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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Review of low-cost self-driving laboratories in chemistry and materials science: the “frugal twin” concept

This review proposes the concept of a “frugal twin,” similar to a digital twin, but for physical experiments. Frugal twins range from simple toy examples to low-cost surrogates of high-cost research systems. For example, a color-mixing self-driving laboratory (SDL) can serve as a low-cost version of a costly multi-step chemical discovery SDL. Frugal twins already provide hands-on experience for SDLs with low costs and low risks. They can also offer as test beds for software prototyping (e.g., optimization, data infrastructure), and a low barrier to entry for democratizing SDLs. However, there is room for improvement. The true value of frugal twins can be realized in three core areas. Firstly, hardware and software modularity; secondly, purpose-built design (human-inspired vs. hardware-centric vs. human-in-the-loop); and thirdly state-of-the-art (SOTA) software (e.g., multi-fidelity optimization). We also describe the ethical benefits and risks that come with the democratization of science through frugal twins. For future work, we suggest ideas for new frugal twins, SDL educational course outcomes, and a classification scheme for autonomy levels.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Quantum computing for energy correlators

In recent years, energy correlators have emerged as powerful observables for probing the fragmentation dynamics of high-energy collisions. We introduce the first numerical strategy for calculating energy correlators using the Hamiltonian lattice approach, providing access to the intriguing nonperturbative dynamics of these observables. Furthermore, motivated by rapid advances in quantum computing hardware and algorithms, we propose a quantum algorithm for calculating energy correlators in quantum field theories. This algorithm includes ground state preparation, the application of source, sink, energy flux and real-time evolution operators, and the Hadamard test. We validate our approach by applying it to the SU(2) pure gauge theory in 2 + 1 dimensions on 3 × 3 and 5 × 5 honeycomb lattices with 𝑗 max = $\frac{1}{2}$ at various couplings, utilizing both classical methods and the quantum algorithm, the latter tested using the IBM emulator for specific configurations. The results are consistent with the expected behavior of the strong coupling regime and motivate a more comprehensive study to probe the confinement dynamics across the weak and strong coupling regimes.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2016

Passive Leak Detection Using Commercial Hydrogen Colorimetric Indicator

Element One, Inc. (www.elem.com), a small business with in Boulder, CO, has been developing hydrogen detection technology based upon a highly selective colorimetric indicator. In its native state, the indicator pigment is a pale gray color, but becomes black upon exposure to hydrogen. The colorimetric change can be readily observed by the naked eye without the need for supplemental electronics or other hardware. Recently, the colorimetric indicator was integrated into a pliable, self-adhesive tape that can readily wrap around pneumatic fittings to serve as a hydrogen leak detector. A prototype version of the Element One indicator tape was tested within an NREL hydrogen system and successfully identified the unexpected presence of a small leak; a summary document for this case study is presented in Appendix 1. The tape was subsequently configured into 10-foot rolls as a product prototype that has just recently been commercialized and marketed under the tradename DetecTape(R). Figure 1 shows the commercial version of DetecTape along with an indicator sample in its native state and one that had been exposed to hydrogen. DetecTape is a self-adhesive silicone-based tape impregnated with a proprietary hydrogen-sensitive indicator based on transition metal oxides. A length of the tape can be cut from the roll and stretched by a factor of two or three times around a fitting. Due to the self-adhesive property of the tape, this provides a tight seal around the fitting. The seal is not hermetic, and is not intended to prevent the release of a leaking gas. However, a portion of the hydrogen leaking from a wrapped fitting will pass through the tape and react with the active indicator impregnated within the tape, thereby inducing blackening.

08 HYDROGEN↗
DOE OSTI2025

Accelerating Neutrino Event Generation in MARLEY Using CUDA-Based RNG and GPU Parallelization

MARLEY is a simulation tool that helps scientists study how low-energy neutrinos interact with matter. To work properly, MARLEY uses random numbers thousands of times in each simulation. These random numbers are important for modeling things like how neutrinos collide with atoms and what particles they produce. Right now, MARLEY runs on a regular computer processor (CPU) and uses a built-in random number generator called the Mersenne Twister. This setup works, but it can be slow, especially when trying to simulate many events. This research focuses on making MARLEY run faster by moving the random number generation and some of the repetitive calculations from the CPU to a graphics processing unit (GPU), which can handle many tasks at the same time. We use CUDA (a tool for programming NVIDIA GPUs) and cuRAND (a GPU-based random number library) to test faster alternatives to the current random number system. We compare different GPU-based generators, like curand_mtgp32, xorwow, and philox, to see which ones are the quickest and still give reliable results. Early tests show that using the GPU can make MARLEY simulations much faster. This project not only helps improve current simulation performance but also moves closer to a full simulation chain where all stages can run on modern GPU hardware.

