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At least 1,099 records · Page 61

Viscosity Meaurement Technique for Metal Fuels

Metallic fuels have exceptional transient behavior, excellent thermal conductivity, and a more straightforward reprocessing path, which does not separate out pure plutonium from the process stream. Fabrication of fuel containing minor actinides and rare earth (RE) elements for irradiation tests, for instance, U-20Pu-3Am-2Np-1.0RE-15Zr samples at the Idaho National Laboratory, is generally done by melt casting in an inert atmosphere. For the design of a casting system and further scale up development, computational modeling of the casting process is needed to provide information on melt flow and solidification for process optimization. Therefore, there is a need for melt viscosity data, the most important melt property that controls the melt flow. The goal of the project was to develop a measurement technique that uses fully sealed melt sample with no Americium vapor loss to determine the viscosity of metallic melts and at temperatures relevant to the casting process. The specific objectives of the project were to: develop mathematical models to establish the principle of the measurement method, design and build a viscosity measurement prototype system based on the established principle, and calibrate the system and quantify the uncertainty range. The result of the project indicates that the oscillation cup technique is applicable for melt viscosity measurement. Detailed mathematical models of innovative sample ampoule designs were developed to not only determine melt viscosity, but also melt density under certain designs. Measurement uncertainties were analyzed and quantified. The result of this project can be used as the initial step toward the eventual goal of establishing a viscosity measurement system for radioactive melts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Utility of Big Area Additive Manufacturing (BAAM) For The Rapid Manufacture of Customized Electric Vehicles

This Oak Ridge National Laboratory (ORNL) Manufacturing Development Facility (MDF) technical collaboration project was conducted in two phases as a CRADA with Local Motors Inc. Phase 1 was previously reported as Advanced Manufacturing of Complex Cyber Mechanical Devices through Community Engagement and Micro-manufacturing and demonstrated the integration of components onto a prototype body part for a vehicle. Phase 2 was reported as Utility of Big Area Additive Manufacturing (BAAM) for the Rapid Manufacture of Customized Electric Vehicles and demonstrated the high profile live printing of an all-electric vehicle using ONRL's Big Area Additive Manufacturing (BAAM) technology. This demonstration generated considerable national attention and successfully demonstrated the capabilities of the BAAM system as developed by ORNL and Cincinnati, Inc. and the feasibility of additive manufacturing of a full scale electric vehicle as envisioned by the CRADA partner Local Motors, Inc.

33 ADVANCED PROPULSION SYSTEMS↗

Scalable, Economical Fabrication Processes for Ultra-Compact Warm-White LEDs

Conventional warm-white LED component fabrication consists of a large number of sequential steps which are required to incorporate electrical, mechanical, and optical functionality into the component. Each of these steps presents cost and yield challenges which multiply throughout the entire process. Although there has been significant progress in LED fabrication over the last decade, significant advances are needed to enable further reductions in cost per lumen while not sacrificing efficacy or color quality. Cree conducted a focused 18-month program to develop a new low-cost, high-efficiency light emitting diode (LED) architecture enabled by novel large-area parallel processing technologies, reduced number of fabrication steps, and minimized raw materials use. This new scheme is expected to enable ultra-compact LED components exhibiting simultaneously high efficacy and high color quality. By the end of the program, Cree fabricated warm-white LEDs with a room-temperature “instant on” efficacy of >135 lm/W at ~3500K and 90 CRI (when driven at the DOE baseline current density of 35 A/cm2). Cree modified the conventional LED fabrication process flow in a manner that is expected to translate into simultaneously high throughput and yield for ultra-compact packages. Building on its deep expertise in LED wafer fabrication, Cree developed these ultra-compact LEDs to have no compromises in color quality or efficacy compared to their conventional counterparts. Despite their very small size, the LEDs will also be robustly electrically integrated into luminaire systems with the same attach yield as conventional packages. The versatility of the prototype high-efficacy LED architecture will likely benefit solid-state lighting (SSL) luminaire platforms ranging from bulbs to troffers. We anticipate that the prototype LEDs will particularly benefit luminaires with large numbers of distributed compact packages, such as linear and area luminaires (e.g. troffers). The fraction of total SSL luminaire cost made up by the LEDs themselves has steadily fallen over the past several years, but can still make up 30% or more of the bill of materials; the new LED design will radically lower this proportion. Ultra-compact, highly efficient LEDs with optimal distribution in the system will further benefit luminaire materials and assembly costs by reducing the complexity and volume of thermal management and optical subsystems.

