases with controlled flow rates. The injection section is equipped with a low-flow Coriolis flow that monitors the density of foam to ensure the injection is in the range of target foam quality2. Experimental results of foam fracturing are reported for cylindrical granite specimens using water and aqueous N2 foam as the fracturing fluids. All experiments were performed for unconfined conditions. The effects of injection mode (i.e., monotonic vs cyclic pressurization) on breakdown pressure and failure response sample were investigated using water alone as a fracturing fluid and foams with a range of compositions. It was found that in the case of monotonic injection, the breakdown pressure of granite specimens tended to be slightly higher when fracturing with foam. Additionally, with a foam quality of 90%, the water use can be reduced by 50 to 84%, depending on hole size. On the other hand, it was observed that the breakdown pressure can be brought down to 70% of the monotonic breakdown pressure by using low cycle fatigue. Finally, discussions are presented regarding injectivity and water use reduction.

15 GEOTHERMAL ENERGY↗

DOE OSTI2020

Evaluation of the DC bus link capacitors and power transistor modules in the qualification testing of PV inverters

To achieve useful, fair, and cost-effective design qualification and type approval testing for PV inverters, two procedures were developed and demonstrated to evaluate the bus link capacitors and power transistor—and where applicable, its module—for long-term reliability. We evaluate the inverter under simulated use conditions with heat run tests to find the highest operating temperatures reached by these components. The procedures are demonstrated in this study with a 4-kVA class string inverter. The maximum temperature of the DC bus link capacitors was determined to be 76.4°C when the ambient temperature was at the inverter's maximum rated temperature of 60°C with derating occurring. On the other hand, the power transistor module's maximum temperature using the heat sink temperature as the index, 92.6°C, occurred in an ambient of 40.8°C when derating was not occurring. The conditions found for upper temperatures exhibited by these components are, respectively, proposed for implementation in the dry heat and thermal cycling tests in the IEC 62093 “Power conversion equipment for photovoltaic systems – Design qualification testing” international standard draft so that the levels applied in the tests are in proportion to those experienced in the field. Finally as a result, fairer evaluation of inverter reliability is realized.

14 SOLAR ENERGY↗

DOE OSTI2021

Ensuring statistical reproducibility of ocean model simulations in the age of hybrid computing

Novel high performance computing systems that feature hybrid architectures require large scale code refactoring to unravel underlying exploitable parallelism. Such redesign can often be accompanied with machine-precision changes as the order of computation cannot always be maintained. For chaotic systems like climate models, these round-off level differences can grow rapidly. Systematic errors may also manifest initially as machine-precision differences. Isolating genuine round off level differences from such errors remains a challenge. Here, we apply two-sample equality of distribution tests to evaluate statistical reproducibility of the ocean model component of US Department of Energy's Energy Exascale Earth System Model (E3SM). A 2-year control simulation ensemble is compared to a modified ensemble as a test case - after a known non-bit-for-bit change in a model component is introduced - to evaluate the null hypothesis that the two ensembles are statistically indistinguishable. To quantify the false negative rates of these tests, we conduct a formal power analysis using a targeted suite of short simulation ensembles. The ensemble suite contains several perturbed ensembles, each with a progressively different climate than the baseline ensemble - obtained by perturbing the magnitude of a single model tuning parameter, the Gent and McWilliams κ, in a controlled manner. The null hypothesis is evaluated for each of perturbed ensembles using these tests. The power analysis informs on the detection limits of the tests for given ensemble size allowing model developers to evaluate the impact of an introduced non-bit-for-bit change to the model.

Mahajan, Salil↗

DOE OSTI2021

Photographic Mitigation Documentation Related to the Engine Assembly and Disassembly Facility, Area 25, Nevada National Security Site, Nye County, Nevada

This letter report provides documentation in partial fulfillment of the mitigation of adverse effects to the Engine Maintenance Assembly and Disassembly (E-MAD) facility, a major component of the Nuclear Rocket Development Station (NRDS) Historic District located in Area 25 of the Nevada National Security Site (NNSS). Construction of the E-MAD facility began in 1962 for the purpose of disassembling and maintaining nuclear-powered rocket engines. Once the building was complete in 1967, the E-MAD facility remained in continuous operation until the nuclear rocket program was terminated in 1973. The mothballed facility was repurposed in 1977 for spent nuclear fuel handling and packaging activities. By the mid-1980s, all activities at the E-MAD facility had ceased (Reno et al. 2019). This submission is intended to comply with Stipulation III.D.1 of the Memorandum of Agreement DE-GM58-20NA25534 between the U.S. Department of Energy and the Nevada State Historic Preservation Officer Regarding Corrective Action Activities and Demolition of the Engine Maintenance Assembly and Disassembly Facility and the Test Cell C Historic District, Major Components of the Nuclear Rocket Development Station Historic District Located in Area 25 at the Nevada National Security Site Nye County (hereafter referred to as the MOA). Stipulation III.D.1 states the U.S. Department of Energy (DOE) will submit the existing supplementary collection of the large-format, black-and-white photographic prints taken during the 1996 Historic American Engineering Record (HAER) documentation of the E-MAD facility to the Nuclear Testing Archive (NTA), located on the second floor of the Rogers Building at Desert Research Institute (DRI) in Las Vegas, Nevada.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Considerations for realistic atmospheric environments: An application to corrosion testing

