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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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At least 163 records · Page 9

Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors

This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Membranes in Solar-Driven Evaporation: Design Principles and Applications

In this study, solar-driven evaporation process brings exciting opportunities to recover clean water and resources in a sustainable way from diverse sources like seawater and wastewater. Separation membranes, as a vital material in many environmental and energy applications, can contribute significantly to this process owing to their structural features. However, the unique roles of membranes in solar evaporator construction and process design are seldom recognized and not summarized yet from scientific principles and application demands, which forms the motivation of this review. Herein, the roles of membranes in different processes based on solar-driven evaporation are focused and the design principles of membrane materials and devices to meet the requirements of these applications are discussed. Fabrication strategies for photothermal membranes are introduced primarily, followed by a discussion on how to design membrane materials, devices, and processes to pursue optimal performance and realize advanced functions accompanied by evaporation. Furthermore, the future of this field is forecast with both challenges and opportunities.

14 SOLAR ENERGY↗

Initial development and verification of a primary load design method based on elastic-perfectly plastic analysis

This report describes a new primary load design method to supplement the current design-by-elastic-analysis rules in Section III, Division 5, Subsection HB, Subpart B of the ASME Boiler and Pressure Vessel Code, covering the design and construction of Class A high temperature nuclear structural components. The main objectives for the new design method are to provide a procedure that can be applied to components with complicated geometries and to simplify the primary load design process by providing rules more compatible with modern finite element analysis. The report includes a complete set of design rules, presented as a draft ASME Code Case, as well as a commentary on the rules and a set of verification problems. The verification design problems demonstrate the new primary load design rules produce safe, efficient components when compared to the current Division 5 approach, while greatly simplifying the design analysis process.

42 ENGINEERING↗

Building a Computational and Experimental Rapid Response Pipeline to Counter the Coronavirus Disease 2019 Outbreak and Emerging Biothreats

The COVID-19 pandemic underscored the promise of monoclonal antibody-based prophylactic and therapeutic drugs, especially where protective candidates can be rapidly identified or developed for emerging biothreats and escape variants. Current cutting-edge technologies for this purpose still rely on pathogen-exposed convalescent volunteers and a large screening effort to find a proverbial needle in a haystack. Computational design of protective antibodies based on pre-existing templates skips those requirements and allows for greater control over the breadth and target epitope, while also co-optimizing for potency and developability or other biophysical characteristics. We approached this problem by building and expanding an in vitro experimental rapid antibody production and characterization pipeline to support development of an autonomous, closed loop, active learning software system based on structural simulation and ground truth experimental data to design and evaluate antibody antigen interactions. Starting from early in the pandemic, we targeted SARS-CoV-2, the causative agent of COVID-19, by re-purposing neutralizing antibodies against SARS-CoV-1 that had been identified in the wake of that outbreak in the early 2000’s. We successfully re-targeted three different anti-SARS-CoV-1 antibodies to neutralize SARS-CoV-2 in vitro, where the antibodies were generated externally and tested through conventional binding and neutralization assays internally or with collaborators. As antibodies were identified from the blood of humans infected with SARS-CoV-2, we shifted to collaborate with academic partners to develop improved versions of their human-derived antibodies. This work reached its most important stage in rapid response to the emergence of the Omicron variant of concern (VOC) in late 2021. In a matter of weeks, enabled by on demand innovation to our screening pipeline, we computationally designed and experimentally characterized derivative antibodies of COV2-2130, one of two antibodies from Vanderbilt that form the basis of the AstraZeneca Evusheld prophylactic drug product. This drug product suffers a serious loss of efficacy against Omicron BA.1 and BA.1.1, the first Omicron strains. Due to tight integration of computational design and experimental evaluation, we were able to identify a pair of designs with potent neutralization of the main targets Omicron BA.1 and BA.1.1; but also the earlier Delta variant, and subsequent Omicron strains including BA.2, BA.4, BA.5, and BA.2.75, demonstrating that our multi-target design process can, by its nature, produce robust antibody designs that strictly improve over the parental antibody. These results, recognized by a 2022 Director’s Science and Technology award, have enabled the follow-on GUIDE program, to commence in FY23. While earlier design campaigns were substantially outsourced, we have engineered better and faster processes internally to better compliment, calibrate, and speed computational designs. As part of the follow-on GUIDE program, we will stand up a rapid and high-throughput antibody production and characterization facility staffed with the expertise and capabilities to foster our current collaboration across PLS and ENG as well as other partnerships toward computational design of biologics.

