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DOE OSTI2023

The Circular Home: Development and Demonstration of a Net Negative Carbon, Reusable Residence

This project started the development of an innovative modular building system intended for residential construction. The project was centered around single-family homes that were carbon-negative cradle-to-grave over a 100 year time frame, which is approximately double the current standard for operational life. The project sought to accomplish this objective by designing the modular home in a manner that ensures circularity, where the main house components can be used over several consecutive 50-year lifespans. To accomplish these objectives, this project utilized integrated design with the inclusion of life-cycle assessment to design the single-family house for architectural, structural, energy, mechanical, thermal, and moisture demands, while ensuring carbon negativity and annual net-zero energy use. The core technology of this project was the use of cross-laminated timber and biogenic materials, such as wood-fiber insulation, in the construction of the modular building units. The robustness and factory manufacturing ability of cross-laminated timber allow for factory construction of most of the home, which minimizes on-site time, saving money and reducing construction waste. During this project, initial milestones were met that delivered the architectural plans for the circular home and an initial structural testing matrix. Compared to current code-built homes, which average 13 kg CO2eq. / ft2 and are demolished at their end of life, the circular home has an estimated -30 kg CO2eq. / ft2 of embodied carbon emissions during its first build iteration. It is estimated that approximately 60%-70% of the total building mass could be reused and/or recycled during subsequent rebuilds. This project was concluded at approximately the 1/3 point and a separate project was established to conclude the remaining milestones. This project promises to benefit the public by delivering another option for single-family, and eventually multi-family, housing using a novel building construction system. The system of reusable modular construction facilitates not only lower emissions during the first building iteration, but also lower emissions during subsequent iterations that drastically reduce waste and help society meet its climate goals. Many other industries, such as clothing and technology sectors, are starting to focus on circularity and this project adds the residential building construction industry to that list.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Mechanical Characterization of Fe-Co-2V (Hiperco): Fatigue/Monotonic Testing Hardness Testing and Fractography

Fe-Co-2V is a popular metallic alloy used in electromagnetic applications. However, there is a lack of mechanical fatigue characterization of this alloy in the literature. In this work, Fe-Co-2V specimens with rectangular cross-sections were carefully prepared in accordance with standards. They were measured for surface roughness and then subjected to quasi-static monotonic testing, as well as fatigue testing at both 0.5 Hz and 1 Hz frequencies. Both Rockwell hardness and Vickers micro- hardness testing were performed. Additionally, scanning electron microscopy imaging of the fractured surfaces was done. The quasi-static testing revealed a flat yield region characteristic of Laders bands. Here, the fatigue results did not show significant differences or sensitivity to change in frequency, although the fatigue life was higher on average for the 0.5 Hz. However, the fatigue results differed from published work at 0.33 Hz. The fractography revealed purely brittle fracture, with clear chevron marks and fracture initiation always starting at the surface. Lastly, it was identified that the C, D, and F Rockwell hardness scales were appropriate for testing this material and that the grain size necessitated the use of the upper end of indentation force for Vickers micro-hardness testing.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Infrared Thermographic Testing of Steel Structures by Using the Phenomenon of Heat Release Caused by Deformation

Deformation of steel parts is accompanied by either heating or cooling of particular zones depending on deformation mechanism. The use of infrared thermographic equipment allows analyzing spatial/temporal temperature distributions on the surface of steel parts thus allowing the evaluation of heat release caused by deformation in bulk material. Determination of stressed state in critical parts by analyzing infrared thermograms can be most simply conducted for components subjected to uniaxial tension–compression. The paper describes some potentials and problems of nondestructive testing of steel parts and constructions based on the analysis of heat release caused by deformation. By analyzing this methodology, it is possible to better evaluate the life expectancy of critical parts in steel structures (components of offshore oil platforms, seismic-resistant buildings, frames of large mining trucks, etc.).

42 ENGINEERING↗

DOE OSTI2016

MO-FG-202-04: Gantry-Resolved Linac QA for VMAT: A Comprehensive and Efficient System Using An Electronic Portal Imaging Device

