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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2015

Final Report for Grant DOE DE-FG02-08ER64573 (Relating to Turbulence Modeling)

Turbulence enhances transport and mixing. Turbulent ocean currents can increase the encounter rate between fish larvae and their prey. Without turbulence, the fuel and air injected into the cylinder of an internal combustion engine would mix too slowly to be effective. Birds extract energy from turbulent winds to soar for great distances without flapping their wings. Turbulence can be detrimental as well. The efficiencies of vehicles, pipelines, and industrial equipment are all hindered by turbulence. Turbulence can also cause structural fatigue, generate unwanted noise, and distort the propagation of electromagnetic signals. These observations highlight the importance of turbulence research. Our ability to predict and control turbulence and, thus, to intensify or suppress its effects as circumstances warrant is contingent on our understanding of the underlying mechanisms. Turbulence is also immensely interesting from a purely scientific perspective and is a great source of fundamentally important, challenging problems for physicists, engineers, and mathematicians. Moreover, various methods and tools developed in the field have found applications in other fields, including nonlinear optics, nonlinear acoustics, pattern formation, image processing, data compression, and econophysics. It is possible, at least away from walls, to derive LES models of very high-order accuracy. However, these models also lead to correspondingly intense computational complexity for their numerical solution. Some also introduce yet more questions on the already difficult problem of specifying needed and sometimes artificial local boundary conditions for the inherently nonlocal flow averages. For these two (and other) reasons, there has been a resurgence of interest in basing simulations of turbulent flows on much simpler regularizations of the Navier–Stokes equations rather than on full models of local averages--i.e., LES models. Initially these were developed as pure theoretical tools. The influx of ideas from LES and the added constraint that the regularization be amenable to numerical simulation have breathed new perspective and thus new life into this thread of ideas.Over the past year, a significant portion of our research activity has focused on numerical studies of the Navier–Stokes-$αβ$ model and extensions thereof. Our results regarding these and other approaches to turbulence modeling are described below.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Calibration and Forward Uncertainty Propagation for Large-eddy Simulations of Engineering Flows

The objective of this work is to investigate the efficacy of using calibration strategies from Uncertainty Quantification (UQ) to determine model coefficients for LES. As the target methods are for engineering LES, uncertainty from numerical aspects of the model must also be quantified. 15 The ultimate goal of this research thread is to generate a cost versus accuracy curve for LES such that the cost could be minimized given an accuracy prescribed by an engineering need. Realization of this goal would enable LES to serve as a predictive simulation tool within the engineering design process.

42 ENGINEERING↗
DOE OSTI2015

A Reduced Order Model of Force Displacement Curves for the Failure of Mechanical Bolts in Tension.

Assembled mechanical systems often contain a large number of bolted connections. These bolted connections (joints) are integral aspects of the load path for structural dynamics, and, consequently, are paramount for calculating a structure's stiffness and energy dissipation prop- erties. However, analysts have not found the optimal method to model appropriately these bolted joints. The complexity of the screw geometry causes issues when generating a mesh of the model. This report will explore different approaches to model a screw-substrate connec- tion. Model parameters such as mesh continuity, node alignment, wedge angles, and thread to body element size ratios are examined. The results of this study will give analysts a better understanding of the influences of these parameters and will aide in finding the optimal method to model bolted connections.

42 ENGINEERING↗
DOE OSTI2016

Rendering and Compositing Infrastructure Improvements to VisIt for Insitu Rendering

Compared to posthoc rendering, insitu rendering often generates larger numbers of images, as a result rendering performance and scalability are critical in the insitu setting. In this work we present improvements to VisIt's rendering and compositing infrastructure that deliver increased performance and scalability in both posthoc and insitu settings. We added the capability for alpha blend compositing and use it with ordered compositing when datasets have disjoint block domain decomposition to optimize the rendering of transparent geometry. We also made improvements that increase overall efficiency by reducing communication and data movement and have addressed a number of performance issues. We structured our code to take advantage of SIMD parallelization and use threads to overlap communication and compositing. We tested our improvements on a 20 core workstation using 8 cores to render geometry generated from a $256^3$ cosmology dataset and on a Cray XC31 using 512 cores to render geometry generated from a $2000^2 \times 800$ plasma dataset. Our results show that ordered compositing provides a speed up of up to $4 \times$ over the current sort first strategy. The other improvements resulted in modest speed up with one notable exception where we achieve up to $40 \times$ speed up of rendering and compositing of opaque geometry when both opaque and transparent geometry are rendered together. We also investigated the use of depth peeling, but found that the implementation provided by VTK is substantially slower,both with and without GPU acceleration, than a local camera order sort.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Task Order 22 – Engineering and Technical Support, Deep Borehole Field Test. AREVA Summary Review Report

