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A Reliability Model to Assess Reliability of Shuttle Derived Launch Vehicle and Next Generation Vehicles

One important thrust in NASA s space exploration vision is to improve the safety and reliability of future launch vehicles. A quantitative reliability model is an essential technical tool to evaluate launch vehicle reliability and to enhance launch vehicle configuration down selection and detailed designs. A quantitative reliability model that supports NASA's thrust has been developed and implemented in an MS Excel spreadsheet. The model addresses key reliability parameters, and provides for sensitivity analysis of various vehicle designs. This paper presents the specific elements of the model and examples of selected sensitivity analysis results. Reliability input parameters in the model include the following: 1. Main propulsion element failure probability; 2. Propulsion element catastrophic failure fraction (Cf). This is defined as the ratio of probability of uncontained failures over sum of probability of uncontained failures and contained failures); 3. Engine-out design vs. no-engine-out design; 4. Engine with redlines vs. no redlines; 5. Different levels of health management system implementation; 6. Launch Escape System (LES) reliability; and 7. Power level correlation with reliability. The sensitivity results will illustrate the impact of each of the above parameters on several reliability metrics: Loss of Mission (LOM), LOV (Loss of Vehicle) and Loss of Crew (LOC).

Huang, Zhao↗

Demonstration/Validation of Environmentally-Preferable Coatings for Launch Facilities

Kennedy Space Center (KSC) is responsible for a number of facilities/structures with metallic structural and non-structural components in a highly corrosive environment. Metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the application of an applied coating system. Applied coating systems work via a variety of methods (barrier, galvanic and/or inhibitor) and adhere to the substrate through a combination of chemical and physical bonds. Maintenance at KSC and other NASA Centers is governed by NASA-STD-50088 (Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment) which establishes practices for the protective coating of ground support equipment and related facilities used by or for NASA programs and projects. The Standard is for the design of non-flight hardware used to support the operations of receiving, transportation, handling, assembly, inspection, test, checkout, service, and launch of space vehicles and payloads at NASA launch, landing, or retrieval sites. These criteria and practices contained within the Standard may be used for items used at the manufacturing, development, and test sites upstream of the launch, landing, or retrieval sites. The objective of this effort is to demonstrate and validate environmentally-preferable alternatives in accordance with NASA-STD-50088 and KSC requirements which can then be added to the Approved Products List. This Test Protocol contains the critical requirements and tests necessary to qualify alternatives for structural steel applications. These tests were derived from engineering, performance, and operational impact (supportability) requirements defined by a consensus of KSC participants. A Test Report will document the results of the testing as well as any test modifications made during the execution of the testing. Users of this Test Protocol should check the project's Test Report for additional test details or minor modifications that may have been necessary in the execution of the testing. The technical stakeholders will have agreed upon test procedures modifications documented in the Test Report.

Lewis, Pattie↗

National Campaign (NC)-1 Strategic Conflict Management Simulation (X4) Community Based Rules

