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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Task 12 PV Sustainability - Life Cycle Inventories and Life Cycle Assessments of Photovoltaic Systems

Life Cycle Assessment (LCA) is a structured, comprehensive method of quantifying material- and energy-flows and their associated impacts in the life cycles of products (i.e., goods and services). One of the major goals of IEA PVPS Task 12 is to provide guidance on assuring consistency, balance, transparency and quality of LCA to enhance the credibility and reliability of the results. The current report presents the latest consensus life cycle inventories among the authors, PV LCA experts in North America, Europe, Asia and Australia. At this time consensus is limited to four technologies for which there are well-established and up-to-date life cycle inventory (LCI) data (mono- and multi-crystalline Si, CdTe, CIGS, as well as one emerging technology (perovskite silicon tandem). LCIs are necessary for LCA and the availability of such data is often the greatest barrier for conducting LCA. The Task 12 LCA experts have put great efforts in gathering and compiling the LCI data presented in this report. These include detailed inputs and outputs during manufacturing of cell, wafer, module, and balance-of-system (i.e., structural and electrical components) that were estimated from actual production and operation facilities. In addition, data are presented to enable analyses of various types of PV installations; these include operational data of rooftop and ground-mount PV systems and country-specific PV-mixes. The LCI datasets presented in this report are the latest that are available to the public describing the status in 2018 for crystalline Si (some manufacturing data from 2011 were not updated), 2015 and 2017-2018 for CdTe, 2010 for CIGS, 2010 for HCPV, and 2017 for perovskite silicon tandem technology.

14 SOLAR ENERGY↗
DOE OSTI2020

Flexible linkages for thermal management at cryogenic temperatures

Cryogenic system design often presents the competing requirements of thermal coupling between components while de-coupling them structurally. Good thermal coupling is necessary for adequate thermal management during cryogenic operation of the system and to reduce the cooldown time from the ambient to cryogenic temperature. Structural de-coupling is essential to reduce thermal stresses during cooldown, mitigate the trasmission of vibration and loads to sensitive and/or fragile components, and compensate for integration misalignments. Flexible thermal links (FTLs) are an essential component of cryogenic systems that provides a balance between thermal coupling and structural isolation.

42 ENGINEERING↗
DOE OSTI2023

An Assessment of Machine Learning Applied to Ultrasonic Nondestructive Evaluation

In the United States, the nuclear industry performs inservice inspection (ISI) through nondestructive examination (NDE) methods in accordance with guidelines specified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. Ultrasonic nondestructive testing and evaluation (NDT&E) is one of the more commonly used techniques for inspecting Class 1 structural components in nuclear power systems. As the number of qualified NDE inspectors declines, the nuclear industry is looking to take advantage of advances in automation to enhance inspection capabilities. Advances in computational power, cloud-based computing, and machine learning algorithms make automated data analysis possible. Machine learning (ML) has shown huge potential in automated data analyses for ultrasonic NDE in the context of weld inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Fast Modular Reactor Nuclear Design Parameters of Fuel Cycle and Power Distributions

This paper describes conceptual design of a 112 MW thermal (50 MW electric) Fast Modular Reactor (FMR) system operating at 7 MPa with inlet/outlet temperatures of 509/800 ºC. The reactor system includes the reactor core, fuel assemblies, fuel rods, reactor internals, reflector, neutron control system, flow control, and structural components. The nuclear design and analysis were conducted to search for a baseline core with a cycle length greater than 8-year and the power peaking factor less than 1.5 by adjusting the fuel assembly, reactor core, and reflector configurations. The neutronics calculations of the baseline core showed that a refueling interval of 9-year is achieved with a total peaking factor of 1.47 and a fuel rod average linear power of 3.6 kW/m.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Fast modular reactor nuclear design parameters of fuel cycle and power distributions

This paper describes conceptual design of a 112 MW thermal (50 MW electric) Fast Modular Reactor (FMR) system operating at 7 MPa with inlet/outlet temperatures of 509/800 Celsius degrees. The reactor system includes the reactor core, fuel assemblies, fuel rods, reactor internals, reflector, neutron control system, flow control, and structural components. The nuclear design and analysis were conducted to search for a baseline core with a cycle length greater than 8-year and the power peaking factor less than 1.5 by adjusting the fuel assembly, reactor core, and reflector configurations. The neutron transport calculations of the baseline core showed that a refueling interval of 9-year is achieved with a total peaking factor of 1.47 and a fuel rod average linear power of 3.6 kW/m. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Initiation of dusting corrosion in high-temperature alloys under CO exposure