Under Task Order 22 of the industry Advisory and Assistance Services (A&AS) Contract to the Department of Energy (DOE) DE-NE0000291, AREVA has been tasked with providing assistance with engineering, analysis, cost estimating, and design support of a system for disposal of radioactive wastes in deep boreholes (without the use of radioactive waste). As part of this task order, AREVA was requested, through a letter of technical direction, to evaluate Sandia National Laboratory’s (SNL’s) waste package borehole emplacement system concept recommendation using input from DOE and SNL. This summary review report (SRR) documents this evaluation, with its focus on the primary input document titled: “Deep Borehole Field Test Specifications/M2FT-15SN0817091” Rev. 1 [1], hereafter referred to as the “M2 report.” The M2 report focuses on the conceptual design development for the Deep Borehole Field Test (DBFT), mainly the test waste packages (WPs) and the system for demonstrating emplacement and retrieval of those packages in the Field Test Borehole (FTB). This SRR follows the same outline as the M2 report, which allows for easy correlation between AREVA’s review comments, discussion, potential proposed alternatives, and path forward with information established in the M2 report. AREVA’s assessment focused on three primary elements of the M2 report: the conceptual design of the WPs proposed for deep borehole disposal (DBD), the mode of emplacement of the WP into DBD, and the conceptual design of the DBFT. AREVA concurs with the M2 report’s selection of the wireline emplacement mode specifically over the drill-string emplacement mode and generically over alternative emplacement modes. Table 5-1 of this SRR compares the pros and cons of each emplacement mode considered viable for DBD. The primary positive characteristics of the wireline emplacement mode include: (1) considered a mature technology; (2) operations are relatively simple; (3) probability of a radiological release due to off-normal events are relatively low; (4) costs are relatively low; and (5) maintenance activities are relatively simple. The primary drawback associated with the wireline emplacement mode for DBD is the number of emplacement trips-in to the borehole, which results in a relatively higher probability for a drop event. Fortunately, the WPs can be engineered with impact limiters that will minimize the likelihood of a breach of the WP due to a drop. The WP designs presented in the M2 report appear to be focused on compatibility with the drill-string emplacement mode (e.g., the threaded connections). With the recommendation that the wireline emplacement mode be utilized for the DBFT, some changes may be warranted to these WPs. For example, the development of a WP release connection that is more reliable than the currently credited connection, which is considered to have a high failure probability, and the integration of an impact limiter into its design. The M2 report states the engineering demonstration of the DBFT will occur in the FTB over a 4-year period. AREVA recommends development and testing of the WP emplacement handling equipment occur separately (but concurrently, if not earlier) from the FTB at a mock-up facility. The separation of this activity would prevent schedule interference between the science and engineering thrusts of the project. Performing tests in a mock-up facility would allow additional control and observation compared to the FTB. The mock-up facility could also be utilized as a training facility for future operations. Terminal velocity and impact limiter testing would require the FTB for testing, since these areas would be difficult to reproduce in a limited depth mock-up. Although only at the end of the conceptual stage of design development, DBD appears to be a viable solution for some waste forms produced by the nuclear industry. However, regulatory requirements have yet to be established for pre- and post-closure performance of DBD and should be established as soon as possible. Some of the main areas of focus from a regulatory perspective include: (1) establishing acceptable performance requirements for the long-term behavior of DBD; (2) determining acceptable borehole abandonment criteria; (3) establishing retrievability requirements; (4) developing a consensus on the factor of safety (FoS) for the emplacement mode and WP; and (5) establishing safety and safeguards performance requirements for DBD. Although conservative requirements have been utilized to provide the foundation for the conceptual design of DBD, regulatory requirements and feedback are necessary to confirm recommendations made herein and to ensure the long-term performance of DBD is acceptable. The combination of the M2 report and this SRR is intended to facilitate the completion of the conceptual design for DBD for the Cs and Sr capsules and calcined waste forms. Using the conceptual design, preliminary design activities (the second stage of a three-stage process described in the M2 report) can proceed and the DBFT utilized to support, demonstrate, and confirm engineering elements of this design.