Projected demand for transportation services in the urban environment has led to the development of several Concepts of Operation for Urban Air Mobility, or UAM. UAM is a concept for the transportation of people and goods in the metropolitan environment using small, efficient aircraft over short distances as part of an expanding multimodal transportation network. UAM will leverage emerging technologies including electric Vertical Takeoff and Landing (eVTOL) aircraft, increasing levels of automation and a new operational paradigm in dense airspace where a set of agreed-upon rules govern the procedures and interactions defining a cooperative environment in which operators are entrusted with a range of functions typically conducted by Air Traffic Control (ATC). These rules, proposed in the FAA NextGen Office’s UAM Concept of Operations [1], were originally termed Community Based Rules or Community Business Rules (CBRs), and will in the future termed Cooperative Operating Practices (COPs); this document uses the original term, CBR. CBRs are a set of rules, developed by the UAM community and (where necessary) approved by the FAA that govern the interactions between UAM entities and limit the need for ATC services including, but not limited to, separation control by ATC, addressing a fundamental challenge to scaling UAM operations. UAM community development of CBRs is anticipated to accelerate the adoption of new practices while retaining the regulatory authority of the FAA within required domains (e.g., NAS safety, security and equal access). However, there currently exists no agreed industry forum or defined procedures for CBR development. Investigation of best practices for the development of UAM CBRs was identified by NASA and the FAA NextGen Office as a research need. In collaboration with seven industry partners, NASA participated in a series of simulations that investigated elements of the envisioned UAM operations, with a primary focus on Strategic Conflict Management (SCM). The development and conduct of cooperative UAM simulations with seven industry partners provided a unique opportunity to investigate CBR development practices. Development of CBRs for the UAM SCM simulations was conducted in parallel with simulation capability development and was closely related to requirements definition for the simulations. As such, the CBR development effort presented herein had two objectives: explore CBR development practices in collaboration with the industry partners and develop an initial set of UAM CBRs to support simulation requirements definition and development. Consensus was achieved among NASA and the industry partners on 24 CBRs that were developed to support the cooperative simulation operations across five topic areas: General (related to test requirements), Operational Intent, Conformance Monitoring, Demand Capacity Balancing, and Airspace Constraint Management. Additional topic areas and CBRs were discussed but were deemed outside the scope of the simulation; these are included in the appendices. A collaborative, iterative process was employed for developing the CBRs engaging both NASA and Industry; because CBR development is envisioned to be community-driven, opportunities were sought that provided industry partners leadership roles in developing CBRs. The following key observations and recommendations may aid the UAM industry in future CBR development efforts: - The lack of a defined process proved challenging initially. Stakeholder engagement in the early stages of CBR development was intermittent and may have been due to the lack of a clear definition of roles and responsibilities of those involved in the effort. - Industry leadership of CBR topic areas proved successful. Discussions in these topic areas were engaging, with alternate viewpoints freely discussed and detailed CBRs resulting. This points to the importance of identifying the best-suited leadership in technical areas for CBR development. - Discussions within a CBR topic area were typically dominated by only a few participants. Whereas all industry partners contributed to CBR development, within each topic area, technical leadership was evident even when not formally established. This observation may indicate that smaller, focused groups may be more effective in initial CBR development than an open forum or large standards development effort (although both maybe required prior to FAA review and approval for some CBRs). - Identifying suitable forums for initial UAM CBR development and identifying the most effective industry participants and leadership will be crucial for successful CBR development. Although the operational need for UAM CBRs may not be immediate, establishing the forums and leadership to define the processes for CBR development is a prudent early step to UAM realization.

Community Based Rules↗

Transportation Package Seal Performance in Beyond Design Basis Thermal Exposures - 12472

The Nuclear Regulatory Commission (NRC) technical report, NUREG/CR-6886, 'Spent Fuel Transportation Package Response to the Baltimore Tunnel Fire Scenario', describes, in detail, an evaluation of the potential for a theoretical release of radioactive material from three different spent nuclear fuel (SNF) transportation packages, had they been exposed to the Baltimore tunnel fire that occurred in July of 2001. This evaluation determined the temperatures of various components of the packages, including the seals, using temperatures resulting from models of the Baltimore tunnel fire (as boundary conditions) and finite element models of the SNF packages. For two of the packages evaluated, the analyses indicated that the seals used would have exceeded their continuous-use rated service temperatures, meaning the release of radioactive material could not be ruled out with available information; However, for both of the packages evaluated, the analysis determined, by a bounding calculation, that the maximum potential release was well below the regulatory requirements for releases from a SNF package during the hypothetical accident condition (HAC) sequence of events in 10CFR Part 71. The NRC is investigating the performance of seals in SNF transportation packages exposed to fires that could exceed the HAC fire described in 10CFR Part 71, such as the Baltimore Tunnel Fire that occurred in 2001. The performance of package seals is important for determining the potential release of radioactive material from a package during a beyond-design-basis accident. The seals have lower temperature limits than other package components and are the containment barrier between the environment and the cask contents. The NRC Office of Nuclear Regulatory Research contracted the National Institute of Standards and Technology (NIST) to conduct small-scale thermal testing to obtain experimental data of the performance of seals during extreme temperature exposures. The experimental testing consisted of several small-scale pressure vessels fabricated with a modified ASME flange design and tested metallic and elastomeric seals, similar to those that might be used on an actual SNF transportation package. The vessels were heated in an electrical oven to temperatures as high as 800 deg. C (1472 deg. F), exceeding the rated temperatures of the seals in question. This paper will provide a summary of the testing conducted and present test results and conclusions. Fifteen metallic and elastomeric seal performance tests including two shakedowns were performed under beyond-design-basis thermal exposure conditions; twelve tests used metallic seals, two used ethylene-propylene seals, and one used a Teflon seal. Of the five repeat metallic-seal tests (Tests No.2, 3, 4, 8, and 9), leakage (decreasing vessel pressure) was observed in three of the tests (Tests No.3, 4, and 8) during the 9 h 800 deg. C (1472 deg. F) exposure. The times when the leakage occurred (the vessel pressure started to decrease) varied in the three tests performed. The two shakedown tests were conducted using a 30 min and 4 h exposure to 800 deg. C (1472 deg. F), respectively, and the seal appeared to hold vessel pressure. No leakage (unchanged vessel pressure within the pressure measurement uncertainty) was also observed in the two metallic seal tests that used 100 deg. C incremental heating from 427 deg. C (800 deg. F) to 627 deg. C (1160 deg. F) and from 427 deg. C (800 deg. F) to 727 deg. C (1340 deg. F), respectively, with at least 9 h exposure to each temperature increment. Three repeat metallic seal tests were also conducted at the seal maximum operating temperature of 427 deg. C (800 deg. F) for 9 h. The seal maintained vessel pressure within the measurement of the pressure transducer in all three tests. No leakage was observed in one ethylene-propylene seal tested at 300 deg. C (572 deg. F) for more than 20 hours; however, leakage was found in another ethylene-propylene seal tested at 450 deg. C (842 deg. F) for more than 20 hours (Test No.15). Leakage was also observed in the test (Test No.12) that used a TFE seal subject to 300 deg. C (572 deg. F) exposure. In these fifteen tests the temperature and time exposure variables were changed to map the performance of the metallic and polymeric seals at elevated temperatures beyond the rated operating temperatures. Both the metallic and polymeric seals were able to hold pressure even after leaks were detected and no catastrophic seal failure (i.e., a rapid release of pressure to atmospheric) occurred. Further testing on the polymeric seals would need to be performed to confirm the results in these tests.(authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Technical Assistance for Igiugig, Alaska

