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DOE OSTI2023

Investigating Marine Environmental Degradation Of Additive Manufacturing Materials For Renewable Energy Applications

Marine renewable energy is a relatively young industry where there is a great need for rapid prototyping in design-build-test campaigns to quickly mature ground-breaking technologies. Additive manufacturing has an important role to play in the industry; however, little information is available to marine energy developers to help inform them on which additive manufacturing materials are appropriate for harsh marine environments. This paper presents an initial study on the mechanical characterization of polymeric additive manufacturing materials and degradation effects due to the marine environment. Ultem 9085, acrylonitrile styrene acrylate (ASA), and chopped carbon-filled Nylon, as well as continuous carbon and glass fiber reinforced Nylon were chosen for this study. Samples were manufactured to perform a variety of tension, shear, and compression mechanical characterization tests on the materials. Half of the samples were conditioned in Pacific Ocean water for approximately 6 months at the Pacific Northwest National Laboratory’s Marine and Coastal Research Laboratory before being returned for mechanical characterization. The mechanical testing results showed that the Ultem 9085 and ASA materials experienced little to no degradation in stiffness or strength after exposure to the marine environment. On the other hand, the Nylon-based materials suffered significant stiffness and strength degradation (over 50% in some cases) after environmental conditioning. Ultimately, these results should serve as starting points to allow marine renewable energy developers to make informed additive manufacturing material choices for their prototype deployments.

Murdy, Paul↗
DOE OSTI2022

EERC Final Topical Report – Findings on Subtask 3.2 – Produced Water Management Through Geologic Homogenization, Conditions, and Reuse

The Energy & Environmental Research Center (EERC) was awarded a contract by the North Dakota Industrial Commission (NDIC) Oil and Gas Research Program (NDIC No. G-051-101) to conduct a study on the recycling of water used in oil and gas operations, also known as produced water, from oil- and gas-producing regions of North Dakota as directed by Section 19 of North Dakota House Bill 1014. This final report provides a compilation of results of the study, which include regulatory, scientific, technological, and feasibility methods and considerations associated with North Dakota produced water management. The report provides a synopsis of this project’s previously submitted produced water assessment report entitled “Produced Water Management and Recycling Options in North Dakota” (Energy & Environmental Research Center, 2020), with updated values provided as appropriate. The report provides the results from the investigation of a novel produced water management strategy, referred to as geologic homogenization, conditioning, and reuse (GHCR), which aims to use a subsurface geologic formation as a natural medium for managing produced water recycling and reuse. Water management is a significant technical and economic challenge for sustainable oil and gas production, and water volumes are intrinsically linked to oil production volumes. North Dakota oil production rose to over 1.5 million barrels (MMbbl)/day in 2019, and despite a downturn in oil price in early 2020, North Dakota oil production has recovered to 1.1 MMbbl/day as of August 2021. Bakken petroleum system development between 2008 and 2020 has resulted in a nearly fourfold increase in produced water volumes to 642 MMbbl/yr in 2020 after peaking at 740 MMbbl/yr in 2019 and a fivefold increase in saltwater disposal (SWD) volumes to 565 MMbbl/yr in 2020 after a peak of 682 MMbbl/yr in 2019. Produced water and SWD volumes are forecasted to double by 2030. SWD is the primary method of produced water management used in North Dakota, with approximately 95% of the SWD volume occurring through subsurface injection into sandstones of the Dakota Group (Dakota). Localized pressurization of the Dakota resulting from SWD and projected increases in produced water volumes could impact the economics of North Dakota oil production. As a result, there is an emerging need to pursue alternative produced water management approaches, including recycling and reuse. While produced water recycling is not yet widespread, commercial operators are making strides in overcoming the technical challenges of using high salinity produced water in completion operations (Marathon Oil, 2020). As water management continues to be a key focal point in companies’ environmental, social, and governance (ESG) initiatives, focus on water management, including recycling, will likely continue to increase. Laboratory column testing, field sample collection, geologic modeling and numerical simulation, and techno-economic analysis all indicate that GHCR could feasibly be implemented as a potential water management option. Laboratory column testing and field sample collection indicate that the Inyan Kara sandstone and native formation fluid are capable of homogenizing with the Bakken produced water to a point where the fluid composition appears to stabilize. Extracting that stabilized fluid could be considered homogeneous and capable of providing individual batches of hydraulic fracturing fluid. Numerical simulation results indicate that extraction of fluids from the Inyan Kara in a GHCR implementation scenario is capable of reducing formation pressure, which would help ease localized pressurization of the Inyan Kara and extend the available capacity for nearby existing SWD wells. Economic analysis indicates that there are scenarios where GHCR implementation can be a competitive or even lower-cost option than a conventional water management approach. Site-specific conditions will dictate the economic potential of GHCR, but potentially attractive sites for GHCR implementation will be those that are located above a pressurized zone of the Inyan Kara, need six or more Bakken infill wells, and face high costs for conventional SWD and/or freshwater. Based on the regulatory review, drilling into the Inyan Kara for SWD and to harness as a source water for industrial use have precedent in North Dakota, and a workable regulatory solution for GHCR seems likely. However, restrictions in the state regarding surface storage and transport of produced fluids may limit some activities, which will affect how GHCR could ultimately be implemented. In summary, this study reveals pursuing GHCR can be a viable approach to water management in North Dakota. The GHCR concept addresses some of the challenges that hinder the more traditional approaches to recycling in the industry. Furthermore, an assessment of the current landscape of water management within the state reveals the ongoing trend of increasing volumes of produced water and SWD. Projections reveal that the volumes of produced water that need to be managed are expected to double over the next decade (Energy & Environmental Research Center, 2020). With the continued development of the Bakken and continuing driving factors related to ESG initiatives, implementing a practice such as GHCR is a feasible approach to adding recycling of produced water to industry within the state. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission Oil and Gas Research Program. References Energy & Environmental Research Center, 2020, Produced water management and recycling options in North Dakota: Final Report for North Dakota Legislative Management Energy Development and Transmission Committee and North Dakota Industrial Commission. Marathon Oil, 2020, Sustainability report: https://cdn.sanity.io/files/ghcnw9z2/website/ 91744eb6ef8fbe59505a911c6b8d2e8dd9a537fa.pdf?dl (accessed November 2021).

