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DOE OSTI2018

Adaptation of Commercially Available Robots for Conditioning and Packaging ILW at Sellafield - 18282

The Legacy Ponds and Silos at Sellafield site contain some of the most hazardous Intermediate Level Waste (ILW) in the UK. As part of a multi-billion pound decommissioning programme, this waste will be retrieved and transported across the site for conditioning and packaging in the Box Encapsulation Plant (BEP). Current plans are to commence plant active commissioning in 2022, which will represent a major milestone in the UK nuclear decommissioning programme. Within the plant, skips of waste will be transferred from the shielded transport package into standard 3 cubic metre ILW containers. Waste from the Pile Fuel Storage Pond and First Generation Magnox Storage Pond will be immobilised in cementitious grout before being transferred to an adjacent store. Waste from the Magnox Swarf Storage Silo will not be immobilised in grout, but will be packaged, providing multi-barrier containment. During the concept design, the project team selected commercially available robots as the most viable technology for carrying out the numerous dexterous and repetitive tasks involved in characterising, conditioning and packaging the waste within the shielded 'hot' cells. Significant technical challenges had to be overcome during the design to adapt a commercially available robot for use within a high radiation / high contamination environment, where human access is not safe even for short periods of time. These challenges included: - Designing robot assemblies that could be retrofitted into the existing cell structure that was constructed as part of an earlier project but never completed; - Designing robot assemblies that could be recovered to their 'transport' position without requiring manual intervention; - Designing robot assemblies that could be remotely removed and replaced with new ones if they failed part way through the plant operational life; - Designing through-wall service and power connections that allow maintenance and recovery; - Designing control systems and human-machine interfaces that enable both manual and automated operation of the robot, whilst avoiding collisions with the in-cell cranes and other in cell furniture; - Assessing the radiation tolerance of all items. Bespoke computer simulations and full-scale development trials have been carried out, using non-active test materials, in order to demonstrate the Technology Readiness Level (TRL) required by Sellafield Limited (SL) at each stage of the project [1]. The results of these trials have been recorded in both video and written form so that they can form part of the project's Knowledge Management database. Detailed designs and specifications for the robot assemblies have been updated to incorporate the recommendations from the development trials. Procurement and manufacture of robot assemblies has already commenced to deliver two waste handling robots, two waste container lidding / swabbing robots and associated critical spares. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Automated Analysis, Reporting, and Archiving for Robotic Nondestructive Assay of Holdup Deposits - 19508

To decommission deactivated gaseous diffusion enrichment facilities, miles of contaminated pipe must be measured. The current method requires thousands of manual measurements, repeated manual data transcription, and months of manual analysis. The Pipe Crawling Activity Measurement System (PCAMS), developed by Carnegie Mellon University and in commissioning for use at the DOE Portsmouth Gaseous Diffusion Enrichment Facility, uses a robot to measure Uranium-235 from inside pipes and automatically log the data. Radiation measurements, as well as imagery, geometric modeling, and precise measurement positioning data are digitally transferred to the PCAMS server. On the server, data can be automatically processed in minutes and summarized for analyst review. Measurement reports are auto-generated with the push of a button. A database specially-configured to hold heterogeneous data such as spectra, images, and robot trajectories serves as archive. This paper outlines the features and design of the PCAMS Post-Processing Software, currently in commissioning for use at the Portsmouth Gaseous Diffusion Enrichment Facility. The analysis process, the analyst interface to the system, and the content of auto-generated reports are each described. Example pipe-interior geometric surface models, illustration of how key report features apply in operational runs, and user feedback are discussed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing

Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.

Grain orientation↗

DOE OSTI2017

Hanford Waste End Effector Prototype Test Plan

This test plan describes the Phase 1 testing program of the Hanford Waste End Effector (HWEE) at the Washington River Protection Solutions (WRPS) Cold Test Facility (CTF) using a Pacific Northwest National Laboratory (PNNL)-designed testing setup. This task supports Phase 1 development testing of the HWEE to support the informational needs for initial assessment of the HWEE to support Hanford single shell tank A-105 retrieval. This task will install the HWEE on a PNNL-designed robotic gantry system at CTF, install instrumentation to measure reaction forces and process parameters, prepare and characterize simulant materials, and implement the test program. The tests will involve retrieval of water, sludge, and hardpan simulants to determine pumping rate, dilution factors, and screen fouling rate.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Hanford Waste End Effector Prototype Test Plan (Rev.1)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Simulation of the transport, vertical distribution, optical properties and radiative impact of smoke aerosols with the ALADIN regional climate model during the ORACLES-2016 and LASIC experiments