Purpose: To automate gantry-resolved linear accelerator (linac) quality assurance (QA) for volumetric modulated arc therapy (VMAT) using an electronic portal imaging device (EPID). Methods: A QA system for VMAT was developed that uses an EPID, frame-grabber assembly and in-house developed image processing software. The system relies solely on the analysis of EPID image frames acquired without the presence of a phantom. Images were acquired at 8.41 frames per second using a frame grabber and ancillary acquisition computer. Each image frame was tagged with a gantry angle from the linac’s on-board gantry angle encoder. Arc-dynamic QA plans were designed to assess the performance of each individual linac component during VMAT. By analysing each image frame acquired during the QA deliveries the following eight machine performance characteristics were measured as a function of gantry angle: MLC positional accuracy, MLC speed constancy, MLC acceleration constancy, MLC-gantry synchronisation, beam profile constancy, dose rate constancy, gantry speed constancy, dose-gantry angle synchronisation and mechanical sag. All tests were performed on a Varian iX linear accelerator equipped with a 120 leaf Millennium MLC and an aS1000 EPID (Varian Medical Systems, Palo Alto, CA, USA). Results: Machine performance parameters were measured as a function of gantry angle using EPID imaging and compared to machine log files and the treatment plan. Data acquisition is currently underway at 3 centres, incorporating 7 treatment units, at 2 weekly measurement intervals. Conclusion: The proposed system can be applied for streamlined linac QA and commissioning for VMAT. The set of test plans developed can be used to assess the performance of each individual components of the treatment machine during VMAT deliveries as a function of gantry angle. The methodology does not require the setup of any additional phantom or measurement equipment and the analysis is fully automated to allow for regular routine testing.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

Very High Cycle Fatigue of a Cast Aluminum Alloy: Size Effect and Crack Initiation

Fatigue properties of an Al-Si-Cu cast alloy were investigated with life up to very high cycle fatigue regime. Particular attention was given to specimen size effect and fatigue crack initiation mechanism. Uniaxial fatigue tests with constant amplitudes were carried out by using ultrasonic fatigue testing machine operating at 20 kHz, compared to the results obtained by using conventional hydraulic fatigue machine at 35 Hz. In order to evaluate the size effect, two sets of specimens with different dimensions were used. The results show that the fatigue strength of the studied alloy decreases with the increase in specimen size. Scanning electron microscopy observation of fracture surfaces revealed that most fatigue cracks initiated from microstructural defects such as porosity located on specimen surface or in subsurface. Weibull statistical analysis of fatigue data accounting for size effect was performed to predict the fatigue life of the Al-Si-Cu alloy in the very high cycle regime. Good agreement was found between the fatigue life prediction and the experimental data.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗

DOE OSTI2015

High temperature abatement of acid gases from waste incineration. Part II: Comparative life cycle assessment study

Highlights: • Two scenarios of acid gases removal in WTE plants were compared in an LCA study. • A detailed inventory based on primary data has been reported for the production of the new dolomitic sorbent. • Results show that the comparison between the two scenarios does not show systematic differences. • The potential impacts are reduced only if there is an increase in the energy efficiency of the WTE plant. - Abstract: The performances of a new dolomitic sorbent, named Depurcal®MG, to be directly injected at high temperature in the combustion chamber of Waste-To-Energy (WTE) plants as a preliminary stage of deacidification, were experimentally tested during full-scale commercial operation. Results of the experimentations were promising, and have been extensively described in Biganzoli et al. (2014). This paper reports the Life Cycle Assessment (LCA) study performed to compare the traditional operation of the plants, based on the sole sodium bicarbonate feeding at low temperature, with the new one, where the dolomitic sorbent is injected at high temperature. In the latter the sodium bicarbonate is still used, but at lower rate because of the decreased load of acid gases entering the flue gas treatment line. The major goal of the LCA was to make sure that a burden shifting was not taking place somewhere in the life cycle stages, as it might be the case when a new material is used in substitution of another one. According to the comparative approach, only the processes which differ between the two operational modes were included in the system boundaries. They are the production of the two reactants and the treatment of the corresponding solid residues arising from the neutralisation of acid gases. The additional CO{sub 2} emission at the stack of the WTE plant due to the activation of the sodium bicarbonate was also included in the calculation. Data used in the modelling of the foreground system are primary, derived from the experimental tests described in Biganzoli et al. (2014) and from the dolomitic sorbent production plant. The results of the LCA show minor changes in the potential impacts between the two operational modes of the plants. These differences are for 8 impact categories in favour of the new operational mode based on the addition of the dolomitic sorbent, and for 7 impact categories in favour of the traditional operation. A final evaluation was conducted on the potential role of the dolomitic sorbent in enhancing the electric energy production efficiency of the plant, thanks to the better cleaning of the heat exchange surface that can be achieved. If such improvement is accounted for, all the potential impacts are considerably decreased (e.g. the Climate change by 28%), and in the comparison with the traditional operation 17 impact categories out of 19 are reduced.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Defect Length and Profile Influence on Frequency Domain Reflectometry