02 PETROLEUM↗
DOE OSTI2020

Initial Radiation of Nuclear Power Plant Components (CRADA NFE-17-06892 Final Report)

As advanced reactor concepts are developed, instrumentation and control (I&C) cables and sensors will play a significant role in assuring their operation is well understood, and safety-related process information can be collected reliably over the course of their design life. As a first step to develop acceptance criteria and define the limits of currently available nuclear I&C cable and sensor technology, a collaboration between Oak Ridge National Laboratory and Analysis and Measurement Services (AMS) Corporation was initiated under the Gateway for Accelerated Innovation in Nuclear (GAIN) Program. This collaborative effort focused on providing technical information related to the combined thermal and radiation aging of nuclear power plant (NPP) cables, companion NPP cable insulation samples, and two prototype temperature and two pressure sensors. This work was carried out using the instrumented gamma irradiation system that is part of the High Flux Isotope Reactor Gamma Irradiation Facility (HFIR GIF). This system provided the opportunity for the condition of the prototype sensors to be tracked during the irradiation in order to determine their functional limits with greater granularity when compared to a simple irradiation insertion at the HFIRGIF. Experimental assemblies for sensor irradiation were successfully completed, and sensor irradiation to accumulated dose of 3000 kGy at a rate of approximately 6 kGy/hr was carried out. Two prototype temperature assemblies were continuously monitored during exposure to 3000 kGy and found to have no observable degradation from the irradiation. Two pressure sensors were first irradiated to 1000 kGy. At which point, one of the sensors was found to operate normally; however, a second sensor failed the operability test. The operable pressure sensor output was then continuously monitored from 1000 kGy to 3000 kGy. The sensor output exhibited steady trendable drift versus the accumulated radiation dose. At the conclusion of the irradiation, the four test sensors were released for laboratory calibration checks. The calibration check of the temperature sensors found no significant change after irradiation compared to baseline measurements before irradiation; however, both pressure sensors failed the post-test calibration checks and both sensors were not functioning properly. These results will help inform sensor manufacturers and I&C design engineers of potential limitations of these types of sensors for use in high radiation environments associated with the compact configuration of new Small Modular Reactors (SMRs) such as NuScale’s reactor power module. Irradiations on NPP cables and companion samples were not completed due to programmatic delays, however a path forward that was based on lessons learned from this project was defined to accommodate future, comparable instrumented gamma irradiations at the HFIR GIF.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Soil Water Retention and Hydraulic Conductivity Data and Model at Snodgrass Mountain in East River Watershed, Colorado 2020-2025

