Results for “component performance” — Page 9

DOE OSTI2023

Analysis of Pitting Corrosion on Wrought and Additively Manufactured 316L Stainless Steel in Atmospheric Environments

Additive manufacturing of metal components enables rapid fabrication of complex geometries. However, metal additive manufacturing also introduces new morphological and microstructural characteristics which might be detrimental to component performance. Here we report the pitting corrosion properties of wrought and additively manufactured 316L stainless steel after atmospheric exposure to coastal environments and laboratory-created environments. Qualitative visualization in combination with quantitative analysis of resulting pits provided an in-depth understanding of pitting differences between wrought and additively manufactured 316L stainless steel and between coastal and laboratory-based exposure. Optical and scanning electron microscopy were utilized for visualization, while white light interferometry measured pits across approximately 5mm x 5mm areas on each sample. Post-processing of the interferometry data enables quantification of pitting attack for each sample in terms of both pit depth and pit volume. The pitting analysis introduced herein offers a new technique to compare pitting attack between different manufacturing processes and materials.

36 MATERIALS SCIENCE↗

DOE OSTI2025

U.S. Efforts in Support of Examinations at Fukushima Daiichi - September 2024 Meeting Notes

Information obtained from Fukushima Daiichi Nuclear Power Station (Daiichi) is required to inform future Decontamination and Decommissioning (D&D) activities, improving the ability of the Tokyo Electric Power Company Holdings, Incorporated (TEPCO Holdings) to characterize potential hazards and to ensure the safety of workers involved with cleanup activities. This information also has important implications for the safety and operation of U.S. Commercial nuclear power plants. A collaborative U.S. and Japanese effort was initiated in 2014 by the Department of Energy Office of Nuclear Energy to identify Daiichi examination needs and evaluate recent Daiichi examination data to address these needs. This document summarizes information presented at and findings, action items, and recommendations by U.S. and Japanese experts in reactor safety and plant operations during the September 2024 Forensics Effort meeting. Significant safety insights were obtained in several areas: system and component performance, radionuclide surveys and sampling, debris end-state location, combustible gas effects, and plant operations and maintenance. In addition to reducing uncertainties and knowledge gaps in severe accident modeling progression, these insights continue to be used to assess whether additional updates are needed in guidance for severe accident prevention, mitigation, and emergency planning. Furthermore, Daiichi-related activities, such as code modeling improvements and analysis, testing, and new technology deployment efforts, have the potential to offer additional safety and economic benefits to the operating fleet and new light water reactor (LWR) and non-LWR designs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Assessment of Heavy-Duty Fueling Methods and Components

Chevron, NLR, ANL, and NextEnergy partnered in the development of a comprehensive assessment of heavy-duty (HD) fuel cell electric vehicle fueling protocols. The project leveraged and built upon existing international heavy-duty (HD) fueling protocols and fueling component development activities to deliver component performance assessments, modeling tools and methods evaluations, techno-economic assessments of industry-selected protocol structures and experimental validations of the strategies performed at NLR's HD hydrogen fueling station.

08 HYDROGEN↗

DOE OSTI2026

NRC Reactor Operating Experience Analysis and Trend Summary: 2024 Update

This report presents a summary of the Nuclear Regulatory Commission’s (NRC’s) reactor operating experience analyses with data through 2024 as well as the reliability and frequency trends identified in the 2024 update reports for the component performance studies, loss-of-offsite power analysis, initiating events analysis, and system studies provided on the NRC Reactor Operating Experience Results and Databases website (https://nrcoe.inl.gov/).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

SULI Report - Development of a Molten Salt Circulation Loop for in-situ Spectroscopy

