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At least 127 records · Page 7

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DOE OSTI2022

Full-scale Demonstration of Multi-process Sensor at a Cycling PC-fired Boiler

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2020

Posiva's Onkalo{sup R} FST (Full-Scale In Situ System Test) - 20051

The FST - Full-scale In Situ System Test - is a unique full-scale demonstration of disposal system in crystalline host rock. The FST was constructed in ONKALO{sup R} demonstration area at the disposal depth of 420 metres, in Posiva's actual final disposal facility at Olkiluoto, Finland. The demonstration has included design, manufacture, installation and comprehensive instrumentation for monitoring the evolution of the disposal system and its components. The demonstration tunnel and experimental deposition holes were excavated in 2010 in ONKALO to address that they can be excavated to meet the requirements set for them. Two experimental deposition holes, bored in the floor of the tunnel, host each a canister surrounded by bentonite clay buffer rings/segments in the holes. Inside the canisters are heating elements to simulate decay heat emitted by spent fuel. The tunnel part used for the test is about 50 m long and it was filled with bentonite clay backfill after the installation of the canisters and buffer components. The tunnel is closed with a steel-reinforced concrete plug. The test is equipped with 500 sensors to monitor early evolution of the system. To forecast the evolution of the system, a mathematical model has been created. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Design, construction, and test of the Gas Pixel Detectors for the IXPE mission

Due to be launched in late 2021, the Imaging X-ray Polarimetry Explorer (IXPE) is a NASA Small Explorer mission designed to perform polarization measurements in the 2–8 keV band, complemented with imaging, spectroscopy and timing capabilities. At the heart of the focal plane is a set of three polarization-sensitive Gas Pixel Detectors (GPD), each based on a custom ASIC acting as a charge-collecting anode. In this paper we shall review the design, manufacturing, and test of the IXPE focal-plane detectors, with particular emphasis on the connection between the science drivers, the performance metrics and the operational aspects. We shall present a thorough characterization of the GPDs in terms of effective noise, trigger efficiency, dead time, uniformity of response, and spectral and polarimetric performance. In addition, we shall discuss in detail a number of instrumental effects that are relevant for high-level science analysis—particularly as far as the response to unpolarized radiation and the stability in time are concerned.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

A method and tool to determine the colorimetric and photobiological properties of light transmitted through glass and other optical materials

Here we describe a framework and provides a computational tool to characterize the color quality and biological potential of light that is transmitted through glass and other optical materials. The IES TM-30 framework and Excel computation tool were adapted to evaluate color quality, with measures from CIE S 026, UL 24480, and the WELL Building Standard v2 added to evaluate biological potential. The user selects a pre-transmittance spectral power distribution (SPD), such as for a CIE D-Series Illuminant, Planckian radiation, electric lamp, or measurement of daylight at a building site. The tool allows a user to populate a database with spectral data for glazing or other optical materials, comprising spectral transmission and the spectral reflectance of both sides. The user creates a unit with one, two, or three panes of glazing or other optical materials, and the tool calculates the composite spectral transmittance accounting for reflections between materials. The tool computes the transmitted SPD, then determines colorimetric and photobiological outputs using the transmitted SPD as the test source. Glass, window, and skylight manufacturers can employ the tool to optimize glazing spectral transmission to achieve intentional colorimetric and photobiological performance with transmitted light. Electric lighting manufacturers, designers, and researchers can use the tool to evaluate the impact of glazing units and other optical materials on the color quality and biological potential of transmitted light.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Quest for environmentally sustainable materials: A case for animal-based fillers and fibers in polymeric biocomposites

This review explores the potential of animal-based fillers and fibers as eco-friendly alternatives to conventional synthetic ones. Examining materials such as wool, silk, feather, hair and beak, the review elucidates their chemistry, structure, properties and sources, emphasizing biodegradability and renewability. It also discusses the compatibility of these materials with polymer matrices and their mechanical, acoustic and thermal performances. Further, the review critically analyzes environmental and ethical implications, presenting challenges and opportunities in the emerging field. By addressing ecological and performance aspects, it contributes to global efforts in fostering sustainability in materials science. Future research to address gaps and enhance the design, manufacture and application of animal-based reinforcements in various industries are clearly outlined at the end of the review.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Mechanically induced thermal runaway severity analysis for Li-ion batteries