This data package includes soil water retention and hydraulic conductivity data and model fitting results from measurements of ex-situ soil samples and in-situ soil sensors at Snodgrass Mountain. Soil water retention curves (SWRC) characterize soil water content as a function of soil water potential. SWRC depends on soil texture and pore structure and can be used to describe the constraints on biogeochemical processes in terms of soil water availability. In this data package, the sample identification follows the format SG-X-Y, where SG refers to Snodgrass Mountain, X is the location identifier, and Y is the depth identifier at the same X (shallow Y=1). Specifically, SG-EHS is associated with ecohydrology sites under the East-Taylor Watershed Community Observatory Sites directory, and SG-ERTn (upslope n=1) are points along the Snodgrass electrical resistivity tomography transect not associated with the existing site names in the directory. The sample and location information can be found in metadata.csv. Sampling and Measurements Each sample falls into one of the three sampling methods – (1) intact cores, (2) repacked samples, or (3) soil sensors – and one of the two measurement methods – (a) laboratory or (b) in-situ. Both intact cores and repacked samples were measured using the laboratory methods, which include measurements of soil water potential (HYPROP & WP4C, METER), saturated (KSAT, METER) and unsaturated hydraulic conductivity (HYPROP). The in-situ method uses a pair of co-located soil sensors to measure volumetric water content (TEROS12, METER) and soil water potential (TEROS21, METER), and the hydraulic conductivity was not measured. In comparison, the laboratory methods progress from full saturation to dry conditions, and the in-situ method includes both dry-to-wet and wet-to-dry cycles. The sampling and measurement methods for each sample can be found in metadata.csv, and more information about the measurements is detailed in the Methods section below. Models Retention and hydraulic conductivity data were fitted with four van-Genuchten-type models (specified by “model_name” column in the files): (1) traditional constrained van Genuchten model (“vG_constrained”), (2) traditional unconstrained van Genuchten model (“vG_unconstrained”), (3) PDI-variant of the constrained van Genuchten model (“vG_constrained_PDI”), and (4) PDI-variant of the unconstrained van Genuchten model (“vG_unconstrained_PDI”). The difference between the constrained (1: n) and the unconstrained (2: n, m) van Genuchten models is the number of pore-size distribution parameters in the model equations, giving the unconstrained model more degrees of freedom when fitting the data. Between the traditional and the PDI-variant models, model fitting differs the most at the dry end of the measurements. The traditional models allow infinite suction at the residual water content (water content does not drop below residual water content), and the PDI-variant models enforce a soil water potential value of pF=6.8 (~ -630 MPa) at oven-dryness (water content reaches 0). The inclusion of the van-Genuchten-type models is due to their common application. If other retention models are required, users can access the data in data.csv for further data fitting. More information about the models can be found in the Methods section below. Fitting Tasks The model fitting can be categorized into three levels of tasks (specified by “fitting_task” column in the files). Level 1 (“fit_retention”) only includes retention data fitting (the only level available for the in-situ method). Level 2 (“fit_retention_conductivity”) includes both retention and hydraulic conductivity data fitting, and the saturated hydraulic conductivity (Ks, a parameter of the hydraulic conductivity functions) is fixed by the measurements from KSAT. Level 3 (“fit_retention_conductivity_Ks”) also includes both retention and hydraulic conductivity data fitting, but Ks is a fitted parameter without the constraints from KSAT measurements. Among the same retention models (e.g. vG_constrained models of the same sample), level 1 should produce the best retention data fitting. Level 2 should have the highest misfit of the retention and hydraulic conductivity data, because the retention and hydraulic conductivity