This project supports the development of real time optical monitoring capabilities for molten salt reactor (MSR) environments by designing, testing, and refining a molten salt circulation loop suitable for combined laser induced breakdown spectroscopy (LIBS) and ultraviolet visible (UV Vis) absorption measurements. Online spectroscopic monitoring is increasingly important for nuclear safeguards, corrosion tracking, and material accountancy, yet MSR process fluids present substantial challenges due to their chemical complexity and hazards such as high temperatures and radiation. To address these needs, this work focuses on Phase I, the development of a room temperature aqueous circulation loop that serves as a surrogate platform for evaluating flow behavior, optical access, and component performance prior to high temperature salt operation. Initial testing identified several practical issues—including leaks, obstructions, and two-phase flow through the absorption cell—that were systematically resolved through hardware replacement, flow path redesign, and venturi pressure optimization. Relocating the flow cell upstream of the primary venturi enabled periods of stable single-phase flow, demonstrating the feasibility of integrating optical diagnostics into a circulation system. The results of Phase I provide essential design insight for Phase II, which will incorporate furnace compatible materials and LiCl KCl eutectic salt. Completion of the molten salt system will deliver a reusable testbed for evaluating multimodal spectroscopic techniques, advancing nondestructive, real time monitoring tools for future MSR and nuclear fuel cycle applications.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗

DOE OSTI2024

Machine Learning for Additive Manufacturing of Functionally Graded Materials

Additive Manufacturing (AM) is a transformative manufacturing technology enabling direct fabrication of complex parts layer-by-layer from 3D modeling data. Among AM applications, the fabrication of Functionally Graded Materials (FGMs) has significant importance due to the potential to enhance component performance across several industries. FGMs are manufactured with a gradient composition transition between dissimilar materials, enabling the design of new materials with location-dependent mechanical and physical properties. This study presents a comprehensive review of published literature pertaining to the implementation of Machine Learning (ML) techniques in AM, with an emphasis on ML-based methods for optimizing FGMs fabrication processes. Through an extensive survey of the literature, this review article explores the role of ML in addressing the inherent challenges in FGMs fabrication and encompasses parameter optimization, defect detection, and real-time monitoring. The article also provides a discussion of future research directions and challenges in employing ML-based methods in the AM fabrication of FGMs.

36 - MATERIALS SCIENCE↗

DOE OSTI2022

CALET Search for Electromagnetic Counterparts of Gravitational Waves during the LIGO/Virgo O3 Run

The CALorimetric Electron Telescope (CALET) on the International Space Station consists of a high-energy cosmic-ray CALorimeter (CAL) and a lower-energy CALET Gamma-ray Burst Monitor (CGBM). CAL is sensitive to electrons up to 20 TeV, cosmic-ray nuclei from Z = 1 through Z ~ 40, and gamma rays over the range 1 GeV–10 TeV. CGBM observes gamma rays from 7 keV to 20 MeV. The combined CAL-CGBM instrument has conducted a search for gamma-ray bursts (GRBs) since 2015 October. We report here on the results of a search for X-ray/gamma-ray counterparts to gravitational-wave events reported during the LIGO/Virgo observing run O3. No events have been detected that pass all acceptance criteria. We describe the components, performance, and triggering algorithms of the CGBM—the two Hard X-ray Monitors consisting of LaBr 3 (Ce) scintillators sensitive to 7 keV–1 MeV gamma rays and a Soft Gamma-ray Monitor BGO scintillator sensitive to 40 keV–20 MeV—and the high-energy CAL consisting of a charge detection module, imaging calorimeter, and the fully active total absorption calorimeter. The analysis procedure is described and upper limits to the time-averaged fluxes are presented.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2013