42 ENGINEERING↗
DOE OSTI2015

Planning for Pre-Exascale Platform Environment (Fiscal Year 2015 Level 2 Milestone 5216)

This Plan for ASC Pre-Exascale Platform Environments document constitutes the deliverable for the fiscal year 2015 (FY15) Advanced Simulation and Computing (ASC) Program Level 2 milestone Planning for Pre-Exascale Platform Environment. It acknowledges and quantifies challenges and recognized gaps for moving the ASC Program towards effective use of exascale platforms and recommends strategies to address these gaps. This document also presents an update to the concerns, strategies, and plans presented in the FY08 predecessor document that dealt with the upcoming (at the time) petascale high performance computing (HPC) platforms. With the looming push towards exascale systems, a review of the earlier document was appropriate in light of the myriad architectural choices currently under consideration. The ASC Program believes the platforms to be fielded in the 2020s will be fundamentally different systems that stress ASC’s ability to modify codes to take full advantage of new or unique features. In addition, the scale of components will increase the difficulty of maintaining an errorfree system, thus driving new approaches to resilience and error detection/correction. The code revamps of the past, from serial- to vector-centric code to distributed memory to threaded implementations, will be revisited as codes adapt to a new message passing interface (MPI) plus “x” or more advanced and dynamic programming models based on architectural specifics. Development efforts are already underway in some cases, and more difficult or uncertain aspects of the new architectures will require research and analysis that may inform future directions for program choices. In addition, the potential diversity of system architectures may require parallel if not duplicative efforts to analyze and modify environments, codes, subsystems, libraries, debugging tools, and performance analysis techniques as well as exploring new monitoring methodologies. It is difficult if not impossible to selectively eliminate some of these activities until more information is available through simulations of potential architectures, analysis of systems designs, and informed study of commodity technologies that will be the constituent parts of future platforms.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

DIORAMA Communications

Diorama is written as a collection of modules that can run in separate threads or in separate processes. This defines a clear interface between the modules and also allows concurrent processing of different parts of the pipeline. The pipeline is determined by a description in a scenario file[Norman and Tornga, 2012, Tornga and Norman, 2014]. The scenario manager parses the XML scenario and sets up the sequence of modules which will generate an event, propagate the signal to a set of sensors, and then run processing modules on the results provided by those sensor simulations. During a run a variety of “observer” and “processor” modules can be invoked to do interim analysis of results. Observers do not modify the simulation results, while processors may affect the final result. At the end of a run results are collated and final reports are put out. A detailed description of the scenario file and how it puts together a simulation are given in [Tornga and Norman, 2014]. The processing pipeline and how to program it with the Diorama API is described in Tornga et al. [2015] and Tornga and Wakeford [2015]. In this report I describe the communications infrastructure that is used.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Programming Models in HPC

These are the slides for a presentation on programming models in HPC, at the Los Alamos National Laboratory's Parallel Computing Summer School. The following topics are covered: Flynn's Taxonomy of computer architectures; single instruction single data; single instruction multiple data; multiple instruction multiple data; address space organization; definition of Trinity (Intel Xeon-Phi is a MIMD architecture); single program multiple data; multiple program multiple data; ExMatEx workflow overview; definition of a programming model, programming languages, runtime systems; programming model and environments; MPI (Message Passing Interface); OpenMP; Kokkos (Performance Portable Thread-Parallel Programming Model); Kokkos abstractions, patterns, policies, and spaces; RAJA, a systematic approach to node-level portability and tuning; overview of the Legion Programming Model; mapping tasks and data to hardware resources; interoperability: supporting task-level models; Legion S3D execution and performance details; workflow, integration of external resources into the programming model.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