59 BASIC BIOLOGICAL SCIENCES↗

Control co-design of 13 MW downwind two-bladed rotors to achieve 25% reduction in levelized cost of wind energy

Wind energy is recognized worldwide as cost-effective and environmentally friendly and is among the fastest-growing sources of electrical energy. To further decrease the cost of wind energy, wind turbines are being designed at ever larger scales, which is challenging due to greater structural loads and deflections. Large-scale systems such as modern wind turbines increasingly require a control co-design approach, whereby the system design and control design are performed in a more integrated fashion. We overview a two-bladed downwind morphing rotor concept that is expected to lower the cost of energy at wind turbine sizes beyond 13 megawatts (MW) compared with continued upscaling of traditional three-bladed upwind rotor designs. We describe an aero-structural-control co-design process that we have used in designing such extreme-scale wind turbines, and we discuss how we were able to achieve a 25% reduction in levelized cost of energy for our final turbine design compared to a conventional upwind three-bladed rotor design.

17 WIND ENERGY↗

Mechanics of Dynamic and Deformable DNA Nanostructures

In DNA nanotechnology, DNA molecules are designed, engineered, and assembled into arbitrary-shaped architectures with predesigned functions. Static DNA assemblies often have delicate designs with structural rigidity to overcome thermal fluctuations. Dynamic structures reconfigure in response to external cues, which have been explored to create functional nanodevices for environmental sensing and other applications. However, the precise control of reconfiguration dynamics has been a challenge due partly to flexible single-stranded DNA connections between moving parts. Deformable structures are special dynamic constructs with deformation on double-stranded parts and single-stranded hinges during transformation. These structures often have better control in programmed deformation. However, related deformability and mechanics including transformation mechanisms are not well understood or documented. In this review, we summarize the development of dynamic and deformable DNA nanostructures from a mechanical perspective. We present deformation mechanisms such as single-stranded DNA hinges with lock-and-release pairs, jack edges, helicity modulation, and external loading. Theoretical and computational models are discussed for understanding their associated deformations and mechanics. We elucidate the pros and cons of each model and recommend design processes based on the models. The design guidelines should be useful for those who have limited knowledge in mechanics as well as expert DNA designers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Serpentine Magnet Designs for the Interaction Region of the Electron-Ion Collider (EIC)

The Electron-Ion Collider (EIC), hosted by Brookhaven National Laboratory, is designed to deliver a peak luminosity of 1 × 10 34 cm −2 sec −1 . The interaction region (IR) of the EIC imposes several constraints in terms of field quality, aperture, and spatial layout, which necessitates the development of several unique superconducting serpentine direct wind magnets. These magnets are constructed using either a single strand or a small-diameter 6-around-1 NbTi cable, presenting unique challenges for design and optimization. This paper introduces a new computational code specifically developed to streamline and integrate the design process for these magnets, enabling faster design iterations while addressing their complex requirements. Here, in this paper, we first introduce the code, which builds on established electromagnetic fundamentals. The code incorporates tools for optimizing winding patterns and for correcting magnetic multipoles; additionally, it interfaces with established magnet design software. We also present the design of several serpentine magnets for the EIC IR, demonstrating the code’s capability to deliver precise and efficient solutions. These designs highlight the code’s ability to accelerate the development cycle, ensuring the serpentine magnets meet the demanding specifications of the EIC project.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Group-velocity-dispersion engineering of tantala integrated photonics

Designing integrated photonics, especially to leverage Kerr-nonlinear optics, requires accurate and precise knowledge of the refractive index across the visible to infrared spectral ranges. Tantala ( T a 2 O 5 ) is an emerging material platform for integrated photonics and nanophotonics that offers broadband ultralow loss, moderately high nonlinearity, and advantages for scalable and heterogeneous integration. We present refractive index measurements on a thin film of tantala, and we explore the efficacy of this data for group-velocity-dispersion (GVD) engineering with waveguide and ring-resonator devices. In particular, the observed spectral extent of supercontinuum generation in fabricated waveguides and the wavelength dependence of free spectral range (FSR) in optical resonators provide a sensitive test of our integrated photonics design process. Our work opens up new design possibilities with tantala, including with octave-spanning soliton microcombs.

