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DOE OSTI2025

What Is a Polyolefin? A Critical Overview of Ethylene Copolymers Used as Solar Photovoltaic Module Encapsulants

In recent years, photovoltaic (PV) encapsulant films marketed as polyolefins (POs), more specifically as PO elastomers (POEs) and thermoplastic POs (TPOs), have gained significant market share and are projected to become the dominant encapsulation films by 2030. Relative to other industries, there are significant misconceptions about the term PO in the PV industry. Both in the scientific literature as well as in sales and advertising, the terms PO, POE, and TPO are often misused to describe the same type of material with comparable properties, while in reality these may each consist of separate material classes. This paper provides a comprehensive literature and market review, to showcase a broad range of PO and other ethylene copolymer encapsulants from recent studies, and discusses the materials' properties to clarify what constitutes a “polyolefin.” In addition, to promote a clearer comparison of encapsulant properties, we propose a two‐dimensional taxonomy to categorize polymers used in module manufacturing, including POs. In terms of improving the reliability of solar PV modules, PO‐based encapsulants have several advantages (including lower water uptake and ion diffusion), but might come with disadvantages too, such as a more complex processing and a higher sensitivity to the storage conditions and shelf life. All this might prospectively impact adhesion properties of the encapsulant to other materials' interfaces (glass, cells etc.) and end‐product quality. Because the track record of field‐deployed PV modules containing PO encapsulants is also limited, we hope to contribute to better material understanding and precision in communication in PV to secure quality.

14 SOLAR ENERGY↗

DOE OSTI2021

Geolocated dataset of Chinese overseas development finance

China is now the world's largest source of bilateral development finance and will likely continue to play a prominent role in sovereign lending through its multi-billion-dollar Belt and Road Initiative. This paper introduces major methodological enhancements in tracking this finance: the use of an original application programming interface (API) to gathers news in multiple languages; double verification of every record to ensure every finance commitment has been formalized; and visual geo-location to trace the precise footprint of every project. The resulting dataset enables economic, environmental, and social analyses with high-precision spatial accuracy, as well as spatiotemporal monitoring by project stakeholders and enhanced planning by project managers. It covers the years 2008-2019 to enable analysis before and after the announcement of the Belt and Road Initiative. It includes 862 finance commitments, 669 of which have geographic location, to 94 countries across the world.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

FEgen (v.1): Field Emission Distribution Generator Freeware Based on Fowler–Nordheim Equation

This work presents an open-source code, FEgen, that generates initial field emission distributions based on the time-dependent Fowler–Nordheim equation. Current in-demand and open-source beam tracking software—such as ASTRA, IMPACT-T, and GPT—do not contain native distribution generator functions suitable for field emitted electron tracking and phase space analysis. Furthermore, the intuitive graphical user interface of FEgen generates input files shown to be fully compatible with both ASTRA and GPT. Here, detailed application examples demonstrating a subset of FEgen’s capabilities are given by creating a customized emitter pattern with application to transverse beam shaping and longitudinal beam dynamic experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Employing Eye Trackers to Reduce Nuisance Alarms

When process operators anticipate an alarm prior to its annunciation, that alarm loses information value and becomes a nuisance. This study investigated using eye trackers to measure and adjust the salience of alarms with three methods of gaze-based acknowledgement (GBA) of alarms that estimate operator anticipation. When these methods detected possible alarm anticipation, the alarm’s audio and visual salience was reduced. A total of 24 engineering students (male = 14, female = 10) aged between 18 and 45 were recruited to predict alarms and control a process parameter in three scenario types (parameter near threshold, trending, or fluctuating). The study evaluated whether behaviors of the monitored parameter affected how frequently the three GBA methods were utilized and whether reducing alarm salience improved control task performance. The results did not show significant task improvement with any GBA methods (F(3,69) = 1.357, p = 0.263, partial η 2 = 0.056). However, the scenario type affected which GBA method was more utilized (X 2 (2, N = 432) = 30.147, p < 0.001). Alarm prediction hits with gaze-based acknowledgements coincided more frequently than alarm prediction hits without gaze-based acknowledgements (X 2 (1, N = 432) = 23.802, p < 0.001, OR = 3.877, 95% CI 2.25–6.68, p < 0.05). Participant ratings indicated an overall preference for the three GBA methods over a standard alarm design (F(3,63) = 3.745, p = 0.015, partial η 2 = 0.151). This study provides empirical evidence for the potential of eye tracking in alarm management but highlights the need for additional research to increase validity for inferring alarm anticipation.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Systems Innovation: Modernization & Efficiencies for ESH&Q Reviews