Dunkley, Kimieka [Florida A-M]↗
DOE OSTI2015

An optimization of the FPGA trigger based on the artificial neural network for a detection of neutrino-origin showers

Observations of ultra-high energy neutrinos became a priority in experimental astro-particle physics. Up to now, the Pierre Auger Observatory did not find any candidate on a neutrino event. This imposes competitive limits to the diffuse flux of ultra-high energy neutrinos in the EeV range and above. A very low rate of events potentially generated by neutrinos is a significant challenge for a detection technique and requires both sophisticated algorithms and high-resolution hardware. A trigger based on a artificial neural network was implemented into the Cyclone{sup R} V E FPGA 5CEFA9F31I7. The prototype Front-End boards for Auger-Beyond-2015 with Cyclone{sup R} V E can test the neural network algorithm in real pampas conditions in 2015. Showers for muon and tau neutrino initiating particles on various altitudes, angles and energies were simulated in CORSICA and Offline platforms giving pattern of ADC traces in Auger water Cherenkov detectors. The 3-layer 12-10-1 neural network was taught in MATLAB by simulated ADC traces according the Levenberg-Marquardt algorithm. Results show that a probability of a ADC traces generation is very low due to a small neutrino cross-section. Nevertheless, ADC traces, if occur, for 1-10 EeV showers are relatively short and can be analyzed by 16-point input algorithm. For 100 EeV range traces are much longer, but with significantly higher amplitudes, which can be detected by standard threshold algorithms. We optimized the coefficients from MATLAB to get a maximal range of potentially registered events and for fixed-point FPGA processing to minimize calculation errors. Currently used Front-End boards based on no-more produced ACEXR PLDs and obsolete Cyclone{sup R} FPGAs allow an implementation of relatively simple threshold algorithms for triggers. New sophisticated trigger implemented in Cyclone{sup R} V E FPGAs with large amount of DSP blocks, embedded memory running with 120 - 160 MHz sampling may support to discover neutrino events in the Pierre Auger Observatory. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

The problem analysis of data processing performance in nuclear power plant computerized information and control system - 288

This paper is based on the data processing performance problems of operating command delay and system display not updating real-time for nuclear power plant computerized information and control system. The plant computerized information and control system is responsible for monitoring and controlling the plant operation, and it is a key part in the plant DCS system. Its data processing performance will affect the operation stability of nuclear power plant. The architecture, hardware configuration and data communication for plant computerized information and control system among the different levels in DCS are described. The main reasons affecting data processing performance in different signal channels are analyzed according to the plant load test results. The CPU load curves for real time server and central processing server are displayed, although the detailed cause for operating command delay and system display not updating realtime are not found, central processing server load is heavier than real time server which remind us to analyze the data processing of software resource scheduling deeply. So the resource distribution problem of software execution task is also analyzed according to CPU load test results. This paper provides the optimization analysis for data processing performance, and it is available and effective according to the latest test results. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Quantum fluctuation theorem for error diagnostics in quantum annealers

Near term quantum hardware promises unprecedented computational advantage. Crucial in its development is the characterization and minimization of computational errors. We introduce the use of the quantum fluctuation theorem to benchmark the accuracy of quantum annealers. This versatile tool provides simple means to determine whether the quantum dynamics are unital, unitary, and adiabatic, or whether the system is prone to thermal noise. Our proposal is experimentally tested on two generations of the D-Wave machine, which illustrates the sensitivity of the fluctuation theorem to the smallest aberrations from ideal annealing. In addition, for the optimally operating D-Wave machine, our experiment provides the first experimental verification of the integral fluctuation in an interacting, many-body quantum system.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Blade Designs For Improved Multi-Phase Performance In sCO 2 Compressors; Part II - Optical Diagnostics In sCO 2 And Experimental Evaluation With Particle Image Velocimetry

