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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 OSTI2013

Towards a 100mA Superconducting RF Photoinjector for BERLinPro

For BERLinPro, a 100 mA CW-driven SRF energy recovery linac demonstrator facility, HZB needs to develop a photo-injector superconducting cavity which delivers a at least 1mm*mr emittance beam at high average current. To address these challenges of producing a high peak brightness beam at high repetition rate, at first HZB tested a fully superconducting injector with a lead cathode*,followed now by the design of a SC cavity allowing operation up to 4 mA using CW-modified TTF-III couplers and inserting a normal conducting high quantum efficiency cathode using the HZDR-style insert scheme. This talk will present the latest results and an overview of the measurements with the lead cathode cavity and will describe the design and optimization process, the first production results of the current design and an outlook to the further development steps towards the full power version.

Neumann, Axel↗
DOE OSTI2024

Alternatives to MARVEL Power Conversion – Comparison of Stirling Engine Thermal Efficiency and Design to other Power Conversion Cycles

The Microreactor Applications, Research, Validation, and Evaluation (MARVEL) Reactor is a small liquid-metal thermal reactor that will be built at the Idaho National Laboratory to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. Power conversion in the MARVEL design is provided by Stirling engines, which have disadvantages in nuclear environments. Compared to Stirling engine performance, some alternative power cycles can increase power production when coupled to a liquid-metal thermal reactor In this paper, the thermal efficiency of MARVEL’s power production with Stirling engines is compared to the thermal efficiency of power production with MARVEL and alternative power cycles. Those cycles include a superheated Rankine cycle, open and closed Brayton cycles, and a supercritical carbon dioxide cycle. All cycles (except the Stirling engines) were modeled with an intermediate helium loop to meet MARVEL’s principal design criteria. All models are simple designs with conservative assumptions for consistent comparison. Detailed optimization will depend largely on reactor location and application, and the relative merit of each cycle is discussed for different environmental conditions. The study informs significant early decisions on power cycle design and economic

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Designing Advanced Ceramic Waste Forms for Electrochemical Processing Salt Waste

This report describes the scientific basis underlying the approach being followed to design and develop “advanced” glass-bonded sodalite ceramic waste form (ACWF) materials that can (1) accommodate higher salt waste loadings than the waste form developed in the 1990s for EBR-II waste salt and (2) provide greater flexibility for immobilizing extreme waste salt compositions. This is accomplished by using a binder glass having a much higher Na 2 O content than glass compositions used previously to provide enough Na+ to react with all of the Cl– in the waste salt and generate the maximum amount of sodalite. The phase compositions and degradation behaviors of prototype ACWF products that were made using five new binder glass formulations and with 11-14 mass% representative LiCl/KCl-based salt waste were evaluated and compared with results of similar tests run with CWF products made using the original binder glass with 8 mass% of the same salt to demonstrate the approach and select a composition for further studies. About twice the amount of sodalite was generated in all ACWF materials and the microstructures and degradation behaviors confirmed our understanding of the reactions occurring during waste form production and the efficacy of the approach. However, the porosities of the resulting ACWF materials were higher than is desired. These results indicate the capacity of these ACWF waste forms to accommodate LiCl/KCl-based salt wastes becomes limited by porosity due to the low glass-to-sodalite volume ratio. Three of the new binder glass compositions were acceptable and there is no benefit to further increasing the Na content as initially planned. Instead, further studies are needed to develop and evaluate alternative production methods to decrease the porosity, such as by increasing the amount of binder glass in the formulation or by processing waste forms in a hot isostatic press. Increasing the amount of binder glass to eliminate porosity will decrease the waste loading from about 12% to 10% on a mass basis, but this will not significantly impact the waste loading on a volume basis. It is likely that heat output will limit the amount of waste salt that can be accommodated in a waste canister rather than the salt loading in an ACWF, and that the increase from 8 mass% to about 10 mass% salt loadings in ACWF materials will be sufficient to optimize these waste forms. Although the waste salt composition used in this study contained a moderate amount of NaCl, the test results suggest waste salts with little or no NaCl can be accommodated in ACWF materials by using the new binder glass, albeit at waste loadings lower than 8 mass%. The higher glass contents that will be required for ACWF materials made with salt wastes that do not contain NaCl are expected to result in much lower porosities in those waste forms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

SU-E-T-760: Tolerance Design for Site-Specific Range in Proton Patient QA Process Using the Six Sigma Model