42 ENGINEERING↗

AOI [3]: Smart Refractory Sensor Systems for Wireless Monitoring of Temperature, Health, and Degradation of Slagging Gasifiers

The objective of the work was to develop refractory “smart bricks”, which would contain embedded temperature, strain/stress, and spallation sensors throughout the volume of highchromia (-Cr 2 O 3 ) refractory brick. The proposed work included work to interconnect the sensors to the reactor exterior, where the sensor signals may be processed by low-power electronics and transmitted wirelessly to a central processing hub. The data processing and wireless transmitter hardware was specifically designed to be isolated (with low power consumption) and to be adaptable to future implementation of energy-harvesting strategies for extended life. Finally, the collected data was incorporated into a model to estimate refractory degradation, a technique that could help monitor the health of the refractory in real-time. The long-term goal of this program was to demonstrate high-temperature, wireless sensor arrays for in situ three-dimensional (3-D) refractory monitoring or mapping for slagging gasification systems. The research was in collaboration with HarbisonWalker International (HWI) Technology Center in West Mifflin, PA. HWI is a leading developer and manufacturer of ceramic refractory products for high-temperature applications. The work completed focused on the following areas: 1) Investigation of the chemical stability, microstructural evolution, grain growth kinetics, degree of homogeneity (quantitative image analysis), and electrical properties of refractory oxide-silicide composites at temperatures between 750-1450ºC; 2) Fabrication of silicide-alumina composite and oxide thermocouples and thermistor preforms and the development of techniques to embed them into high-chromia refractory bricks to form “smart bricks”; 3) Utilization of commercial off-the-shelf discrete components to prototype circuits for interfacing between smart brick sensors and the wireless sensor network. The prototypes were then used to design an integrated circuit for thermistor, thermocouple, and capacitive-based smart brick sensor interfacing; 4) Interfacing of the smart bricks with embedded sensors with wireless motes thus yielding a complete signal chain. This end-to-end data collection system was tested on a furnace heated to 1350°C; 5) Development of a slag penetration model and a nonlinear unknown input filter for the data from the embedded sensors for estimating temperature and extent of slag penetration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Electric Drive Technologies Research: ELT223 Component Modeling, Co-Optimization, and Trade-Space Evaluation Annual Report

This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap (WBG) devices and ceramic capacitors. This project included: (1) a survey of available technologies; (2) investigating new technologies, that for example, reduce volume of thermal management or magnetic components; (3) the development of computer aided design tools that consider the converter volume, reliability, and electrical performance; (4) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, ceramic thermal management components, and select topologies; (5) building and testing hardware prototypes to validate models and concepts. The design tools enable co-optimization of the power module and passive elements and provide some design guidance. At the end of the project, new advanced computing methods, such as machine learning approaches, were considered.

33 ADVANCED PROPULSION SYSTEMS↗

Conformable, Composite Tank for Liquid Hydrogen Storage in Heavy-duty Ground Transportation