Igiugig, Alaska received technical assistance through the Energy Technology Innovation Partnership Project (ETIPP) to implement high-priority strategies detailed in their 2022 Community Energy Plan.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Instantaneous velocity field imaging instrument for supersonic reacting flows

The technical tasks conducted to develop and demonstrate a new gas velocity measurement technique for high enthalpy reacting flows is described. The technique is based on Doppler-shifted Planar Laser-induced Fluorescence (PLIF) imaging of the OH radical. The imaging approach permits, in principle, single-shot measurements of the 2-D distribution of a single velocity component in the measurement plane, and is thus a technique of choice for applications in high enthalpy transient flow facilities. In contrast to previous work in this area, the present program demonstrated an approach which modified the diagnostic technique to function under the constraints of practical flow conditions of engineering interest, rather than vice-versa. In order to accomplish the experimental demonstrations, the state-of-the-art in PLIF diagnostic techniques was advanced in several ways. Each of these tasks is described in detail and is intended to serve as a reference in supporting the transition of this new capability to the fielded PLIF instruments now installed at several national test facilities. Among the new results of general interest in LlF-based flow diagnostics, a detailed set of the first measurements of the collisional broadening and shifting behavior of OH (1,0) band transitions in H7-air combustion environments is included. Such measurements are critical in the design of a successful strategy for PLIF velocity imaging; they also relate to accurate concentration and temperature measurements, particularly in compressible flow regimes. Furthermore, the results shed new light on the fundamental relationship between broadening and energy transfer collisions in OH A(sup 2)Sigma(+)v(sup ') = 1. The first single-pulse, spectrally-resolved measurements of the output of common pulsed dye lasers were also produced during the course of this effort. As with the OH broadening measurements, these data are a significant aspect of a successful velocity imaging strategy, and also have potential implications for many other LIF measurement techniques. Our results indicated the need to modify the commercially available laser cavity in order to accommodate the constraints imposed by typical SCRAMJET combustion characteristics as well as to increase the instrument's velocity dynamic range to span an intra-image range in excess of 2 km/s. The various technical efforts were brought together in a series of experiments demonstrating the applicability of the technique in a high pressure, high temperature H2-air combustion system. The resultant images were compared with 2-D flow simulations in order to determine the accuracy of the instrument. Mean velocity imaging in flows with an axis of symmetry was demonstrated with an accuracy of +/- 50 m/s out of an intra-image dynamic range of 1600 m/s, including reversed flow. A more complex configuration amenable to single-shot imaging in flows without an axis of symmetry was also demonstrated. Limitations imposed by available equipment resulted in an accuracy of about +/- 200 m/s out of 1750 m/s in these demonstrations. Minor modifications to the present configuration were suggested to improve this performance. Each technical task is described in detail, along with significance of the results for the overall imaging velocimeter configuration. This report should allow the user community to integrate this new measurement capability in their existing instrumentation platforms.

