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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120 C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Energy Saving Glass Lamination via Selective Radio Frequency Heating

This project focused on advancing radio-frequency (RF) lamination technology closer to commercial implementation, in order to reduce the energy intensity of glass lamination by up to 90%. Lamination comprises a wide range of products including autoglass, architectural safety and innovative design glass, transparent armor (e.g. bullet proof glass), smart glass, mirrors, and encapsulation of photovoltaics. Lamination is also the fastest growing segment of glass manufacturing, with photovoltaics, architectural needs, and an anticipated transition to laminated side windows in vehicles. The state-of-the-art for glass lamination is to use autoclaves, which apply heat and uniform gas pressure to bond the laminates over the course of 1 to 18 hours. Laminates consist of layers of glass or other materials bonded with vinyl or urethane interlayers. In autoclaving, significant heat energy is lost heating the chamber, pressurized air, glass racks, and the glass. In RF lamination, the heat is generated directly in the vinyl interlayer, causing it to heat and melt quickly, in just 1 to 10 minutes, without significantly heating the glass or the equipment. The main purpose of this project was to provide evidence that low energy, rapid RF lamination quality met the same standards as conventionally autoclaved windows. The development of concepts for laminating curved glass with RF lamination was a major goal. Other primary goals included developing a stronger understanding of the lamination product markets described above, and to refine the potential benefits of commercial implementation. The scope of the project was to complete implementation concept studies in preparation for continuation into advanced development, pilot studies, and commercial implementation. The project consisted of 6 main tasks. The first dealt with lamination with poly-vinyl butyral (PVB) interlayers, which prior work had shown difficulties in achieving good quality laminates, working with Pilkington North America. The second task dealt with a study of current lamination processes in the various laminate industries, and development of concepts for integrating RF lamination into new or existing processes. The third task explored the use of a non-destructive technique for analyzing laminate adhesion with the University of Illinois at Urbana-Champaign. The fourth task focused on developing concepts for curved glass lamination using RF lamination. The fifth and sixth tasks together comprised an analysis of laminate product markets, ranking for applicability and commercialization potential, and the development of commercialization strategies for those products. In addition, throughout the project as new experimental data and conventional process data were obtained, the benefits analysis of RF lamination was refined. The goals of the project described above were achieved, positioning RF lamination for the next stage growth envisioned in the original Industrial Grand Challenge proposal. Working with Pilkington North America, lamination of flat autoglass with PVB was achieved, meeting all 16 stringent industry tests. In particular, PVB laminates made with RF lamination passed environmental tests including the high temperature, 120°C bake test, without significant formation of bubbles (defects). The adhesion of PVB to glass was measured using the pummel method. Adhesion values ranging from 1 to 7 out of 10 were obtained. The significant process parameters affecting the environmental and adhesion performance were identified through a designed experiment. Pre-lamination process variables including PVB storage humidity and the de-airing process (vacuum or nip rolling) were significant, as well as the level of pressure applied to the laminate during the RF process. Analysis of manufacturing with RF lamination equipment, based on the processes developed indicated that 3 RF presses could replace a typical auto-industry autoclave to achieve equal or greater throughput with possibly less capital cost and smaller footprint. Concepts for curved lamination identifying castable molds for prototyping were developed, which allowed Ceralink to obtain commitment to begin curved tooling development. The project significantly helped to advance RF lamination past the feasibility and novelty stage and into the realm of commercial acceptance as a viable alternative to autoclaves. The demonstration of autoclave-quality autoglass produced in just 1 minute with RF lamination, with validation by Pilkington, has fueled industry motivation to seriously consider RF lamination. The industry and other contacts and outreach made in the study of laminate markets (including 3 technical publications and 5 conference presentations), has resulted in a recent surge in RF lamination activity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

New Developments in the Technology Readiness Assessment Process in US DOE-EM - 13247