This paper presents the second part of a study in which the leading-edge and suction surface of a compressor blade was modified to delay onset of phase change for sCO 2 compressors operating near the critical point. Using a first-of-its-kind apparatus for the measurement of sCO 2 flow fields, Particle Image Velocimetry (PIV) is used for local flow field measurements of two compressor blade geometries: the modified “biased-wedge,” and a conventional constant thickness blade. Utilizing the developed hardware, the feasibility of a simple, laser-based diagnostic for qualitatively measuring liquid phase regions, is also presented. The design of the optical diagnostics rig, a discussion of numerous challenges, and necessary considerations involved in performing optical-based measurements like PIV, in sCO 2 , are discussed. Velocity field measurements for the modified compressor profile show a much lower suction peak compared to a conventional blade. Furthermore, these results validate numerical results at the tested conditions, where the suction side profile of the biased wedge works to minimize the local pressure gradient.

14 SOLAR ENERGY↗
DOE OSTI2019

Parallel beamlet dose calculation via beamlet contexts in a distributed multi‐GPU framework

Purpose Dose calculation is one of the most computationally intensive, yet essential tasks in the treatment planning process. With the recent interest in automatic beam orientation and arc trajectory optimization techniques, there is a great need for more efficient model‐based dose calculation algorithms that can accommodate hundreds to thousands of beam candidates at once. Foundational work has shown the translation of dose calculation algorithms to graphical processing units ( GPU s), lending to remarkable gains in processing efficiency. But these methods provide parallelization of dose for only a single beamlet, serializing the calculation of multiple beamlets and under‐utilizing the potential of modern GPU s. In this paper, the authors propose a framework enabling parallel computation of many beamlet doses using a novel beamlet context transformation and further embed this approach in a scalable network of multi‐ GPU computational nodes. Methods The proposed context‐based transformation separates beamlet‐local density and TERMA into distinct beamlet contexts that independently provide sufficient data for beamlet dose calculation. Beamlet contexts are arranged in a composite context array with dosimetric isolation, and the context array is subjected to a GPU collapsed‐cone convolution superposition procedure, producing the set of beamlet‐specific dose distributions in a single pass. Dose from each context is converted to a sparse representation for efficient storage and retrieval during treatment plan optimization. The context radius is a new parameter permitting flexibility between the speed and fidelity of the dose calculation process. A distributed manager‐worker architecture is constructed around the context‐based GPU dose calculation approach supporting an arbitrary number of worker nodes and resident GPU s. Phantom experiments were executed to verify the accuracy of the context‐based approach compared to Monte Carlo and a reference CPU ‐ CCCS implementation for single beamlets and broad beams composed by addition of beamlets. Dose for representative 4 π beam sets was calculated in lung and prostate cases to compare its efficiency with that of an existing beamlet‐sequential GPU ‐ CCCS implementation. Code profiling was also performed to evaluate the scalability of the framework across many networked GPU s. Results The dosimetric accuracy of the context‐based method displays <1.35% and 2.35% average error from the existing serialized CPU ‐ CCCS algorithm and Monte Carlo simulation for beamlet‐specific PDD s in water and slab phantoms, respectively. The context‐based method demonstrates substantial speedup of up to two orders of magnitude over the beamlet‐sequential GPU ‐ CCCS method in the tested configurations. The context‐based framework demonstrates near linear scaling in the number of distributed compute nodes and GPU s employed, indicating that it is flexible enough to meet the performance requirements of most users by simply increasing the hardware utilization. Conclusions The context‐based approach demonstrates a new expectation of performance for beamlet‐based dose calculation methods. This approach has been successful in accelerating the dose calculation process for very large‐scale treatment planning problems ‐ such as automatic 4 π IMRT beam orientation and VMAT arc trajectory selection, with hundreds of thousands of beamlets ‐ in clinically feasible timeframes. The flexibility of this framework makes it as a strong candidate for use in a variety of other very large‐scale treatment planning tasks and clinical workflows.