Thermal runaway is one of the most important safety concerns in the deployment of Li-ion batteries. For this study, we developed a standardized single-side indentation test protocol to induce an internal short-circuit. Cell voltage, temperature, and applied compressive force are monitored as a function of time. Each cell is given an observed hazard severity (OHS in five categories) modified from the EUCAR table. Meanwhile a calculated hazard severity (CHS) is obtained solely based on temperature and voltage curves. The calculation formula considers the cell temperature, rate of temperature increase, cell capacity, state of charge (SOC), voltage drop, and voltage drop rate. Each term is assigned with an appropriate weight to scale the calculated score from 0 to100. This method was applied to >100 Li-ion batteries with various SOCs and chemistries, and their OHS and CHS were displayed against SOC. The purpose is to provide battery designers, manufacturers, and end-users a clear comparison of thermal runaway severity of different batteries.

25 ENERGY STORAGE↗

DOE OSTI2023

A study of examiner accuracy in cartridge case comparisons. Part 1: Examiner error rates

This report describes a study undertaken to estimate examiner (not laboratory) error rates for false Identifications and false Eliminations when comparing an unknown to a collection of three known cartridge cases. Volunteer active examiners with Association of Firearm and Toolmark Examiners (AFTE) membership or working in laboratories that participate in the Association of Crime Laboratory Directors (ASCLD) were provided with 15 sets of three known and one questioned cartridge cases fired from a collection of 25 new Ruger SR9 handguns. Remington 9-mm Luger (manufacturer designation L9MM3) ammunition was used and comparison sets were made up of cartridge cases fired within 100 cartridges of each other for each gun. Examiners were provided with a background survey, an answer sheet allowing for the AFTE Range of Conclusions, and return shipping materials. In addition to determining whether the known and questioned cartridge cases were fired with the same handgun, examiners were also asked to assess how many of the three knowns in each set were suitable for comparison, providing an estimated rate of how often each firearm used in the study produces useable, quality marks. The participating examiners were provided with both same-source and different-source comparison sets allowing the study to assess both error rates. Responses were received from 218 participating examiners. The overall rate of false Eliminations was estimated as 0.367% from comparisons known to be from the same firearm but reported as Eliminations. The overall rate of false Identifications was estimated as 1.01% from comparisons known to be from different firearms but reported as Identifications. The rates are not uniform across the sample population with a few examiners providing most of the false Identification responses. Rates of poor-quality mark production varied across the 25 sample handguns; those rates were 2.3% (±1.4%). Both false Elimination and false Identification rates are comparable to or lower than the rate of production of poor-quality marks by the firearms used in this study.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

A study of examiner accuracy in cartridge case comparisons. Part 2: Examiner use of the AFTE range of conclusions

Here, this report describes an analysis of how examiners used the Association of Firearm and Toolmark Examiners (AFTE) Range of Conclusions in a controlled study undertaken to estimate examiner error rates in comparing cartridge cases. Results of the error rate analysis are reported in [1]; this paper focuses on a broader analysis of how the entire collection of classification categories, especially those in the Inconclusive range, were used by the participating examiners. Volunteer active examiners with AFTE membership or working in laboratories that participate in Association of Crime Laboratory Directors (ASCLD) were provided with 15 sets of three known and one questioned cartridge cases fired from a collection of 25 new Ruger SR9 handguns. Remington 9-mm Luger (manufacturer designation L9MM3) ammunition was used and comparison sets were made up of cartridge cases fired within 100 cartridges of each other for each gun. Examiners were provided with a background survey, an answer sheet allowing for the AFTE Range of Conclusions, and return shipping materials. The participating examiners were provided with both same-source and different-source comparison sets allowing the study to assess both error rates. Responses were received from 218 participating examiners. The overall rate of false-negatives was estimated as 0.367 % from comparisons known to be from the same firearm but reported as eliminations. The overall rate of false-positives was estimated as 1.01 % from comparisons known to be from different firearms but reported as identifications. In the case of true different-source examinations, it is clear that the three Inconclusive categories and the Elimination category are not used consistently by all examiners. We identify five different apparent patterns of use of the AFTE Range of Conclusions scale, and discuss possible reasons for and implications of these differences.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

A snapshot of high-entropy alloy processing techniques and their effects on resulting mechanical properties