Degradation of the cable jacket, electrical insulation, and other cable components of installed cables within nuclear power plants (NPPs) is known to occur as a function of age, temperature, radiation, and other environmental factors. Although system tests verify cable function under normal loads, demonstration of some cable’s ability to perform under exceptional loads associated with design-basis events is essential to assuring plant integrity. The cable’s ability to perform safely over the initial 40 year planned and licensed life has generally been demonstrated and there have been very few age-related cable failures. With greater than 1000 km of power, control, instrumentation, and other cables typically found in an NPP, replacing all the cables would be a severe cost burden. Justification for life extension to 60 and 80 years requires a cable aging management program that includes condition monitoring to justify cable performance under normal operation as well as accident conditions. A variety of tests are available to assess various aspects of electrical and mechanical cable performance, but none are suitable for all cable configurations nor does any single test confirm all features of interest. One particularly promising test that is beginning to be used more and more by utilities is frequency domain reflectometry (FDR). FDR is a nondestructive electrical inspection technique used to detect and localize faults in power and communication system conductors along the length of a cable from a single connection point. FDR detects discontinuities in the electrical impedance that arise due to cable splices or similar changes along the path of the conductor pair. In addition, FDR has the potential to provide sensitivity to insulation degradation by detecting small changes in impedance between the cable conductors being examined. The technique is also sensitive to cable bends, the particular lay of the cable in tray, proximity to other cable, and other factors that bear consideration when interpreting the test results. This paper examines various influences on the FDR approach particularly using FEM modeling methods and focusing on defect length and defect profile.

Cable Inspection, Frequency Domain Reflectometry, ↗

DOE OSTI2011

Materials for High-Pressure Fuel Injection Systems

The high-level goal of this multi-year effort was to facilitate the Advanced Combustion Engine goal of 20% improvement (compared to 2009 baseline) of commercial engine efficiency by 2015. A sub-goal is to increase the reliability of diesel fuel injectors by investigating modelbased scenarios that cannot be achieved by empirical, trial and error methodologies alone. During this three-year project, ORNL developed the methodology to evaluate origins and to record the initiation and propagation of fatigue cracks emanating from holes that were electrodischarge machined (EDM), the method used to form spray holes in fuel injector tips. Both x-ray and neutron-based methods for measuring residual stress at four different research facilities were evaluated to determine which, if any, was most applicable to the fuel injector tip geometry. Owing to the shape and small volumes of material involved in the sack area, residual stress data could only be obtained in the walls of the nozzle a few millimeters back from the tip, and there was a hint of only a small compressive stress. This result was consistent with prior studies by Caterpillar. Residual stress studies were suspended after the second year, reserving the possibility of pursuing this in the future, if and when methodology suitable for injector sacks becomes available. The smooth specimen fatigue behavior of current fuel injector steel materials was evaluated and displayed a dual mode initiation behavior. At high stresses, cracks started at machining flaws in the surface; however, below a critical threshold stress of approximately 800 MPa, cracks initiated in the bulk microstructure, below the surface. This suggests that for the next generation for high-pressure fuel injector nozzles, it becomes increasingly important to control the machining and finishing processes, especially if the stress in the tip approaches or exceeds that threshold level. Fatigue tests were also conducted using EDM notches in the gage sections. Compared to the smooth specimens, EDM notching led to a severe reduction in total fatigue life. A reduction in fatigue life of nearly four orders of magnitude can occur at an EDM notch the approximate size of fuel injector spray holes. Consequently, the initiation and propagation behavior of cracks from small spray holes is relevant for generation of design quality data for the next generation diesel fuel injection devices. This is especially true since the current design methodologies usually rely on the less conservative smooth specimen fatigue testing results, and since different materials can have varying levels of notch fatigue resistance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

FY25 Status Update on A709 Code Case Testing at ANL

This report provides an update on the status of the creep rupture testing on the precipitation-treated (PT) Alloy 709 samples fabricated from the first, the second and the third commercial heats, in support of the first, 100,000-hour Alloy 709 Code Case development under the American Society of Mechanical Engineers (ASME) Section III, Division 5 for high-temperature reactor construction. In Fiscal Year (FY) 25, no new tests were initiated, while 5 previously loaded tests were completed. This report presents an overview of the creep-rupture data gathered at Argonne National Laboratory (ANL) since FY21 that totaled 52 completed tests. Metallographic images showing crack morphologies in some representative samples ruptured in FY25 are also included. Key conclusions include: 1) the creep behavior of the three heats of Alloy 709 can be well described by the Larson-Miller relationship; 2) higher temperatures and larger stresses lead to shorter creep life and higher minimum creep rate; 3) Alloy 709 is overall very ductile under creep; 4) the crack morphologies near fracture surfaces are dependent on material’s grain size and test conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Implications of Abiotic Oxygen Buildup for Earth-like Complex Life

