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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing

Artificial intelligence (AI) embedded within digital models of manufacturing processes can be used to improve process productivity and product quality significantly. The application of such advanced capabilities particularly to highly digitalized processes such as metal additive manufacturing (AM) is likely to make those processes commercially more attractive. AI capabilities will reside within Digital Twins (DTs) which are living virtual replicas of the physical processes. DTs will be empowered to operate autonomously in a diagnostic control capacity to supervise processes and can be interrogated by the practitioner to inform the optimal processing route for any given product. The utility of the information gained from the DTs would depend on the quality of the digital models and, more importantly, their faster-solving surrogates which dwell within DTs for consultation during rapid decision-making. In this article, we point out the exceptional value of DTs in AM and focus on the need to create high-fidelity multiscale-multiphysics models for AM processes to feed the AI capabilities. We identify technical hurdles for their development, including those arising from the multiscale and multiphysics characteristics of the models, the difficulties in linking models of the subprocesses across scales and physics, and the scarcity of experimental data. We discuss the need for creating surrogate models using machine learning approaches for real-time problem-solving. We further identify non-technical barriers, such as the need for standardization and difficulties in collaborating across different types of institutions. We offer potential solutions for all these challenges, after reflecting on and researching discussions held at an international symposium on the subject in 2019. Here, we argue that a collaborative approach can not only help accelerate their development compared with disparate efforts, but also enhance the quality of the models by allowing modular development and linkages that account for interactions between the various sub-processes in AM. A high-level roadmap is suggested for starting such a collaboration.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Bond-centric modular design of protein assemblies

Directional interactions that generate regular coordination geometries are a powerful means of guiding molecular and colloidal self-assembly, but implementing such high-level interactions with proteins remains challenging due to their complex shapes and intricate interface properties. Here we describe a modular approach to protein nanomaterial design inspired by the rich chemical diversity that can be generated from the small number of atomic valencies. We design protein building blocks using deep learning-based generative tools, incorporating regular coordination geometries and tailorable bonding interactions that enable the assembly of diverse closed and open architectures guided by simple geometric principles. Experimental characterization confirms the successful formation of more than 20 multicomponent polyhedral protein cages, two-dimensional arrays and three-dimensional protein lattices, with a high (10%–50%) success rate and electron microscopy data closely matching the corresponding design models. Due to modularity, individual building blocks can assemble with different partners to generate distinct regular assemblies, resulting in an economy of parts and enabling the construction of reconfigurable networks for designer nanomaterials.

Biomaterials – proteins↗
DOE OSTI2022

Deterministic modelling of the SPERT IV reactor transients using the multi-physics capability of WIMS

The ANSWERS WIMS reactor physics code is being developed for whole core multi-physics modelling. The established neutronics capability for lattice calculations has recently been extended to be suitable for whole core modelling of Small Modular Reactors (SMRs). A whole core transport, SP3 or diffusion flux solution is combined with fuel assembly resonance shielding. An integrated thermal hydraulic solver permits temperature and density variations to feedback to the neutronics calculation. This capability can be applied to both steady state and time dependent transient problems. Nuclear reactor design and safety case development requires assessment of a range of reactor transients, to inform both normal operation limitations and accident scenario analysis. This paper presents new methodology developed in WIMS to couple the core neutronics to the integrated core thermal hydraulics solver for the simulation of reactor transients in whole core models. To support the validation of the multi-physics capability of WIMS, this capability has been applied to the reactivity insertion transient experiments performed in the plate fuelled SPERT-IV reactor. This study employs WIMS using the whole core solver MERLIN, which calculates the time-dependent flux distribution and magnitude, coupled to ARTHUR, which solves for the time-dependent thermal hydraulics solution, and provides thermal feedback via the cross sections generated by GEOM, which performs resonance shielding calculations and generates cross section data for the plate geometry. This spatial kinetics model, with dynamic cross section generation, allows for variations in the temperature and neutron flux profile with time.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