A Technology Readiness Assessment (TRA) is a systematic, metric-based process and accompanying report that evaluates the maturity of the technologies used in systems; it is designed to measure technology maturity using the Technology Readiness Level (TRL) scale pioneered by the National Aeronautics and Space Administration (NASA) in the 1980's. More recently, DoD has adopted and provided systematic guidance for performing TRAs and determining TRLs. In 2007 the GAO recommended that the DOE adopt the NASA/DoD methodology for evaluating technology maturity. Earlier, in 2006-2007, DOE-EM had conducted pilot TRAs on a number of projects at Hanford and Savannah River. In March 2008, DOE-EM issued a process guide, which established TRAs as an integral part of DOE-EM's Project Management Critical Decision Process. Since the development of its detailed TRA guidance in 2008, DOE-EM has continued to accumulate experience in the conduct of TRAs and the process for evaluating technology maturity. DOE has developed guidance on TRAs applicable department-wide. DOE-EM's experience with the TRA process, the evaluations that led to recently developed proposed revisions to the DOE-EM TRA/TMP Guide; the content of the proposed changes that incorporate the above lessons learned and insights are described. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Optical coherence and energy-level properties of a Tm 3+ -doped LiNbO 3 waveguide at subKelvin temperatures

We characterize the optical coherence and energy-level properties of the 795-nm 3 H 6 to 3 H 4 transition of Tm 3+ in a Ti 4+ :LiNbO 3 waveguide at temperatures as low as 0.65 K. Coherence properties are measured with varied temperature, magnetic field, optical excitation power and wavelength, and measurement timescale. We also investigate nuclear spin-induced hyperfine structure and population dynamics with varying magnetic field and laser excitation power. Except for accountable differences due to different Ti 4+ - and Tm 3+ -doping concentrations, we find that the properties of Tm 3+ :Ti 4+ :LiNbO 3 produced by indiffusion doping are consistent with those of a bulk-doped Tm 3+ :LiNbO 3 crystal measured under similar conditions. Furthermore, our results, which complement previous work in a narrower parameter space, support using rare-earth ions for integrated optical and quantum signal processing.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2023

Advancing Energy Equity Considerations in Distribution Systems Planning

Current distribution system planning (DSP) processes do not explicitly account for energy equity considerations, such as who is most affected by power system burdens, where those burdens are concentrated, and what investments can be made to improve baseline conditions. This paper proposes an iterative framework for advancing energy equity as an objective of the DSP process, showing how measurement strategies, or metrics (informed by conceptual foundations of energy justice), can be applied to benchmark equity performance at various stages. This methodology is applied for equity-aware distributed energy resource (DER) hosting capacity analysis and outage analysis to provide critical insights on infrastructure upgrade decisions compared to a business-as-usual (BAU) case. The analysis is performed on a taxonomy feeder representing the West Coast urban/semi-urban system with augmentation of electric vehicles (EVs) and rooftop solar photovoltaic (PV) generators. The study considers disadvantaged community (DAC) and non-disadvantaged community (NDAC) load regions to enable equity-aware simulations. The results demonstrate how equity-aware planning could reveal the limitations of the traditional DSP process as DAC regions are found to have lower DER hosting capacity and higher outage vulnerability. Overall, this work provides insights on the need to incorporate energy equity as an integral part of the DSP process.

Energy Equity, Distribution System Planning, DER a↗
DOE OSTI2016

Poster - 01: LabPET II Pixelated APD-Based PET Scanner for High-Resolution Preclinical Imaging