Estimates of the direct radiative effect (DRE) from absorbing smoke aerosols over the southeast Atlantic Ocean (SAO) require simulation of the microphysical and optical properties of stratocumulus clouds as well as of the altitude and shortwave (SW) optical properties of biomass burning aerosols (BBAs). In this study, we take advantage of the large number of observations acquired during the ObseRvations of Aerosols above Clouds and their intEractionS (ORACLES-2016) and Layered Atlantic Smoke Interactions with Clouds (LASIC) projects during September 2016 and compare them with datasets from the ALADIN-Climate (Aire Limitée Adaptation dynamique Développement InterNational) regional model. The model provides a good representation of the liquid water path but the low cloud fraction is underestimated compared to satellite data. The modeled total-column smoke aerosol optical depth (AOD) and above-cloud AOD are consistent ( ~0.7 over continental sources and ~0.3 over the SAO at 550 nm) with the Modern-Era Retrospective analysis for Research and Applications version 2 (MERRA-2), Ozone Monitoring Instrument (OMI) or Moderate Resolution Imaging Spectroradiometer (MODIS) data. The simulations indicate smoke transport over the SAO occurs mainly between 2 and 4 km, consistent with surface and aircraft lidar observations. The BBA single scattering albedo is slightly overestimated compared to the Aerosol Robotic Network (AERONET) and more significantly when compared to Ascension Island surface observations. The difference could be due to the absence of internal mixing treatment in the ALADIN-Climate model. The SSA overestimate leads to an underestimation of the simulated SW radiative heating compared to ORACLES data. ALADIN-Climate simulates a positive (monthly mean) SW DRE of about +6 W m -2 over the SAO (20 ° S–10 ° N and 10 ° W–20 ° E) at the top of the atmosphere and in all-sky conditions. Over the continent, the presence of BBA is shown to significantly decrease the net surface SW flux, through direct and semi-direct effects, which is compensated by a decrease (monthly mean) in sensible heat fluxes ( -25 W m -2 ) and surface land temperature ( -1.5 ° C) over Angola, Zambia and the Democratic Republic of the Congo, notably. The surface cooling and the lower tropospheric heating decrease the continental planetary boundary layer height by about ~200 m.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Chemically controlled shape-morphing of elastic sheets

Two-dimensional responsive materials that change shape into complex three-dimensional structures are valuable for creating systems ranging from wearable electronics to soft robotics. Typically, the final 3D structure is unique and predetermined through the materials’ processing. Here, we use theory and simulation to devise a distinctive approach for driving shape changes of 2D elastic sheets in fluid-filled microchambers. The sheets are coated with catalyst to generate controllable fluid flows, which transform the sheets into complex 3D shapes. A given shape can be achieved by patterning the arrangement of the catalytic domains on the sheet and introducing the appropriate reactant to initiate a specific catalytic reaction. Moreover, a single sheet that encompasses multiple catalytic domains can be transformed into a variety of 3D shapes through the addition of one or more reactants. Materials systems that morph on-demand into a variety of distinct structures can simplify manufacturing processes and broaden the utility of soft materials.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Hanford Waste End Effector Phase I Test Report

This test plan describes the Phase 1 testing program of the Hanford Waste End Effector (HWEE) at the Washington River Protection Solutions’ Cold Test Facility (CTF) using a Pacific Northwest National Laboratory (PNNL)-designed testing setup. This effort fulfills the informational needs for initial assessment of the HWEE to support Hanford single-shell tank A-105 retrieval. This task will install the HWEE on a PNNL-designed robotic gantry system at CTF, install and calibrate instrumentation to measure reaction forces and process parameters, prepare and characterize simulant materials, and implement the test program. The tests will involve retrieval of water, sludge, and hardpan simulants to determine pumping rate, dilution factors, and screen fouling rate.