INL Contributions to Draft HTTF Benchmark Specifications

The High-Temperature Test Facility (HTTF) is an integral effects thermal hydraulics test facility at Oregon State University designed as a 1/4 length scale model of the Modular High-Temperature Gas-Cooled Reactor 350 MW core (mHTGR-350). In the spring and summer of 2019, several experiments were conducted at HTTF providing a valuable source of gas-cooled reactor thermal hydraulics data. Idaho National Laboratory (INL), Oregon State University, Argonne National Laboratory, and Canadian Nuclear Laboratories have partnered to use this experimental data to develop a gas-cooled reactor thermal hydraulics benchmark led by INL under the auspices of the Advanced Reactor Technologies (ART) program. This report provides some context on the benchmark, HTTF, and previous Reactor Excursions and Leak Analysis Program (RELAP)5-3D modeling of HTTF. It also provides a draft of the benchmark specifications for the Depressurized Conduction Cooldown problem, which is the INL-led benchmark problem.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Generation of Synthetic Data for a Radiation Detection Algorithm Competition

This paper details the generation of synthetic radiation data using large-scale Monte Carlo transport models to evaluate radiation search detection algorithms. Modular 3-D Monte Carlo models spanning multiple city blocks were constructed, loosely based on downtown Knoxville, TN, containing buildings composed of multiple materials (brick, granite, and concrete), sidewalks, a four-lane road, side streets, parking lots, and grassy fields. Background and simulated source detector response calculations from these models were used to create synthetic list mode data sets for a 2"×4"×16" NaI(Tl) detector moving through a city street at a constant speed. For the background simulations, major isotopes were computed individually so that background composition and variability could be computed efficiently outside Monte Carlo. The source detector response included six simulated sources placed at 15 source locations. Detector response was developed to be periodic through the city street so that a detector path could begin at one end of the model and wrap around to the other. This framework allowed for the creation of diverse data sets, each with its own unique background and simulated source detector response. Synthetic data allows for high-quality labels, which are useful in developing data-driven radiation detection algorithms. This methodology was used to create synthetic data sets which were released as part of a public data competition to spur the development of new radiation detection algorithms for radiological search applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

A modular chromosomally integrated toolkit for ectopic gene expression in Vibrio cholerae

The ability to express genes ectopically in bacteria is essential for diverse academic and industrial applications. Two major considerations when utilizing regulated promoter systems for ectopic gene expression are (1) the ability to titrate gene expression by addition of an exogenous inducer and (2) the leakiness of the promoter element in the absence of the inducer. Here, we describe a modular chromosomally integrated platform for ectopic gene expression in Vibrio cholerae . We compare the broadly used promoter elements P tac and P BAD to versions that have an additional theophylline-responsive riboswitch (P tac -riboswitch and P BAD -riboswitch). These constructs all exhibited unimodal titratable induction of gene expression, however, max induction varied with P tac > P BAD > P BAD -riboswitch > P tac -riboswitch. We also developed a sensitive reporter system to quantify promoter leakiness and show that leakiness for P tac > P tac -riboswitch > P BAD ; while the newly developed P BAD -riboswitch exhibited no detectable leakiness. We demonstrate the utility of the tightly inducible P BAD -riboswitch construct using the dynamic activity of type IV competence pili in V. cholerae as a model system. The modular chromosomally integrated toolkit for ectopic gene expression described here should be valuable for the genetic study of V. cholerae and could be adapted for use in other species.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Design of a High-Assay Low-Enriched Uranium Tri-Structural Isotropic Critical Experiment for Advanced Reactor Validation