Carbon monoxide is commonly encountered in energy systems, yet its reactivity with structural alloys—critical heat-resistant components in these systems—has been largely overlooked compared to the well-documented effects of oxidizing gases. In contrast, we demonstrate the high-temperature reaction of CO with NiAl using in-situ low-energy electron microscopy and X-ray photoemission electron microscopy. Our results show that CO dissociates into atomic oxygen and carbon, resulting in two concurrent reactions: selective oxidation of aluminum to form Al 2 O 3 and the initiation of dusting corrosion through carbon dissolution into the alloy and subsequent carbon deposition on the surface. These reactions produce spatially distinct surface products, preventing the formation of a continuous protective Al oxide layer. These results reveal a preference for the dissociative pathway of CO over the classic Boudouard disproportionation reaction that forms CO 2 . These insights not only advance our understanding of CO-induced alloy degradation but also highlight the practical implications for managing alloy stability and optimizing catalysis in carbon-rich environments, such as those in petrochemical processing and hydrocarbon combustion.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Applications of Digital Twin System in a Smart City System with Multi-Energy

With the increasing number of electric vehicles (EV), the smart transportation system is becoming more closely related to the smart energy system in a smart city. However, because of the high complexity, dynamics, and large-scale of these two systems, it is challenging to study their operation problems systematically, especially in severe conditions, e.g., the 2021 winter Texas power traffic crisis. With artificial intelligence, federated learning, edge computing, and automatic control, a digital twin based smart city is proposed in this paper and it focuses on two applications: smart transportation and smart energy grid. Both systems are presented in a structured design manner with several components in the digital twin system, which also contains many real-implementations of different scenarios. The proposed digital twin of a smart city provides a potential clue for the problems mentioned above.

artificial intelligence↗
DOE OSTI2025

Novel technology of non-contact real-time radiation damage sensors for high power targets.

This report summarizes the contributions of an intern participating in the Community College Internship (CCI) program at Fermilab, focusing on the development of a novel, non-contact, real-time radiation damage sensor technology. The core objective is to create a reliable sensor capable of measuring radiation-induced degradation on high-power targets without physical contact. The experiment involves using a Class 3B supercontinuum laser directed toward a single material sample placed within a vacuum test chamber. The laser beam reflects off the sample's surface, with changes in reflectivity, indicative of radiation damage, measured by a spectrometer positioned at the chamber’s output port. The intern’s primary responsibilities included designing an interlock system to ensure laser operational safety, developing a camera-based monitoring system using Raspberry Pi devices, and creating structural supports using 3D modeling and printing techniques. Components for the interlock and camera systems were successfully designed and ordered, with preliminary 3D models printed and refined through iterative testing. Challenges encountered in the 3D printing process, such as fragile initial prototypes and difficult support removal, were overcome by adjusting printer settings and incorporating design enhancements like chamfered edges. Future activities, pending component delivery, involve installing and configuring the interlock and camera systems, as well as further improving the structural supports. Overall, the internship significantly enhanced the intern’s technical proficiency in hardware design, software integration, and advanced 3D printing, contributing directly to Fermilab’s operational safety standards and experimental effectiveness in high-energy physics research.

Pumarino Meza, Rafael [Unlisted; Fermilab]↗
DOE OSTI2021

Improving protein tertiary structure prediction by deep learning and distance prediction in CASP14

Abstract Substantial progresses in protein structure prediction have been made by utilizing deep‐learning and residue‐residue distance prediction since CASP13. Inspired by the advances, we improve our CASP14 MULTICOM protein structure prediction system by incorporating three new components: (a) a new deep learning‐based protein inter‐residue distance predictor to improve template‐free (ab initio) tertiary structure prediction, (b) an enhanced template‐based tertiary structure prediction method, and (c) distance‐based model quality assessment methods empowered by deep learning. In the 2020 CASP14 experiment, MULTICOM predictor was ranked seventh out of 146 predictors in tertiary structure prediction and ranked third out of 136 predictors in inter‐domain structure prediction. The results demonstrate that the template‐free modeling based on deep learning and residue‐residue distance prediction can predict the correct topology for almost all template‐based modeling targets and a majority of hard targets (template‐free targets or targets whose templates cannot be recognized), which is a significant improvement over the CASP13 MULTICOM predictor. Moreover, the template‐free modeling performs better than the template‐based modeling on not only hard targets but also the targets that have homologous templates. The performance of the template‐free modeling largely depends on the accuracy of distance prediction closely related to the quality of multiple sequence alignments. The structural model quality assessment works well on targets for which enough good models can be predicted, but it may perform poorly when only a few good models are predicted for a hard target and the distribution of model quality scores is highly skewed. MULTICOM is available at https://github.com/jianlin-cheng/MULTICOM_Human_CASP14/tree/CASP14_DeepRank3 and https://github.com/multicom-toolbox/multicom/tree/multicom_v2.0 .