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DOE OSTI2015

Aerosol single-scattering albedo over the global oceans: Comparing PARASOL retrievals with AERONET, OMI, and AeroCom models estimates

The aerosol Single Scattering Albedo (SSA) over the global oceans is evaluated based on polarimetric measurements by the PARASOL satellite. The retrieved values for SSA and Aerosol Optical Depth (AOD) agree well with the ground-based measurements of the AErosol RObotic NETwork (AERONET). The global coverage provided by the PARASOL observations represents a unique opportunity to evaluate SSA and AOD simulated by atmospheric transport model runs, as performed in the AeroCom framework. The SSA estimate provided by the AeroCom models is generally higher than the SSA retrieved from both PARASOL and AERONET. On the other hand, the mean simulated AOD is about right or slightly underestimated compared with observations. An overestimate of the SSA by the models would suggest that these simulate an overly strong aerosol radiative cooling at top-of-atmosphere (TOA) and underestimate it at surface. This implies that aerosols have a potential stronger impact within the atmosphere than currently simulated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Advancing Rare-Earth (4 f ) and Actinide (5 f ) Separation through Machine Learning and Automated High-Throughput Experiments

Not Available

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Friction Stir Scribe Joining of CFRP to Aluminum (Abstract)

The objective of this project is to develop and demonstrate friction stir scribe (FSS) joining of carbon fiber reinforced polymer (CFRP) to aluminum on light-duty vehicle body-in-white (BIW) joints. The project will also overcome the major obstacles of implementing FSS technology in a fully 3-D production robotic work cell and demonstrate the required CFRP-aluminum joint strengths in industrially relevant light-duty, BIW components. Specifically the project will develop the critical process technology, models and tools necessary to advance the FSS method through experimentation, validation at the laboratory scale, and integration into a production-like robotic environment. The ultimate goal is to demonstrate the technology on industrially relevant components based on process development and numerical simulation performed at scale.

42 ENGINEERING↗

DOE OSTI2026

Multibody for Everybody (M4E): A Symbolic Dynamics Modeling Tool with Applications in Simulation, Control, and Optimization

Developing the analytical model of a multibody system is often the initial step in control and optimization. The analytical model (equations of motion) describes a system’s time evolution under specified forcing conditions. Although developing these equations is easy for simple systems, this process becomes more complex for systems composed of multiple bodies. Deriving equations of motion for complex multibody systems requires specialized expertise in multibody dynamics, is time-consuming, and is susceptible to error. To address this issue, this paper presents an open-source, easy-to-use, systematic framework to derive symbolic equations of motion in both Python and MATLAB using the joint coordinate formulation. This formulation results in a set of ordinary differential equations that use the minimum set of coordinates needed to model a system. The symbolic representation provides better insight into the influence of design parameters on system performance, facilitates sensitivity analysis and parameter studies, and supports direct implementation of control and optimization routines. The tool enables numerical simulation for specified parameter sets, is modular for straightforward integration with other tools and libraries, and allows incorporation of hydrodynamics, mooring, and other external forces. The result is a reproducible, extensible pipeline for modeling, simulation, and design of complex multibody systems. The proposed tool is versatile and can be applied to domains such as robotics, control, and design. In addition, we integrated external libraries that provide capabilities for modeling offshore systems such as underwater robots and marine energy converters.

16 TIDAL AND WAVE POWER↗

DOE OSTI2018

Autonomous Radiation Survey Inside Contaminated Buildings at Fukushima Daiichi with the Riser UAV - 18299

Nuclear decommissioning is constrained and defined by radiation and radioactive contamination. Where radiation is high and its distribution is unknown simply gathering the data needed for project planning can become a challenge. Fukushima Daiichi epitomises this challenge. The complex sequence of events at the plant following the March 2011 earthquake and tsunami has resulted in extensive physical damage and an essentially unpredictable distribution of contamination. TEPCO have applied a range of manual and robotics techniques to map the status of the plant, but many significant areas have remained no-go zones due to a combination of high radiation, physical hazards and obstacles. Further, even in areas where manual survey is feasible, there is strong desire to minimise human exposure to radiation by deploying robots where possible. Riser is a fully autonomous UAV equipped with an infrastructure-free 3D navigation and mapping system, inspection cameras and a CZT spectrometric measurement capability. The system has been custom designed specifically to meet the needs of the nuclear inspection. Riser is capable of accessing areas with dose rates of hundreds of milli-sievert per hour and producing 3D models and radiation surveys with accurately located data points. The data from Riser can subsequently be fused using Createc's N-Visage engine to produce three-dimensional contamination maps which can be used for predictive modelling of future D and D activity. Riser has been deployed at Fukushima Daiichi since March 2017. We present examples of data and analysis outputs, as well as general learning about deploying autonomous robots at a nuclear site. (authors)

