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DOE OSTI2021

How Austenitic Is a Martensitic Steel Produced by Laser Powder Bed Fusion? A Cautionary Tale

Accurate phase fraction analysis is an essential element of the microstructural characterization of alloys and often serves as a basis to quantify effects such as heat treatment or mechanical deformation. Additive manufacturing (AM) of metals, due to the intrinsic nonequilibrium solidification and spatial variability, creates additional challenges for the proper quantification of phase fraction. Such challenges are exacerbated when the alloy itself is prone to deformation-induced phase transformation. Using commonly available in-house X-ray diffraction (XRD) and electron backscatter diffraction (EBSD) and less commonly used synchrotron-based high-energy X-ray diffraction, we characterized nitrogen-atomized 17-4 precipitation-hardening martensitic stainless steel, a class of AM alloy that has received broad attention within the AM research community. On the same build, our measurements recovered the entire range of reported values on the austenite phase fractions of as-built AM 17-4 in literature, from ≈100% martensite to ≈100% austenite. Aided by Calphad simulation, our experimental findings established that our as-built AM 17-4 is almost fully austenitic and that in-house XRD and EBSD measurements are subject to significant uncertainties created by the specimen’s surface finish. Hence, measurements made using these techniques must be understood in their correct context. Our results carry significant implications, not only to AM 17-4 but also to AM alloys that are susceptible to deformation-induced structure transformation and suggest that characterizations with less accessible but bulk sensitive techniques such as synchrotron-based high energy X-ray diffraction or neutron diffraction may be required for proper understanding of these materials.

17-4 steel↗

DOE OSTI2023

The complex momentum representation approach and its application to low-lying resonances in ${^{17}}$O and ${^{29,31}}$F

Approaches for predicting low-lying resonances, uniformly treating bound, and resonant levels have been a long-standing goal in nuclear theory. Accordingly, we explored the viability of the complex momentum representation (CMR) approach coupled with new potentials. We focus on predicting the energy of the low-lying 2p 3/2 resonance in 17 O, which is critical for s-process nucleosynthesis and missing in previous theoretical research. Here, using a Woods-Saxon potential based on the Koning-Delaroche optical model and constrained by the experimental one-neutron separation energy, we successfully predicted the resonant energy of this level for the first time. Our predictions of the bound levels and 1d 3/2 resonance agree well with the measurement results. Additionally, we utilize this approach to study the near-threshold resonances that play a role when forming a two-neutron halo in 29,31 F. We found that the CMR-based predictions of the bound-level energies and unbound 1f 7/2 level agree well with the results obtained using the scattering phase shift method. Subsequently, we successfully found a solution for the 2p 3/2 resonance with energy just above the threshold, which is decisive for halo formation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Energy Analysis: Ways to Save Energy and Reduce the Emissions in Wastewater Treatment Plants

The key of this study is to explore the primary energy consumers in wastewater treatment plants, which is considered as one of the major energy consumers, and introduces the best solution to save energy and reduce emissions in these facilities. This study is based on the energy assessment and analyses of eleven wastewater treatment plants. Through the investigation, it was found that plants can save up to 44,158 MWh of the energy consumption which is 47% from the total electricity consumption with a 17% reduction in the total utility bills and that about 2.5 million dollars cost savings after reviewing the currently facilitated energy system. Additionally, an average of five years' payback period resulted in most energy-saving recommendations. A vast potential of greenhouse gas emissions can be reduced with a total range reduction between 13 to 35 million kg of CO 2 based on the speed reduction percentage.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Solar Energy Technical Publications Catalog: Solar Thermal Technology