High-entropy alloys (HEAs) exhibit exceptional strength, corrosion resistance, and thermal stability, making them promising candidates for nuclear, aerospace, and other extreme applications. While most prior work has focused on compositional design, manufacturing techniques themselves can alter microstructure and mechanical properties as dramatically as alloy chemistry. This review compiles and compares the effects of processing routes—including arc melting, induction melting, mechanical alloying with spark plasma sintering, and additive manufacturing—on the structure and properties of HEAs. Quantitative comparisons highlight, for example, that SPS-processed alloys can achieve ∼20–45 % higher yield and tensile strength than arc-melted counterparts, while Bridgman solidification produces nearly single-crystal structures with elongation to failure exceeding 80 %. Additive manufacturing routes such as selective laser melting offer fine microstructures but also introduce anisotropy and porosity, leading to yield strengths spanning 100–600 MPa for the same composition. By synthesizing such results, this review provides actionable insight into how processing routes interact with HEA core effects (high entropy, lattice distortion, sluggish diffusion, and cocktail effect) to determine performance, thereby offering a practical guide for optimizing manufacturing strategies.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Design and development of the magnetic diagnostic systems for the first operational phase of the SMART tokamak

A set of magnetic diagnostics has been designed, manufactured, and calibrated for the first operational phase of the small aspect ratio tokamak. The sensor suite comprises of Rogowski coils; 2D magnetic probes; and poloidal, saddle, and diamagnetic flux loops. Here, a set of continuous Rogowski coils has been manufactured for the measurement of plasma current and induced eddy currents in conductive elements. A set of flux loops and magnetic probes will be used as input for the reconstruction of the magnetohydrodynamic equilibrium. The quantity and position of these sensors have been verified to be sufficient with synthetic equilibrium reconstructions using the equilibrium fitting code and baseline scenarios computed with the Fiesta code. These sensors will also be used as input for the real-time control system, and magnetic probes will be used for the detection of plasma instabilities. The calibration procedure for the magnetic probes is described, and the results are shown. The signal conditioning and data acquisition systems are described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Construction of precision wire readout planes for the Short-Baseline Near Detector (SBND)

The Short-Baseline Near Detector time projection chamber is unique in the design of its charge readout planes. These anode plane assemblies (APAs) have been fabricated and assembled to meet strict accuracy and precision requirements: wire spacing of 3 mm ± 0.5 mm and wire tension of 7 N ± 1 N across 3,964 wires per APA, and flatness within 0.5 mm over the 4 m × 2.5 m extent of each APA . Here, we describe the design, manufacture and assembly of these key detector components, with a focus on the quality assurance at each stage.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

New Roadmap for Microelectronics: Charting the Semiconductor Industry's Path Over the Next 5, 10, and 20 Years

In the past, the role of strategic planning for semiconductor industry was met by the International Technology Roadmap for Semiconductors (ITRS), serving as a guiding light that provided manufacturers, designers, equipment suppliers, and researchers with direction years in advance. By providing a common framework for coordination across semiconductor industry stakeholders, technology development efforts were efficient and aligned. However, the dissolution of the ITRS in 2015 left a void, leading to years of disjointed efforts. Recognizing the need for unified guidance, the industry rallied for the creation of a new strategic plan, the Microelectronics and Advanced Packaging Technologies (MAPT) Roadmap (2023) was developed, through the efforts of hundreds of industry, academic and government experts, to provide detailed strategies for achieving these goals. This comprehensive plan outlines ambitious goals for the industry's future.

HPC, Roadmap, AI, Liquid Cooling, Power, Silicon, ↗

DOE OSTI2024

Surrogate Distributed Radiological Sources—Part II: Aerial Measurement Campaign

In this second part of a multipaper series, we present results from outdoor aerial measurements of surrogate distributed gamma-ray sources. Here we detail the design, manufacture, and testing of 300 individual ~7 mCi Cu-64 sealed sources at the Washington State University (WSU) research reactor and their deployment in various source patterns (each comprising up to 100 point sources) during the aerial measurement campaign. We show the results of two such measurements, in which approximate source shapes and qualitative source intensities can be seen from the count rate versus position plots, even without performing reconstructions. We also detail our efforts in ground-truthing the deployed sources and comparing measured gamma-ray data to model predictions. In particular, we compare measured versus expected count data using the Poisson deviance formalism of Part I to evaluate whether the fielded surrogate point-source arrays “look like” their truly continuous distributed source analogs. More generally, we find that the point-source array technique provides high source placement accuracy, relative ease of quantifying the true source configuration, scalability to source dimensions of ≲100 m, ease of reconfiguration and removal, and relatively low dose to personnel. Finally, we consider potential improvements and generalizations of the point-source array technique for future measurement campaigns.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