Raytheon Technologies Research Center (RTRC), with its partners, Argonne National Labs and University of Dayton Research Institute proposed to design and manufacture a conformable composite tank prototype to store liquid Hydrogen (LH2) for heavy-duty truck applications. A dual-wall tank concept was proposed where an outer shell covers and protects an inner pressure vessel that stores liquid hydrogen. The inner pressure vessel is liner-less and designed with a conformable concept, derived from prior RTRC ARPA-E program where multiple vessels are coalesced into one, maximizing space utilization and reducing surface area for heat leak. The gap between the dual wall is evacuated of air pressure, and filled with multi-layer insulation to minimize radiative heat transfer. Fiber reinforced composites were proposed for light-weighting and conformable shape manufacture. To minimize LH2 leakage, carbon nanotubes-infused composites were proposed, in addition to use of thin plies. The project was divided into two 18-month budget periods (BP), BP1 and BP2, separated by a Go/No-Go gate review. The high-level goal for BP1 was to demonstrate the feasibility of the overall approach, the tank design, material selection, and manufacturing methodology, build and test a prototype tank; and the goal for BP2 was to design and manufacture a conformal tank per DOE requirements (minimum 20 kg of LH2) and perform a successful test of the tank. The program was terminated about two-thirds of the way through BP1. The outcome of this program would have permitted long-haul trucks and construction vehicles to use liquid Hydrogen, reducing the emission of green-house gases. This technology is applicable to other transportation sectors as well.

08 HYDROGEN↗

Internal Reaction Mass Taxonomy and Narrow-Down Study

Internal reaction mass (IRM) wave energy converters (WEC) capture wave energy by reacting against a moving mass that is suspended within their hulls. Due to their hermetically sealed Power Take Off (PTO), compact form factor and relatively simple mooring requirements, the National Renewable Energy Laboratory has identified IRM WECs are good candidates for applications such as ocean observation. A literature review of existing IRM mechanisms lead to the classification of IRM WECs based on their principal method of energy capture and principal axes of operation. The IRM categories include sliding mass, pendular and gyroscopic devices. A narrow down study was conducted to ascertain the most promising mechanisms for further investigation; devices were evaluated based on a decision matrix of weighted criteria that included device power output, prototypability and power to mass ratio. The narrow down study identified the issue of achieving resonance with pendulum-based designs, as well as the poor response produced by reaction to long period waves. Chaotic pendula and methods to multiply agitation were identified as a means to increase power output. Alternative methods of power generation, such as triboelectric nanogenerators, were also identified as a technology that would benefit from multiplied agitation and chaotic motion. This work was funded under the U.S. Department of Energy's Water Power Technologies Office's Powering the Blue Economy portfolio.

ENGINEERING,TIDAL AND WAVE POWER↗

Carbon-conserving bioproduction of malate in an E. coli -based cell-free system

Formate, a biologically accessible form of CO 2 , has attracted interest as a renewable feedstock for bioproduction. However, approaches are needed to investigate efficient routes for biological formate assimilation due to its toxicity and limited utilization by microorganisms. Cell-free systems hold promise due to their potential for efficient use of carbon and energy sources and compatibility with diverse feedstocks. However, bioproduction using purified cell-free systems is limited by costly enzyme purification, whereas lysate-based systems must overcome loss of flux to background reactions in the cell extract. Here, we engineer an E. coli-based system for an eight-enzyme pathway from DNA and incorporate strategies to regenerate cofactors and minimize loss of flux through background reactions. We produce the industrial di-acid malate from glycine, bicarbonate, and formate by engineering the carbon-conserving reductive TCA and formate assimilation pathways. We show that in situ regeneration of NADH drives metabolic flux towards malate, improving titer by 15-fold. Background reactions can also be reduced 6-fold by diluting the lysate following expression and introducing chemical inhibitors of competing reactions. Together, these results establish a carbon-conserving, lysate-based cell-free platform for malate production, producing 64 μM malate after 8 h. This system conserves 43 % of carbon otherwise lost as CO 2 through the TCA cycle and incorporates 0.13 mol CO 2 equivalents/mol glycine fed. Finally, techno-economic analysis of cell-free malate production from formate revealed that the high cost of lysate is a key challenge to the economic feasibility of the process, even assuming efficient cofactor recycling. This work demonstrates the capabilities of cell-free expression systems for both the prototyping of carbon-conserving pathways and the sustainable bioproduction of platform chemicals.