The research and development described in these documents was conducted within the U.S . Department of Energy's (DOE) Solar Thermal Technology Program. The goal of this program is to advance the engineering and scientific understanding of solar thermal technology and to establish the technology base from which private industry can develop solar thermal power production options for introduction into the competitive energy market. Solar thermal technology concentrates the solar flux using tracking mirrors or lenses onto a receiver where the solar energy is absorbed as heat and converted into electricity or incorporated into products as process heat. The two primary solar thermal technologies, central receivers and distributed receivers, employ various point and line-focus optics to concentrate sunlight. Current central receiver systems use fields of heliostats (two-axis tracking mirrors) to focus the sun's radiant energy onto a single, tower- mounted receiver. Point focus concentrators up to 17 meters in diameter track the sun in two axes and use parabolic dish mirrors or Fresnel lenses to focus radiant energy onto a receiver. Troughs and bowls are line-focus tracking reflectors that concentrate sunlight onto receiver tubes along their focal lines. Concentrating collector modules can be used alone or in a multimodule system. The concentrated radiant energy absorbed by the solar thermal receiver is transported to the conversion process by a circulating work fluid. Receiver temperatures range from l00 degrees C in low-temperature troughs to over 1500 degrees C in dish and central receiver systems. The Solar Thermal Technology Program is directing efforts to advance and improve each system concept through solar thermal materials, components, and subsystems research and development and by testing and evaluation. These efforts are carried out with the technical direction of DOE and its network of field laboratories that works with private industry. Together they have established a comprehensive, goal-directed program to improve performance and provide technically proven options for eventual incorporation into the nation's energy supply. To successfully contribute to an adequate energy supply at reasonable cost, solar thermal energy must be economically competitive with a variety of other energy sources. The Solar Thermal Technology Program has developed components and system-level performance targets as quantitative program goals. These targets are used in planning research and development activities, measuring progress, assessing alternative technology options, and developing optimal components. These targets are pursued vigorously to ensure a successful program. This catalog represents part of an effort to provide information on publications about solar thermal research and development activities conducted by DOE's laboratories. Publications listed include technical and research reports and special publications. The following national laboratories are represented in this edition: Sandia National Laboratories, Solar Energy Research Institute, Jet Propulsion Laboratory. This catalog is a product of the DOE Solar Technical Information Program, which is dedicated to providing information to scientific and industrial users in ways most convenient and useful to them. This catalog focuses on solar thermal technologies, and its purpose is to keep the scientific and industrial communities informed of the latest developments in federally sponsored research in this technology.

140000* -- Solar Energy↗

DOE OSTI2021

3D printing of anisotropic Sm–Fe–N nylon bonded permanent magnets

Abstract Fabricating a bonded magnet with a near‐net shape in suitable thermoplastic polymer binders is of paramount importance in the development of cost‐effective energy technologies. In this work, anisotropic Sm 2 Fe 17 N 3 (Sm–Fe–N) bonded magnets are additively printed using SmFeN anisotropic magnetic particles in a polymeric binder polyamide‐12 (PA12). The anisotropic SmFeN bonded magnets are fabricated by Big Area Additive Manufacturing followed by post‐printing alignment in a magnetic field. Optimal post‐alignment results in an enhanced remanence of ∼0.68 T in PA12 reflected in a parallel‐oriented (aligned) measured direction. The maximum energy product achieved for the additively printed anisotropic bonded magnet of Sm–Fe–N in PA12 polymer is 78.8 KJ m −3 . Our results show advanced processing flexibility with 3D printing of the development of SmFeN nylon bonded magnets designed for applications with no critical rare earth magnets.

42 ENGINEERING↗

DOE OSTI2023

Performance assessment of active insulation systems in residential buildings for energy savings and peak demand reduction