High-assay low-enriched uranium (HALEU) fuel is a key component of many small modular reactor designs. Critical experiments are an important way to understand the neutronic performance of systems by obtaining nuclear data validations through measurements. Data reduce uncertainty and risk by showing that systems respond as predicted to changes such as temperature, subsequently advancing the overall technology readiness level of the materials within. Numerous critical experiments have been performed at the National Criticality Experiments Research Center (NCERC) operated by Los Alamos National Laboratory at the Nevada National Security Site since it became operational in 2011. However, the first experiment with HALEU fuel did not occur until 2024. Through extensive engineering, the experiment described in this paper was successfully designed and executed for the Comet vertical lift assembly at NCERC to perform measurements with HALEU tri-structural isotropic fuel that will assist in validation of nuclear data and computational modeling of small modular reactors for years to come.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗
DOE OSTI2023

Sandia Contributions to WaterTAP

SAND2023-06591O Through National Alliance for Water Innovation funding, Sandia will be contributing to the Water treatment Technoeconomic Assessment Platform (WaterTAP) project. WaterTAP is an open-source, Python-based software package that supports the technoeconomic assessment of full water treatment trains. WaterTAP includes a modular water treatment model library spanning a broad set of water treatment processes composed of unit, property, and costing models.

Rawlings, EdnaSoraya↗
DOE OSTI2020

Real-World Demonstration of a New, American Low-Head Hydropower Turbine (Final Technical Report)

Hydro Green Energy (HGE) has designed and model tested a Modular Bulb Turbine (MBT) with a simplified civil structure which shows potential to provide an economical alternative for undeveloped low-head projects in the United States, such as at existing locks and dams and constructed waterways. The primary objective of this project was to fabricate, install and operate a full scale interchangeable Modular Bulb Turbine (MBT), which will be inserted in a Large Frame Module (LFM) and supporting civil infrastructure designed by Hydro Green Energy at Braddock Locks and Dam, a low-head hydropower project site at an existing lock and dam currently in federal licensing by Hydro Green Energy. HGE would finance and install the remaining six turbines, which would have completed the larger 5.2 MW head hydropower project.

13 HYDRO ENERGY↗
DOE OSTI2023

Assessment of Microreactor Safety Analysis Challenges and Recommendations for Utilization of the Comprehensive Reactor Analysis Bundle

To enable the broad deployment of microreactors in fundamentally new application regimes (i.e., mobile and autonomous operations), their safety must be indisputable in terms of possessing inherent resistance to severe offsite dose consequences. Therefore, mechanistic beyond-design-basis event source term calculations that demonstrate a sufficiently large margin of safety will be required to accommodate these new application regimes, which have no history of commercial regulation. Even for traditional reactor operation configurations, safety analysis expertise and familiarity with accident phenomena and conditions in microreactors—specifically those with heat pipe primary cooling arrangements—are lacking compared with other advanced reactor concepts and small modular reactors. Recently, modeling and simulation tools to account for unique heat pipe design aspects have been developed by Sandia National Laboratories with MELCOR and by the US Department of Energy’s (DOE’s) Office of Nuclear Energy Advanced Modeling and Simulation Program with BlueCRAB. However, further demonstration and assessment of potential knowledge gaps are needed to support these codes’ broad usage by the microreactor community. Through the DOE Microreactor Program, an initial assessment of these two tools and guidance on how an evaluation model could be constructed was performed and is reported herein. Moreover, a proposed approach for demonstrating an evaluation model using these two tools is outlined.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Assessment of the Impact of Realistic Sensor Physics and the Integration of Ex-Core Sensors on Reactor Power Synthesis