Environmental compliance reviews at INL have traditionally been managed through fragmented systems, relying on multiple spreadsheets and manual processes. This inefficiency led to time-consuming status updates and redundant tasks, such as manually sending reminder emails and transferring data from Excel to the Environmental Review Process (ERP). Initial attempts to streamline these processes using Power Automate and Excel revealed significant limitations, necessitating a more comprehensive solution. To address these immediate inefficiencies, automated workflows were developed using Power Automate. These workflows were designed to send scheduled status update reminders and capture responses through standardized forms, with submitted data flowing directly into centralized Excel trackers. This automation reduced the administrative burden, improved data accuracy, and enabled faster, more consistent reporting. Specifically, email automation achieved a 65% efficiency gain, while data integration saw a 48% improvement, resulting in 91% of project statuses being updated within two months. Despite the improvements brought by Power Automate, the fragmented nature of the review processes persisted. To further enhance efficiency and accuracy, the Integrated Review Tool (IRT) was developed. The IRT aims to centralize review initiation and connect team systems, creating an interconnected data infrastructure that preserves team autonomy while enhancing overall efficiency. This tool automates email reminders, centralizes reviews, and streamlines data integration, significantly improving the accuracy and efficiency of environmental compliance reviews. The design and development of the IRT involved advanced systems methodology, process mapping, project management, and collaboration with subject matter experts. The minimum viable product design is 100% complete, and system development is currently underway, with expected outcomes including a centralized entry point for all ESH&Q reviews, automated routing, real-time tracking and analytics, AI integration, and a user-friendly interface. This project demonstrates the potential of leveraging automation and integrated systems to enhance efficiency, accuracy, and decision-making in environmental reporting and compliance processes at INL.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2017

Simulating Bubble Deformations Using the Intersection Marker (ISM) Front-Tracking method

Surface and volume tracking methods have been under continuous development over the last 50+ years since the first MAC (Marker and Cell) and SLIC (Simple Line Interface Calculation) methods appeared in the 1960's. The sustained interest in simulating multiphase flow stem from their many practical applications in the physical world; from biological systems, to chemical systems, to boiling dynamics and atmospheric heat and mass transfer. The ability to capture the details of interface evolution as well as the physics of interfacial heat and mass transfer has thus been a tempting goal for many numerical researchers. Numerical analysts, apart from the well-established and popular VOF PLIC (Volume of Fluid, Piecewise Linear Interface Construction) method, can now call upon even more computationally intensive options such as the LS (Level Set) method, the FT (Front Tracking) method, the MoF (Moment of Fluid) method and hybrid methods.

42 ENGINEERING↗

DOE OSTI2021

Meshfree simulation and experimental validation of extreme thermomechanical conditions in friction stir extrusion

Abstract Friction stir extrusion (FSE) is a novel solid-phase processing technique that consolidates and extrudes metal powders, flakes, chips, or billets into high-performance parts by plastic deformation, which has the potential to save substantial processing time and energy. Currently, most studies on FSE are experimental and only a few numerical models have been developed to explain and predict the complex physics of the process. In this work, a meshfree simulation framework based on smoothed particle hydrodynamics (SPH) was developed for FSE. Unlike traditional grid-based methods, SPH is a Lagrangian particle-based method that can handle severe material deformations, capture moving interfaces and surfaces, and monitor the field variable histories explicitly without complicated tracking schemes. These aspects of SPH make it attractive for the FSE process, where in situ evolution of field variables is difficult to observe experimentally. To this end, a 3-D, fully thermomechanically coupled SPH model was developed to simulate the FSE of aluminum wires. The developed model was thoroughly validated by comparing the numerically predicted material flow, strain, temperature history, and extrusion force with experimental results for a certain set of process parameters. The validated SPH model can serve as an effective tool to predict and better understand the extreme thermomechanical conditions during the FSE process.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Modeling the Impact of Grain Size on Corrosion Behavior of Ni-Based Alloys in Molten Chloride Salt via Cellular Automata

Molten chloride salts hold significant promise as both thermal transfer and storage media for next-generation concentrated solar power (CSP) systems. However, molten chlorides pose a considerable corrosion risk to structural materials, particularly Ni-based alloys. One approach to enhancing corrosion resistance is through the optimization of grain structure; however, it remains uncertain whether increasing or decreasing grain size enhances corrosion resistance. A cellular automata (CA) program was developed to evaluate the interplay between grain size and corrosion in Ni-based alloy. Our CA program tracks alloy composition, surface roughness, and thickness loss via a graphical user interface, displaying corrosion and diffusion status, and multiple user input cards for tuning the simulation. CA simulations of Inconel 625 indicate enhanced corrosion resistance with increased grain size, with passivating oxides offering limited protection. Additionally, the temporal evolution of alloy surface roughness demonstrates notable fluctuations, with abrupt increases attributed to corrosion along vertical grain boundaries and sudden decreases to grain detachment from the protective film.