Purpose: To show how tolerance design and tolerancing approaches can be used to predict and improve the site-specific range in patient QA process in implementing the Six Sigma. Methods: In this study, patient QA plans were selected according to 6 site-treatment groups: head &neck (94 cases), spine (76 cases), lung (89 cases), liver (53 cases), pancreas (55 cases), and prostate (121 cases), treated between 2007 and 2013. We evaluated a model of the Six Sigma that determines allowable deviations in design parameters and process variables in patient-specific QA, where possible, tolerance may be loosened, then customized if it necessary to meet the functional requirements. A Six Sigma problem-solving methodology is known as DMAIC phases, which are used stand for: Define a problem or improvement opportunity, Measure process performance, Analyze the process to determine the root causes of poor performance, Improve the process by fixing root causes, Control the improved process to hold the gains. Results: The process capability for patient-specific range QA is 0.65 with only ±1 mm of tolerance criteria. Our results suggested the tolerance level of ±2–3 mm for prostate and liver cases and ±5 mm for lung cases. We found that customized tolerance between calculated and measured range reduce that patient QA plan failure and almost all sites had failure rates less than 1%. The average QA time also improved from 2 hr to less than 1 hr for all including planning and converting process, depth-dose measurement and evaluation. Conclusion: The objective of tolerance design is to achieve optimization beyond that obtained through QA process improvement and statistical analysis function detailing to implement a Six Sigma capable design.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

MARVEL Reactor Digital Engineering Developments

The MARVEL reactor project has served to introduce a new generation of engineers to the processes required to transform a reactor design from simply an idea on paper into what will be an approved, constructed, and operational nuclear power system. Much as there have been advances in materials, analysis, and evaluation methodologies over the 50 years since the last reactor was built at INL, so too has the technology for managing the engineering process itself advanced. Digital Engineering tools and methods provide improved coordination between previously siloed engineering disciplines, reduced burdens of non-value-added data transcription processes and bring forward insights and improvements that might otherwise fall later in the design stage, where changes are much more costly. While the tools and techniques to support the full digital engineering vision are not yet complete, the MARVEL design processes provide valuable demonstrations and validations of key aspects and illuminate further areas for implementation by subsequent projects.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2013

Comparative Analysis Between US NRC Requirements and US DOE Orders - 13402

Small modular reactor (SMR) is a nuclear reactor design approach that is expected to herald in a new era of clean energy in the U.S. These reactors are less than one-third the size of conventional large nuclear power reactors, and have factory-fabricated components that may be transported by rail or truck to a site selected to house a small nuclear reactor. To facilitate the licensing of these smaller nuclear reactor designs, the Nuclear Regulatory Commission (NRC) is in the process of developing a regulatory infrastructure to support licensing review of these unique reactor designs. As part of these activities, the NRC has been meeting with the Department of Energy (DOE) and with individual SMR designers to discuss potential policy, licensing, and key technical differences in SMR designs. It is anticipated by the NRC that such licensing interaction and guidance early in the design process will contribute towards minimizing complexity while adding stability and predictability in the licensing and subsequent regulation of new reactor designs such as SMRs. In conjunction with the current NRC initiative of developing the SMR licensing process, early communication and collaboration in the identification and resolution of any potential technical and licensing differences between NRC requirements and similar requirements applicable at DOE sites would help to expedite demonstration and implementation of SMR technology in the US. In order to foster such early communication, Savannah River Nuclear Solutions (SRNS) has begun taking the first steps in identifying and evaluating potential licensing gaps that may exist between NRC and DOE requirements in siting SMRs at DOE sites. A comparison between the existing NRC regulations for Early Site Permits and the DOE Orders was undertaken to establish the degree of correlation between NRC requirements and compliance methods in place at DOE sites. The ability to use existing data and information to expedite the development of the Environmental Report is being evaluated at the Savannah River Site as a case study for application across the DOE Complex. This paper will present areas of direct correlation as well as those where the need for site specific data for either DOE operations or NRC compliance warrant additional interaction between the agencies. Areas where further refinement of the SMR technologies may drive collaborative development of revised regulations through such means as industry consensus standards will also be highlighted. Both NRC and DOE have requirements that mandate public involvement in their processes. The importance and value of early engagement with the public as well as collaborating regulatory agencies is of critical importance when deploying new technologies. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Update on the Simulation of Commercial Drying of Spent Nuclear Fuel