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Quantifying motion blur by imaging shock front propagation with broadband and narrowband X-ray sources

Time-integrated radiography using MeV Bremsstrahlung X-ray sources is the norm for imaging during system-level testing of components and structures under dynamic condition. One source of error in the analysis of the time-integrated radiography data sets stems from motion blur which smears out sharp interfaces to a greater degree with longer exposure times, which become necessary to provide sufficient signal-to-noise with low X-ray penetration of objects of interest. To quantify motion blur, a 1D shock wave through PMMA was investigated experimentally at The Dynamic Compression Sector at The Advanced Photon Source (DCS@APS) with tapered broadband and 25.46 ± 1.06 keV narrowband X-rays. Four cameras with different exposure times were used for each experiment to compare the effect that exposure time has on motion blur. In addition, our methodology to accurately simulate motion blur in terms of transmission and shape is presented and compared to our experimental results and quantified. There is a high level of agreement between the experimental and simulation results across the range of data sets investigated in this study with a percent difference range of 0.29–1.31% for the four shots. The methodology of this work serves as a steppingstone towards a physically validated model that could be used in conjunction with experimental results to deconvolve physical parameters, densities, and interfaces of interest in a way that would not be possible with experimental results alone.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part I—Analysis Methods

Use of corrosion-resistant cladding can greatly extend the design life of structural components in many advanced reactor systems. However, there are currently no ASME design rules for cladded components to guard against creep-fatigue failure and ratcheting strain accumulation in elevated temperature nuclear service. This paper, presented in two parts, addresses this gap by proposing a design strategy for cladded components that do not require long-term testing of clad materials. The proposed approach relies on approximate design analysis methods for two types of clad materials—a soft clad that creeps much faster than and has lower yield stress than the class A base material and a hard clad that creeps much slower than and has higher yield stress than the class A base material. Part I discusses the approximate analysis strategies for the clad materials—treat a soft clad as perfectly compliant and a hard clad as linear elastic—and Part II develops a complete set of design rules for each of the two types of cladded components. In conclusion, finite element analyses of representative high temperature reactor components show that the proposed design analysis methods can bound the design quantities in soft cladded components and approximate the design quantities in hard cladded components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Stress-Controlled Creep–Fatigue of an Advanced Austenitic Stainless Steel at Elevated Temperatures

Creep–fatigue interaction occurs in many structural components of high-temperature systems operating under cyclic and steady-state service conditions, such as in nuclear power plants, aerospace, naval, and other industrial applications. Thus, understanding micromechanisms governing high-temperature creep–fatigue behavior is essential for safety and design considerations. In this work, stress-controlled creep–fatigue tests of advanced austenitic stainless steel (Alloy 709) were performed at a 400 MPa stress range and 750 °C with tensile hold times of 0, 60, 600, 1800, and 3600 s, followed by microstructural examinations. The creep–fatigue lifetime of the Alloy 709 was found to decrease with increasing hold time until reaching a saturation level where the number of cycles to failure did not exhibit a significant decrease. Softening behavior was observed at the beginning of the test, possibly due to the recovery of entangled dislocations and de-twining. In addition, hysteresis loops showed ratcheting behavior, although the mean stress was zero during creep–fatigue cycling, which was attributed to activity of partial dislocations. Microstructural examination of the fracture surfaces showed that fatigue failure dominated at small hold times where the cracks initiated at the surface of the sample. Larger creep cracks were found for longer hold times with a lower probability of dimpled cavities, indicating the dominance of creep deformation. The results were compared with other commonly used stainless steels, and plausible reasons for the observed responses were described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Environmentally Assisted Fatigue in Light Water Reactor Environment

