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DOE OSTI2021

INTEGRATE - Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project is developing a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. This AI-based design technology can capture complex non-linear aerodynamic effects while being 100 times faster than design approaches based on computational fluid dynamics. This project enables innovation in wind turbine design by accelerating time to market through higher-accuracy early design iterations to reduce the levelized cost of energy. INVERTIBLE NEURAL NETWORKS Researchers are leveraging a specialized invertible neural network (INN) architecture along with the novel dimension-reduction methods and airfoil/blade shape representations developed by collaborators at the National Institute of Standards and Technology (NIST) learns complex relationships between airfoil or blade shapes and their associated aerodynamic and structural properties. This INN architecture will accelerate designs by providing a cost-effective alternative to current industrial aerodynamic design processes, including: - Blade element momentum (BEM) theory models: limited effectiveness for design of offshore rotors with large, flexible blades where nonlinear aerodynamic effects dominate - Direct design using computational fluid dynamics (CFD): cost-prohibitive - Inverse-design models based on deep neural networks (DNNs): attractive alternative to CFD for 2D design problems, but quickly overwhelmed by the increased number of design variables in 3D problems AUTOMATED COMPUTATIONAL FLUID DYNAMICS FOR TRAINING DATA GENERATION - MERCURY FRAMEWORK The INN is trained on data obtained using the University of Marylands (UMD) Mercury Framework, which has with robust automated mesh generation capabilities and advanced turbulence and transition models validated for wind energy applications. Mercury is a multi-mesh paradigm, heterogeneous CPU-GPU framework. The framework incorporates three flow solvers at UMD, 1) OverTURNS, a structured solver on CPUs, 2) HAMSTR, a line based unstructured solver on CPUs, and 3) GARFIELD, a structured solver on GPUs. The framework is based on Python, that is often used to wrap C or Fortran codes for interoperability with other solvers. Communication between multiple solvers is accomplished with a Topology Independent Overset Grid Assembler (TIOGA). NOVEL AIRFOIL SHAPE REPRESENTATIONS USING GRASSMAN SPACES We developed a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation as an analytic generative model, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data , (ii) improved low-dimensional parameter domain for inferential statistics informing design/manufacturing, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes. TECHNOLOGY TRANSFER DEMONSTRATION - COUPLING WITH NREL WISDEM Researchers have integrated the inverse-design tool for 2D airfoils (INN-Airfoil) into WISDEM (Wind Plant Integrated Systems Design and Engineering Model), a multidisciplinary design and optimization framework for assessing the cost of energy, as part of tech-transfer demonstration. The integration of INN-Airfoil into WISDEM allows for the design of airfoils along with the blades that meet the dynamic design constraints on cost of energy, annual energy production, and the capital costs. Through preliminary studies, researchers have shown that the coupled INN-Airfoil + WISDEM approach reduces the cost of energy by around 1% compared to the conventional design approach. This page will serve as a place to easily access all the publications from this work and the repositories for the software developed and released through this pr...

aerodynamics↗

DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2019 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations, though the ink processing, coating and drying processes, to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product.

42 ENGINEERING↗

DOE OSTI2015

Annual Report for the QCL Calibration Project

Under the Quantum Cascade Laser (QCL) Calibrations project, Pacific Northwest National Laboratory (PNNL) is collaborating with Utah State University and Space Dynamics Laboratory to design, build, and test a QCL calibration source system suitable for insertion into remote sensing platforms. In FY14, the second year of this project, PNNL completed the radiation testing of QCLs using radiation levels that are typical for a space environment. These tests involved both 64-MeV protons, and 1.17-MeV and 1.33-MeV gamma rays. No changes were observed above the measurement uncertainty indicating that QCLs are viable sources for space-based missions. High-level testing was also carried out with gamma rays to determine if QCLs are sensitive to high doses of gamma radiation. After an accumulated dose of 1.5 Mrad(Si), the QCLs continue to demonstrate high performance although a small increase in threshold current, 0.11 ± 0.14% and 0.51 ± 0.15% for M1244D and M664M, respectively, was observed. At this stage, it is unclear if this small increase is from the radiation exposure, because generally it is within the observed experimental uncertainty, which is most likely because of mechanical changes through repeated mounting cycles. There was also some accidental damage to the laser chips and their front facets from the extensive but necessary handling of the devices during these tests. Regardless, the QCLs are robust and should not be susceptible to degradation for most missions.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Sierra/RKPM: Current State and Applications