The purpose of this report is to document improvements in the simulation of commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Response of a Pressurized Water Reactor Dashpot Region to Commercial Drying Cycles

The purpose of this report is to document updates to the simulation of commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents testing updates for the Dashpot Drying Apparatus (DDA), an apparatus constructed at a reduced scale with multiple Pressurized Water Reactor (PWR) fuel rod surrogates and a single guide tube dashpot. This apparatus is fashioned from a truncated 5×5 section of a prototypic 17×17 PWR fuel skeleton and includes the lowest segment of a single guide tube, often referred to as the dashpot region. The guide tube in this assembly is open and allows for insertion of a poison rod (neutron absorber) surrogate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Importance of Higher Fidelity Model Geometries during Optimization of Critical Experiments

PARADIGM, PARallel Approach of Differential and InteGral Measurements, is a cross-collaborative effort at Los Alamos National Laboratory between nuclear data theorists, differential and integral experimenters, as well as machine learning statisticians to tackle uncertainties in the intermediate region of 239 Pu. In essence, the idea behind PARADIGM is to remove the linear conceptualization of the nuclear data pipeline, shown in Figure 1, and replace it with a far more parallelized approach. The novel approach leverages machine learning to guide which differential measurements and integral experiments will result in the largest decrease in uncertain ties for a nuclide reaction pair in a given energy range. The concept builds off earlier work, EUCLID, which focused on the fast region of 239 Pu. The practical benefit of having evaluation, differential measurement, and integral experiment personnel in collaboration with machine learning is to represent the entire nuclear data in one snapshot. This enable large reduction in the time to deliver improved nuclear data, which using the PARADIGM approach could be done in 3 years. A general outline of PARADIGM and specific topics are available in other papers. The discussion here will pertain directly to the integral experiment design. More specifically, the process of taking a rough design and transforming it into a finalized neutronic model will be discussed.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites

With the growing demand for enhanced automotive fuel efficiency and environmental sustainability, there is a need for lightweighting automotive components through innovative design and manufacturing processes. Here, this study leverages a combination of numerical iterative design optimization and hybrid additive manufacturing–compression molding (AM-CM) technique for metal polymer composites to lightweight an automotive seatback. The AM-CM process enables robust mechanical interlocking between metals and composites, boasting high stiffness and strength with low overall density. Replacing metallic components with such metal polymer composites allows for comparable mechanical performance while significantly reducing the overall weight. First, the automotive seatback design space is reduced to critical load carrying regions using topology optimization and high stress concentration areas are identified using finite element analysis. Next, a lightweight metal polymer subcomponent is designed for a high stress concentration region. The full seatback frame with spatially heterogeneous material-specific design is then iteratively optimized to enable enhanced stiffness with minimal weight. Overall, the automotive seatback frame designed with location-specific metal, polymer, and metal polymer composite materials weighs 20% less than the metal-only design while exhibiting similar stiffness.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Comparative Policy Study for Green Buildings in U.S. and China

Prominent barriers facing the U.S. green building industry include the fact that government bodies that supervise health, fire safety, land, and other public operations are slow to revise codes to accommodate green building (regulatory barrier). In China, the lack of a green building professional accreditation process similar to the Leadership in Energy and Environmental Design (LEED) AP process limits the green building workforce capacity development (informational barrier). The main policies highlighted in this report to tackle these barriers are 1) comprehensive codes and labeling plan (informational, institutional), 2) government-led targets and demonstrations (risk), 3) education and awareness programs (informational), 4) fiscal policy that supports green building investment (financial), and 5) integrated design promotion (institutional, financial).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Supply Chain Sustainability Analysis of Indirect Liquefaction of Blended Biomass to Produce High Octane Gasoline