Allen, M. G.↗

Bench-Scale Testing of a High Efficiency, Ultra-Compact Process for Pre-Combustion CO 2 Capture (Final Report)

The overarching objective of this bench-scale study is to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift (WGS) reaction process that employs a carbon molecular sieve (CMS) membrane reactor (MR) followed by an adsorption reactor (AR) for pre-combustion CO 2 capture while demonstrating progress towards achievement of the overall performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) of 30% less than the baseline capture approaches. The main goal of this bench-scale project is to advance the proposed MR-AR transformative CO 2 capture technology to a sufficient maturity level so that our present industrial partners (M&PT and Worley) can potentially adapt the technology for further small pilot-scale testing. The project began at TRL 4, as the system prototype had already been validated in the laboratory on simulated syngas (as part of project DE-FE0026423). The project ended at TRL 5, via scaling-up of the prototype system and testing it on actual syngas at a host site (CAER at the University of Kentucky (UKy)). The project was carried-out in two different phases: In Phase I (during BP1 of the project), the team designed, constructed, and assembled the bench-scale experimental MR-AR system, prepared the membranes, adsorbents, and catalysts, tested the bench-scale unit with simulated syngas to validate functionality, and prepared a preliminary TEA of the technology. In Phase II (during BP2 of the project), the team installed the unit at the test site at the UKy site and completed all utility connections and hookups, field-tested the novel MR-AR process in the bench-scale system using real syngas, collected and analyzed experimental data, and completed a detailed TEA of the technology. A key aim of the project was to identify and address the technical and process risks and to generate information to advance the technology to the next stage of development. All project milestones and success criteria were met. Specifically, the team: (i) designed, constructed and assembled a bench scale system that handled 1 – 5 scfm syngas and tested its functionality with simulated syngas; (ii) prepared high performance CMS membrane tubes (ID: 3.5 mm, OD: 5.7 mm, 30” long) that meet the target H 2 permeance ( > 1 m 3 /(m 2 .hr.bar) or (> 370.3 GPU)) and a target H 2 /CO selectivity >80 at the relevant temperature (up to 300oC) and pressure conditions (up to 25 bar) with a <10% decline in performance over each 250 hr. testing period (iii) procured commercial sour-shift catalyst in sufficient quantity and prepared up to 10 kg of pelletized adsorbent for use at relevant conditions (250oC 2.5wt.% and target sorbent attrition rate < 0.2; (iv) installed the bench-scale unit at the test site (UKy) and tested the MR-AR technology using real syngas for over 250 hr. for both static and flow experiments; (v) updated the TEA analysis based on bench-scale data and met CO 2 capture goals of 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. The CMS membranes, HTC adsorbents and catalysts employed all exhibited very robust and stable performance during the long-term run (over a >250 hr live syngas run). Furthermore, the proposed MR-AR IGCC system achieved a LCOE with a N 2 sale price of $\$$ 30/ton, with N 2 compression (no N 2 compression) of 101.2 $\$$/MWh (95.3 $\$$/MWh), which represents a 29.8% (33.9%) LCOE reduction in the baseline IGCC with carbon capture of 144.2 $\$$/MWh. The proposed MR-AR IGCC delivers a CO 2 capture cost of 44.8 $\$$/tonne (39.9 $\$$/tonne) vs 98.1 $\$$/tonne of the baseline capture case and a net power production of 586 MWe (623 MWe) vs 556 MWe of the baseline capture case.

01 COAL, LIGNITE, AND PEAT↗

ITOS VHRR on-board data compression study

Data compression methods for ITOS VHRR data were studied for a tape recorder record-and playback application. A playback period of 9 minutes was assumed with a nominal 18 minute record period for a 2-to-1 compression ratio. Both analog and digital methods were considered with the conclusion that digital methods should be used. Two system designs were prepared. One is a PCM system and the other is an entropy-coded predictive-quantization, sometimes called entropy-coded DPCM or just DPCM, system. Both systems use data management principles to transmit only the necessary data. Both systems use a medium capacity standard tape recorder from specifications provided by the technical officer. The 10 to the 9th power bit capacity of the recorder is the basic limitation on the compression ratio. Both systems achieve the minimum desired 2 to 1 compression ratio. A slower playback rate can be used with the DPCM system due to a higher compression factor for better link performance at a given CNR in terms of bandwidth utilization and error rate. The report is divided into two parts. The first part summarizes the theoretical conclusions of the second part and presents the system diagrams. The second part is a detailed analysis based upon an empirically derived random process model arrived at from specifications and measured data provided by the technical officer.