Development of a Residential Ground-Source Integrated Heat Pump

A residential-size ground-source integrated heat pump (GSIHP) system has been developed and is currently being field tested. The system is a nominal 2-ton (7 kW) cooling capacity, variable-speed unit, which is multi-functional, e.g. space cooling, space heating, dedicated water heating, and simultaneous space cooling and water heating. High-efficiency brushless permanent-magnet (BPM) motors are used for the compressor, indoor blower, and pumps to obtain the highest component performance and system control flexibility. Laboratory test data were used to calibrate a vapor-compression simulation model (HPDM) for each of the four primary modes of operation. The model was used to optimize the internal control options and to simulate the selected internal control strategies, such as controlling to a constant air supply temperature in the space heating mode and a fixed water temperature rise in water heating modes. Equipment performance maps were generated for each operation mode as functions of all independent variables for use in TRNSYS annual energy simulations. These were performed for the GSIHP installed in a well-insulated 2600 ft2(242 m2) house and connected to a vertical ground loop heat exchanger(GLHE). We selected a 13 SEER (3.8 CSPF )/7.7 HSPF (2.3 HSPF, W/W) ASHP unit with 0.90 Energy Factor (EF) resistance water heater as the baseline for energy savings comparisons. The annual energy simulations were conducted over five US climate zones. In addition, appropriate ground loop sizes were determined for each location to meet 10-year minimum and maximum design entering water temperatures (EWTs) to the equipment. The prototype GSIHP system was predicted to use 52 to 59% less energy than the baseline system while meeting total annual space conditioning and water heating loads.

Energy Efficiency↗

DOE OSTI2016

Energy Factor Analysis for Gas Heat Pump Water Heaters

Gas heat pump water heaters (HPWHs) can improve water heating efficiency with zero GWP and zero ODP working fluids. The energy factor (EF) of a gas HPWH is sensitive to several factors. In this work, expressions are derived for EF of gas HPWHs, as a function of heat pump cycle COP, tank heat losses, burner efficiency, electrical draw, and effectiveness of supplemental heat exchangers. The expressions are used to investigate the sensitivity of EF to each parameter. EF is evaluated on a site energy basis (as used by the US DOE for rating water heater EF), and a primary energy-basis energy factor (PEF) is also defined and included. Typical ranges of values for the six parameters are given. For gas HPWHs, using typical ranges for component performance, EF will be 59 80% of the heat pump cycle thermal COP (for example, a COP of 1.60 may result in an EF of 0.94 1.28). Most of the reduction in COP is due to burner efficiency and tank heat losses. Gas-fired HPWHs are theoretically be capable of an EF of up to 1.7 (PEF of 1.6); while an EF of 1.1 1.3 (PEF of 1.0 1.1) is expected from an early market entry.

Gluesenkamp, Kyle R↗

DOE OSTI2016

A Practical Look at Assumptions and Constraints for Steady State Modeling of sCO2 Brayton Power Cycles

Modeling supercritical CO2 (sCO2) power cycles requires specification of system constraints and component performance metrics such as pressure losses and temperature limitations.? Differing assumptions made by the model designers may lead to significantly different results which are due to the assumptions and not to the underlying thermodynamics which characterize the cycle performance. As leaders in setting standards for techno-economic analyses, NETL and EPRI have collaborated to propose a set of practical modeling assumptions that can serve as a common baseline for both indirect and direct sCO2 power plant studies, allowing for more meaningful cycle comparisons. These include specifications for turbine inlet temperature (high temperature and pressure limitations), compressor inlet temperature and pressure (cooling limitations), heat exchanger effectiveness/temperature differentials and pressure drop, and full- and part-load turbine and compressor efficiencies.

Weiland, Nathan↗

DOE OSTI2016

A Practical Look at Assumptions and Constraints for Steady State Modeling of sCO2 Brayton Power Cycles

Modeling supercritical CO2 (sCO2) power cycles requires specification of system constraints and component performance metrics such as pressure losses and temperature limitations.? Differing assumptions made by the model designers may lead to significantly different results which are due to the assumptions and not to the underlying thermodynamics which characterize the cycle performance. As leaders in setting standards for techno-economic analyses, NETL and EPRI have collaborated to propose a set of practical modeling assumptions that can serve as a common baseline for both indirect and direct sCO2 power plant studies, allowing for more meaningful cycle comparisons. These include specifications for turbine inlet temperature (high temperature and pressure limitations), compressor inlet temperature and pressure (cooling limitations), heat exchanger effectiveness/temperature differentials and pressure drop, and full- and part-load turbine and compressor efficiencies.