A Fault-oblivious Extreme-scale Execution Environment

Exascale computing systems will provide a thousand-fold increase in parallelism and a proportional increase in failure rate relative to today's machines. Systems software for exascale machines must provide the infrastructure to support existing applications while simultaneously enabling efficient execution of new programming models that naturally express dynamic, adaptive, irregular computation; coupled simulations; and massive data analysis in a highly unreliable hardware environment with billions of threads of execution. We propose a new approach to the data and work distribution model provided by system software based on the unifying formalism of an abstract file system. The proposed hierarchical data model provides simple, familiar visibility and access to data structures through the file system hierarchy, while providing fault tolerance through selective redundancy. The hierarchical task model features work queues whose form and organization are represented as file system objects. Data and work are both first class entities. By exposing the relationships between data and work to the runtime system, information is available to optimize execution time and provide fault tolerance. The data distribution scheme provides replication (where desirable and possible) for fault tolerance and efficiency, and it is hierarchical to make it possible to take advantage of locality. The user, tools, and applications, including legacy applications, can interface with the data, work queues, and one another through the abstract file model. This runtime environment will provide multiple interfaces to support traditional Message Passing Interface applications, languages developed under DARPA's High Productivity Computing Systems program, as well as other, experimental programming models. We will validate our runtime system with pilot codes on existing platforms and will use simulation to validate for exascale-class platforms. In this final report, we summarize research results from the work done at the Ohio State University towards the larger goals of the project listed above.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

OpenMPI and ExxonMobil Topics

These are a series of slides for a presentation for ExxonMobil's visit to Los Alamos National Laboratory. Topics covered are: Open MPI - The Release Story, MPI-3 RMA in Open MPI, MPI dynamic process management and Open MPI, and new options with CLE 6. Open MPI RMA features are: since v2.0.0 full support for the MPI-3.1 specification, support for non-contiguous datatypes, support for direct use of the RDMA capabilities of high performance networks (Cray Gemini/Aries, Infiniband), starting in v2.1.0 will have support for using network atomic operations for MPI_Fetch_and_op and MPI_Compare_and_swap, tested with MPI_THREAD_MULTIPLE.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Closeout Report ARRA supplement to DE-FG02-08ER41546, 03/15/2010 to 03/14/2011 - Advanced Transfer Map Methods for the Description of Particle Beam Dynamics

The ARRA funds were utilized to acquire a cluster of high performance computers, consisting of one Altus 2804 Server based on a Quad AMD Opteron 6174 12C with 4 2.2 GHz nodes of 12 cores each, resulting in 48 directly usable cores; as well as a Relion 1751 Server using an Intel Xeon X5677 consisting of 4 3.46 GHz cores supporting 8 threads. Both systems run the Unix flavor CentOS, which is designed for use without need of updates, which greatly enhances their reliability. The systems are used to operate our COSY INFINITY environment which supports MPI parallelization. The units arrived at MSU in September 2010, and were taken into operation shortly thereafter.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

This report summarizes the final product developed for the US DOE Small Business Innovation Research (SBIR) Phase II grant made to Engineering Mechanics Corporation of Columbus (Emc 2 ) between April 16, 2014 and August 31, 2016 titled ‘Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures’. Many US companies have moved fabrication and production facilities off shore because of cheaper labor costs. A key aspect in bringing these jobs back to the US is the use of technology to render US-made fabrications more cost-efficient overall with higher quality. One significant advantage that has emerged in the US over the last two decades is the use of virtual design for fabrication of small and large structures in weld fabrication industries. Industries that use virtual design and analysis tools have reduced material part size, developed environmentally-friendly fabrication processes, improved product quality and performance, and reduced manufacturing costs. Indeed, Caterpillar Inc. (CAT), one of the partners in this effort, continues to have a large fabrication presence in the US because of the use of weld fabrication modeling to optimize fabrications by controlling weld residual stresses and distortions and improving fatigue, corrosion, and fracture performance. This report describes Emc 2 ’s DOE SBIR Phase II final results to extend an existing, state-of-the-art software code, Virtual Fabrication Technology (VFT®), currently used to design and model large welded structures prior to fabrication - to a broader range of products with widespread applications for small and medium-sized enterprises (SMEs). VFT® helps control distortion, can minimize and/or control residual stresses, control welding microstructure, and pre-determine welding parameters such as weld-sequencing, pre-bending, thermal-tensioning, etc. VFT® uses material properties, consumable properties, etc. as inputs. Through VFT®, manufacturing companies can avoid costly design changes after fabrication. This leads to the concept of joint design/fabrication where these important disciplines are intimately linked to minimize fabrication costs. Finally service performance (such as fatigue, corrosion, and fracture/damage) can be improved using this product. Emc 2 ’s DOE SBIR Phase II effort successfully adapted VFT® to perform efficiently in an HPC environment independent of commercial software on a platform to permit easy and cost effective access to the code. This provides the key for SMEs to access this sophisticated and proven methodology that is quick, accurate, cost effective and available “on-demand” to address weld-simulation and fabrication problems prior to manufacture. In addition, other organizations, such as Government agencies and large companies, may have a need for spot use of such a tool. The open source code, WARP3D, a high performance finite element code used in fracture and damage assessment of structures, was significantly modified so computational weld problems can be solved efficiently on multiple processors and threads with VFT®. The thermal solver for VFT®, based on a series of closed form solution approximations, was extensively enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) was re-written to permit SMEs access to an HPC environment at the Ohio Super Computer Center (OSC) to integrate these solutions with WARP3D. The GUI is used to define all weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was enhanced to make it more user-friendly so that non-experts can perform weld modeling. Finally, an extensive outreach program to market this capability to fabrication companies was performed. This access will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Effective Vectorization with OpenMP 4.5