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DOE OSTI2020

Savannah River Site H-Canyon Advancing Technologies for Remote Inspections - 20345

In 2017, the DOE Environmental Management Office of Technology Development (DOE-EM TD) sponsored the H-Canyon Advanced Technology Demonstration (ATD) to demonstrate to DOE facilities the value of using new commercial-off-the-shelf (COTS) and near-ready technologies to solve difficult problems and enhance worker safety. The DOE Savannah River Site (SRS) H-Canyon Air Exhaust Tunnel (HCAEX) inspection task was identified as representative of the hazardous, human denied environments which could benefit from advanced technologies. The HCAEX underground concrete tunnel is visually inspected biannually using a camera mounted on a remotely operated vehicle (ROV) designed and built by SRNL. While tunnel images have provided valuable visual information, it is desirable to have a higher order of understanding of the environment to support a more thorough structural integrity (SI) analysis and for long term planning purposes. As part of the ATD, the Concrete Integrated Product Team (CIPT) was formed to identify and evaluate available sensors and methods mature enough to remotely obtain tunnel concrete characterization data of high value and with a high probability of success. The team included SMEs and H-Canyon stakeholders in the field of concrete, nondestructive examination (NDE), structural integrity, sensors and remote systems from SRNL, SRNS, LANL, DOE-SR and the Army Corps of Engineering. The CIPT completed an in-depth identification of customer concrete inspection needs and potential technology solutions. Sensors and methods were evaluated on performance, data usefulness, cost and the feasibility of a successful deployment given the unique tunnel access challenges and environment. Two technologies were identified as promising by the CIPT for near term demonstration and evaluation: Lidar (Light Detection and Ranging) 3-dimensional (3D) mapping and remote robotic deployment of NDE instrumentation. Laser spectroscopy to characterize tunnel surface chemical changes was also of interest, but presently cost prohibitive. This paper will include a discussion of the two efforts underway to evaluate and implement the CIPT recommendations. First, the status of the November 2019 deployment of Lidar at a single location into the tunnel is presented. This initial deployment provided the team a learning curve and lessons learned on the challenges of tunnel deployment to include remote operation and data collection, stabilization of the sensor in high air flow (∼30 mph), ability to achieve a tolerance accuracy of 0.25-inches, and the probability to identify change in tunnel dimensions over time. Secondly, a discussion on the development of the Robotic Arm Concrete Inspection Test Bed capable of deploying NDE instruments to examine custom concrete forms will be presented. Concrete forms simulating the rough concrete surfaces, strength, composition and potential structural defects that can be found at our DOE EM facilities have been designed and built for the test bed. Two state-of-the art concrete NDE instruments have been identified as having potential to work on rough concrete walls, they are being tested and characterized as to their ability to provide desired structural integrity data to include wall thickness and defect identification on the developed test beams. Lastly, lessons learned, and the path forward will be presented. (authors)

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DOE OSTI2019

Novel Radiometry for In-Pipe Robotic Inspection of Holdup Deposits in Gaseous Diffusion Piping - 19503