Materials Science↗

DOE OSTI2017

Fitness Tracker for Weight Lifting Style Workouts

This document proposes an early, high level design for a fitness tracking system which can automatically log weight lifting style workouts. The system will provide an easy to use interface both physically through the use of several wireless wristband style motion trackers worn on the limbs, and graphically through a smartphone application. Exercise classification will be accomplished by calibration of the user’s specific motions. The system will accurately track a user’s workout, miscounting no more than one repetition in every 20, have sufficient battery life to last several hours, work with existing smartphones and have a cost similar to those of current fitness tracking devices. This document presents the mission background, current state-of-theart, stakeholders and their expectations, the proposed system’s context and concepts, implementation concepts, system requirements, first sublevel function decomposition, possible risks for the system, and a reflection on the design process.

42 ENGINEERING↗

DOE OSTI2018

Enhancement of Eye Tracking for Highly Dynamic Displays

Eye-Tracking and Sandia have established a collaborative arrangement whereby the two entities worked in a no-funds arrangement to study and share information about interface, software and algorithmic capabilities for dynamic, user-driven workflows. Sandia researchers developed the GazeAppraise algorithm for analysis of so-called “smooth pursuit” eye tracking datasets and used Eye Tracking, Inc’s experimental tasks and data to evaluate algorithmic performance. Although the results were quite positive, the partners ultimately decided it did not fit Eye Tracking’s market niche, and Sandia is pursuing opensource alternatives for disseminating the Gaze Appraise algorithms.

McNamara, Laura A.↗

DOE OSTI2018

Energy Efficiency and Infrastructure Upgrades on Nuclear Clean-up Sites: The Hanford Experience - 18641

The Hanford site, located in southeastern Washington, produced much of our nation's weapons-grade plutonium for the Defense nuclear weapons program. This production lasted the better part of four decades with production ending in 1987. Since 1987, the focus of the Hanford site has turned to clean-up activities. Mission Support Alliance (MSA) is the integrator of the multi-contractor effort to clean up the Hanford site. MSA collaborates with the U.S. Department of Energy (DOE) and all Hanford site contractors in finding and implementing new, cost-saving, safe and practical solutions to cleanup challenges with a continual focus on innovative processes and technologies that reduce costs, energy use and bring safety improvements to the site. Support Services include environmental integration and land management; fleet and road maintenance; water/electric and utilities; cyber security and information management as well as the preservation of the site's cultural artifacts. This paper describes the process, challenges, and focus on infrastructure upgrade and energy efficiency projects in the context of a multi-contractor nuclear clean-up site. Project development and new technology deployment at Hanford has long been plagued with economic challenges. For example, despite extensive auditing, analysis, and project development, most of the energy-related projects on the Hanford site have gone unfunded due to the low cost of electricity, the relatively high cost of labor, and costs associated with detailed safety and cultural reviews. - The Hanford site is a direct-service customer of the Bonneville Power Administration (BPA) and has a marginal electricity rate of $0.033/kWh. - Labor costs on the Hanford site track high because of the requirements associated with the safety and security necessary to operate a legacy nuclear weapons complex. - In partnership with three federally recognized and other affected Native American tribes (Yakama Nation, Confederated Tribes of the Umatilla Indian Reservation, the Nez Perce Tribe, and Wanapum People), most activities on the Hanford site are afforded in-depth cultural reviews. To work within these constraints, the MSA Energy Management team has embarked on a three-pronged approach to energy project development: Program Visibility: The MSA Energy Management team has promoted both project opportunities and requirements across the Hanford site. This information comes in the form of site-wide newsletters, group meetings, e-mails, success stories, and recognition of staff. Single-point Analysis: To by-pass the inevitable duplications of effort, learning curve issues, and to improve project consistency/delivery, the MSA Energy Management team serves as the single resource to the site for energy project analysis. This resource includes initial assessment, engineering analysis, efficiency calculation and project recommendations. Contractor/utility Interface: In addition to the infrastructure under its own purview, MSA provides all support services for the contractor/utility interface. These activities include formulation and submission of incentive-based efficiency projects, project tracking, and incentive awards. All incentive awards are forwarded to the relevant contractor and then highlighted in the visibility campaign. Successful energy efficiency projects at Hanford have included high efficiency heating, ventilation, air conditioning (HVAC) systems, interior and exterior lighting/lighting control systems, pump and motor systems, and the right-sizing of transformers and area-wide electrical distribution systems. Prior to the initiation of this program and structure (roughly 3 years ago) the average annual energy efficiency incentive applied for and received was under $10,000, with an annual energy savings of approximately 36,000 kilowatt hours (kWh). In fiscal year 2017, the annual incentive received was over $419,000, with identified energy savings of over 1.3 million kWh. Details and case studies of the major project accomplishments are included. The success of this program can be traced to an understanding of the constraints, the development of a program to address these constraints, and good communication/coordination across DOE and the multiple contractors serving the Hanford site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Design of a supervisory control system for autonomous operation of advanced reactors