The Reproducing Kernel Particle Method (RKPM), a meshfree method, has been implemented in Sandia's Sierra/Solid Mechanics in a collaboration between Sandia and the University of California San Diego's Center for Extreme Events Research (UCSD/CEER). Meshfree methods, like RKPM, have an advantage over mesh-based methods, like the Finite Element Method (FEM), in applications where achieving or maintaining a quality mesh becomes burdensome or impractical. For example, using FEM for problems with very large deformations will result in poor element Jacobians which causes problems with the parametric mapping. RKPM constructs the approximation functions in the physical domain, circumventing the parametric mapping issue. Also, reconstructing the approximation functions at very large deformations is straight-forward. RKPM has an advantage over traditional meshfree methods such as Smoothed-Particle Hydrodynamics (SPH) due to its ability to reproduce linear or higher-order functions exactly. This removes the tensile instabilities that are present in SPH and allows preservation of angular momentum. The point of this memo is to explore the capabilities and limitations of the current implementation by testing it on three different applications: 1) a quasi-static ductile shearing problem 2) a dynamic concrete panel perforation problem and 3) a set of dynamic metal panel perforation problems. In summary, areas where RKPM appears to be a promising alternative to current methods have been identified. Also, outstanding inefficiencies and issues (bugs) with code are noted, ways to improve the capabilities using material from literature are mentioned and areas deserving of new research are highlighted.

42 ENGINEERING↗

DOE OSTI2016

Simulation methodology for fuel assembly drop accident during handling

Fresh and irradiated fuel assembly handling is a routine part of Nuclear Power Plant activities. Fuel Assembly handling occurs during fresh fuel receipt, core refueling, spent fuel assemblies transfer from spent fuel pool to the storage containers, etc. Westinghouse, ENUSA and KEPCO-NF have collaborated in the technical area of Fuel Assembly Drop Accident (FADA) Simulation to update the approach for estimating the number of failed fuel rods as a consequence of a fresh or irradiated fuel assembly drop, which might occur during a handling accident in a PWR-type reactor. The proposed FADA simulation methodology starts with an assessment of fuel assembly impact velocity at the final stage of the drop in water or air. The vertical, horizontal or inclined drop directions are considered. This velocity is an input to determine a fuel assembly structural response during impact which defines the loading function for the fuel assembly components including spacer grids. The dynamic load on the fuel rod is calculated from the detailed spacer grid model and the corresponding loading function. Finally, the load from the spacer grid spring and dimples are applied to the fuel rod model to determine the cladding parameters for use in compliance to fuel rod cladding failure criteria. A combination of first principal, finite element analysis (FEA) and computational fluid dynamic (CFD) methods has been utilized to create a technically sound methodology. A number of specific and traditional tests for the fuel assembly and its components has been used to confirm that the proposed approaches which describe the physical phenomena related to the fuel assembly drop accident are reasonably conservative.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Energy Efficiency and Infrastructure Upgrades on Nuclear Clean-up Sites: The Hanford Experience - 18641

The Hanford site, located in southeastern Washington, produced much of our nation's weapons-grade plutonium for the Defense nuclear weapons program. This production lasted the better part of four decades with production ending in 1987. Since 1987, the focus of the Hanford site has turned to clean-up activities. Mission Support Alliance (MSA) is the integrator of the multi-contractor effort to clean up the Hanford site. MSA collaborates with the U.S. Department of Energy (DOE) and all Hanford site contractors in finding and implementing new, cost-saving, safe and practical solutions to cleanup challenges with a continual focus on innovative processes and technologies that reduce costs, energy use and bring safety improvements to the site. Support Services include environmental integration and land management; fleet and road maintenance; water/electric and utilities; cyber security and information management as well as the preservation of the site's cultural artifacts. This paper describes the process, challenges, and focus on infrastructure upgrade and energy efficiency projects in the context of a multi-contractor nuclear clean-up site. Project development and new technology deployment at Hanford has long been plagued with economic challenges. For example, despite extensive auditing, analysis, and project development, most of the energy-related projects on the Hanford site have gone unfunded due to the low cost of electricity, the relatively high cost of labor, and costs associated with detailed safety and cultural reviews. - The Hanford site is a direct-service customer of the Bonneville Power Administration (BPA) and has a marginal electricity rate of $0.033/kWh. - Labor costs on the Hanford site track high because of the requirements associated with the safety and security necessary to operate a legacy nuclear weapons complex. - In partnership with three federally recognized and other affected Native American tribes (Yakama Nation, Confederated Tribes of the Umatilla Indian Reservation, the Nez Perce Tribe, and Wanapum People), most activities on the Hanford site are afforded in-depth cultural reviews. To work within these constraints, the MSA Energy Management team has embarked on a three-pronged approach to energy project development: Program Visibility: The MSA Energy Management team has promoted both project opportunities and requirements across the Hanford site. This information comes in the form of site-wide newsletters, group meetings, e-mails, success stories, and recognition of staff. Single-point Analysis: To by-pass the inevitable duplications of effort, learning curve issues, and to improve project consistency/delivery, the MSA Energy Management team serves as the single resource to the site for energy project analysis. This resource includes initial assessment, engineering analysis, efficiency calculation and project recommendations. Contractor/utility Interface: In addition to the infrastructure under its own purview, MSA provides all support services for the contractor/utility interface. These activities include formulation and submission of incentive-based efficiency projects, project tracking, and incentive awards. All incentive awards are forwarded to the relevant contractor and then highlighted in the visibility campaign. Successful energy efficiency projects at Hanford have included high efficiency heating, ventilation, air conditioning (HVAC) systems, interior and exterior lighting/lighting control systems, pump and motor systems, and the right-sizing of transformers and area-wide electrical distribution systems. Prior to the initiation of this program and structure (roughly 3 years ago) the average annual energy efficiency incentive applied for and received was under $10,000, with an annual energy savings of approximately 36,000 kilowatt hours (kWh). In fiscal year 2017, the annual incentive received was over $419,000, with identified energy savings of over 1.3 million kWh. Details and case studies of the major project accomplishments are included. The success of this program can be traced to an understanding of the constraints, the development of a program to address these constraints, and good communication/coordination across DOE and the multiple contractors serving the Hanford site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2011