Active insulation systems (AISs) in buildings are envelopes that integrate thermal insulation, thermal energy storage, and controls. Although different designs for AISs have been proposed in the literature, a comprehensive analysis of feasible AISs is lacking. This paper discusses the energy performance, peak demand reduction potential, and performance characteristics of an AIS that uses a concrete wall as thermal mass sandwiched between two solid-state thermal switches (STSs). These STSs change their thermal conductivity using an on/off metal switch to create or break a thermal bridge across the STS. This paper first describes the experimental setup, used to determine the ratio of thermal resistance during R-high (low thermal conductivity) and R-low (high thermal conductivity) states of the STSs. This ratio was then used in whole-building energy simulations to evaluate the performance of AIS walls across different climate zones with/without a freeze timer of 60 min. The timer was added to reduce the number of switches of STSs from one state to another, and hence the energy needed for these switches. Analysis of the switching frequency and interval of STSs, thermal conductivity of walls, impact of wall orientation, and heat transfer through the wall from the use of AIS at different climate zones/locations were performed. The simulation results show that the AIS can achieve energy savings ranging from ~980 to 2,290 kWh in a single-family home with a floor area of ~220 m 2 compared with an IECC 2018 baseline. We found the energy savings was higher in dry climate zones which represent 17% of residential buildings in the United States, compared to humid or marine climate.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

A backing detector for order-keV neutrons

In this work, we have designed and tested a large-area (0.15 m 2 ) neutron detector based on neutron capture on 6Li. The neutron detector design has been optimized for the purpose of tagging the scattering angle of keV-scale neutrons. These neutron detectors would be employed to calibrate the low-energy (<100 eV) nuclear recoil in detectors for dark matter and coherent elastic neutrino nucleus scattering (CE$\textit{v}$NS). We describe the design, construction, and characterization of a prototype. The prototype is designed to have a tagging efficiency of ~25% at the relevant $\mathcal{O}$(keV) neutron energies, and with a mean capture time of ~ 17 μs. The prototype was characterized using a 252 Cf neutron source and agreement with the simulation was observed within a few percent level.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Hyperstoichiometric Uranium Dioxides: Rapid Synthesis and Irradiation-Induced Structural Changes

Uranium dioxide (UO 2 ), the primary fuel for commercial nuclear reactors, incorporates excess oxygen forming a series of hyperstoichiometric oxides. Thin layers of these oxides, such as UO 2.12 , form readily on the fuel surface and influence its properties, performance, and potentially geologic disposal. This work reports a rapid and straightforward combustion process in uranyl nitrate–glycine–water solutions to prepare UO 2.12 nanomaterials and thin films. We also report on the investigation of the structural changes induced in the material by irradiation. Despite the simple processing aspects, the combustion synthesis of UO 2.12 has a sophisticated chemical mechanism involving several exothermic steps. Raman spectroscopy and single-crystal X-ray diffraction (XRD) measurements reveal the formation of a complex compound containing the uranyl moiety, glycine, H 2 O, and NO 3 – groups in reactive solutions and dried combustion precursors. Combustion diagnostic methods, gas-phase mass spectroscopy, differential scanning calorimetry (DSC), and extracted activation energies from DSC measurements show that the rate-limiting step of the process is the reaction of ammonia with nitrogen oxides formed from the decomposition of glycine and uranyl nitrate, respectively. However, the exothermic decomposition of the complex compound determines the maximum temperature of the process. In situ transmission electron microscopy (TEM) imaging and electron diffraction measurements show that the decomposition of the complex compound directly produces UO 2 . The incorporation of oxygen at the cooling stage of the combustion process is responsible for the formation of UO 2.12 . Spin coating of the solutions and brief annealing at 670 K allow the deposition of uniform films of UO 2.12 with thicknesses up to 300 nm on an aluminum substrate. Irradiation of films with Ar 2+ ions (1.7 MeV energy, a fluence of up to 1 × 10 17 ions/cm 2 ) shows unusual defect-simulated grain growth and enhanced chemical mixing of UO 2.12 with the substrate due to the high uranium ion diffusion in films. As a result, the method described in this work allows the preparation of actinide oxide targets for fundamental nuclear science research and studies associated with stockpile stewardship.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2022

Tungsten doped diamond shells for record neutron yield inertial confinement fusion experiments at the National Ignition Facility