60 APPLIED LIFE SCIENCES↗

Advanced CdTe Photovoltaic Technology: September 2007 - March 2009

During the last eighteen months, Abound Solar (formerly AVA Solar) has enjoyed significant success under the SAI program. During this time, a fully automated manufacturing line has been developed, fabricated and commissioned in Longmont, Colorado. The facility is fully integrated, converting glass and semiconductor materials into complete modules beneath its roof. At capacity, a glass panel willenter the factory every 10 seconds and emerge as a completed module two hours later. This facility is currently undergoing trials in preparation for large volume production of 120 x 60 cm thin film CdTe modules. Preceding the development of the large volume manufacturing capability, Abound Solar demonstrated long duration processing with excellent materials utilization for the manufacture ofhigh efficiency 42 cm square modules. Abound Solar prototype modules have been measured with over 9% aperture area efficiency by NREL. Abound Solar demonstrated the ability to produce modules at industry leading low costs to NREL representatives. Costing models show manufacturing costs below $1/Watt and capital equipment costs below $1.50 per watt of annual manufacturing capacity. Under this SAIprogram, Abound Solar supported a significant research and development program at Colorado State University. The CSU team continues to make progress on device and materials analysis. Modeling for increased device performance and the effects of processing conditions on properties of CdTe PV were investigated.

14 SOLAR ENERGY↗

SULI Research Report

Acoustic levitation allows for the containerless manipulation of small samples limited by density, size, and shape. Modern acoustic levitators are either constructed with Langevin horns, which need to be machined to high tolerance and require at least 100V, or ultrasonic transducers, which are robust to changes in temperature and require low voltage. We investigated the ability of the TinyLev, a commercially available single axis levitator, and prototyped a two-axis levitator. Both the TinyLev and our two-axis levitator employ phased arrays of transducers and operate at 40 kHz. Models produced with the Python toolbox Levitate showed the characteristic nodes of the TinyLev and found two previously unpublished “traps” (stable local pressure minima) of the twoaxis levitator. We plan to use these levitators at the Advanced Photon Source (APS) to study a variety of samples, via white beam diffraction and high speed imaging. It is our goal to calculate the radial distribution function with respect to temperature across phase transitions.

42 ENGINEERING↗

Prototype Development, Testing, and Modeling for a Solar Light-Trapping Planar-Cavity Particle Receiver

Many applications for concentrating solar thermal power (CSP) technologies of high efficiency power cycles or thermochemical processes require higher operating temperatures and alternative heat transfer media. Inert solid particles for next-generation CSP and reactive gas and/or solid media for solar thermochemical processes are common options; however, these have significantly lower heat transfer capabilities than thermal oil, molten salt, or molten metal media. Conventional solar receivers operating temperatures >700 degrees Celsius face challenges including thermal performance and thermal-mechanical issues. To overcome these limitations, we have developed a novel light-trapping, planar-cavity receiver (LTPCR) that can heat solid-phase media within an enclosed receiver while maintaining a high aperture solar flux concentration for high efficiency. This paper presents progress on design, fabrication, and testing of a 100 kWt prototype receiver to demonstrate the LTPCR operability and its commercial feasibility.

14 SOLAR ENERGY↗

Propagation of priors for more accurate and efficient spectroscopic functional fits and their application to ferroelectric hysteresis

Multi-dimensional spectral-imaging is a mainstay of the scanning probe and electron microscopies, micro-Raman, and various forms of chemical imaging. In many cases, individual spectra can be fit to a specific functional form, with the model parameter maps, providing direct insight into material properties. Since spectra are often acquired across a spatial grid of points, spatially adjacent spectra are likely to be similar to one another; yet, this fact is almost never used when considering parameter estimation for functional fits. On datasets tried here, we show that by utilizing proximal information, whether it be in the spatial or spectral domains, it is possible to improve the reliability and increase the speed of such functional fits by ~2-3x, as compared to random priors. We explore and compare three distinct new methods: (1) spatially averaging neighborhood spectra, and propagating priors based on functional fits to the averaged case, (2) hierarchical clustering-based methods where spectra are grouped hierarchically based on response, with the priors propagated progressively down the hierarchy, and (3) regular clustering without hierarchical methods with priors propagated from fits to cluster means. Our results highlight that utilizing spatial and spectral neighborhood information is often critical for accurate parameter estimation in noisy environments, which we show for ferroelectric hysteresis loops acquired on a prototypical PbTiO3 thin film with piezoresponse spectroscopy. This method is general and applicable to any spatially measured spectra where functional forms are available. Examples include exploring the superconducting gap with tunneling spectroscopy, using the Dynes formula, or current-voltage curve fits in conductive atomic force microscopy mapping. Here we explore the problem for ferroelectric hysteresis, which, given its large parameter space, constitutes a more difficult task than, for example, fitting current-voltage curves with a Schottky emission formula.