Collaborative Lubricating Oil Study on Emissions: November 28, 2006 - March 31, 2011

The Collaborative Lubricating Oil Study on Emissions (CLOSE) project was a pilot investigation of how fuels and crankcase lubricants contribute to the formation of particulate matter (PM) and semi-volatile organic compounds (SVOC) in vehicle exhaust. As limited vehicles were tested, results are not representative of the whole on-road fleet. Long-term effects were not investigated. Pairs ofvehicles (one normal PM emitting, one high-PM emitting) from four categories were selected: light-duty (LD) gasoline cars, medium-duty (MD) diesel trucks, heavy-duty (HD) natural-gas-fueled buses, and HD diesel buses. HD vehicles procured did not exhibit higher PM emissions, and thus were labeled high mileage (HM). Fuels evaluated were non-ethanol gasoline (E0), 10 percent ethanol (E10),conventional low-sulfur TxLED diesel, 20% biodiesel (B20), and natural gas. Temperature effects (20 degrees F, 72 degrees F) were evaluated on LD and MD vehicles. Lubricating oil vintage effects (fresh and aged) were evaluated on all vehicles. LD and MD vehicles were operated on a dynamometer over the California Unified Driving Cycle, while HD vehicles followed the Heavy Duty Urban DynamometerDriving Schedule. Regulated and unregulated emissions were measured. Chemical markers from the unregulated emissions measurements and a tracer were utilized to estimate the lubricant contribution to PM.

03 NATURAL GAS↗

DOE OSTI2016

Development of SiC-based Cladding for Accident Tolerant Fuels

Fuels and core structures in current light water reactors (LWR's) are vulnerable to catastrophic failure in severe accidents. This vulnerability is attributed primarily to the rapid oxidation kinetics of zirconium alloys in a water vapor environment at very high temperatures. Alternative materials to zirconium alloys with reduced oxidation kinetics are sought to enable enhanced accident-tolerant fuels and cores. Among the candidate alternatives, silicon carbide (SiC) - based materials, in particular continuous SiC fiber-reinforced SiC matrix ceramic composites (SiC/SiC composites), are considered to offer outstanding safety benefits. The primary objective of this work is to provide with updated overviews of the concepts, development status, and future prospect for the SiC-based accident-tolerant fuel (ATF) claddings. A systematic technology evaluation program plan was developed and updated to review the technologies needed, to identify and analyze critical gaps, and to lay out a road-map toward establishing key technologies. The technology review and the gap analysis in this exercise were based on an early study and community workshops. Many of the technical gaps identified are related with the three key feasibility issues: hydrothermal corrosion, mechanical failure, and fuel compatibility. Additional performance issues including accident-tolerance features and fission product retention during the normal operation have also been identified. The program plan was designed to systematically address the key gap issues and is formulated in a work breakdown structure. Simultaneously, the plan is being established to set a technical program for advancing the technological readiness levels of concept non-specific essential technologies in three top-level categories of Design and Failure, Environmental Effects, and Off-normal Behavior. The execution of the program plan is in progress across the U.S. Department of Energy laboratories, industries, universities, and international collaborators. The critical issues for SiC composite-based fuel cladding concepts were found to be related to the performance in the normal operation. In particular, radiation-assisted hydrothermal corrosion and the gaseous fission product (FP) retention are identified to be the most critical issues. The primary ORNL concept pursues the use of dual-purpose coating on the SiC composite cladding wall to mitigate the corrosion and the gas permeation issues at the same time, whereas the alternative approaches such as the dense monolithic SiC protective layer combined with the water chemistry control may be feasible. Surface metallization through variations of physical vapor deposition and electroplating are being demonstrated. The FP gas retention is an issue associated with the cracking for the ceramic matrix composite cladding. To establish the probabilistic failure behavior, the relevant test methods were developed in ASTM Committee C28 on Advanced Ceramics. Toward the end-plugging technology development, various methods for joining SiC to SiC had been developed and tested for mechanical properties, irradiation effects, and environmental effects. Multiple methods including the pressureless transient eutectic SiC joining and CVD-based SiC joining were identified particularly promising. In addition, a multi-physics, three-dimensional finite element-based modeling is in progress toward an integrated simulation of the SiC composite-cladded fuel evolutions. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