We report on fabrication and characterization of layered, tungsten doped, spherical about 2 mm diameter microcrystalline diamond ablator shells for inertial confinement fusion (ICF) experiments at the National Ignition Facility. As previously reported, diamond ICF ablator shells can be fabricated by chemical vapor deposition (CVD) on solid spherical silicon mandrels using an ellipsoidal microwave plasma reactor. In the present work, we further developed these ablator shells by embedding a W -doped diamond layer sandwiched between two undoped diamond regions. W incorporation in diamond was achieved by adding tungsten hexacarbonyl to the CH 4 /H 2 CVD feed gas. We observe that the W doping concentration decreases with increasing deposition rate which, in turn, is controlled by adjusting the total gas pressure. Cross sectional microstructural analysis reveals sharp interfaces between doped and undoped regions of the diamond shell and uniform W distribution with concentrations up to about 0.3 at.%. At higher W concentrations (>0.3 at.%) formation of tungsten carbide precipitates is observed. Using a 3-shock 1.6 MJ laser pulse, the targets described in this work produced the first laser driven implosion to break the 1 × 10 16 neutron yield barrier, followed by experiments (described in future publications) with similar targets and slightly more laser energy producing yields as high as 4 × 10 17 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Methods for R&D Portfolio Analysis and Evaluation (Workshop Report)

The Workshop on Methods for R&D Portfolio Analysis and Evaluation convened on 17–18 July 2019 at the National Renewable Energy Laboratory in Golden, Colorado, and examined strengths and weaknesses of the various methodologies applicable to R&D portfolio modeling, analysis, and decision support, given pragmatic constraints such as data availability, uncertainties in estimating the impact of R&D spending, and practical operational overheads. Participants employed their deep expertise in approaches such as stochastic optimization, real options, Monte-Carlo analysis, Bayesian networks, decision theory, complex systems analysis, deep uncertainty, and technology-evolution modeling to critique the initial example models developed by the project’s core team and to conduct thought experiments grounded in real-life technology models, progress data, expert elicitation, and portfolio information. This engagement of participants’ methodological expertise with the practical requirements of real-life portfolio decision support yielded ideas for improved approaches, alternative methodological hypotheses, and hybridization of methodologies that are well-grounded theoretically, computationally sound, and realistically executable given data availability and other practical constraints.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Methods for R&D Portfolio Analysis and Evaluation (Workshop Report)

The Workshop on Methods for R&D Portfolio Analysis and Evaluation convened on 17-18 July 2019 at the National Renewable Energy Laboratory in Golden, Colorado, and examined strengths and weaknesses of the various methodologies applicable to R&D portfolio modeling, analysis, and decision support, given pragmatic constraints such as data availability, uncertainties in estimating the impact of R&D spending, and practical operational overheads. Participants employed their deep expertise in approaches such as stochastic optimization, real options, Monte-Carlo analysis, Bayesian networks, decision theory, complex systems analysis, deep uncertainty, and technology-evolution modeling to critique the initial example models developed by the project’s core team and to conduct thought experiments grounded in real-life technology models, progress data, expert elicitation, and portfolio information. This engagement of participants’ methodological expertise with the practical requirements of real-life portfolio decision support yielded ideas for improved approaches, alternative methodological hypotheses, and hybridization of methodologies that are well-grounded theoretically, computationally sound, and realistically executable given data availability and other practical constraints.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

A physics-based model of cladding wastage layer formation rate

In this report, lower length scale simulations to inform an engineering-scale model of fuel-cladding chemical interaction (FCCI) conducted under the auspices of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program in FY22 are described. An overall strategy for the implementation of the BISON model is described, and the past and current lower length scale work on FCCI formation is put into the context of this overall strategy. Density functional theory and kinetic Monte Carlo simulations are used to determine the diffusion coefficient of neodymium in iron. Density functional theory calculations are also used to parameterize a parabolic approximation for the dependence of free energy on composition for the intermetallic compound Fe 17 Nd 2 . A phase-field model of the Fe-Nd system was developed that includes the random solid solution body-centered cubic phase and the intermetallic Fe 17 Nd 2 . The model was used to simulate growth of the intermetallic layer in a diffusion couple and the results were compared to experiment. The model’s prediction of the parabolic growth constant is within 40 % of the experimental value. The model is also used to simulate the formation of a grain boundary attack layer that is observed in experiment. The simulations show enhanced Nd concentration along the grain boundaries, but do not clearly show formation of a Fe 17 Nd 2 layer