Neph, Ryan↗
DOE OSTI2023

Design and Optimization of High-frequency Transformer for Isolated Single-Stage Three-Phase AC/DC Converter using Bidirectional Switches

This paper presents the design and optimization of the high-frequency transformer for an isolated single-stage threephase AC/DC converter enabled by the 4H-SiC BiDirectional Field Effect Transistor (BiDFET). Non-dominated Sorting Genetic Algorithm II (NSGA-II) is used to perform a multiobjective optimization to minimize loss, weight, and volume. A 20 kW, 50 kHz hardware prototype based on the selected optimal point is characterized by a power amplifier. The finite element analysis simulation results are also presented to validate the core magnetic flux density and winding electric field strength. The experimental prototype was tested at 800 Vdc/480 Vrms at 10 kW rated power.

BiDFET, High-frequency transformer, Multiobjective↗
DOE OSTI2014

Design and Integrate Improved Systems for Nuclear Facility Ventilation and Exhaust Operations

Objective: The objective of this R&D project would complete the development of three new systems and integrate them into a single experimental effort. However, each of the three systems has stand-alone applicability across the DOE complex. At US DOE nuclear facilities, indoor air is filtered and ventilated for human occupancy, and exhaust air to the outdoor environment must be regulated and monitored. At least three technical standards address these functions, and the Los Alamos National Laboratory would complete an experimental facility to answer at least three questions: (1) Can the drag coefficient of a new Los Alamos air mixer be reduced for better operation in nuclear facility exhaust stacks? (2) Is it possible to verify the accuracy of a new dilution method for HEPA filter test facilities? (3) Is there a performance-based air flow metric (volumetric flow or mass flow) for operating HEPA filters? In summary, the three new systems are: a mixer, a diluter and a performance-based metric, respectively. The results of this project would be applicable to at least four technical standards: ANSI N13.1 Sampling and Monitoring Releases of Airborne Radioactive Substances from the Stacks and Ducts of Nuclear Facilities; ASTM F1471 Standard Test Method for Air Cleaning Performance of a High-Efficiency Particulate Air Filter System, ASME N511: In-Service Testing of Nuclear Air Treatment, Heating, Ventilating, and Air-Conditioning Systems, and ASME AG-1: Code On Nuclear Air And Gas Treatment. All of the three proposed new systems must be combined into a single experimental device (i.e. to develop a new function of the Los Alamos aerosol wind tunnel). Technical Approach: The Radiation Protection RP-SVS group at Los Alamos has an aerosol wind tunnel that was originally (2006) designed to evaluate small air samplers (cf. US EPA 40 CFR 53.42). In 2009, the tunnel was modified for exhaust stack verifications per the ANSI N13.1 standard. In 2010, modifications were started on the wind tunnel for testing HEPA filters (cf. ASTM F1471 and ASME N511). This project involves three systems that were developed for testing the 24*24*11 (inch) HEPA filters (i.e. the already mentioned mixer, diluter and metric). Prototypes of the mixer and the diluter have been built and individually tested on a preliminary basis. However, the third system (the HEPA metric method) has not been tested, since that requires complete operability of the aerosol wind tunnel device. (The experimental wind tunnel has test aerosol injection, control and measurement capabilities, and can be heated for temperature dependent measurements.) Benefits: US DOE facilities that use HEPA filters and/or require exhaust stacks from their nuclear facility buildings will benefit from access to the new hardware (mixer and diluter) and performance-based metric (for HEPA filter air flow).