functions share common model parameters, and the unsaturated hydraulic conductivity (HYPROP) data fitting is subject to Ks measured independently by KSAT. Level 3 should have mid-level misfits of the retention and hydraulic conductivity data. While level 3 fits the hydraulic conductivity data better than level 2, the fitted Ks value might be unreasonable due to the lack of constraints at the wet end of the measurements. General recommendation when using this data package: (1) Choice of sampling methods: Intact cores and in-situ soil sensors could be prioritized because these sampling methods are less destructive. While the repacked samples were packed to the target bulk density (estimated post-sampling, when sample volume was known), these samples had altered pore structures. Nevertheless, intact cores might suffer from sample gaps that would lead to overestimation of Ks (sample gaps can be inferred from the “soil_sample_volume” column in metadata.csv when the value is < 249). In-situ method also has higher uncertainty in characterizing the wet end of the SWRC because of sensor limitations and the difficulty in reaching full saturation under natural conditions. (2) Choice of fitting tasks: When only retention data is needed, level 1 (“fit_retention”) should be prioritized. When both retention and hydraulic conductivity data are needed, level 2 (“fit_retention_conductivity”) could be prioritized. (3) Choice of models: This could depend on what the downstream models call for. If no specific model is required, model misfit could be used as a ranking criterion. Model misfit values in terms of RMSE can be found in model_parameters.csv. The following files are included in this data package: (1) metadata.csv – This file includes the general information of each sample, including location (description, geocoordinates, elevation), sampling and measurements details (method, depth, time or period, volume, instruments), and soil physical properties (bulk density, saturated hydraulic conductivity, only applicable to physical soil samples). (2) data.csv – This file includes soil water potential, volumetric water content, and unsaturated hydraulic conductivity data of each sample. Column “instrument” specifies the instrument (HYPROP, WP4C, or TEROS) used to perform the measurements. (3) model_fit.csv – This file includes soil water potential, volumetric water content, and unsaturated hydraulic conductivity fitted from the four models and three fitting tasks. Column “model_name” specifies the retention model used, and “fitting_task” specifies the level of data fitting. Missing values indicate that the variable does not apply to that fitting task. (4) model_parameters.csv – This file includes the fitted model parameters, model misfits, and conventional water content thresholds (field capacity and wilting point) from the four models and three fitting tasks. Column “model_name” specifies the retention model used, and “fitting_task” specifies the level of data fitting. Missing values indicate that the parameter does not apply to that model and/or that fitting task. (5) data_Ks.csv – This file includes the saturated hydraulic conductivity measurements from KSAT. (6) /figure/*.png – This folder includes three quick visualizations of the data, retention model fitting results and misfits, and hydraulic conductivity model fitting results, misfits, and parameters. The model fitting results are separated by samples and fitting tasks and colored by models. Zoom-in required. (7) /hyprop/*.bdhx – This folder includes proprietary hyprop files that require the free Labros SoilView-Analysis (METER) to open. Users can explore data fitting using other retention models (i.e. Brooks-Corey, Fredlund-Xing, Kosugi, bimodal models). Be aware that Ks value is pre-entered under “Fitting tab, Conductivity functions parameters” for level 2 fitting. If the value is lost, please refer to metadata.csv under “Ks” column. (8) Six file-level metadata that summarize file, header, column, and variable information of all files. This work was supported by the Watershed Function Science Focus Area at Lawrence Berkeley National Laboratory funded by the US Department of Energy, Office of Science, Biological and Environmental Research under Contract No. DE-AC02-05CH11231.