42 ENGINEERING↗

Underground Imaging by Sub-Terahertz Radiation

Sub-terahertz ground-penetrating radar systems offer an alternative to radio wave-based systems in the airborne imaging of buried objects. Laboratory prototype systems operating in W-band (75–110 GHz) and F-band (90–140 GHz) are presented, detecting the distance between target and source and imaging metal objects buried in mixed soil. The experimental results show that imaging in the 100–150 GHz frequency range is feasible for underground applications but significantly restricted by the attenuation characteristics of the medium covering the targets. A higher power source and more sensitive receiving components are essential to increase the penetration capability and expand the application settings of this approach.

42 ENGINEERING↗

HOW TO RUN A CONTROL ROOM SIMULATOR RESEARCH STUDY

The design and modernization of main control rooms in nuclear power plants benefits considerably from high-fidelity simulator research. These research simulators may be faithful replicas of existing control rooms or may represent advanced prototypes for future implementation. The recent availability of low-cost training simulators has made the entry point to using simulators in research much more achievable. Yet, the acquisition of a training or research simulator is only the first step to carrying out successful simulator studies. This panel brings together four current human factors researchers who are involved in conducting studies using control room simulators for nuclear power plants. The goal of the panel is to present the uses of research simulators, research methods and measures, and tips and tricks for running a simulator study from four separate research institutions. Each presenter explains their research configuration as well as research philosophy and practices. Korea Atomic Research Institute (KAERI) and OECD Halden Reactor Project, two research institutes with a long history of running simulator studies, present their experiences and insights gained from many simulator studies. Idaho National Laboratory (INL) and the Center for Advanced Engineering Research (CAER), two research institutes who have freshly started simulator research, chronicle their recent installations and studies. Each presenter provides an overview presentation of simulator research conducted at their institution followed by a panel discussion based on audience questions. This panel represents the opportunity for other researchers who are newly undertaking simulator studies to learn the human factors considerations for simulator research from existing researchers.

99 GENERAL AND MISCELLANEOUS↗

Need for advanced research reactors for the next-generation reactor physics, analysis tools, and technology

Full text of publication follows. There is an urgent need for design and deployment of advanced research and test reactors in support of design, licensing and operation of advanced power reactors and education of next generation nuclear workforce. Existing research reactors mostly were designed and constructed decades ago with the main objectives of training operators, performing reactor physics experiments, and educating nuclear engineers and scientists. There are already gaps and significant concern about future capabilities for the existing research reactor facilities to address modern instrumentation and/or flexible environments for: performing reactor physics studies for advanced designs which have significantly different core materials forms and compositions, reactor shapes and size; validation of advanced high-fidelity software; development of machine learning algorithms for enhancement of human-machine collaboration in support of reactor monitoring, operation and safeguards; and, effective education of the next-generation workforce. The authors will focus on the need for advanced research reactors to improve and validate fast and accurate simulation tools for high-fidelity modeling and analysis of nuclear reactors in support of their design, optimization, licensing, operation, and monitoring. In the past, simulation tools were limited to relatively coarse models using approximate methodologies that benefited from two main factors: i) allowance for large margins and tolerances; ii) ability to construct prototype (e.g., zero power) reactors for adjustment of approximate methodologies. The next generation reactors have to be designed mainly by using novel high-fidelity computational tools that are accurate and fast, and therefore can be used for parametric studies and uncertainty quantification. To sufficiently demonstrate the accuracy of these tools, advanced research reactors are needed. The authors argue the need for new computational paradigms such as the MRT (Multistage, Response- function Transport) methodology which has resulted in the development of the novel high-fidelity RAPID (Real-time Analysis for Particle-transport and In-situ Detection) code system. Such code systems have to be robust in modeling any complex system, and should be fast and accurate, henceforth their uncertainties can be quantified at reasonable costs. Again, advanced research reactors are needed for the validation of the fidelity and accuracy of new computational tools. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