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2020

An Intelligent Adaptable Monitoring Package. Final Report

The “Intelligent Adaptable Monitoring Package” project was a four-year effort that demonstrated the feasibility of integrated sensing packages at tidal and wave energy sites. Such integration is generally required by the breadth of sensors required to understand environmental effects at marine energy sites and the operational difficulty of deploying, maintaining, and recovering such sensors. Over the course of the project, the Adaptable Monitoring Package (AMP) was deployed in multiple settings, each corresponding to a project budget period: - Budget Period 1: Demonstration of cabled deployment at Pacific Northwest National Laboratory’s Marine Science Laboratory. The deployment highlighted AMP hardware endurance over a 4-month deployment in a tidally-dominated environment and laid the groundwork for machine learning algorithms to detect and classify targets present in active sonar data. - Budget Period 2: Demonstration of an autonomous deployment at PacWave South off the coast of Newport, Oregon. The deployment highlighted the stability of AMP hardware and software, with the autonomous package collecting data on a duty cycle over a 1.5-month deployment. - Budget Period 3: Demonstration of an autonomous deployment powered by a wave energy converter at the U.S. Navy’s Wave Energy Test Site. The deployment highlighted the potential of wave energy to power ocean observatories and led to the development of machine learning algorithms to detect and classify targets in optical camera data. In aggregate, this project’s greatest success was demonstrating the AMP’s flexibility in a range of deployment scenarios. Each budget period represented a “first of a kind” demonstration of integrated instrumentation – cabled AMP, autonomous AMP, wave-energy powered AMP – and each deployment helped to identify and set goals for the next. Further, despite the exploratory nature of these deployments, each one achieved high system up-time and proved that flexible integration of multiple sensors in a single package represents a viable strategy for marine energy environmental monitoring. The key lessons learned from the project are: - Without continuous power, either from a shore cable or in situ source, many of the benefits of integration are lost (If continuous power is not available, the ability to detect rare events is lost, as is the ability to minimize the risk of behavioral changes through adaptive sensing. However, even on a duty cycle, there is still value in being able to acquire synchronous data from multiple sensors.); and - Observations from a moving platform present substantially greater data processing challenges than those from stationary platforms. Finally, these deployments also demonstrate an important truth: successful integration alone does not guarantee that relevant data are collected. To grow the knowledge base about environmental interactions with marine energy converters, integrated systems, like the AMP, need to include the right sensor mix and connect the data pipelines to effective processing algorithms. These deployments establish a strong foundation for future collaborations with the environmental research community: not only to understand the environmental effects of marine energy, but also to improve our general ability to study life in the sea.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Upgrade of Core Conduction Cooldown Test Facility Control System

The CCCTF was designed and installed at ORNL in the 1990s for high-temperature gas-cooled reactor accident simulation. It is located within a modular hot cell housed in the IFEL facility. In 2008 and 2009, modifications were made to the CCCTF in preparation for AGR safety testing. A new airlock was designed and installed to better support periodic exchange of the fission product deposition cups while maintaining the fuel at safety test temperature, and modifications were made to add routines to the existing user interface software for computer-controlled automation of the He sweep gas flow and liquid nitrogen supply to the 85Kr cold traps. However, the furnace control hardware and software remained essentially unchanged. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, continued use of the CCCTF was in question because of the gradual obsolescence of the hardware and software used to control the furnace and ancillary systems that make up the CCCTF. Therefore, an effort was undertaken to replace all the obsolete components with new hardware and update the software to increase system reliability and ensure this capability’s maintenance for future research and fuel qualification efforts. The modifications included creating a new National Instruments (NI) LabVIEW-based control system with a graphical user interface (GUI).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Scoping Study for Fast Flux Testing in the Advanced Test Reactor

The value of fast spectrum reactors remains prominent in the nuclear technology portfolio. The performance of these reactors can be maximized with advancements in nuclear fuel technologies, but development of these technologies is currently held back by lack of fast spectrum test reactors available to the United States. Spectral modification of experiment positions in the thermal spectrum Advanced Test Reactor (ATR) has long been used to support fast reactor fuel development, but these methods have not been progressed to their full potential. This study investigated the use of concentric rings of aluminum-clad fuel plates in ATR flux traps and thermal neutron absorbing filters to increase fast neutron flux on test specimens. This concept was termed the Boosted Energy Advanced Spectrum Test (BEAST). This approach will enable irradiation of advanced fuel designs in prototypic-length fuel pins and representative flux environment to support post irradiation exams, enable transient testing, and produce the type of data that will permit lead test assembly irradiations in true Sodium Fast Reactors (SFRs) when they become available. Neutronic predictions were performed to investigate BEAST design options and thermal hydraulic models were produced to ensure feasibility of BEAST. Two versions were considered based on the geometric limitations of ATR’s small and large flux traps. The small version was found to be preferable due to slightly higher fast flux and fast-to-thermal neutron ratio. Perhaps more influentially, the small flux trap option was also preferred to avoid conflict with ongoing very high temperature reactor fuel irradiation programs in ATR’s large northeast flux trap. The small flux trap option provided less than half the test volume of the large version, but still had adequate volume for seven SFR pins in cross section which could be stacked two-high in ATR’s 1.2m long core to accommodate up to 14 EBR-II size pins. The preference for the small flux trap configuration should be revisited if additional collaborative test programs emerge with the need to irradiate a significant volume of additional specimens. Calculations were performed regarding a lithium deuteride ring to convert thermal neutrons into 14 MeV fusion neutrons. At the time this report was written these calculations were partially complete and it remains to be seen whether the concept would be worth including in BEAST. Given the preference for the small flux trap option, which does not afford enough room for the 14 MeV ring, it was concluded to defer future work on the lithium deuteride ring. This decision could be revisited if fusion material research programs emerge for collaborative testing in BEAST. A cadmium-lined specimen holder design was found to be adequate in filtering thermal neutrons and preferred over other neutron absorbers based on past experience with cadmium baskets. It was acknowledged that cadmium-bearing hardware would become depleted and need to be replaced occasionally, which appeared feasible from a mechanical design perspective. Neutronic studies investigated different enrichment levels in the booster fuel using uranium-molybdenum alloy dispersion fuel which has performed well in past ATR irradiations. Both options were able to drive fuel pins to SFR-like fission heating rates. The high enriched booster fuel option outperformed the low enriched option by ~20% on key metrics including fast flux and fast-to-thermal ratio, but the low enriched option was favored in order to broaden options for potential fuel suppliers. The preferred BEAST design options including cadmium filter with low enriched booster fuel in the small flux trap configuration was predicted to achieve 6.2E14 n/cm2sec fast flux (>0.1 MeV) with a fast-to-thermal ratio of 44.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Localized Deformation Investigation in Irradiated Materials via Electron Microscopy, EBSD, and In-Situ Mechanical Testing