One of the chief paradoxes of molecular oxygen (O{sub 2}) is that it is an essential requirement for multicellular eukaryotes on Earth while simultaneously posing a threat to their survival via the formation of reactive oxygen species. In this paper, the constraints imposed by O{sub 2} on Earth-like complex life are invoked to explore whether worlds with abiotic O{sub 2} inventories can harbor such organisms. By taking the major O{sub 2} sources and sinks of Earth-like planets into account using a simple model, it is suggested that worlds that receive time-averaged X-ray and extreme ultraviolet fluxes that are ≳10 times higher than Earth might not be capable of hosting complex lifeforms because the photolysis of molecules such as water may lead to significant O{sub 2} buildup. Methods for testing this hypothesis by searching for anticorrelations between biosignatures and indicators of abiotic O{sub 2} atmospheres are described. In the event, however, that life successfully adapts to high-oxygen environments, these worlds could permit the evolution of large and complex organisms.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

FLC Award: QED: Quantum Ensured Defense of the Smart Electric Grid

A reliable electric power supply is crucial for modern day life as well as national security, economic productivity, and life-and-death essentials. During the COVID pandemic, internet and cell communications became a “must-have” for government and business operations, education, and communicating COVID testing for vaccine information. Loss of electric power quickly leads to human health and national security emergencies. When a major winter storm hit Texas in mid-February 2021, the system was overwhelmed and over 4M people lost power. Although this crisis arose from an unprecedented weather event - not a cyberattack - it serves as a vivid illustration of the impact power disruption can have on our American way of life. The recent cyberattack on the Colonial Oil Pipeline also provides a stark reminder that infrastructure supporting our daily lives has vulnerabilities.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2012

Ceramic HEPA Filter Program

Potential benefits of ceramic filters in nuclear facilities: (1) Short term benefit for DOE, NRC, and industry - (a) CalPoly HTTU provides unique testing capability to answer questions for DOE - High temperature testing of materials, components, filter, (b) Several DNFSB correspondences and presentations by DNFSB members have highlighted the need for HEPA filter R and D - DNFSB Recommendation 2009-2 highlighted a nuclear facility response to an evaluation basis earthquake followed by a fire (aka shake-n-bake) and CalPoly has capability for a shake-n-bake test; (2) Intermediate term benefit for DOE and industry - (a) Filtration for specialty applications, e.g., explosive applications at Nevada, (b) Spin-off technologies applicable to other commercial industries; and (3) Long term benefit for DOE, NRC, and industry - (a) Across industry, strong desire for better performance filter, (b) Engineering solution to safety problem will improve facility safety and decrease dependence on associated support systems, (c) Large potential life-cycle cost savings, and (d) Facilitates development and deployment of LLNL process innovations to allow continuous ventilation system operation during a fire.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Pathway modeling of microarray data: A case study of pathway activity changes in the testis following in utero exposure to dibutyl phthalate (DBP)

Pathway activity level analysis, the approach pursued in this study, focuses on all genes that are known to be members of metabolic and signaling pathways as defined by the KEGG database. The pathway activity level analysis entails singular value decomposition (SVD) of the expression data of the genes constituting a given pathway. We explore an extension of the pathway activity methodology for application to time-course microarray data. We show that pathway analysis enhances our ability to detect biologically relevant changes in pathway activity using synthetic data. As a case study, we apply the pathway activity level formulation coupled with significance analysis to microarray data from two different rat testes exposed in utero to Dibutyl Phthalate (DBP). In utero DBP exposure in the rat results in developmental toxicity of a number of male reproductive organs, including the testes. One well-characterized mode of action for DBP and the male reproductive developmental effects is the repression of expression of genes involved in cholesterol transport, steroid biosynthesis and testosterone synthesis that lead to a decreased fetal testicular testosterone. Previous analyses of DBP testes microarray data focused on either individual gene expression changes or changes in the expression of specific genes that are hypothesized, or known, to be important in testicular development and testosterone synthesis. However, a pathway analysis may inform whether there are additional affected pathways that could inform additional modes of action linked to DBP developmental toxicity. We show that Pathway activity analysis may be considered for a more comprehensive analysis of microarray data.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Yeasts from temperate forests