Thimsen, David↗

DOE OSTI2015

Transportation Database Development Using Floating Car Data

In support of projects funded by the U.S. Department of Transportation and the U.S. Department of Energy, the National Renewable Energy Laboratory (NREL) has received on average 4 million floating car data (FCD) points each day over a 3-year period. To handle data sets of this size, the Transportation & Hydrogen Systems Center at NREL has developed a series of transportation databases (Transportation Secure Data Center and Fleet DNA projects) to support real-world vehicle and transportation infrastructure analysis on a national scale. To ensure the quality of the FCD received by NREL and to ensure that data can be accessed and applied quickly and easily across transportation research disciplines, a customized data processing routine and database were required. 'Floating car data' is a general term for location data recorded by a vehicle or by a person traveling in a vehicle. FCD are used to support real-time traffic information systems and have proven to be beneficial in a large number of research applications. For large-scale traffic information systems, FCD are logged from smart phones using either the GPS included in the device, or if GPS is disabled, triangulation from the network. Additionally, in scientific applications FCD are oftentimes collected on a smaller scale using onboard GPS-enabled data logging systems. Through the fusion of real-time data and historically logged results, up-to-date and accurate vehicle operating information are provided in near real-time to support routing and operation decisions. The approach outlined within this paper builds upon methods developed for advanced traffic information systems to link FCD to the street of travel and further extends the link to data recorded by components within a vehicle. Linking vehicle component performance to the infrastructure a vehicle is operating within provides the path to assess vehicle and infrastructure interactions, going far beyond providing information on traffic flow alone.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Integrated Hardfacing of Stellite-6 Using Hybrid Manufacturing Process

Hybrid manufacturing systems provide a platform for integrated additive, subtractive and inspection methods on a single machine setup. The present work explores use of hybrid manufacturing for hardfacing of performance components for improving wear resistance. In this work, Stellite-6 was applied to a 410 stainless steel substrate using a hybrid manufacturing system incorporating multi-axis directed energy deposition and machining. Experimental testing was conducted to determine the effects of hybrid manufacturing parameters on internal porosity, surface porosity and microstructure in the cladded material, as well as on the roughness of the final machined surface. Correlation between porosity measurements made by x-ray tomography and surface dye-penetrant testing is presented and determination of ideal process parameters for hardfacing of components using hybrid manufacturing systems is briefly discussed.

Praniewicz, Maxwell↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

42 ENGINEERING↗

DOE OSTI2020

Component and Circuit Performance Measurements for Coherent Radar - A Systems Perspective

A useful performance metric for Intelligence, Surveillance, and Reconnaissance (ISR) radar systems is the Impulse Response (IPR). This is true for a fidelity metric for the signal channel, as well as a stability measure across multiple pulses. The IPR represents performance with respect to both amplitude and phase modulations of the transfer function for components, circuits, subassemblies, and even the looped radar hardware. The proper IPR performance specification limits will depend on radar operating mode. Generally, it will be the intersection of the strictest requirements.

42 ENGINEERING↗

DOE OSTI2025

From Machine Learning to Machine Reasoning: A Model-based Approach to Analyze Equipment Reliability Data

In current nuclear power plants (NPPs) a large amount of condition-based data which can be used to assess and monitor component health and performance. Assessing component health from such data can be performed with a large variety of methods. While the analysis of numeric data can be performed with several methods, the extraction of information from textual data remains a challenge. Currently employed natural language processing (NLP) methods do not really provide quantitative information that might be contained in IRs. In addition, the integration of numeric and textual data to identify possible causal relationships between data elements is still an unresolved challenge. This paper presents an approach to extract information from textual (e.g., incident or maintenance reports) and numeric data that relies on model based system engineer (MBSE) models. MBSE are diagrams designed to represent system and component dependencies (from both a form and functional point of view). In our approach, MBSE models emulate system engineer knowledge about component/system architecture. NLP methods are employed to perform syntactic and semantic analyses. Syntactic analysis analyzes the grammatical structure of a sentence while semantic analysis is designed to analyze the logic structure of a sentence. An innovative element of our approach is that semantic analysis uses MBSE models to identify links between textual elements. Similarly, numeric data is directly linked to elements of the MBSE models in order to map which functions are being monitored.

97 - MATHEMATICS AND COMPUTING↗