Gray, R. M.↗

International Linear Collider-A Technical Progress Report

The International Linear Collider: A Technical Progress Report marks the halfway point towards the Global Design Effort fulfilling its mandate to follow up the ILC Reference Design Report with a more optimised Technical Design Report (TDR) by the end of 2012. The TDR will be based on much of the work reported here and will contain all the elements needed to propose the ILC to collaborating governments, including a technical design and implementation plan that are realistic and have been better optimised for performance, cost and risk. We are on track to develop detailed plans for the ILC, such that once results from the Large Hadron Collider (LHC) at CERN establish the main science goals and parameters of the next machine, we will be in good position to make a strong proposal for this new major global project in particle physics. The two overriding issues for the ILC R&D programme are to demonstrate that the technical requirements for the accelerator are achievable with practical technologies, and that the ambitious physics goals can be addressed by realistic ILC detectors. This GDE interim report documents the impressive progress on the accelerator technologies that can make the ILC a reality. It highlights results of the technological demonstrations that are giving the community increased confidence that we will be ready to proceed with an ILC project following the TDR. The companion detector and physics report document likewise demonstrates how detector designs can meet the ambitious and detailed physics goals set out by the ILC Steering Committee. LHC results will likely affect the requirements for the machine design and the detectors, and we are monitoring that very closely, intending to adapt our design as those results become available.

43 PARTICLE ACCELERATORS↗

The development of laser speckle velocimetry for the study of vortical flows

A research program was undertaken to develop a new experimental technique commonly known as particle image displacement velocity (PIVD) to measure an instantaneous two dimensional velocity field in a selected plane of flow field. This technique was successfully developed and applied to the study of several aerodynamic problems. A detailed description of the technique and a broad review of all the research activity carried out in this field are reported. A list of technical publications is also provided. The application of PIDV to unsteady flows with large scale structures is demonstrated in a study of the temporal evolution of the flow past an impulsively started circular cylinder. The instantaneous two dimensional flow in the transition region of a rectangular air jet was measured using PIDV and the details are presented. This experiment clearly demonstrates the PIDV capability in the measurement of turbulent flows. Preliminary experiments were also conducted to measure the instantaneous flow over a circular bump in a transonic flow. Several other experiments now routinely use PIDV as a non-intrustive measurement technique to obtain instantaneous two dimensional velocity fields.

Krothapalli, A.↗

ATF Neutron Irradiation Program Technical Plan

The Japan Atomic Energy Agency (JAEA) under the Civil Nuclear Energy Working Group (CNWG) is engaged in a cooperative research effort with the U.S. Department of Energy (DOE) to explore issues related to nuclear energy, including research on accident-tolerant fuels and materials for use in light water reactors. This work develops a draft technical plan for a neutron irradiation program on the candidate accident-tolerant fuel cladding materials and elements using the High Flux Isotope Reactor (HFIR). The research program requires the design of a detailed experiment, development of test vehicles, irradiation of test specimens, possible post-irradiation examination and characterization of irradiated materials and the shipment of irradiated materials to JAEA in Japan. This report discusses the technical plan of the experimental study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Technical report series on global modeling and data assimilation. Volume 3: An efficient thermal infrared radiation parameterization for use in general circulation models

A detailed description of a parameterization for thermal infrared radiative transfer designed specifically for use in global climate models is presented. The parameterization includes the effects of the main absorbers of terrestrial radiation: water vapor, carbon dioxide, and ozone. While being computationally efficient, the schemes compute very accurately the clear-sky fluxes and cooling rates from the Earth's surface to 0.01 mb. This combination of accuracy and speed makes the parameterization suitable for both tropospheric and middle atmospheric modeling applications. Since no transmittances are precomputed the atmospheric layers and the vertical distribution of the absorbers may be freely specified. The scheme can also account for any vertical distribution of fractional cloudiness with arbitrary optical thickness. These features make the parameterization very flexible and extremely well suited for use in climate modeling studies. In addition, the numerics and the FORTRAN implementation have been carefully designed to conserve both memory and computer time. This code should be particularly attractive to those contemplating long-term climate simulations, wishing to model the middle atmosphere, or planning to use a large number of levels in the vertical.