In the work documented in this report, a weighting function–based core power synthesis method was applied to multiple Monte Carlo N-Particle (MCNP) reactor models, which are informed based on simulated self-powered neutron detector (SPND) responses. The weighting function method used has been coined the point-based iterative (PBI) method. The goal of this application is to assess the impact of considering realistic sensor physics in the generation of the simulated SPND outputs as well as to consider how the synthesis is impacted based on the inclusion of ex-core detectors in the model. The NuScale small modular reactor (SMR) and Westinghouse AP1000 pressurized water reactor (PWR) are the models that served as the testbeds for the assessment of realistic sensor physics; this was achieved by using Geant4 SPND models in comparison with analytical models, such that the effect of electron transport in realistic SPND geometries in the Geant4 model can be understood in terms of synthesis error and convergence time. The comparison was considered for fuel burnup–induced perturbations, for a range of sensor string densities and synthesized power distribution axial fidelities. The Texas A&M Testing, Research, Isotopes, General Atomics Reactor (TAMU TRIGA) reactor MCNP model was used to assess the impact of ex-core sensors; this was done by performing synthesis with and without the ex-core detectors and by quantifying the synthesis error and number of iterations associated with Gaussian-type perturbations in many locations in the core. The TAMU TRIGA model was particularly pertinent for this study because of the interest in future experimental tests with SPNDs in this reactor, as well as the ease of modifying the MCNP model to include ex-core detectors with heterogeneously described response functions. Results from the comparison between the Geant4 and analytical SPND models indicate that similar average and maximum synthesis errors were obtained for burnup-induced perturbations in both the NuScale SMR and the AP1000. This was true for a range of sensor string densities and axial fidelities. However, there were marked differences between both the Geant4 and analytically informed models in terms of the iterations required to converge on the synthesized power distribution. Namely, the Geant4-informed models tended to lead to fewer iterations, except for a few sensor–core configurations that had particularly numerous iterations. Results from the ex-core sensor assessment with the TAMU TRIGA model indicate that the inclusion of ex-core sensors drastically reduces the synthesis error of Gaussian-type perturbations close to the edge of the core, and it slightly reduces synthesis errors for perturbations closer to the center of the core. This was achieved with a minimal increase in computational cost—that is, the number of iterations required for convergence. The errors were identified to be in the same location as the perturbation in the core, indicating that the methodology remains robust for unperturbed regions of the core. A secondary result from this study with the TAMU TRIGA was yielded by analysis of the neutron flux levels in the in-core and ex-core sensor locations of the core; these flux levels indicate that SPNDs could be used as both in-core and ex-core sensors, so long as the emitter material is sensitive to thermal neutrons. The results from these studies provide a quantitative understanding of the importance of considering realistic sensor physics and including ex-core sensors to perform accurate and timely power distribution synthesis of a reactor core.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

MEMPHIS (Mesoscle Multiphysics Phase Field Simulator v.0

SAND2024-01427O Mesoscale Multiphysics Phase Field Simulator (MEMPHIS) is used for solving interfacial problems and can be applied to many evolutionary problems. Some examples are solidification dynamics, viscous fingering, fracture mechanics, hydrogen embrittlement, vesicle dynamics, electro-mechanical degradation of batteries, aging of microstructures, and segregation. MEMPHIS is written in Fortran 90 in a modular fashion, where model and numerical solvers are decoupled from one another. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Dingreville, Remi↗
DOE OSTI2025

LAROMance Grade 91 Model Integration in NEML2

New reactor designs are targeting higher operating temperatures for increased thermal efficiency when compared to the current fleet of light water reactors. Designing structural components for these high temperature environments with reliable long-term operations requires material models that can accurately capture the deformation mechanisms active in these environments. The LAROMance surrogate material models are based on a database of mechanistic crystal plasticity simulations for high-temperature conditions. Inputs to the LAROMance models reflect the microstructural pedigree of the material, like dislocation densities and precipitate contents. Based on the evolution of these microstructural features, the LAROMance model provides the engineering scale constitutive model response. The LAROMance model was recently parameterized for Grade 91, a high temperature alloy. In the present work, the Grade 91 LAROMance model is implemented in the New Material Model Library, version 2 (NEML2). NEML2 provides a modular way to build material models from smaller blocks and was developed to vectorize the material update to efficiently run on modern computational architectures with graphics processing unit accelerators. NEML2 constitutive models can be used in simulations based on the multiphysics object-oriented simulation environment (MOOSE). This report provides details on the implementation of the Grade 91 LAROMance model in NEML2 and its verification of engineering scale finite element simulations in MOOSE.