Measured salt compositions in dust collected over roughly the last decade from surfaces of in-service stainless-steel alloys at four locations around the United States are presented, along with the predicted brine compositions that would result from deliquescence of these salts. The salt compositions vary greatly from ASTM seawater and from laboratory salts (i.e., NaCl or MgCl 2 ) commonly used on corrosion testing. The salts contained relatively high amounts of sulfates and nitrates, evolved to basic pH values, and exhibited deliquescence relative humidity values (RH) higher than seawater. Additionally, inert dust in components were quantified and considerations for laboratory testing are presented. The observed dust compositions are discussed in terms of the potential corrosion behavior and are compared to commonly used accelerated testing protocols. Finally, ambient weather conditions and their influence on diurnal fluctuations in temperature (T) and RH on heated metal surfaces are evaluated and a relevant diurnal cycle for laboratory testing a heated surface has been developed. Suggestions for future accelerated tests are proposed that include exploration of the effects of inert dust particles on atmospheric corrosion, chemistry considerations, and realistic diurnal fluctuations in T and RH. Understanding mechanisms in both realistic and accelerated environments will allow development of a corrosion factor (i.e., scaling factor) for the extrapolation of laboratory-scale test results to real world applications.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Comparing wall performance predicted from hygrothermal simulations to wall performance measured from environmental chamber experiments

To effectively mitigate prevailing perceptions of potential moisture risks in high-R wall assemblies, a comprehensive moisture durability assessment that incorporates BA team field evaluations, lab tests and simulations has been completed over the last couple years. In FY18, three stick-built walls were succumbed to typical Chicago weather in ORNL’s Heat, Air and Moisture chamber. The measured temperature, relative humidity and moisture content within these walls were compared to WUFI hygrothermal simulation results. In FY19, similar experiments and comparison to WUFI results were completed with two walls, a Structural Insulated Panel (SIP) based wall and a Concrete Masonry Unit (CMU) based wall. The following tasks were completed for these two walls: 1. Measure air permeance of each individual wall using ASTM E283 Standard Test Method. 2.Test walls in diffusion scenario as only moisture transport mechanism and compare measured transient temperature and relative humidity of select wall components to WUFI model results. Chicago summer and weather will be investigated. 3. Test walls in wetting event scenario and compare measured transient temperature and relative humidity of select wall components with Chicago summer weather to WUFI model results. 4. Test walls in diffusion/advection scenario. In addition to controlling outdoor chamber to match real outdoor weather, a pressure differential across the wall will be varied. Measured transient temperature and relative humidity of select wall components will be compared to WUFI model results. 5. Test walls in diffusion/advection with solar heating of cladding. In addition to the variables above, IR lamps will be used to heat the cladding on a diurnal cycle. Measured transient OSB MC and temperature will be compared to WUFI model results. This report documents the experimental method, results and comparison of the measured experimental hygrothermal performance of the two walls to simulations results.

42 ENGINEERING↗

DOE OSTI2024

Mechanical Characterization of Electrolyzer Membranes and Components Under Compression

Proton-exchange membrane (PEM) water electrolysis is a promising technology for producing clean hydrogen by electrochemically splitting water when paired with renewable energy sources. A major roadblock to improving electrolyzer durability is the mechanical degradation of the cell components, which requires an understanding of their mechanical response under device-relevant conditions. However, there is a lack of studies on the mechanical characterization of the PEM and other components, as well as and their interactions. This study aims to address this gap by using a custom-designed testing apparatus to investigate the mechanics of electrolyzer components in uniaxial compression at 25 and 80 °C. Findings show stress-strain response of components have a varying degree of nonlinearity owing to their distinct deformation mechanisms and morphologies, from porous structures to polymers. These results are used to develop an expression for compressive stress-strain response of Nafion membranes and then analyze the deformation of components under applied pressure by using a 1-D spring network model of cell assembly. This work provides a new understanding of mechanical responses of the electrolyzer membrane and cell components, which can help assess material design and cell assembly strategies for improved electrolyzer durability.

08 HYDROGEN↗