Black, Jennifer A.↗

Design and Development of the Handling Frame Assembly Table for the NIF Sustainment Project (Draft)

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The NIF Sustainment project's goal is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, design analysis and validation, and final design. Future work will focus on building and commissioning the system.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗

Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields

The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.

42 ENGINEERING↗

General Failure Modes and Effects Analysis for Accelerator and Detector Magnet Design at JLab

The aim of this article is to develop a risk management procedure, which could be applied to the magnet design process, for both superconducting and normal magnets at the Jefferson Laboratory (JLab). This procedure allowed us to identify the key risks at each of the critical phases of design and propose procedures, tests, and checks to mitigate each risk. In this article, we present a qualitative and quantitative risk management procedure commonly referred to a “failure modes and effects analysis.” As part of this procedure, we calculated a risk priority number (RPN) for each activity of the process, identified the most critical activities and proposed mitigation activities, which in turn resulted in a revised RPN. Additionally, another benefit of this procedure was the identification of appropriate “control and hold” points within the design process, which allowed one to review and approve a particular outcome before proceeding to the next sequential activity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Optimizing Batch Crystallization with Model-based Design of Experiments

Poster for Foundations of Computer Aided Process Design (FOCAPD) 2024 describing the formality of model-based design of experiments for batch crystallization. This paper focuses on the implementation of model-based design of experiments for parameter precision, enabled by Pyomo.DoE, a package in Python. Specifically, this work outlines an identifiability analysis for the estimability of the model parameters in a batch crystallization system.

Lynch, Hailey↗

Machine learning-driven design and self-sensing capabilities of automotive bumper lattices for adaptive impact response

We present a novel approach to design an automotive bumper energy absorber using carbon fiber reinforced polymer composites, optimized to meet conflicting performance requirements for two distinct impact scenarios. The design must satisfy both a low-speed (2.5 mph) pendulum intrusion test, simulating vehicle-to-vehicle collisions, and a high-speed (25 mph) leg flexion test, replicating pedestrian impacts. These tests demand opposing deformation characteristics: high flexibility (deformation < 85 mm) for the former and high stiffness (deformation < 22 mm) for the latter. To address these contradictory requirements, we developed a machine learning (ML) framework for inverse optimization of lattice designs and material selection. Unlike traditional iterative design processes, our ML model directly outputs optimal design parameters and material choices based on target performance inputs. The energy absorber was fabricated using advanced additive manufacturing techniques, including extrusion deposition and digital light processing. The integration of carbon fibers provides multifunctionality to the bumper structure, enabling self-sensing capabilities through changes in electrical resistivity under compression. This electrical response demonstrates high repeatability under multiple cycles at 2% compression and exhibits distinct signatures during crack formation under high deformation. This research offers adaptive performance through innovative design methodologies and smart material integration. The approach has potential applications in various fields requiring adaptive energy absorption and real-time structural health monitoring.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗

Safety-Related Instrumentation and Control Pilot Upgrade (Initial Scoping Phase Implementation Report)