This paper describes how the Single Instruction Multiple Data (SIMD) model and its extensions in OpenMP work, and how these are implemented in different compilers. Modern processors are highly parallel computational machines which often include multiple processors capable of executing several instructions in parallel. Understanding SIMD and executing instructions in parallel allows the processor to achieve higher performance without increasing the power required to run it. SIMD instructions can significantly reduce the runtime of code by executing a single operation on large groups of data. The SIMD model is so integral to the processor s potential performance that, if SIMD is not utilized, less than half of the processor is ever actually used. Unfortunately, using SIMD instructions is a challenge in higher level languages because most programming languages do not have a way to describe them. Most compilers are capable of vectorizing code by using the SIMD instructions, but there are many code features important for SIMD vectorization that the compiler cannot determine at compile time. OpenMP attempts to solve this by extending the C++/C and Fortran programming languages with compiler directives that express SIMD parallelism. OpenMP is used to pass hints to the compiler about the code to be executed in SIMD. This is a key resource for making optimized code, but it does not change whether or not the code can use SIMD operations. However, in many cases critical functions are limited by a poor understanding of how SIMD instructions are actually implemented, as SIMD can be implemented through vector instructions or simultaneous multi-threading (SMT). We have found that it is often the case that code cannot be vectorized, or is vectorized poorly, because the programmer does not have sufficient knowledge of how SIMD instructions work.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

MPAS-Ocean NESAP Status Report

NESAP performance improvements on MPAS-Ocean have resulted in a 5% to 7% speed-up on each of the examined systems including Cori-KNL, Cori-Haswell, and Edison. These tests were configured to emulate a production workload by using 128 nodes and a high-resolution ocean domain. Overall, the gap between standard and many-core architecture performance has been narrowed, but Cori-KNL remains considerably under-performing relative to Edison. NESAP code alterations affected 600 lines of code, and most of these improvements will benefit other MPAS codes (sea ice, land ice) that are also components within ACME. Modifications are fully tested within MPAS. Testing in ACME across many platforms is underway, and must be completed before the code is merged. In addition, a ten-year production ACME global simulation was conducted on Cori-KNL in late 2016 with the pre-NESAP code in order to test readiness and configurations for scientific studies. Next steps include assessing performance across a range of nodes, threads per node, and ocean resolutions on Cori-KNL.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Progress Report on Alloy 617 Notched Specimen Testing