Purpose: LabPET II is a new generation APD-based PET scanner designed to achieve sub-mm spatial resolution using truly pixelated detectors and highly integrated parallel front-end processing electronics. Methods: The basic element uses a 4×8 array of 1.12×1.12 mm{sup 2} Lu{sub 1.9}Y{sub 0.1}SiO{sub 5}:Ce (LYSO) scintillator pixels with one-to-one coupling to a 4×8 pixelated monolithic APD array mounted on a ceramic carrier. Four detector arrays are mounted on a daughter board carrying two flip-chip, 64-channel, mixed-signal, application-specific integrated circuits (ASIC) on the backside interfacing to two detector arrays each. Fully parallel signal processing was implemented in silico by encoding time and energy information using a dual-threshold Time-over-Threshold (ToT) scheme. The self-contained 128-channel detector module was designed as a generic component for ultra-high resolution PET imaging of small to medium-size animals. Results: Energy and timing performance were optimized by carefully setting ToT thresholds to minimize the noise/slope ratio. ToT spectra clearly show resolved 511 keV photopeak and Compton edge with ToT resolution well below 10%. After correction for nonlinear ToT response, energy resolution is typically 24±2% FWHM. Coincidence time resolution between opposing 128-channel modules is below 4 ns FWHM. Initial imaging results demonstrate that 0.8 mm hot spots of a Derenzo phantom can be resolved. Conclusion: A new generation PET scanner featuring truly pixelated detectors was developed and shown to achieve a spatial resolution approaching the physical limit of PET. Future plans are to integrate a small-bore dedicated mouse version of the scanner within a PET/CT platform.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Quantifying the indirect impacts of climate on agriculture: an inter-method comparison

Climate change and increases in CO2 concentration affect the productivity of land, with implications for land use, land cover, and agricultural production. Much of the literature on the effect of climate on agriculture has focused on linking projections of changes in climate to process-based or statistical crop models. However, the changes in productivity have broader economic implications that cannot be quantified in crop models alone. How important are these socio-economic feedbacks to a comprehensive assessment of the impacts of climate change on agriculture? In this paper, we attempt to measure the importance of these interaction effects through an inter-method comparison between process models, statistical models, and integrated assessment model (IAMs). We find the impacts on crop yields vary widely between these three modeling approaches. Yield impacts generated by the IAMs are 20%-40% higher than the yield impacts generated by process-based or statistical crop models, with indirect climate effects adjusting yields by between - 12% and + 15% (e.g. input substitution and crop switching). The remaining effects are due to technological change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Note: On-chip multifunctional fluorescent-magnetic Janus helical microswimmers

Microswimmers integrated into microfluidic devices that are capable of self-illumination through fluorescence could revolutionize many aspects of technology, especially for biological applications. Few illumination and propulsion techniques of helical microswimmers inside microfluidic channels have been demonstrated. This paper presents the fabrication, detachment, and magnetic propulsions of multifunctional fluorescent-magnetic helical microswimmers integrated inside microfluidics. The fabrication process is based on two-photon laser lithography to pattern 3-D nanostructures from fluorescent photoresist coupled with conventional microfabrication techniques for magnetic thin film deposition by shadowing. After direct integration inside a microfluidic device, injected gas bubble allows gentle detachment of the integrated helical microswimmers whose magnetic propulsion can then be directly applied inside the microfluidic channel using external electromagnetic coil setup. With their small scale, fluorescence, excellent resistance to liquid/gas surface tension, and robust propulsion capability inside the microfluidic channel, the microswimmers can be used as high-resolution and large-range mobile micromanipulators inside microfluidic channels.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Mechanisms of woody-plant mortality under rising drought, CO 2 and vapour pressure deficit

Drought-associated woody plant mortality may have increased over the past several decades, and is projected to increase in the future, impacting terrestrial climate forcing, biodiversity, and resource availability. The mechanisms underlying such mortality, however, are debated owing to interactions between multiple drivers and mechanisms. In this work, we synthesize knowledge of drought-related tree mortality under a warming and drying atmosphere with rising atmospheric CO 2 . Drought-associated mortality results from the depletion of pools of water and carbon within a plant and declines in their fluxes relative to demand by living tissues. These pools and fluxes are interdependent and underlay plant defenses against biotic agents. Death via failure to maintain a positive water balance is particularly dependent on soil-to-root conductance, capacitance, vulnerability to hydraulic failure, cuticular water losses, and dehydration tolerance, all of which could be exacerbated by reduced carbon supply rates to support cellular survival e.g. the carbon starvation process. The depletion of plant water and carbon pools accelerates under rising vapor pressure deficit; however, increasing CO 2 can mitigate these impacts. Advancing knowledge and reducing predictive uncertainties requires studies that integrate carbon, water, and defensive processes, and utilize a range of experimental and modeling approaches.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