This report describes the preliminary results of an analysis of dislocation defect structures in nondeformed and deformed austenitic stainless steels – materials of light water reactor internal components. The analysis was performed using an advanced modern approach: high-resolution electron backscatter diffraction (HR-EBSD). Work was performed at Oak Ridge National Laboratory’s Low Activation Materials Development and Analysis (LAMDA) facility. The report is divided into sections describing specific aspects of the project. Section 1 describes the necessity and importance of the defect microstructure analysis and demonstrates that there are very limited data regarding dislocation and defect population at the meso-level (i.e., a grain or group of interacting grains). Section 1 also introduces the HR-EBSD approach used in this research and provides a limited background. Section 2 describes the scanning electron microscope/EBSD systems available at the LAMDA facility, materials investigated in the present work, and hardware and software requirements for the HR-EBSD analysis. Section 3 provides preliminary HR-EBSD results for nonirradiated austenitic stainless steel in contrast to and in comparison with the conventional EBSD outcome. Section 4 describes the HR-EBSD results for austenitic stainless steel irradiated in a commercial-type nuclear power plant and subjected to in-situ mechanical testing. The analysis is focused on mapping and analyzing the geometrically necessary dislocations before and after deformation at small strain levels. As expected, the results will be beneficial for performing corrosion tests, including electrochemical microscopy, which is currently being performed within the Light Water Reactor Sustainability program at the University of California–Los Angeles (Dr. G. Sant). Section 5 summarizes the work performed, presents conclusions, and discusses future activities for this research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Implementation of ANL’s Mechanics Based Evolutionary Fatigue Modeling Through ABAQUS-WARP3D Based High-Performance Computing Framework