The Department of Energy’s (DOE) Bioenergy Technologies Office (BETO) aims at developing and deploying technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts and biopower through public and private partnerships (DOE, 2015). BETO also performs a supply chain sustainability analysis (SCSA). This report describes the SCSA of the production of renewable high octane gasoline (HOG) via indirect liquefaction (IDL) of lignocellulosic biomass. This SCSA was developed for the 2017 design case for feedstock logistics (INL, 2014) and for the 2022 target case for HOG production via IDL (Tan et al., 2015). The design includes advancements that are likely and targeted to be achieved by 2017 for the feedstock logistics and 2022 for the IDL conversion process. The 2017 design case for feedstock logistics demonstrated a delivered feedstock cost of $80 per dry U.S. short ton by the year 2017 (INL, 2014). The 2022 design case for the conversion process, as modeled in Tan et al. (2015), uses the feedstock 2017 design case blend of biomass feedstocks consisting of pulpwood, wood residue, switchgrass, and construction and demolition waste (C&D) with performance properties consistent with a sole woody feedstock type (e.g., pine or poplar). The HOG SCSA case considers the 2017 feedstock design case (the blend) as well as individual feedstock cases separately as alternative scenarios when the feedstock blend ratio varies as a result of a change in feedstock availability. These scenarios could be viewed as bounding SCSA results because of distinctive requirements for energy and chemical inputs for the production and logistics of different components of the blend feedstocks.

Cai, Hao↗
DOE OSTI2016

Microstructure and mechanical properties of a novel rapidly solidified, high-temperature Al-alloy

Rapid solidification (RS) processing, as a production method, offers a variety of unique properties based on far-from-equilibrium microstructures obtained through rapid cooling rates. In this study, we seek to investigate the microstructures and properties of a novel Al-alloy specifically designed for high temperature mechanical stability. Synthesis of, AlFe{sub 11.4}Si{sub 1.8}V{sub 1.6}Mn{sub 0.9} (wt.%), was performed by two approaches: rotating cup atomization (“shot”) and melt spinning (“flake”). These methods were chosen because of their ability to produce alloys with tailored microstructures due to their inherent differences in cooling rate. The as-solidified precursor materials were microstructurally characterized with electron microscopy. The results show that the higher cooling rate flake material exhibited the formation of nanocrystalline regions as well additional phase morphologies not seen in the shot material. Secondary dendritic branching in the flake material was on the order of 0.1–0.25 μm whereas branching in the shot material was 0.5–1.0 μm. Consolidated and extruded material from both precursor materials was mechanically evaluated at both ambient and high (300 °C) temperature. The consolidated RS flake material is shown to exhibit higher strengths than the shot material. The ultimate tensile strength of the melt spun flake was reported as 544.2 MPa at room temperature and 298.0 MPa at 300 °C. These results forecast the ability to design alloys and processing approaches with unique non-equilibrium microstructures with robust mechanical properties at elevated temperatures. - Highlights: • A novel alloy, AlFe{sub 11.4}Si{sub 1.8}V{sub 1.6}Mn{sub 0.9} was fabricated by rapid solidification. • Room temperature yield strength exceeded 500 MPa. • Elevated temperature (300 °C) yield strength exceeded 275 MPa. • Forging, after extrusion of the alloy resulted in microstructural coarsening. • Decreased strength and ductility was identified as a result of forging.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fracture Toughness of High-Cr Steels after Various Thermomechanical Treatments

This research aimed to improve the mechanical properties of high-Cr steels by developing new thermomechanical processes for application to advanced fast reactors. A simultaneous improvement of fracture toughness and strength was specifically targeted in the design of thermomechanical processing for various 9Cr and 12Cr steels. For the structural materials of fusion and fast reactors, the high-chromium steels with fine ferritic/martensitic (FM) structures are favored because of their high creep strength and excellent resistance to high-temperature radiation damage such as void swelling. After the traditional thermomechanical treatment consisting of normalizing, water quenching, and tempering, however, the high-Cr steels show limited mechanical properties at high temperatures, e.g., significant decrease of strength above ~450°C. Since the high-Cr steels are tempered at high temperatures (typically around 750°C), significant coarsening of the lath structure and carbides and annihilation of dislocations occur in the final thermomechanical treatment. It is believed that the high-temperature tempering can maximize the ductility of the FM steels, but their high-temperature strength is reduced and often with high-temperature fracture toughness. It is also likely that such a fully-tempered structure will demonstrate a lowered radiation resistance when compared to the steels with finer structures. This research was planned to explore new processing routes that can produce ultrafine microstructures and thus can improve the high-temperature mechanical properties of the high-Cr steels. In this research, three 9Cr steels and two 12Cr steels were selected and a series of new thermomechanical process treatments (TMTs) were designed and applied to the five steels to find the TMT routes that will result in increase of both strength and fracture toughness. It was demonstrated for HT-9 steels that some tailored TMTs increased or maintained the fracture toughness of the high-Cr steels while the treatments could significantly increase their strength to the level comparable to those of nanostructured ferritic alloys. This report compares the fracture toughness data of both 9Cr and 12Cr steels after various thermomechanical treatments with the reference data of similar steels. A two-step tempering route is selected for application to the high-Cr steels for reactor core structures.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A HUMAN FACTORS ENGINEERING PROCESS TO SUPPORT HUMAN-SYSTEM INTERFACE DESIGN IN CONTROL ROOM MODERNIZATION