42 - ENGINEERING↗
DOE OSTI2022

Static and dynamic modeling of steam integration for a NuScale small modular reactor and pulp and paper mill coupling for carbon-neutral manufacturing

Small modular reactors (SMRs) are reactor designs producing less than 300 MWe and are generally planned for deployment as multimodule nuclear power plants. The possibility of factory-manufactured, flexibly sized plants expands the opportunities for nuclear power to different communities and industries, including manufacturing plants that currently utilize fossil fuels to produce both steam and electricity. This paper examines the feasibility of coupling a NuScale SMR with a midsize pulp and paper mill in the Southeastern United States. A steady-state mill model was developed in Aspen HYSYS, based on real data from the operation of the mill, and modified it to include the SMR while maintaining steam quality requirements and making as few changes as possible to existing equipment. Dynamic plant models were also developed Dymola to demonstrate possible plant conditions, using three configurations. Preliminary results suggest that, while SMR coupling is physically feasible, its economic feasibility is limited by the differences in steam and electricity demands. Because of limitations in the amount of steam the mill can take from the SMR, sizing the SMR for the plant’s steam demand may result in an electricity deficit, or vice versa. Furthermore, dynamic analyses show that the addition of a thermal storage system could reduce such deficits, but this entails its own challenges. Each plant must determine the best configuration and control scheme for itself, based on its electricity and heat needs, including the peak duration and intensity for both. Ultimately, an implementation of SMRs with manufacturing processes would benefit from partnering with a local utility to purchase excess electricity generated by the SMR. This will help manufacturing facilities meet their environmental and cost-savings goals, in addition to meeting the need for cost-effective baseload power across the United States.

03 NATURAL GAS↗
DOE OSTI2021

Nonlinear proper orthogonal decomposition for convection-dominated flows

Autoencoder techniques find increasingly common use in reduced order modeling as a means to create a latent space. This reduced order representation offers a modular data-driven modeling approach for nonlinear dynamical systems when integrated with a time series predictive model. In this Letter, we put forth a nonlinear proper orthogonal decomposition (POD) framework, which is an end-to-end Galerkin-free model combining autoencoders with long short-term memory networks for dynamics. By eliminating the projection error due to the truncation of Galerkin models, a key enabler of the proposed nonintrusive approach is the kinematic construction of a nonlinear mapping between the full-rank expansion of the POD coefficients and the latent space where the dynamics evolve. We test our framework for model reduction of a convection-dominated system, which is generally challenging for reduced order models. Our approach not only improves the accuracy, but also significantly reduces the computational cost of training and testing.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Nutrient Dynamics in a Coupled Terrestrial Biosphere and Land Model (ELM-FATES-CNP)

We present a representation of nitrogen and phosphorus cycling in the Functionally Assembled Terrestrial Ecosystem Simulator, a demographic vegetation model within the Energy Exascale Earth System land model. This representation is modular, and designed to allow testing of multiple hypothetical approaches for carbon-nutrient coupling in plants. Novel model hypotheses introduced in this work include, (a) the controls on plant acquisition of aqueous mineralized nutrients in the soil and (b) fairly straight forward methods of allocating nutrients to specific plant organs and their losses through live plant turnover as well as litter fluxes generated through plant mortality. This combines the new with pre-existing hypotheses (such as nitrogen fixation and soil decomposition) into a system that can accommodate plant-soil dynamics for a large number of size- and functional-type-resolved plant cohorts within a time-since-disturbance-resolved ecosystem. Root uptake of nutrients is governed by fine root biomass, and plants vary in their fine root biomass allocation in order to balance carbon and nutrient limitations to growth. We test the sensitivity of the model to a wide range of parameter variations and structural representations, and in the context of observations at Barro Colorado Island, Panama. A key model prediction is that plants in the high-light-availability canopy positions allocate more carbon to fine roots than plants in low-light understory environments, given the widely different carbon versus nutrient constraints of these two niches within a given ecosystem. This model provides a basis for exploring carbon-nutrient coupling with vegetation demography within Earth system models.

54 ENVIRONMENTAL SCIENCES↗