GronOR: Massively Parallel and GPU-Accelerated Non-Orthogonal Configuration Interaction for Large Molecular Systems

GronOR is a program package for non-orthogonal configuration interaction calculations for an electronic wave function built in terms of anti-symmetrized products of multi-configuration molecular fragment wave functions. The two-electron integrals that have to be processed may be expressed in terms of atomic orbitals or in terms of an orbital basis determined from the molecular orbitals of the fragments. The code has been specifically designed for execution on distributed memory massively parallel and Graphics Processing Unit (GPU)-accelerated computer architectures, using an MPI+OpenACC/OpenMP programming approach. The task-based execution model used in the implementation allows for linear scaling with the number of nodes on the largest pre-exascale architectures available, provides hardware fault resiliency, and enables effective execution on systems with distinct central processing unit-only and GPU-accelerated partitions. The code interfaces with existing multi-configuration electronic structure codes that provide optimized molecular fragment orbitals, configuration interaction coefficients, and the required integrals. Algorithm and implementation details, parallel and accelerated performance benchmarks, and an analysis of the sensitivity of the accuracy of results and computational performance to thresholds used in the calculations are presented.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

JOINING TECHNIQUES FOR NOVEL METAL POLY MER HYBRID HEAT EXCHANGERS

In the United States, over 50% of the unrecovered e nergy from industrial processes is in the form of low- grade heat (<220°C). Materials and maintenance co sts of common heat exchangers are typically too hig h to justify their usage. Polymers, though more afford able, are usually unsuitable for HX applications due t o their low thermal conductivity (~0.2 W/mK). Here, we show that metal-polymer hybrids may be attractiv e from both performance and cost perspectives. The use of polymers further increases the resistance to c orrosion by sulfuric and carbonic acids often present in flue gases. An ongoing work explores different co nfigurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using numeri cal simulations. This paper explores a manufacturing pathway for producing such layered hybrid tubes tha t involves directly rolling and bonding tapes made of polymer and copper foil into tubes. A critical problem in the fabrication process is the bonding of metal and polymers. We explore approaches involving adhesiv es (epoxy, acrylic and silicone) for metal/polymer inte rfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturi ng process. We report characterizations of the therm omechanical properties of these joining processes. T his work paves the way for realizing cost-effective m anufacturing of heat exchangers for low grade waste heat recovery.

Kuntumalla, Gowtham↗
DOE OSTI2020

FINAL TECHNICAL AND ECONOMIC FEASIBILITY STUDY ON THE APPLICATION OF A HEAT INTEGRATED POST-COMBUSTION CO2 CAPTURE SYSTEM WITH HITACHI ADVANCED SOLVENT INTO EXISTING COAL-FIRED POWER PLANT