Advanced reactors to be deployed in the coming decades will face deregulated energy markets, and may adopt flexible operation to boost profitability. To aid in the transition from baseload to flexible operation paradigm, autonomous operation is sought. This work focuses on the control aspect of autonomous operation. Specifically, a hierarchical control system is designed to support constraint enforcement during routine operational transients. Within the system, data-driven modeling, physics-based state observation, and classical control algorithms are integrated to provide an adaptable and robust solution. A 320 MW Fluoride-cooled High-temperature Pebble-bed Reactor is the design basis for demonstrating the proposed control system. The hierarchical control system consists of a supervisory layer and low-level layer. The supervisory layer receives requests to change the system's operating conditions (e.g., the current reactor power to meet a load -follow), and accepts or rejects them based on constraints that have been assigned. Constraints are issued to keep the plant within an optimal operating region. The low-level layer interfaces with the actuators of the system to fulfill requested changes, while maintaining tracking and regulation duties. Further, to accept requests at the supervisory layer, the Reference Governor algorithm was adopted. To model the dynamics of the reactor, a system identification algorithm, Dynamic Mode Decomposition, was utilized. To estimate the evolution of process variables that cannot be directly measured (e.g., the propagation of delayed neutron precursors), the Unscented Kalman Filter, incorporating a nonlinear model of nuclear dynamics, was adopted. The composition of these algorithms led to a numerical demonstration of constraint enforcement during a 40% power drop transient (at a rate of 5 %/min). Uncontrolled secondary-side temperatures were successfully constrained. Adaptability of the proposed system was demonstrated by modifying the constraint values, and enforcing them during the transient. Robustness was also demonstrated by enforcing constraints under noisy environments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

An automated fast neutron computed tomography instrument with on-line focusing for non-destructive evaluation

A fast neutron tomography imaging instrument has been designed, built, and tested at The Ohio State University 500 kW Research Reactor on a fast neutron beamline with a peak neutron flux ≈5.4 × 107 n·cm−2·s−1 at 1.6 MeV median neutron energy. The instrument and beamline are also configurable for thermal neutron imaging. The imaging apparatus is composed of a lens coupled, water-cooled Electron Multiplying Charge Coupled Device camera, a front-surface mirror, and a high light yield plastic Polyvinyl toluene scintillator. The instrument sits on a mobile cart. A total of 5 motion-control stages are built into the system for XYZ and rotational degrees of freedom for sample positioning; the fifth stage fine tunes the focal distance between the camera and the scintillator to achieve on-line focusing. A Python code with a user-friendly graphical user interface controls the fully automated image acquisition, not requiring user interaction, yet facilitating tracking of the image acquisition. A complete fast neutron computed tomography dataset with 360 projections requires less than 3 h, with 30 s per projection. On-line focusing is accomplished with a commercial, off-the-shelf, dielectrically actuated liquid lens. Finally, tomographic reconstructions are visualized using the Livermore Tomography Tools software package. The effective pixel size (width and height) is ≈0.1058 mm, yielding a minimum voxel size of 0.1058 × 0.1058 × 0.1058 mm3, and produces a spatial resolution of 231 μm when calculated from knife-edge measurements.