The primary objective of the United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program is to sustain operation of the existing commercial nuclear power plants (NPPs) through a multi-pathway approach in conducting research and development (R&D). The Advanced Instrumentation, Information, and Control (II&C) System Technologies pathway conducts targeted R&D to address aging and reliability concerns with legacy instrumentation and control (I&C) and other information systems in existing U.S. NPPs. Control room modernization is an important part following this pathway, and human factors experts at Idaho National Laboratory (INL) have been involved in conducting R&D to support migration of new digital main control room (MCR) technologies from legacy analog and legacy digital I&C. This paper describes a human factors engineering (HFE) process that supports human-system interface (HSI) design in MCR modernization activities, particularly with migration of old digital to new digital I&C. The process described in this work is an expansion from the LWRS Report INL/EXT-16-38576, and is a requirements-driven approach that aligns with NUREG-0711 requirements. The work described builds upon the existing literature by adding more detail around key tasks and decisions to make when transitioning from HSI Design into Verification and Validation (V&V). The overall objective of this process is to inform HSI design and elicit specific, measurable, and achievable human factors criteria for new digital technologies. Upon following this process, utilities should have greater confidence with transitioning from HSI design into V&V.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

A Human Factors Engineering Process to Support Human-System Interface Design in Control Room Modernization

The primary objective of the United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program is to sustain operation of the existing commercial nuclear power plants (NPPs) through a multi-pathway approach in conducting research and development (R&D). The Advanced Instrumentation, Information, and Control (II&C) System Technologies pathway conducts targeted R&D to address aging and reliability concerns with legacy instrumentation and control (I&C) and other information systems in existing U.S. NPPs. Control room modernization is an important part following this pathway, and human factors experts at Idaho National Laboratory (INL) have been involved in conducting R&D to support migration of new digital main control room (MCR) technologies from legacy analog and legacy digital I&C. This paper describes a human factors engineering (HFE) process that supports human-system interface (HSI) design in MCR modernization activities, particularly with migration of old digital to new digital I&C. The process described in this work is an expansion from the LWRS Report INL/EXT-16-38576, and is a requirements-driven approach that aligns with NUREG-0711 requirements. The work described builds upon the existing literature by adding more detail around key tasks and decisions to make when transitioning from HSI Design into Verification and Validation (V&V). The overall objective of this process is to inform HSI design and elicit specific, measurable, and achievable human factors criteria for new digital technologies. Upon following this process, utilities should have greater confidence with transitioning from HSI design into V&V.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Seismic Testing of Glovebox Feedthrough Connectors and Vacuum Pumps

In the design of tritium processing systems, the glovebox stripper system processes the glovebox atmosphere to recover tritium released inside the glovebox confinement. The glovebox stripper system must also be capable of processing the additional in-leakage caused by a Design Basis Accident (DBA) earthquake, in order to maintain the glovebox pressure negative relative to the room. However, it is unknown how much additional leakage occurs from electrical bulkhead feedthrough connectors after a DBA event. As there are dozens of these connectors on a tritium glovebox system, the potential increase in in-leakage can be significant. One vital part of the glovebox stripper system are the vacuum pumps that maintain the negative atmosphere of the glovebox following a DBA earthquake. The pumps must be able to operate following an earthquake. One candidate pump is the Senior Aerospace MB-602 Metal Bellows (Met-Bel) pump. A second alternative is the hermetically sealed Edwards Vacuum nXDS15iC Scroll Pump. The Edwards scroll pump is potentially a less expensive alternative to the Met-Bel pumps, but it is unknown if this scroll pumps will survive a DBA accident and remain operational. In order to determine the electrical feedthrough in-leakage and the candidate pumps’ survivability, a seismic test was performed to simulate a DBA earthquake. This report summarizes the results of seismic test, including helium leak rates and functionality tests for the electrical feedthroughs and vacuum pumps. All components had pre- and post-test leak rates less than the threshold valve of 1x10 -6 scc per sec.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