EARTH SCIENCE > LAND SURFACE > SOILS↗
DOE OSTI2023

Clustering of red sequence galaxies in the fourth data release of the Kilo-Degree Survey

We present a sample of luminous red sequence galaxies as the basis for a study of the large-scale structure in the fourth data release of the Kilo-Degree Survey. The selected galaxies are defined by a red sequence template, in the form of a data-driven model of the colour-magnitude relation conditioned on redshift. In this work, the red sequence template was built using the broad-band optical+near infrared photometry of KiDS-VIKING and the overlapping spectroscopic data sets. The selection process involved estimating the red sequence redshifts, assessing the purity of the sample and estimating the underlying redshift distributions of redshift bins. After performing the selection, we mitigated the impact of survey properties on the observed number density of galaxies by assigning photometric weights to the galaxies. We measured the angular two-point correlation function of the red galaxies in four redshift bins and constrain the large-scale bias of our red sequence sample assuming a fixed ΛCDM cosmology. We find consistent linear biases for two luminosity-threshold samples (‘dense’ and ‘luminous’). We find that our constraints are well characterised by the passive evolution model.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Fast physics-based launcher optimization for electron cyclotron current drive

With the increased urgency to design fusion pilot plants, fast optimization of electron cyclotron current drive (ECCD) launchers is paramount. Traditionally, this is done by coarsely sampling the 4D parameter space of possible launch conditions consisting of (1) the launch location (constrained to lie along the reactor vessel), (2) the launch frequency, (3) the toroidal launch angle, and (4) the poloidal launch angle. For each initial condition, a ray-tracing simulation is performed to evaluate the ECCD efficiency. Unfortunately, this approach often requires a large number of simulations (sometimes millions in extreme cases) to build up a dataset that adequately covers the plasma volume, which must then be repeated every time the design point changes. Here we adopt a different approach. Rather than launching rays from the plasma periphery and hoping for the best, we instead directly reconstruct the optimal ray for driving current at a given flux surface using a reduced physics model coupled with a commercial ray-tracing code. Repeating this throughout the plasma volume requires only hundreds of simulations, constituting a significant speedup. The new method is validated on two separate example tokamak profiles, and is shown to reliably drive localized current at the specified flux surface with the same optimal efficiency as obtained from the traditional approach.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Experimental Investigation of Polymer Induced Fouling of Heater Tubes in the First-Ever Polymer Flood Pilot on Alaska North Slope

Mineral fouling in heat exchangers has been extensively investigated by researchers in recent times. The oil and gas industry has a long history of fouling issues in production systems as a result of produced fluids treatment. Due to decline in production rates in oilfields new technologies are being developed and field tested in pilots. Polymer flooding is one such technology that involves addition of polymers to injection fluids to enhance oil production. A polymer flood pilot has been set up in the Schrader Bluff viscous oil reservoir at Milne Point field on the Alaska North Slope (ANS). The results from the pilot are encouraging, however a major concern of the operator is the influence of polymer on the production system after breakthrough, especially the fouling in heat exchangers. This study investigates the propensity of polymer fouling on the heater tubes as a function of different variables, with the ultimate goal of determining safe and efficient operating conditions. This work applies a multi-experimental approach to study the severity of polymer-induced fouling in both dynamic and static states of produced fluids as well as studying the stability of polymer solutions at different temperatures. A unique experimental setup was designed and developed in-house to simulate the fouling process on the heating tube. The influence of heating tube skin temperature, tube material, and polymer concentration on fouling tendency was investigated. Each test was run five times with the same tube, and in each run, the freshly prepared synthetic brine and polymer solution was heated from 77°F to 122°F to mimic field-operating conditions. The heating time and fouling amount were recorded for each run. Dynamic Scale Loop (DSL) tests were conducted to study fouling due to polymer at different temperatures (165°F to 350°F) in a dynamic state of fluid flow where the fluids mimic the residence time of fluids in the heat exchanger on the field pilot. Cloud point measurement has also been conducted to find the critical temperature at which the polymer in solution becomes unstable and precipitates out. The morphology and composition of the deposit samples were analyzed by environmental scanning electron microscopy (ESEM) and X-ray diffraction (XRD), respectively. It was found that the presence of polymer in produced fluids would aggravate the fouling issues on both carbon steel and stainless-steel surfaces at all tested skin temperatures. Only higher skin temperatures of 250°F and 350°F could cause polymer-induced fouling issues on the copper tube surface, and the fouling tendency increased with polymer concentration. At the lower skin temperatures of 165°F, no polymer-induced fouling was identified on the copper tube. A critical temperature that is related to the cloud point of the polymer solution was believed to exist, below which polymer-induced fouling would not occur, and only mineral scale was deposited but above which the polymer would aggravate the fouling issue. The cloud point of the tested polymer solution was determined to be between 220°F and 230°F. In the DSL tests it was found that at higher skin temperatures of 250°F and 350°F tube blocking was observed in the DSL tests whereas the tests at 165°F and 200°F did not show any tube blocking in the same time period. These experiments also manifested the influence of cloud point of the solution as deposit rate increased significantly in both carbon steel and stainless-steel tubes when the skin temperature was higher than the solution cloud point. The results of this study have provided guidance to the operator for the field-operations.

Dhaliwal, Anshul↗
DOE OSTI2023

Precision redshift-space galaxy power spectra using Zel'dovich control variates

Numerical simulations in cosmology require trade-offs between volume, resolution and run-time that limit the volume of the Universe that can be simulated, leading to sample variance in predictions of ensemble-average quantities such as the power spectrum or correlation function(s). Sample variance is particularly acute at large scales, which is also where analytic techniques can be highly reliable. This provides an opportunity to combine analytic and numerical techniques in a principled way to improve the dynamic range and reliability of predictions for clustering statistics. In this paper we extend the technique of Zel'dovich control variates, previously demonstrated for 2-point functions in real space, to reduce the sample variance in measurements of 2-point statistics of biased tracers in redshift space. We demonstrate that with this technique, we can reduce the sample variance of these statistics down to their shot-noise limit out to k ~ 0.2 h Mpc -1 . This allows a better matching with perturbative models and improved predictions for the clustering of e.g. quasars, galaxies and neutral Hydrogen measured in spectroscopic redshift surveys at very modest computational expense. We discuss the implementation of ZCV, give some examples and provide forecasts for the efficacy of the method under various conditions.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Investigating Marine Environmental Degradation of Additive Manufacturing Materials for Renewable Energy Applications