Suarex, Max J.↗

X-ray pinhole camera setups used in the Atomki ECR Laboratory for plasma diagnostics

Imaging of the electron cyclotron resonance (ECR) plasmas by using CCD camera in combination with a pinhole is a non-destructive diagnostics method to record the strongly inhomogeneous spatial density distribution of the X-ray emitted by the plasma and by the chamber walls. This method can provide information on the location of the collisions between warm electrons and multiple charged ions/atoms, opening the possibility to investigate the direct effect of the ion source tuning parameters to the plasma structure. The first successful experiment with a pinhole X-ray camera was carried out in the Atomki ECR Laboratory more than 10 years ago. The goal of that experiment was to make the first ECR X-ray photos and to carry out simple studies on the effect of some setting parameters (magnetic field, extraction, disc voltage, gas mixing, etc.). Recently, intensive efforts were taken to investigate now the effect of different RF resonant modes to the plasma structure. Comparing to the 2002 experiment, this campaign used wider instrumental stock: CCD camera with a lead pinhole was placed at the injection side allowing X-ray imaging and beam extraction simultaneously. Additionally, Silicon Drift Detector (SDD) and High Purity Germanium (HPGe) detectors were installed to characterize the volumetric X-ray emission rate caused by the warm and hot electron domains. In this paper, detailed comparison study on the two X-ray camera and detector setups and also on the technical and scientific goals of the experiments is presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development and Performance of Superconducting Undulators at the Advanced Photon Source

Several years ago, an article in SRN [1] with the same title as this article summarized the decade-long development of superconducting undulators (SCUs) at the Advanced Photon Source (APS). The article presented those developments leading to the point when the first prototype, called SCU0 and intended for installation at the APS, was under fabrication. SCU0 was built in 2012, its cryogenic performance has been extensively tested, and detailed magnet measurements of the device have been conducted. After verification that SCU0 met all of the technical requirements for APS insertion devices, it was installed in the APS storage ring in January 2013, commissioned in a record short time (two weeks), and became a routinely used source of hard X-rays at the APS Sector 6 ID beamline.

Gluskin, Efim↗

In-Depth Analysis of Simulation Engine Codes for Comparison with DOE's Roof Savings Calculator and Measured Data

The Roof Savings Calculator (RSC) was developed through collaborations among Oak Ridge National Laboratory (ORNL), White Box Technologies, Lawrence Berkeley National Laboratory (LBNL), and the Environmental Protection Agency in the context of a California Energy Commission Public Interest Energy Research project to make cool-color roofing materials a market reality. The RSC website and a simulation engine validated against demonstration homes were developed to replace the liberal DOE Cool Roof Calculator and the conservative EPA Energy Star Roofing Calculator, which reported different roof savings estimates. A preliminary analysis arrived at a tentative explanation for why RSC results differed from previous LBNL studies and provided guidance for future analysis in the comparison of four simulation programs (doe2attic, DOE-2.1E, EnergyPlus, and MicroPas), including heat exchange between the attic surfaces (principally the roof and ceiling) and the resulting heat flows through the ceiling to the building below. The results were consolidated in an ORNL technical report, ORNL/TM-2013/501. This report is an in-depth inter-comparison of four programs with detailed measured data from an experimental facility operated by ORNL in South Carolina in which different segments of the attic had different roof and attic systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Cherokee Wind Energy Development - Feasibility and Pre-Construction Studies

Cherokee Nation Businesses (CNB) received a grant from the US Department of Energy to explore feasibility and pursue development of a wind power generation facility on Cherokee land in north-central Oklahoma. This project followed several years of initial study exploring the possibility of commercial-scale wind power generation on primarily agricultural land owned by the Cherokee Nation. This project produced detailed analysis of the legal, financial and market viability of such generation facilities, and encompassed a full technical evaluation of the engineering, environmental, and geotechnical aspects of installing this capacity. During the course of this project, information gleaned from this exploration changed CNB’s thinking about the best course of action for Cherokee participation in the development, eventually moving away from an equity-owner model and towards utilization of the land asset as a resource while mitigating Cherokee financial and operational risk.

17 WIND ENERGY↗

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclear industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