CEA Contribution to the PIP-II Linear Accelerator

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and will deliver 10 low-beta cryomodules as In-Kind Contribution to the PIP-II project, with cavities supplied by LASA-INFN and power couplers and tuning systems supplied by Fermilab. This paper presents the CEA scope of work that includes the design, manufacturing, assembly and tests of the cryomodules and the upgrade of the existing infrastructures to the PIP-II requirements.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Top Loading Helium Cryostat Integrated with High-Pressure Cell with Fast Remote Pressure Control (Final Report for SBIR Phase 1)

A large number of physical phenomena, such as superconductivity and quantum critical phenomena, often appear only at very low temperatures below 5 K. There is an immense interest to investigate these phenomena at high pressure as a means of tuning interatomic distances, and thus the interaction parameters controlling these phenomena, in a continuous and controlled fashion. The current P-T condition for neutron scattering experiments are limited to either relatively low pressures of about 2 GPa at temperatures below 5 K, or to relatively high temperatures at pressures or tens of GPa. The purpose of this research is to develop neutron sample environment instrumentation for reaching 10-20 GPa at 1-2K with rapid and reliable online pressure and temperature control (i.e. without having to interrupt the experiment). The ultimate goal of the project is to design an integrated fast-cooling low-temperature sample environment cryogenic system compatible with state of the art neutron diamond anvil cells suitable for single-crystal neutron scattering experiments for temperatures down to 2K and pressures of several tens of GPa. The integrated system will consist of top-loading Helium flow cryostat with in-situ sample alignment mechanisms, large-volume diamond anvil cells (DAC) made from novel superalloy Pascalloy and optimized for fast cooling and heating, and a compact remote pressure control mechanism for the DAC based on a novel concept of inflatable bellows integrated with a lever-arm based force amplifier. In Phase I, we have designed, manufactured, and tested prototypes of the novel compact force-amplified pneumatic pressure control mechanism for Neutron Diamond Anvil Cell (nDAC), which allows to use pneumatic bellows system for smooth remote pressure control in the nDAC inside a top-loading cryostat with bore size of 70 mm or larger. This allows significant minimum temperature decrease in remotely controlled nDAC from 5-10 K down to 2 K. We also studied mechanical properties of a novel non-magnetic superalloy Pascalloy with different heat-treatment conditions and preliminary results indicate that up to date this is probably the strongest and most suitable material for making more compact and lightweight cryogenic nDACs for neuron scattering experiments at extreme conditions, allowing much faster cooling and heating. Potential applications: The new developments will allow to create a wide range of compact Diamond Anvil Cells for neutron diffraction which can reach several tens of GPA pressure at 2-4 K while preserving accurate remote pressure control capabilities. The new concepts can be used for developing sample environment instrumentation outside the neutron scattering field. The new development have very strong potential for expanding experimental capabilities in materials sciences and have high commercialization potential. The proposed new cryogenic high-pressure system or any of its individual components will be in high demand not only in neutron scattering facilities, but also at synchrotron beamlines and other high-pressure research facilities around the world.

36 MATERIALS SCIENCE↗

DOE OSTI2020

NNSA GenScen 2.1 Methodology

Nuclear weapons stockpile planning is a complex process. The Non-Proliferation Treaty,' New START Treaty,2 DOE/NNSA, STRATCOM, Navy, Air Force, and Executive-Branch all have objectives that drive requirements for the types and quantities of nuclear weapons, which in turn drive how nuclear weapons are designed, manufactured, tested, maintained, deployed, transported, stored, retired, and ultimately dismantled. An estimated 200 distinct individuals contribute to the development, completion, and approval of this plan. And once that plan is completed, herein called the N NSA Program of Record (POR), ensuring that the plan is feasible — that the stockpile work can get done — ensures that the Nuclear Security Enterprise (NSE) can deliver the intended nuclear force posture.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

Novel Seal Design for Effective Mitigation of Methane Emissions from Reciprocating Compressors

The objective of this project was to reduce leakage of compressor rod packing because rod packing accounts for a significant portion of leakage of compressors. To meet the objectives, the project team designed, manufactured, and tested a liquid seal in a full-scale setting to demonstrate the operability of the seal, verify the performance of components, and demonstrate the potential for producing a seal that reduces methane emissions by a minimum of 95% of 1% of the total mass flow of the compressor with minimal wear to the seal.

03 NATURAL GAS↗