Marine renewable energy is a relatively young industry where there is a great need for rapid prototyping in design-build-test campaigns to quickly mature groundbreaking technologies. Additive manufacturing has an important role to play in the industry; however, little information is available to marine energy developers to help inform them on which additive manufacturing materials are appropriate for highly loaded structures in harsh marine environments. This paper presents an initial study on the mechanical characterization of polymeric additive manufacturing materials and the degradation effects due to the marine environment. Ultem 9085, acrylonitrile styrene acrylate, and chopped carbon-filled nylon, as well as continuous carbon and glass fiber-reinforced nylon were chosen for this study. Samples were manufactured to perform a variety of tension, shear, and compression mechanical characterization tests on the materials. Half of the samples were conditioned in Pacific Ocean water for approximately 6 months at the Pacific Northwest National Laboratory's Marine and Coastal Research Laboratory before being returned for mechanical characterization. The mechanical testing results showed that the Ultem 9085 and acrylonitrile styrene acrylate materials experienced little to no degradation in stiffness or strength after exposure to the marine environment. On the other hand, the nylon-based materials suffered significant stiffness and strength degradation (over 50% in some cases) after environmental conditioning. Ultimately, these data sets should serve as starting points to allow marine renewable energy developers to make informed additive manufacturing material choices for their prototype deployments.

additive manufacturing↗
DOE OSTI2022

A quantitative model of charge injection by ruthenium chromophores connecting femtosecond to continuous irradiance conditions

A kinetic framework for the ultrafast photophysics of tris(2,2-bipyridine)ruthenium(II) phosphonated and methyl-phosphonated derivatives is used as a basis for modeling charge injection by ruthenium dyes into a semiconductor substrate. By including the effects of light scattering, dye diffusion, and adsorption kinetics during sample preparation and the optical response of oxidized dyes, quantitative agreement with multiple transient absorption datasets is achieved on timescales spanning femtoseconds to nanoseconds. In particular, quantitative agreement with important spectroscopic handles—the decay of an excited state absorption signal component associated with charge injection in the UV region of the spectrum and the dynamical redshift of a ~500 nm isosbestic point—validates our kinetic model. Pseudo-first-order rate coefficients for charge injection are estimated in this work, with an order of magnitude ranging from 10 11 to 10 12 s –1 . The model makes the minimalist assumption that all excited states of a particular dye have the same charge injection coefficient, an assumption that would benefit from additional theoretical and experimental exploration. Here, we have adapted this kinetic model to predict charge injection under continuous solar irradiation and find that as many as 68 electron transfer events per dye per second take place, significantly more than prior estimates in the literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Extreme Wind and Waves in U.S. East Coast Offshore Wind Energy Lease Areas

The Outer Continental Shelf along the U.S. east coast exhibits abundant wind resources and is now a geographic focus for offshore wind deployments. This analysis derives and presents expected extreme wind and wave conditions for the sixteen lease areas that are currently being developed. Using the homogeneous ERA5 reanalysis dataset it is shown that the fifty-year return period wind speed (U50) at 100 m a.s.l. in the lease areas ranges from 29.2 to 39.7 ms -1 . After applying corrections to account for spectral smoothing and averaging period, the associated pseudo-point U50 estimates are 34 to 46 ms -1 . The derived uncertainty in U50 estimates due to different distributional fitting is smaller than the uncertainty associated with under-sampling of the interannual variability in annual maximum wind speeds. It is shown that, in the northern lease areas, annual maximum wind speeds are generally associated with intense extratropical cyclones rather than cyclones of tropical origin. Extreme wave statistics are also presented and indicate that the 50-year return period maximum wave height may substantially exceed 15 m. From this analysis, there is evidence that annual maximum wind speeds and waves frequently derive from the same cyclone source and often occur within a 6 h time interval.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame rates of 20 kHz with a 2 µm pixel resolution, and the coincident diagnostic sensor data are recorded at 470 kHz. Furthermore, this work shows that the current system enables the in situ detection of defects during the LPBF process and permits direct correlation of diagnostic signatures at the exact time of defect formation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Demonstrate new plasticity models for doped UO 2 that capture dislocation mechanisms