Yeasts are ubiquitous in temperate forests. While this broad habitat is well-defined, the yeasts inhabiting it and their life cycles, niches, and contributions to ecosystem functioning are less understood. Yeasts are present on nearly all sampled substrates in temperate forests worldwide. They associate with soils, macroorganisms, and other habitats and no doubt contribute to broader ecosystem-wide processes. Researchers have gathered information leading to hypotheses about yeasts' niches and their life cycles based on physiological observations in the laboratory as well as genomic analyses, but the challenge remains to test these hypotheses in the forests themselves. Here, we summarize the habitat and global patterns of yeast diversity, give some information on a handful of well-studied temperate forest yeast genera, discuss the various strategies to isolate forest yeasts, and explain temperate forest yeasts' contributions to biotechnology. Here, we close with a summary of the many future directions and outstanding questions facing researchers in temperate forest yeast ecology. Yeasts present an exciting opportunity to better understand the hidden world of microbial ecology in this threatened and global habitat.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2014

Radiation effects in concrete for nuclear power plants, Part II: Perspective from micromechanical modeling

The need to understand and characterize the effects of neutron irradiation on concrete has become urgent because of the possible extension of service life of many nuclear power generating stations. Current knowledge is primarily based on a collection of data obtained in test reactors. These results are inherently difficult to interpret because materials and testing conditions are inconsistent. A micromechanical approach based on the Hashin composite sphere model is presented to derive a first-order separation of the effects of radiation on cement paste and aggregate, and, also, on their interaction. Although the scarcity of available data limits the validation of the model, it appears that, without negating a possible gamma-ray induced effect, the neutron-induced damage and swelling of aggregate plays a predominant role on the overall concrete expansion and the damage of the cement paste. Finally, the radiation-induced volumetric expansion (RIVE) effects can also be aided by temperature elevation and shrinkage in the cement paste.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Relative reproductive phenology and synchrony affect neonate survival in a nonprecocial ungulate

Abstract Degree of reproductive synchronization in prey is hypothesized as a predator defense strategy reducing prey risk via predator satiation or predator avoidance. Species with precocial young, especially those exposed to specialist predators, should be highly synchronous to satiate predators (predator satiation hypothesis), while prey with nonprecocial (i.e. altricial) young, especially those exposed to generalist predators, should become relatively asynchronous to avoid predator detection (predator avoidance hypothesis). The white‐tailed deer Odocoileus virginianus in North America is an example of a nonprecocial ungulate that uses the hider strategy early in life; its primary predator (coyote; Canis latrans ) is a generalist, making white‐tailed deer a good model species to test the predator avoidance hypothesis. We used birth dates and known fates of white‐tailed deer neonates ( n = 1,032) across nine study sites varying in relative synchrony and predator assemblages to test the predator avoidance hypothesis. We predicted that relative birthing asynchrony of the population would increase relative survival at the population level; therefore, at the individual scale, neonate birth date nearer to mean birthing date in a respective population would not influence individual survival. Coyotes were responsible for the majority of predation events, and survival of those neonates increased the closer the individual was born to peak birthing season in each respective population. Also, at the population level, reproductive asynchronization negatively affected survival. Contrary to the predator avoidance hypothesis, our data indicate patterns in neonate survival for white‐tailed deer better support the predator satiation hypothesis at the individual and population level. Additionally, coyotes may present a selective force great enough to shift reproductive synchrony such that predator satiation may become a feasible defense strategy for neonates at local spatial scales. Our results indicate that synchronizing reproduction may still be the most effective strategy to reduce individual predation risk from generalist predators, particularly when the window of heightened resource availability to the prey is narrow. A free Plain Language Summary can be found within the Supporting Information of this article.

Michel, Eric S.↗

DOE OSTI2014

Active Power Controls from Wind Power: Bridging the Gaps

This paper details a comprehensive study undertaken by the National Renewable Energy Laboratory, Electric Power Research Institute, and the University of Colorado to understand how the contribution of wind power providing active power control (APC) can benefit the total power system economics, increase revenue streams, improve the reliability and security of the power system, and provide superior and efficient response while reducing any structural and loading impacts that may reduce the life of the wind turbine or its components. The study includes power system simulations, control simulations, and actual field tests using turbines at NREL's National Wind Technology Center (NWTC). The study focuses on synthetic inertial control, primary frequency control, and automatic generation control, and analyzes timeframes ranging from milliseconds to minutes to the lifetime of wind turbines, locational scope ranging from components of turbines to large wind plants to entire synchronous interconnections, and additional topics ranging from economics to power system engineering to control design.

17 WIND ENERGY↗