This report contains the results of a techno-economic assessment (TEA) conducted of a heat integrated post-combustion CO2 capture process with Hitachi advanced solvent for retrofit into an existing coal-fired power plant (but treated as greenfield plant on cost analysis). The process has been developed by the University of Kentucky Center for Applied Energy (UK CAER). EPRI was chiefly responsible for this analysis, with significant input from WorleyParsons, Hitachi Power Systems America (Hitachi) and UK CAER. The project also involves the design, fabrication, installation, testing, and analyses of a slipstream facility located at L&GE-KU’s E.W. Brown Generating Station to demonstrate the UK CAER carbon capture system that could utilize heat integration with the main power plant. The design, start-up, and baseline of the pilot system was performed with a generic 30 wt% MEA solvent to obtain data for direct comparison with the DOE/NETL Reference Case followed by testing Hitachi’s proprietary solvent H3-1. In this techno-economic analysis, two cases utilizing the UK CAER process are compared, using different approach temperatures and solvent, against the DOE/NETL Reference Case (Case 10). The results are shown comparing the energy demand for post-combustion CO2 capture and the net higher heating value (HHV) efficiency of the power plant integrated with the post-combustion capture (PCC) plant. A levelized cost of electricity (LCOE) assessment was performed showing the costs of the options presented in the study. The key factors contributing to the reduction of LCOE were identified as CO2 partial pressure increase at the flue gas inlet, thermal integration of the process, and performance of the Hitachi H3-1 solvent. Recent UK CAER process pilot-scale testing data and process simualtion data showed that the packing heights of absorber and stripper columns were significantly oversized in the prelimanary TEA (Task 2 of this project) and thus updated in this final TEA for the H3-1 case only. In addition, the solvent make-up cost for H3-1 was updated based on lattest test results. Finally, a heat integration with the main power plant was applied in this final TEA to increase overall energy effciency for both the MEA and H3-1 cases. Additonal reductions in capital and operational costs are expected but not taken into account here. Shorter columns result in reduced pressure drops, smaller blower head and pump hydraulic head requirements. An increase in overall energy efficiency resuls in a decreased size of the power plant, the CCS and a reduced parasitic steam requirement to the CCS. The net efficiency of the UK CAER integrated PC power plant with CO2 capture changes from 26.2% for the Reference Case 10 plant in 2010 revised DOE/NETL baseline report to 27.6% for the MEA options considered, and 29.1% for the options utilizing the Hitachi advanced solvent. The UK CAER Process + Hitachi case also produces an extra 30.9 MW of generation compared to the UK CAER Process + MEA case and total 60.9 MW more than DOE Case 10. LCOE ($/MWh) values are $172.08/MWh for the MEA option and $157.65/MWh for the Hitachi H3-1 solvent cases considered in comparison to $189.59/MWh in January 2012 dollar for the Reference Case 10. The UK CAER CCS process with MEA case lowers energy consumption for CO2 capture to 1340 Btu/lb-CO2 captured as compared to 1540 Btu/lb-CO2 in the Reference Case 10. The UK CAER CCS process with H3-1 case further lowers energy consumption for CO2 capture to 973 Btu/lb-CO2 captured, for an advantage of 36.8% less energy consumption than Case 10. The study also shows 38.1% less heat rejection associated with the carbon capture system from 3398 MBtu/hr (Case 10) to 2104 MBtu/hr for the UK CAER + MEA system. Heat rejection is reduced to 2464 MBtu/hr in the UK CAER + H3-1 case, for a 27.5 % decrease compared to Case 10. Modeling outputs show that in the UK CAER process, the cooling water that is 2-5°C cooler than conventional cooling tower water can be achieved for ambient conditions common to the midwest and other regions. The results from the techno-economic assessment show that the proposed technology can be investigated further as a viable alternative to conventional CO2 capture technology. The evaluation also shows the effect of the critical parameters on the LCOE, with the main variables being the approach temperature and CO2 partial pressure increase at the flue gas inlet. A summary of the key advantages of the UK CAER Process + H3-1 case for LCOE and other economic factors compared to the DOE Case 10 is as follows: • A lower variable operating cost by $1.56/MWh ($1.08MWh less than the UK CAER Process + MEA Case), a 11.7% reduction compared to the DOE Case 10 • A lower COE by $25.32MWh ($13.94/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower LCOE by $31.94/MWh ($17.51/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower cost of CO2 captured by $18.65/tonne CO2 ($9.44/tonne CO2 lower than the UK CAER Process + MEA Case), a 30.4% reduction compared to the DOE Case 10 • A lower cost of CO2 avoided by $34.95/tonne CO2 ($18.53 tonne CO2 lower than the UK CAER Process + MEA Case), a 38.7% reduction compared to the DOE Case 10