Creep behavior of Alloy 617 has been extensively characterized to support the development of a draft Code Case to qualify Alloy 617 in Section III division 5 of the ASME Boiler and Pressure Vessel Code. This will allow use of Alloy 617 in construction of nuclear reactor components at elevated temperatures and longer periods of time (up to 950°C and 100,000 hours). Prior to actual use, additional concerns not considered in the ASME code need to be addressed. Code Cases are based largely on uniaxial testing of smooth gage specimens. In service conditions, components will generally be under multi axial loading. There is also the concern of the behavior at discontinuities, such as threaded components. To address the concerns of multi axial creep behavior and at geometric discontinuities, notched specimens have been designed to create conditions representative of the states that service components experience. Two general notch geometries have been used for these series of tests: U notch and V notch specimens. The notches produce a tri axial stress state, though not uniform across the specimen. Characterization of the creep behavior of the U notch specimens and the creep rupture behavior of the V notch specimens provides a good approximation of the behavior expected of actual components. Preliminary testing and analysis have been completed and are reported in this document. This includes results from V notch specimens tested at 900°C and 800°C. Failure occurred in the smooth gage section of the specimen rather than at the root of the notch, though some damage was present at the root of the notch, where initial stress was highest. This indicates notch strengthening behavior in this material at these temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Spider silk MASP1 and MASP2 proteins as carbon fiber precursors

The objective of this project is to develop an unconventional non-petroleum based carbon fiber precursor which has the potential to be produced in high yield and quantities. Methods will be developed to produce pilot-scale quantities of fibers from spider silk proteins with mechanical properties at least 75% that of the natural dragline silk fibers in tensile strength and elongations of less than 5%. The precursor fibers will be converted to carbon fibers, with a goal of >250Ksi strength and 1-2% elongation. Cost analysis will be performed and the process optimized. Task 1: Subtask 1. Protein production: We exceeded the go/ no go milestone of 1.0g/L of one of the spider silk protein (MSp2) purified last FY and have now increased from 5L to 500L fermentations. We have made a series of changes to the purification protocol from the initial report last FY. These led to a reduction in the time needed for the purification and reduced the purification costs by nearly 90%. Subtask 2. Fiber spinning: The major focus has been to produce more material to send 24 fiber thread to ONRL. We are still developing the methodology to successfully spin 24 fiber yarns. This involves both the spinning dope solutions as well as the methods to keep the fibers from fusing during the post spin stretch. The second area of focus has been to standardize the spin dopes for making the fibers. We now know that the conductivity (indicative of salt remaining with the protein after purification) is an important factor in successful spinning as is the pH. We now know that we need to be below 600 uS conductivity and that the most effective pH is protein dependent. Subtask 3. Silkworm silk: We have found the transgenic silkworms made using gene replacement at the fibroin light chain instead of heavy chain as we did previously have a higher tensile strength. See figures below showing the curve for the top end of the cocoon fibers. This tensile strength is the same as the average for spider dragline silk. Task 2. Carbonization: The major accomplishment in the latter part of the work is that the ONRL group has successfully heated the spider silk protein fibers all the way up to 1700°C and produced a very competitive carbon fiber based on mechanical properties. Several important factors were discovered during these initial trials: 1) the ramp speed for increasing the temperature is critical; 2) maintaining tension on the fiber during the heating process because as it is heated it tends to expand; and 3) narrow temperature window in which stretching the fiber during heating leads to much better final materials. Task 3. Techno-Economic Methods: The techno-economic analysis was expanded to determine the relative cost of production with the bacterial production system compared to the transgenic alfalfa and goat production systems. The comparisons show two important things. For all systems the key factor in the final price is the amount of spider silk protein produced for whatever measure of volume or weight is used. Second alfalfa can be the cheapest but is subject to the possible regulatory control unless the US develops a more comprehensive approach to GMOs. The silkworm analysis was not completed due to a variety of confounding factors. The primary one was that if the production were shifted overseas then the cost would likely be nearly equivalent to current silk prices of $5-15/kg. However if concerns about the location of production is important then it would need to be done in the US and initial costs would be much higher but if the later scenario is utilized then the cost would be lowered but it was not possible to calculate exact costs.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Magnesium Diboride thin Films, multilayers, and coatings for SRF cavities