This paper details the first complete, DOE approved, deployed and operational radiometry for robotic nondestructive assay (NDA) of holdup deposits in gaseous diffusion piping. Some features, like peak-finding, Compton correction, detector efficiency, and material properties are characteristic of typical manual methods. Most features are specific to in-pipe robotic deployment. These include in-motion radiometry, self-determined location, geometric modeling of thick deposits, bounding of self-attenuation thickness and auto-checking of replicate measurements. Significant are the means for determining all the properties, equations, and constants for automatically computing and displaying all the quantities, uncertainties and information needed for NDA reporting, analysis, and review. Earlier work by this team demonstrated rudimentary but convincing robotic in-pipe NDA of holdup deposits in pipes. Cold testing with high-enrichment mat sources and hot tests with low U-235 loadings together succeeded to exhibit convincing proof-of-principle. This research-grade radiometry implementation lacked accurate odometry, efficiency calibration, high-fidelity detector modeling, attenuation modeling, forward geometric modeling, auto-segmenting, uncertainty modeling, replicate checking, deconvolution and much more. This work explains the technical basis behind robotic in-pipe NDA. It includes discussion of a new method for modeling of self-attenuation using in-pipe deposit geometry information, detail of the method's total measurement uncertainty, and explanation of calibration methods and results. Beyond development of automation-specific radiometric elements, the paper highlights analyses, testing, and technical bases specific to and supportive of the methodology. Examples include collimation characterization, detector efficiency determination, auto-calibration methodology, and odometric replicate-checking. Results of this methodology are formalized in a DOE EM Technical Basis Document, implemented in software, formally verified in review and acceptance testing and proceduralized as a means for D and D NDA at the Portsmouth enrichment facility. Measurement of U-235 quantity is a well-known cost and schedule driver in D and D of every defunct gaseous diffusion enrichment facility in the world. The radiometry methodologies and results detailed in this paper were the high hurdles. Having established the technical basis for this automated NDA, the opportunity is to apply this to many sizes and robot forms for addressing holdup deposit NDA throughout the D and D community. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

The Hanford Waste End Effector Phase II Test Report

This report describes the Phase II testing program of the Hanford Waste End Effector (HWEE) at the Washington River Protection Solutions Cold Test Facility (CTF). Phase II testing builds on the completed Phase I development testing (PNNL-26856) to address some key actual waste challenges as outlined in the Phase II test plan (PNNL-27422). This testing demonstrated retrieval of a mixed layered simulant and retrieval of uneven simulant profiles like that found near tank walls. A separate demonstration using only the HWEE conveyance jet pump assessed the lifting capabilities of this device for transporting waste out of an underground tank. The Pacific Northwest National Laboratory (PNNL)-designed robotic gantry system and associated systems (e.g., tanks, high-pressure water delivery and valves, instruments, etc.) used at CTF during Phase I were modified and upgraded to implement the Phase II test program and measure various process parameters. The tests demonstrated retrieval of water and Kaolin (sludge) simulant to determine pumping rate, dilution factors, and screen fouling rate. This report will first describe the test equipment, instrumentation, simulant preparation procedures, and testing methodology. Testing results presented include HWEE water usage versus operating pressure of modified components from Phase I, simulant characterization data, dilution ratios, and retrieval rates. Reaction forces and other factors that would affect the remote operation of the HWEE will also be presented. Results of the separate jet pump vertical lift demonstration to a fixed height of at least 35 feet are also presented.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Robotic NDA of Holdup Deposits in Gaseous Diffusion Piping by Gamma Assay of Uranium-235 - 18331

This research exploits in-pipe access to develop robotically deployed, high-cadence, accurate, certain, paperless assay of U-235 in holdup deposits within process piping. Prior radiometric assay from outside the pipes suffered from manual deployment challenges, attenuation of detection through pipe walls, long counting times, approximate modeling, and shortfalls associated with transcription and human interpretation. These downsides limited the speed, quality, and economy of assay resulting in vast cost and budget consequences to D and D. D and D of outdated facilities cuts into these pipes as part of the demolition process, creating the unique, previously unexploited possibility of robotic in-pipe assay. The assay collimates radiation emanating from all but a short segment of pipe wall from reaching a gamma detector. Hence, the detector only views and measures source from a short segment of pipe at a given time. This is achieved by an innovative pair of collimating discs that are coaxial with the pipe and positioned fore and aft of the detector. The detector assembly is translated through pipes by an autonomous mobile robot. Beyond radiometric assay of U-235, the robot images and geometrically models the pipe interior and deposit appearance. The robot is recovered from the same pipe opening from which it is launched, hence it drives the same distance out and back, measuring the same deposits twice. This achieves redundant radiometric and odometric measurements which adds further to statistical significance of the method. (authors)

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DOE OSTI2023

Drones, Delivery Robots, Driverless Cars, and Intelligent Curbs for Increasing Energy Productivity of First/Last Mile Goods Movement

The objective of the project is to use empirical testing, life cycle assessment, and systems analysis to research and demonstrate energy improvement when using goods delivery drones, eVTOL, ground delivery robots and automated vehicles compared to a baseline network. The research will also develop proof-of-concept testing, a model, and simulation for a smart curb space as an intelligently-managed urban delivery zone demonstrating additional improvement in energy productivity.

Scherer, Sebastian↗