Bhown, Abhoyjit S.↗
DOE OSTI2023

PacWave South SeaRAY k2 Risk Registers

The SeaRAY is a deployable power system for maritime sensors, monitoring equipment, communications, unmanned underwater vehicles, and other similar payloads. This project is to design, deliver, and test a prototype low-power WEC that lowers the total cost of ownership and provides robust, new capabilities for customers in the maritime environment. Failure Modes, Effects, and Criticality Analysis (FMECA) is conducted to systematically identify all potential failure modes and their effects on the system, and to analyze the criticality of each risk based on the likelihood of the event and the severity of the impact. Actions may then be recommended to mitigate the criticality of a risk, either by reducing the likelihood of the risk or the severity of its impact. Risk assessment is executed iteratively as an integral part of the design process. By incorporating risk assessment early in the development cycle, mitigation of risk can be achieved cost effectively. The actions recommended to mitigate risk may be subsequently executed, and as the design progresses the risk assessment is reviewed and revised. Review of the risk assessment is integrated into structured design reviews, ensuring that critical risks are comprehended and that the Project will not progress to e.g. fabrication while intolerable risks remain. The risk assessment process results in the population and maintenance of Risk Registers (RRs). Each major system (and as needed, subsystem) will have a distinct RR. This allows each system or subsystem to be assessed individually, rendering the RRs to a manageable size for review.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Opportunities for Integrating Electric and Gas Planning

Growing demand for electricity in buildings is creating new opportunities and challenges for electric and natural gas planning. To date, electric and gas planning processes have largely been siloed, and only a few jurisdictions have started to examine how these two processes could be linked together. The report explores the current state of electric and gas system planning, and the benefits and challenges of integrating these planning processes. We frame the characteristics of an integrated electric and gas distribution planning process and identify indicators of progress toward the characteristics.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Post weld heat treatment and operating temperature effect on tribological behavior of laser cladded stellite 21 coating

This study intends to investigate the feasibility of using laser cladding as a potential process to repair hot working tools by a hardfacing process. A Stellite 21 alloy coating was printed on a 350 maraging steel via laser cladding and the coating microstructure and tribological performance were characterized in as printed conditions and after heat treatment. Such a laser-processed coating showed a high integrity with little porosity and good bonding with the substrate. The Stellite coating produced substantially lower friction and a smoother contact area but had inferior wear resistance compared with the maraging steel substrate. Post process heat treatment at 650 °C for 20 h led to significant amount of strain-induced FCC to HCP phase transformation but had little improvement in wear resistance. Detailed materials characterization using X-ray diffraction and electron microscopy provided fundamental insights to the underlying mechanisms. This study opens the door for future R&D for tool surface repair by laser cladding.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In-Situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, we report an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.

42 ENGINEERING↗
DOE OSTI2021

University Research to Support the MPACT 2020 Milestone

University research is a strong focus of the Office of Nuclear Energy within the Department of Energy. This research complements existing work in the various program areas and provides support and training for students entering the field. Four university projects have provided support to the Material Protection Accounting and Controls Technologies (MPACT) 2020 milestone focused on safeguards for electrochemical processing facilities. The University of Tennessee Knoxville has examined data fusion of NDA measurements such as Hybrid K-Edge Densitometry and Cyclic Voltammetry. Oregon State University and Virginia Polytechnic Institute have examined the integration of accountancy data with process monitoring data for safeguards. The Ohio State University and the University of Utah have developed a Ni-Pt SiC Schottky diode capable of high temperature alpha spectroscopy for actinide detection of molten salts. Finally, the University of Colorado has developed a key enabling technology for the use of Microcalorimetry.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Phase-based velocity extraction method for photonic Doppler velocimetry with potential higher time resolution

We present an extension of the [Takeda et al., J. Opt. Soc. Am. 72, 156 (1982)] phase extraction method to heterodyne photonic Doppler velocimetry applications. The method yields results equivalent to those obtained by the short-time Fourier transform (STFT), while offering potential improvements in time resolution. Unlike STFT, which relies on window functions, such as the Hamming window, that emphasize central data points and diminish the influence of edges, the extended Takeda method utilizes all data uniformly. This uniform treatment allows for the derivation of empirical equations that directly relate velocity error to the actual time resolution rather than to the local analysis duration. The established equation provides a useful metric for both optimizing hardware configuration and guiding data analysis. Simulation and experimental results confirm that, for a given dataset, specifying a target time resolution yields consistent velocity errors for both methods. These findings underscore the Takeda method’s advantages, particularly its potential higher time resolution and reduced computational burden, making it a valuable tool for high-throughput applications such as laser dynamic compression experiments.

Computer simulation↗