Superconducting radio frequency (SRF) cavities currently use low-temperature superconductor niobium, and the Nb SRF cavities have approached the performance levels predicted theoretically. Compared to Nb, MgB 2 becomes superconducting at a much higher temperature and promises a better RF performance in terms of higher quality factor Q and higher acceleration capability. An MgB 2 SRF technology can significantly reduce the operating costs of particle accelerators when these potentials are realized. This project aimed to advance the development of an MgB 2 SRF technology. It had two main objectives: (1) materials issues of MgB 2 thin films and multilayers related to their applications in SRF cavities; and (2) coating single-cell cavities for testing at RF frequencies. The key technical thrust of the project is the deposition of high quality clean MgB 2 films and coatings by the hybrid physical-chemical vapor deposition (HPCVD) technique, which was developed in my group. We have achieved technical progress in each of the two areas. For the first objective, we have confirmed that MgB 2 thin film coatings can be used to effectively enhance the vortex penetration field of an SRF cavity. A vortex is a normal region in the shape of spaghetti that threads through a superconductor. Its existence is due to an applied magnetic field that is greater than a so-called lower critical field, H c1 . Once a vortex enters the superconductor, its movement leads to loss. This has been shown to be the reason for an SRF cavity to break down. Thus, enhancing the magnetic field for a vortex to enter the superconductor that forms the SRF cavity has be a goal of intense research. To this end, Gurevich proposed that a coating of thin superconductor layer can impede the vortex entrance. In this project, we have done two important experiment to test this concept. One, we showed that the enhancement of H c1 can be achieved by using in both epitaxial and polycrystalline MgB 2 films. Although H c1 is low for bulk MgB 2 samples, about 600 Oe at 5 K, it increases with decreasing film thickness, reaching 1880 Oe when the film thickness is 100 nm. Two, we coated Nb ellipsoids with MgB 2 films to achieve an “inverse cavity” configuration, mimicking the coating of an actual RF cavity. Our results demonstrate that it is indeed possible to increase the vortex penetration field of a cavity by a substantial amount (~600 Oe) by coating it with a thin MgB 2 film. For the second objective, we modified the existing HPCVD system to be able to coat a 3.9 GHz SRF cavity, and using a stainless steel mock cavity showed that a uniform film with good superconducting property can be grown across the cavity interior. Further, we successfully deposited MgB 2 on Cu disc. The two results combined demonstrate that it is possible to coat Cu cavities with high quality MgB 2 films using HPCVD. MgB 2 coated Cu could open up a possibility of using SRF cavities at 20–25 K with cryocoolers.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effects of Laser Etching on the Corrosion Susceptibility of SAVY 4000 and Hagan Containers

Since the late 1990’s, the Hagan container was used as the primary container for packaging of plutonium-bearing materials. The Hagan design consisted of a threaded closure, a Viton® ORing, a carbon-carbon filter, and a 304L stainless steel (SS) body. Over the years, Hagans have shown vulnerability in their design [1]. In 2008, The Department of Energy (DOE) issued DOE M 441.1-1, Nuclear Material Packaging Manual, which detailed an approach to obtain highconfidence in containers by including specific design requirements, material contents and an approach to determine life span from said contents, and surveillance techniques [2]. In response to both the vulnerability issues with the Hagan and DOE M 441.1-1, the SAVY 4000 container with its twist style closure, Viton® O-Ring, Fiberfrax-Gortex filter, and annealed 316L SS body, was designed as the replacement for Hagan containers, but only for a short term lifespan of 5 years [1]. However, both the Hagan and SAVY 4000 are being pushed to maintain a lifespan of 40 years. Therefore, proper confidence must be placed on each component of each container to last a minimum of 40 years. So far, the biggest concern found during surveillance of these containers is corrosion and the potential for failure by corrosion. One concern is that the containers fail due to stress corrosion cracking (SCC), especially around the weld between the collar and the body as welds leave residual stresses. One advantage the SAVY 4000 has is that the body is annealed, but its weld is still susceptible as it was welded after annealing [3, 4]. Moreover, 316L SS is known to have a higher pitting resistance (pits are a precursor to SCC and can also lead to extensive failure of the material), than 304L SS [4]. During recent surveillance activities, two SAVY 4000’s containing Solution Assay Instrument (SAI) solutions were opened. The SAI SAVY 4000’s contained plutonium (Pu) in 3M HCl solution in plastic volumetric flasks placed inside of polyethylene bags. Historically, a SAVY 4000 containing an SAI solution is packaged for 3 weeks, however, these particular containers were not reopened until 14 months later. When opened, brown-red corrosion product was found all over the inside of the container as shown in Figure 1.

36 MATERIALS SCIENCE↗