This research report (1) describes the process followed and products developed during the SR I&C Pilot Project Initial Scoping Phase, and (2) captures lessons learned. Exelon Generation and LWRS collaborated to develop a Digital Transformation Strategy as part of a larger Advanced Concept of Operations. The proposed SR I&C Pilot Upgrade provides a foundation stone for this Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant Total Cost of Ownership (TCO). Initial Scoping Phase activities for this Pilot Project have been performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process (SDP), NISP-EN-04, Standard Digital Engineering Process (SDEP), and Electric Power Research Institute (EPRI) Report 3002011816, Digital Engineering Guide (DEG). Completing Initial Scoping Phase Engineering and Operations, Licensing, and Project Management Activities was necessary to sufficiently bound the scope, schedule, and estimated cost of the Project to enable utility management to authorize moving into the Conceptual Design Phase. A significant finding of the Business Case Analysis (BCA) methodology developed and applied as part of this effort was that the growth rate of material costs for sustaining the operation of obsolete SR I&C equipment is accelerating. This directly contributed to the Project Economic Analysis created to justify continuing the Project. Project Initial Scoping Phase lessons learned have also been captured to assist the larger industry in understanding the Digital Transformation Strategy and SR I&C Pilot Project Initial Scoping Phase efforts. This is in keeping with the public/private partnership that has been established between the Department of Energy (DOE) and Exelon for this effort with engagement from the NRC. By addressing first-of-a-kind (FOAK) risks and capturing lessons learned, the SR I&C Pilot Upgrade Project addresses technical, regulatory, and business risks to enable subsequent implementers of similar upgrade.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Safety-Related Instrumentation & Control Pilot Upgrade Initiation Phase Implementation Report

This research report (1) describes the process followed and products developed during the SR I&C Pilot Project Initial Scoping Phase, and (2) captures lessons learned. Exelon Generation and LWRS collaborated to develop a Digital Transformation Strategy as part of a larger Advanced Concept of Operations. The proposed SR I&C Pilot Upgrade provides a foundation stone for this Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant Total Cost of Ownership (TCO). Initial Scoping Phase activities for this Pilot Project have been performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process (SDP) [Reference 2], NISP-EN-04, Standard Digital Engineering Process (SDEP) [Reference 3], and Electric Power Research Institute (EPRI) Report 3002011816, Digital Engineering Guide (DEG). Completing Initial Scoping Phase Engineering and Operations, Licensing, and Project Management Activities was necessary to sufficiently bound the scope, schedule, and estimated cost of the Project to enable utility management to authorize moving into the Conceptual Design Phase. A significant finding of the Business Case Analysis (BCA) methodology developed and applied as part of this effort was that the growth rate of material costs for sustaining the operation of obsolete SR I&C equipment is accelerating. This directly contributed to the Project Economic Analysis created to justify continuing the Project. Project Initial Scoping Phase lessons learned have also been captured to assist the larger industry in understanding the Digital Transformation Strategy and SR I&C Pilot Project Initial Scoping Phase efforts. This is in keeping with the public/private partnership that has been established between the Department of Energy (DOE) and Exelon for this effort with engagement from the NRC. By addressing first-of-a-kind (FOAK) risks and capturing lessons learned, the SR I&C Pilot Upgrade Project addresses technical, regulatory, and business risks to enable subsequent implementers of similar upgrades.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Safety-Related Instrumentation and Control Upgrade Pilot Project: NUREG- 0711 Process Development, Planning and Analysis Activities, and Lessons Learned

Constellation Energy and the United States Department of Energy (DOE) have established a public/private partnership to implement a pilot digital upgrade to replace legacy analog, safety-related reactor protection and emergency safety feature actuation systems (RPS/ESFAS) with modern digital systems. This effort is occurring at Constellation’s Limerick Generating Station. This project is being performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process, NISP-EN-04, Standard Digital Engineering Process and Electric Power Research Institute Report 3002011816, Digital Engineering Guide. The Light Water Reactor Sustainability (LWRS) Program at the Idaho National Laboratory (INL) has been supporting this effort. Latest INL HFE efforts in support of this project have focused on definition and implementation of the Human Factors Engineering (HFE) Program in support of Constellation design and related licensing efforts. This paper presents the development execution of the HFE Program through completion of the Planning and Analysis Phase as defined by NUREG-0711 as well as HFE lessons learned.

99 GENERAL AND MISCELLANEOUS↗

Robust optimization of flexible diafiltration systems for critical mineral separations

This paper provides major contributions in expanding the literature for membrane process design with critical mineral recovery applications and showcasing the importance of robust design techniques for reducing risks of underperformance in such systems. Here, a membrane process flowsheet featuring PrOMMiS membrane models for recovering lithium/cobalt from spent batteries is showcased, uncertainty in membrane sieving and localized fouling are considered, and robust designs are obtained using the PyROS toolset. This paper is intended for a general audience of researchers working in critical minerals, membranes, and optimization related areas.

36 MATERIALS SCIENCE↗