Bisbee, M. G. (ORCID:0000000313466697)↗

DOE OSTI2022

NIRP Core Software Suite v.5.1

SAND2023-06610O The Nuclear Incident Response Program (NIRP) Core Software Suite is a set of code that supports multiple applications. It includes miscellaneous base code for data objects, mathematic equations, and user interface components that are used for developing large applications, including those used for data management. Among the types of applications: • Analyst Manager is used for managing contact information, which is also often included in reports and identifies the owners of calculations. • Radionuclide Viewer provides access to the Dose Coefficient File Package (DCFPAK) radiological data, and it complements the Mixture Manager tool. • Mixture Manager creates and manages radionuclides mixtures that are commonly used in other applications. • High Explosive Manager manages explosives and properties. • Chart Viewer is used for data charts such as meteorology charts and other charts specific to data needs. • Unit Converter converts numeric values to/from different units. This package includes object-oriented base code such as data objects describing the date, time, and location of an event; weather conditions; data types that support predefined ranges of values; a unit library, and others. The package also includes mathematic equations such as determining the distance between two points; erf functions; factorial functions; incidence fractions of probit curves; and others. Other features are customized user interface components for text fields; unit selectors (combo boxes); menus; panels; bug-tracking; and automated checks for software updates. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Collins, Ian↗

DOE OSTI2018

Quantifying the Contribution of Individual Display Features on Mental Workload to Support Human-System Interface Design in Nuclear Power Plants

Abstract. The integration of new digital instrumentation and control (I&C) technologies like advanced human-system interfaces in U.S. nuclear power plant main control rooms is important for addressing long-term aging and obsolescence of existing I&C. Nonetheless, attention should be made to ensure these technologies reflect state-of-the-art human factors engineering (HFE) principles. Often, there is conflicting guidance from one guideline to another, requiring the analyst to make a judgment call on addressing these 'tradeoffs.' The objective of this research was to inform the analyst of these tradeoffs through an empirical investigation of how certain display features that characterize common HFE guidelines concerning visual clutter and saliency influence information processing in a naturalistic context. By understanding the unique contribution of each display feature using a multilevel model, the HFE analyst should have an understanding of the interrelations of each feature with its impact on cognitive processes. Results and implications are discussed in this paper.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

A Discrete Dendrite Dynamics Model for Epitaxial Columnar Grain Growth in Metal Additive Manufacturing with Application to Inconel

Epitaxial columnar grain growth is a prevalent microstructural feature in the additive manufacturing (AM) of metal components such as Inconel, with cubic unit cell crystal lattice structure (face centered cubic (FCC) or body centered cubic (BCC)). These columnar grains evolve from the partly molten grains in the substrate or the solidified metal. This work proposes an efficient model to simulate the competitive growth of epitaxial columnar dendritic grains. The proposed model tracks the dynamic changes in the dendrites emanating from discrete points along the solid/liquid interface of a quasi-steady melt pool (MP). These dynamic changes include convergence and divergence of growing dendrites. The model is extended to predict the microstructure of large 3D parts and experimentally validated by comparing the simulation results for laser powder bed fusion (L-PBF) and wire-arc additive manufacturing (WAAM) processes. The microstructure and pole figures are predicted for Inconel 718 samples produced by L-PBF and Inconel 740H samples produced by WAAM processes. Finally, the model predictions compare well with the observed microstructure and pole figures results for both the L-PBF and WAAM processes.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Battery Lifecycle Framework

The Battery Lifecycle (BLC) Framework is an open-source platform that provides tools to visualize and share battery data from material characterization, cell testing, manufacturing, and field testing through the technology development cycle. BLC has three components: data importers, a front-end for querying the data and creating visualizations, and an application programming interface to provide access to the data from Python. BLC has been deployed for tracking the development of a battery from the lab to a manufacturing line and systems installed in the field and for comparing studies of multiple cells of the same battery chemistry and configuration. The code was developed around Redash, a robust open-source extract-transform-load engine. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-4546 O

De Angelis, Valerio↗

DOE OSTI2025

Graphene oxide gluing layer enabling macroscale tribology applications of pristine graphene

In recent studies of two-dimensional (2D) nanomaterial-based solid lubricants, the importance of durability has been emerging for real engineering-scale applications. To achieve this, a transfer layer formation is essential to prevent the wear of the mechanical systems. However, it has been challenging for pristine graphene (PG) to induce a material transfer due to chemical inertness. In this study, we suggest an easy-to-process strategy to promote the huge material transfer of the PG onto the counterpart contacting material. We utilized graphene oxide (GO) as a gluing layer between the PG film and the counterpart contact surface to realize the superior tribological performance. The high interaction energy of the GO from its functional groups makes a contribution to the material transfer of PG, which is unveiled by a systematic analysis of the counterpart contact surface and the wear track. The huge solid transfer layer not only makes a wear-resistant contact interface between the transfer layer and the underlying film by densification and oxidation, but also reduces surface interaction energies, finally resulting in a significant improvement in durability.

graphene oxide (GO)↗