In light water reactors, fuel vendors are investigating the use of dopants to modify the properties of UO 2 pellets, with the goal of improving pellet-cladding mechanical interactions during operation. Dopants are expected to ‘soften’ the pellets; that is, the doped pellets have higher plastic deformation than conventional UO 2 . This leads to a reduction in the severity of mechanical pellet-cladding interactions, helping to reduce the hoop strain on the cladding. By minimizing the strain exerted by the pellet on the cladding, it is anticipated that cladding performance under accident conditions can be enhanced (i.e., lowering the risk of burst during a LOCA). Dopants such as chromium (Cr) promote grain growth during pellet fabrication, leading to larger grains; therefore, understanding the link between chemistry, microstructure and mechanical deformation (enhanced creep rates) behavior of UO 2 is critical to helping operators further substantiate the benefits of doping UO 2 . Historically, the nuclear energy industry has relied on empirical models to make assessments of performance. Compared to empirical models, mechanistic physics-based models provide benefits, such as, fewer data points for validation and better extrapolation where experimental data is scarce or non-existent. In this report, Bayesian inference techniques have been applied to a previously developed lower length-scale-informed diffusional creep model. The objective is to i) infer lower-length-scale parameter distributions from available experiment and then ii) determine the uncertainties in the measurable quantity (in this case creep rates) after propagating the inferred lower length scale parameter uncertainties. The approach requires many evaluations of the model, which becomes computationally insurmountable; therefore, a neural-network model is trained to data obtained by sampling the full model over the most important parameters. This neural-network is then used in the Bayesian inference approach to determine probability distributions in the parameter values that represent the uncertainty in the model given what is known from the experiments (posterior). A significant reduction compared to conservative initial (prior) uncertainties is achieved through inference against the experimental data, demonstrating the efficacy of this approach. Furthermore, by accounting for uncertainties in the experimental conditions and sample non-stoichiometry, it is possible to resolve apparent discrepancies in experimental measurements within a self-consistent grain boundary (Coble) creep model that is sensitive to chemistry. This work has been written up and submitted to Nuclear Technology for a special issue on accelerated fuel qualification (AFQ). This uncertainty quantification (UQ) work not only improves the diffusional model, while accounting for uncertainty, but also establishes a framework which can readily be applied to the mechanistic models of dislocation deformation developed in this study. The most likely values from the Bayesian analysis are incorporated into our UO 2 diffusional creep model and a lower length scale-informed irradiation UO 2 creep mechanistic model to generate a dataset. This dataset has been provided to our INL collaborators for training an artificial neural network surrogate model, which will be implemented in the BISON fuel performance code to assess how the results differ from those currently obtained using a fully empirical model and that of using the nominal (uncalibrated) atomic scale parameters in our mechanistic model. Plastic deformation (creep and glide) in UO 2 is a complex phenomenon, governed by multiple underlying processes such as local defect concentrations, applied stresses, and microstructural characteristics. Consequently, there is a need for a meso-scale model with polycrystalline resolution capable of extrapolating to large grain sizes applicable to doped UO 2 , where data is limited and the model can help bridge the knowledge gap. By integrating atomistic data into the polycrystal LApx code, it becomes possible to predict dislocation climb and glide plasticity that simple analytical models cannot accurately represent. The application of atomic-scale data within LApx demonstrated the importance of climb and glide mechanisms in reproducing high-stress UO 2 behavior. Behaviors such as this are crucial to capture and implement in BISON, as parts of the fuel pellet can reach temperatures where glide can occur before pellet cracking. This model which captures dislocation based mechanisms for UO 2 is then used to stand up the doped model accounting for larger grain sizes. It was found that larger grain sizes can lead to enhanced deformation rates in the glide regime, and therefore can help with the pellet cladding mechanical interaction. Therefore if the fuel pellet reaches conditions (stress/temperature) where glide is active, the enhanced creep rates for larger grains in the glide regime (doped UO 2 ) can help with pellet cladding mechanical interactions. Plastic deformation in UO 2 involves multiple mechanisms, including diffusional creep, dislocation climb, and glide. This milestone contains two parts: (1) UQ of a pre-existing lower length scale informed mechanistic diffusional creep model, and (2) development of a new LApx based model for dislocation-mediated creep mechanisms in UO 2 , with application to large-grain doped UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗
DOE OSTI2021