This report presents an update on the environmental fatigue research that is being conducted at Argonne National Laboratory in support of the Department of Energy’s Light Water Reactor Sustainability (LWRS) program. Argonne is developing a fully mechanistic fatigue evaluation approach without using empirical fatigue (S~N) curves. This approach is based on the fundamental concept of the time evolution of progressive fatigue damage rather than on the conventional S~N curve approaches using end-of-life data. In FY 2017, we performed extensive validation of this approach with respect to fatigue test data for 316 stainless steel [1]. This validation was performed for different loading cases, including constant, variable, and random amplitude. In the present FY 2018 semi-annual report, we present the further advances of Argonne’s environmental fatigue research work in the context for more practical applications. In this report, we discuss a methodology for fully mechanistic (i.e., not using S~N curves) fatigue life evaluation of reactor components subjected to realistic loading cycles, namely, design-basis loading cycles. The loading cycles include plant heat-up, full-power, and cool-down operations. As a test case, we considered a typical pressurized water reactor surge line, which is made of 316 SS. To perform the fatigue simulation for thousands of fatigue cycles in a computationally cost effective way, we modified our previous desktop-based finite element (FE) modeling approach to work in a high-performance computing (HPC) framework. For the HPC implementation, we developed a hybrid framework based on commercial FE software (ABAQUS), open-source FE software (WARP3D), and Argonne-developed evolutionary cyclic-plasticity modeling methods. We validated this HPC-based cycle-by-cycle damage model for the entire fatigue life of a Pressurized Water Reactor (PWR) surge line (SL) pipe with respect to assumed loading cycles. The simulated fatigue life was found to be 5855 cycles, which is 85% accurate as compared to the corresponding small-specimen-based experimental fatigue life (6914 cycles). Also, the simulated stress history captures the cyclic hardening and softening behavior of the material for entire fatigue cycles. The FE simulation of the PWR SL pipe was conducted in a reasonable time of 12.5 days. These results show the promise that a fully mechanistic (not using S~N curves) fatigue life evaluation of a safety-critical nuclear reactor component (or even other safety critical components like those in aircraft, aero-engines, etc.) is possible. We anticipate that this type of methodology will drastically reduce the uncertainly associated with conventional fatigue life estimates based on empirical S~N curves. We also proposed an FE model that is based on a hybrid full-component and single-element approach and that can readily be used by industry if HPC resources are not available. In this approach, a single-cycle FE simulation has to be performed first for the required loading cycle. Then, the resulting strain/stress profile at the hotspot (highest strain/stress location) is used as input strain/stress loading to the single-element FE model. The single-element FE model is run under multiple fatigue cycles as long as the failure criteria are achieved. The cycle number at failure gives the fatigue life of the component in question. This cost-effective framework does not require expensive HPC hardware and can be performed in a reasonable time by using a desktop computer. We demonstrated this approach with respect to PWR SL fatigue evaluation under two realistic design-basis loading cycles (simple and detailed). The associated results were validated with respect to test data obtained through fatigue testing of uniaxial specimens under the in-air condition at 300 °C. The approach is in the development stage and requires further improvement and validation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Methane Mitigation Thermoelectric Generator (MMTEG) (Final Scientific/ Technical Report)

Gas Technology Institute (GTI) has completed a $1.815M (plus $500K cost share), 54-month Co-operative agreement with the Department of Energy’s National Energy Technology Laboratory to develop a Methane Mitigation Thermoelectric Generator (MMTEG) system for gas field applications. This novel system uses fugitive gas to produce electrical power and consists of Thermoelectric Generators (TEG) driven by a linear burner, an air compressor, an accumulator, valves, batteries, and power electronics. The electrical power generated by the system is used to compress air and, in turn, the air is used to operate the pneumatic valves at the well site instead of using natural gas (NG) which would then be vented. The team completed the project objectives which included (1) Design, fabricate and test an integrated 6We nominal MMTEG prototype system, (2) Design a “retrofit kit” MMTEG system capable of being field tested at a gas well production site, and (3) build and test the field MMTEG system in a laboratory environment. Multiple system options were developed prior to selecting a “Passive” system which meets cost, NG savings, and greenhouse gas (GHG) reduction targets although not as efficient as initially planned. The MMTEG system is built primarily from commercial off-the-shelf parts (in some cases re-purposed) including the heat exchanger, heat rejection, electronic components, and also the TEGs. The team developed and implemented a novel system including the control system developed by Morrison Applied Sciences (MAS). The team completed incremental demonstrations of the hardware prior to the MMTEG system demonstration. A one-year simulation of the air delivery and battery charging subsystems was completed prior to the integration into the MMTEG system. In addition, the team simulated two-years of thermal cycles for integrated Burner/TEG/heat rejection subsystem. Finally, the entire MMTEG system was assembled, and troubleshooting was completed over a two-week period. Next, the MMTEG system was tested to simulate over 15 weeks of entire system operation over approximately four weeks in an accelerated test fashion with minimal intervention (such as changing fuel tanks). The MMTEG system met the key goals of a unit cost of under $1500 while saving 97% of NG expended today (including leakage) on average by pneumatic systems venting to the atmosphere. The MMTEG system reduced GHG emissions by 1000X (using the methane intensification factor of 28 relative to CO2). GTI is currently pursuing a field test of the MMTEG system. Interfacing with producers has provided additional insight into system improvements. Planned improvements include additional weather protection and control system improvements including the implementation of a long- range radio capability to notify operators if there is a fault.

03 NATURAL GAS↗
DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

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