The Mars Hopper: Development, Simulation and Experimental Validation of a Radioisotope Exploration Probe for the Martian Surface

An advanced exploration probe has been proposed by the Center for Space Nuclear Research (CSNR) to acquire detailed data from the Martian surface and subsurface, ‘hop’ large distances to multiple sites in short periods of time and perform this task repeatedly. Although several similar flying vehicles have been proposed utilizing various power sources and complex designs, e.g. solar-electric and chemical-based, the CSNR’s Mars Hopper is based on a radioisotope thermal rocket (RTR) concept. The Mars Hopper’s design relies on the high specific energies [J/kg] of radioisotopes and enhances their low specific power [W/kg] through the use of a thermal capacitance material to store thermal energy over time. During operation, the RTR transfers the stored thermal energy to a flowing gas, which is then expanded through a converging-diverging nozzle, producing thrust. Between flights, the platform will have ample time to perform in-depth science at each location while the propellant tanks and thermal capacitor recharge. Recharging the propellant tanks is accomplished by sublimation freezing of the ambient CO2 atmosphere with a cryocooler, followed by heating and pressurization to yield a liquid storage state. The proposed Mars Hopper will undergo a ballistic flight, consuming the propellant in both ascent and descent, and by using multiple hopper platforms, information can be gathered on a global scale, enabling better resource resolution and providing valuable information for a possible Mars sample-return mission. The CSNR, collaborating with the Idaho National Laboratory (INL) and three universities (University of Idaho, Utah State University and Oregon State University), has identified key components and sub-systems necessary for the proposed hopper. Current project activities include the development of a lab-scale prototypic Mars Hopper and test facility, along with computational fluid dynamics (CFD)/thermal-hydraulic models to yield a better understanding of the heat transfer process and complex nature of turbulent CO2 flow. Laboratory experimentation will aid design iterations and the development of both tethered and free-flying terrestrial hoppers that utilize an electrically heated core. The knowledge base acquired from these activities will refine the Mars Hopper’s future performance and optimize the RTR core components prior to constructing the final design.

33 ADVANCED PROPULSION SYSTEMS↗

Advanced Simulation Capability for Environmental Management: Development and Demonstrations - 12532

The U.S. Department of Energy Office of Environmental Management (EM), Technology Innovation and Development is supporting development of the Advanced Simulation Capability for Environmental Management (ASCEM). ASCEM is a state-of-the-art scientific tool and approach for understanding and predicting contaminant fate and transport in natural and engineered systems. The modular and open source high-performance computing tool facilitates integrated approaches to modeling and site characterization that enable robust and standardized assessments of performance and risk for EM cleanup and closure activities. The ASCEM project continues to make significant progress in development of capabilities, which are organized into Platform and Integrated Tool-sets and a High-Performance Computing Multi-process Simulator. The Platform capabilities target a level of functionality to allow end-to-end model development, starting with definition of the conceptual model and management of data for model input. The High-Performance Computing capabilities target increased functionality of process model representations, tool-sets for interaction with Platform, and verification and model confidence testing. The new capabilities are demonstrated through working groups, including one focused on the Hanford Site Deep Vadose Zone. The ASCEM program focused on planning during the first year and executing a prototype tool-set for an early demonstration of individual components. Subsequently, ASCEM has focused on developing and demonstrating an integrated set of capabilities, making progress toward a version of the capabilities that can be used to engage end users. Demonstration of capabilities continues to be implemented through working groups. Three different working groups, one focused on EM problems in the deep vadose zone, another investigating attenuation mechanisms for metals and radionuclides, and a third focusing on waste tank performance assessment, continue to make progress. The project experience has been that the working group mechanism continues to be useful for helping guide development and prepare the capabilities for end users. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