Spatially inhomogeneous superconductivity in UTe 2

The newly discovered superconductor UTe 2 is a strong contender for a topological spin-triplet state wherein a multicomponent order parameter arises from two nearly degenerate superconducting states. A key issue is whether both of these states intrinsically exist at ambient pressure. Through thermal expansion and calorimetry, we show that UTe 2 at ambient conditions exhibits two detectable transitions only in some samples, and the size of the thermal expansion jump at each transition varies when the measurement is performed in different regions of the sample. This result indicates that the two transitions arise from two spatially separated regions that are inhomogeneously mixed throughout the volume of the sample, each with a discrete superconducting transition temperature (T c ). Notably, samples with higher T c only show a single transition at ambient pressure. Above 0.3 GPa, however, two transitions are invariably observed in ac calorimetry. Our results not only point to a nearly vertical line (constant pressure) in the pressure-temperature phase diagram but also provide a consistent scenario for the sample dependence of UTe 2 .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Microscopic examination of rf-cavity-quality niobium films through local nonlinear microwave response

The performance of superconducting radio-frequency (SRF) cavities is sometimes limited by local defects. To investigate the rf properties of these local defects, especially those that nucleate rf magnetic vortices, a near-field magnetic microwave microscope is employed. Local third-harmonic response ( P 3 f ) and its temperature dependence and rf power dependence are measured for one Nb / Cu film grown by direct current magnetron sputtering (DCMS) and six Nb / Cu films grown by high-power impulse magnetron sputtering (HiPIMS) with systematic variation of deposition conditions. Five out of the six HiPIMS Nb / Cu films show a strong third-harmonic response that is likely coming from rf vortex nucleation due to a low- T c surface defect with a transition temperature between 6.3 and 6.8 K, suggesting that this defect is a generic feature of air-exposed HiPIMS Nb / Cu films. A phenomenological model of surface-defect grain boundaries hosting a low- T c impurity phase is introduced and studied with time-dependent Ginzburg-Landau (TDGL) simulations of probe-sample interaction to better understand the measured third-harmonic response. The simulation results show that the third-harmonic response of rf vortex nucleation caused by surface defects exhibits the same general features as the data, including peaks in third-harmonic response with temperature, and their shift and broadening with higher microwave amplitude. We find that the parameters of the phenomenological model (the density of surface defects that nucleate rf vortices and the depth an rf vortex travels through these surface defects) vary systematically with film deposition conditions. From the point of view of these two properties, the Nb / Cu film that is most effective at reducing the nucleation of rf vortices associated with surface defects can be identified. Published by the American Physical Society 2024

Wang, Chung-Yang (ORCID:0000000184299633)↗
DOE OSTI2024

Androgynous { 10 1 ¯ 2 } twin in zinc

Under ambient conditions, Zn is a hexagonal metal with a large c / a ratio of 1.856. Plastic deformation is predominantly accommodated by basal 〈 a 〉 slip and compression twins on the { 10 1 ¯ 2 } planes. Increasing hydrostatic pressure drastically reduces the c / a ratio of Zn and, when a critical threshold of c / a = 3 at about 10 GPa is crossed, the { 10 1 ¯ 2 } twins are predicted to change from compressive to tensile in nature. What happens at the transition point, when c / a = 3 , remains unknown. Here, we strain-cycle a textured polycrystalline sample of pure Zn at uniform hydrostatic pressures ranging between 2 and 17 GPa, over which the c / a ratio crosses the c / a = 3 compressive-tensile transition for { 10 1 ¯ 2 } twins. During deformation, the state of the sample is monitored through x-ray diffraction to extract texture and internal strain evolution. By comparing the experimental results with the predictions of an elastoviscoplastic polycrystal simulation, we confirm the androgynous nature of { 10 1 ¯ 2 } twin response at low and high pressures. When c / a = 3 , polycrystalline Zn does not display any evidence of twinning and its plastic behavior is controlled by mostly basal and pyramidal 〈 c + a 〉 slip activity, with a very small contribution of prismatic 〈 a 〉 slip. Evidence for the activity of other { 10 1 ¯ n } twinning modes, which have been suggested for Zn under high pressure, are not observed. Published by the American Physical Society 2024

Merkel, Sébastien (ORCID:000000032767581X)↗