This report summarizes the Environmentally Assisted Fatigue (EAF) research conducted at ANL under the US DOE Light Water Reactor Sustainability (LWRS) program. Starting from a rich background in theoretical and experimental EAF, ANL previously developed an approach to evaluate fatigue performance of reactor materials in light water reactor environments with the correction factor F en . The approach was based on a large body of experimental work performed at ANL and elsewhere, and was consistent with American Society of Mechanical Engineers (ASME)’s methodology governing the design and construction of reactor components. In recent years, the program was focused on component fatigue prediction and made several major and fundamental contributions in this area. These accomplishments help meet the needs identified by the industry concerning component level fatigue predictions in complex, transient conditions. The main contribution of the ANL program involved the development of a system-level model for estimating residual strain and life of nuclear reactor coolant system components under connected-system-thermal-mechanical boundary conditions. The goal was to predict the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the finite element (FE) model results, the strain residuals, strain amplitudes and resulting fatigue lives of reactor coolant system (RCS) components were predicted. The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. In addition, the simulated component-level strain profile can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests. Building upon the system-level model, ANL developed a digital twin (DT) framework to predict the structural states and associated fatigue life of components in real-time. This framework is a comprehensive system designed to predict the structural states and fatigue lives of reactor components. It includes multiple models and integrates artificial intelligence (AI), machine learning (ML), and FE based modeling tools to evaluate the structural states and fatigue lives.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Approaches for handling high-dimensional cluster expansions of ionic systems

Disordered multicomponent systems attract great interest due to their engineering design flexibility and subsequent rich space of properties. However, detailed characterization of the structure and atomic correlations remains challenging and hinders full navigation of these complex spaces. A lattice cluster expansion is one tool to obtain configurational and energetic resolution. While in theory a cluster expansion can be applied to any system of any dimensionality, the method has primarily been used in binary systems or ternary alloys. Here we apply cluster expansions in high-component ionic systems, setting up the largest cluster expansion ever attempted to our knowledge. In doing so, we address and discuss challenges specific to high-component ionic systems, namely charge state assignments, structural relaxations, and rank-deficient systems. We introduce practical procedures to make the fitting and analysis of complex systems tractable, providing guidance for future computational studies of disordered ionic systems.

25 ENERGY STORAGE↗
DOE OSTI2020

Small and mighty: adaptation of superphylum Patescibacteria to groundwater environment drives their genome simplicity

The newly defined superphylum Patescibacteria such as Parcubacteria (OD1) and Microgenomates (OP11) has been found to be prevalent in groundwater, sediment, lake, and other aquifer environments. Recently increasing attention has been paid to this diverse superphylum including > 20 candidate phyla (a large part of the candidate phylum radiation, CPR) because it refreshed our view of the tree of life. However, adaptive traits contributing to its prevalence are still not well known. Results Here, we investigated the genomic features and metabolic pathways of Patescibacteria in groundwater through genome-resolved metagenomics analysis of >600 Gbp sequence data. We observed that, while the members of Patescibacteria have reduced genomes (~ 1 Mbp) exclusively, functions essential to growth and reproduction such as genetic information processing were retained. Surprisingly, they have sharply reduced redundant and nonessential functions, including specific metabolic activities and stress response systems. The Patescibacteria have ultra-small cells and simplified membrane structures, including flagellar assembly, transporters, and two-component systems. Despite the lack of CRISPR viral defense, the bacteria may evade predation through deletion of common membrane phage receptors and other alternative strategies, which may explain the low representation of prophage proteins in their genomes and lack of CRISPR. By establishing the linkages between bacterial features and the groundwater environmental conditions, our results provide important insights into the functions and evolution of this CPR group.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Model Reference Adaptive Control (MRAC) for Additive Manufacturing (AM)

Model Reference Adaptive Control (MRAC) is based on the fundamental concept that the process under investigation is to be controlled to follow or “track” a reference system (model) characterized by a state/input/output model employing an adaptive optimization algorithm to adjust the controller parameters in real-time. The generic structure of the MRAC is shown in Fig. 1 consisting of the following primary components: Reference model, Process (system) model, controller and the adaption algorithm. The basic structure of the controller is specified by a linear construct with the corresponding real-time adaption algorithms given by a gradient-type (so-called MIT rule) or based on stability theory (Lyapunov, hyperstability). This approach to adaptive control is termed “direct”, since the controller (parameters) are adjusted based on the component models/algorithm in contrast to the “indirect” approach that adjusts the process model parameters applying real-time system identification techniques.

42 ENGINEERING↗