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

2023 High Energy Density Science Summer School

The University of California San Diego (UCSD) hosted the High Energy-Density Science (HEDS) Summer School from July 17 – 28, 2023 on the UCSD campus. The goal of the Summer School was to introduce new talent to the breadth of the U.S. HEDS community through lectures, engaging workshops, and discussion sessions with leaders in academia and the national laboratories. The objectives were to inspire young scientists to pursue graduate and professional careers in the fields of HEDS, teach them fundamental HEDS and critical skills, and grant them the opportunity to network with leading academic and national laboratory researchers. Our focus was to attract promising early-career students from across the country.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Impact of Connected Communities

Buildings account for 35% of CO 2 emissions and almost 40% of the United States’ energy use. High-performance homes and neighborhoods play an important role in supporting efforts to decarbonize the US power system by 2035. Significant reductions in CO 2 emissions within the residential sector can be realized through electrification of loads paired with the flexibility created by leveraging smart Internet of Things (IoT) capabilities to shift energy use based on grid signals, thus improving generation/distribution efficiency and maximizing the use of renewable generation capacity. All of this can be achieved while allowing smart home appliances and equipment to meet homeowner needs – including reducing power bills - while optimizing operation in conjunction with the grid using novel control techniques. The Grid-Interactive Efficient Buildings Roadmap by the US Department of Energy’s (DOE’s) Building Technologies Office (BTO) notes that implementing grid-interactive efficient building (GEB) technology has the potential to reduce CO 2 emissions by 80 million tons/year—roughly equivalent to 17 million cars. To achieve this vision, the US Department of Energy’s Oak Ridge National Laboratory (ORNL)—in collaboration with Southern Company Research & Development, Alabama Power, Georgia Power, BTO and the US DOE’s Office of Electricity (OE) —is developing and demonstrating novel connected communities at two locations. Southern Company in turn engaged with industry partners, including design firms, residential developers, and residential HVAC and appliance manufacturers because their participation would be critical to the success of the initial research project, as well as the future scaling to the Southern Company service territory and beyond. Impacts of the Connected Communities projects in Alabama and Georgia are outlined including: energy, grid services and data management learnings; homeowner feedback; vendor engagement; adoption by utilities; technical, policy and business model challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Reaction Pathways and Energy Consumption in NH 3 Decomposition for H 2 Production by Low Temperature, Atmospheric Pressure Plasma

Pathways for NH 3 decomposition to N 2 and N 2 H 4 by atmospheric pressure nonthermal plasma are analyzed using a combination of molecular beam mass spectrometry measurements and zero-dimensional kinetic modeling. Experimental measurements show that NH 3 conversion and selectivity towards N 2 formation scale monotonically with the specific energy input into the plasma with ~ 100% selectivity to N 2 formation achieved at specific energy inputs above 0.12 J cm −3 (3.1 eV (molecule NH 3 ) −1 ). The kinetic model recovers these trends, although it underpredicts N 2 selectivity at low specific energy input. These discrepancies can be explained by the underestimation of reaction rate coefficients for reactions that consume N 2 H x species in collisions with H radicals and/or radial nonuniformities in power deposition, gas temperature, and species concentrations that are not represented by the plug flow approximation used in the model. The kinetic model shows that N 2 formation proceeds through N 2 H x decomposition pathways rather than NH x decomposition pathways in low temperature, atmospheric pressure plasma. Higher selectivity toward N 2 production can be achieved by operating at higher NH 3 conversion and with a higher gas temperature. Furthermore, the high energy cost of NH 3 decomposition by atmospheric pressure nonthermal plasma found in this work (25–50 eV (molecule NH 3 converted) −1 ; 17–33 eV (molecule H 2 formed) −1 ) is a result of the energy requirement for electron-impact dissociation of NH 3 and the significant re-formation of NH 3 by three-body recombination reactions between NH 2 and H.

Nonthermal plasma↗

DOE OSTI2021

Characterization of Two Extraordinary AmLi Neutron Sources

Two legacy AmLi sources, MRC-101 and MRC-103, are routinely used for neutron detector characterization and testing campaigns that Pacific Northwest National Laboratory manages for the Defense Threat Reduction Agency within the U.S. Department of Defense. However, applicability of source measurement data has been substantially limited due to the lack of original manufacturer documentation and cross comparison to other sources. This paper summarizes results of the measurement campaign conducted to better quantify source radionuclide content, neutron energy spectrum and emission rate of the AmLi sources. The source characterization study consisted of three major consecutive measurement exercises. First, gamma spectrometry measurements using a high purity germanium detector were used to estimate the radionuclide content and potential impurities of the AmLi sources. Then neutron spectral measurements were taken to determine the unique neutron energy distribution. Finally, assessments of the total neutron yields of the sources were made with measurements in a neutron well counter. The neutron detection efficiency for these measurements was determined via detailed Monte Carlo modeling based on the neutron energy distribution measured with the rotating neutron spectrometer. The most exciting and unexpected finding of the study was a significant contamination of the source material with beryllium, contributing up to 17% to the total neutron emission rate and correspondingly changing the neutron energy spectrum. Also, the obtained lithium-only portion of the measured energy distribution of the sources was compared against several AmLi spectra previously reported by different researchers.

AWCC, AmLi, beryllium contamination, neutron spect↗

DOE OSTI2026

Standards Library for Distributed Energy Resources

This presentation was presented at the Aggregation and Grid Security Workshop - held on June 17-18, 2025, at NREL in Golden, Colorado. The goal of the two-day workshop was to address the critical cybersecurity challenges for the future electric grid. This presentation overviews the evolution and need for harmonized distributed energy resource standards and a new distributed energy resource standards library.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Irradiation-Driven Restructuring of UO 2 Thin Films: Amorphization and Crystallization

Combustion synthesis in uranyl nitrate–acetylacetone–2-methoxyethanol solutions was used to deposit thin UO 2 films on aluminum substrates to investigate the irradiation-induced restructuring processes. Thermal analysis revealed that the combustion reactions in these solutions are initiated at ~160 °C. The heat released during the process and the subsequent brief annealing at 400 °C allow the deposition of polycrystalline films with 5–10 nm UO 2 grains. The use of multiple deposition cycles enables tuning of the film thicknesses in the 35–260 nm range. Irradiation with Ar 2+ ions (1.7 MeV energy and a fluence of up to 1 × 10 17 ions/cm 2 ) is utilized to generate a uniform distribution of atomic displacements within the films. X-ray fluorescence (XRF) and alpha-particle emission spectroscopy showed that the films were stable under irradiation and did not undergo sputtering degradation. X-ray photoelectron spectroscopy (XPS) showed that the stoichiometry and uranium ionic concentrations remain stable during irradiation. The high-resolution electron microscopy imaging and electron diffraction analysis demonstrated that at the early stages of irradiation (below 1 × 10 16 ion/cm 2 ) UO 2 films show complete amorphization and beam-induced densification (sintering), resulting in a pore-free disordered film. Prolonged irradiation (5 × 10 16 ion/cm 2 ) is shown to trigger a crystallization process at the surface of the films that moves toward the UO 2 /Al interface, converting the entire amorphous material into a highly crystalline film. This work reports on an entirely different radiation-induced restructuring of the nanoscale UO 2 compared to the coarse-grained counterpart. The preparation of thin UO 2 films deposited on Al substrates fills an area of national need within the stockpile stewardship program of the National Nuclear Security Administration and fundamental research with actinides. Here, the method reported in this work produces pure, robust, and uniform thin-film actinide targets for nuclear science measurements

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