The joys and jitters of high‐temperature calorimetry

Abstract High‐temperature calorimetry (HTC) originated in the 20th century as a niche method to enable measurements not easily accomplished with acid solution calorimetry, combustion calorimetry, vapor pressure, or EMF methods. Over time, HTC has evolved into a versatile approach to accurately quantify formation, phase transition, surface and interfacial enthalpies of a wide range of materials including minerals and refractory inorganic compounds. This evolution has been the result of numerous adjustments to experimental setups and procedures, followed by rigorous testing. The commercial availability and the scientific success of this technique have led to an increase in the number of laboratories applying HTC. However, the knowledge acquired by researchers over the past 70 years is scattered throughout the literature or only available as laboratory internal documentation and personal experience. This publication is a collaborative effort among several leading HTC laboratories to summarize and unify current state‐of‐the‐art HTC techniques and procedures. The text starts by summarizing various HT techniques that are commonly used for readers with an interest in HTC in general. It is then directed toward HTC users and includes a brief section on data evaluation procedures as well as a comprehensive compilation of reference data utilizing molten sodium molybdate and lead borate solvents. Finally, for experienced HTC users, an in‐depth discussion of some common difficulties and a discussion of uncertainties are presented.

Scharrer, Manuel [Navrotsky Eyring Center for Mate↗

DOE OSTI2016

Recent Progress on the Stochastic Objective Decision Aide (SODA) Application

Idaho State University, in collaboration with Idaho National Laboratory, is engaged in development of a simple to use software application that utilizes stochastic techniques for the calculation of radiation doses associated with hypothetical radioactive material releases. This work is being performed through a grant from the U.S. Department of Energy (DOE) Nuclear Safety Research and Development (NSR and D) Program. Initial progress on the application was reported previously. Recent additions to the application are reported here. The Stochastic Objective Decision Aide (SODA) provides an easy to use software application to help decision makers support their judgment about the need or lack of need for safety structures, systems, and components. SODA is not intended to replace traditional design basis accident dose calculation methodology, nor is it intended to replace existing software used to perform formal dose consequence calculations. Rather, SODA is intended to supplement information obtained from existing codes to give a decision maker more information about an accident scenario. SODA also provides a simple method to perform parametric or sensitivity studies on individual input parameters. Non-reactor nuclear facilities operated under the approval authority of the US DOE use unmitigated hazard evaluations to determine if potential radiological doses associated with design basis events challenge dose evaluation guidelines. Unmitigated events that sufficiently challenge dose evaluation guidelines merit the selection of safety structures, systems, or components (SSCs) to prevent or mitigate the hazard. Dose consequence calculations traditionally involve use of the 'five-factor' formula: ST = MAR.DR.ARF.RF.LPF where ST is the source term (Bq), MAR is the total available material-at-risk (Bq), DR is the damage ratio (no units), ARF is the airborne release fraction (no units), RF is the respirable fraction (no units), and LPF is the leak path factor (no units). Potential radiation doses are then calculated using: CED = χ/Q.BR.ST.DCF (2) where CED is the committed effective dose (Sv), χ/Q is the plume dispersion (s/m{sup 3}), BR is the breathing rate (m{sup 3}/s), ST is the source term (Bq), and DCF is the dose conversion factor (Sv/Bq). Conservative single value input parameters are typically used to represent ARF, RF, LPF and BR. The traditional methodology, while conservative, can lead to skewed conclusions in the balance between cost and risk reduction resulting in over engineered systems with greater design, construction and operating costs. Rather than using a bounding single point value for each parameter in the dose consequence calculation, SODA uses distributions for some or all of the parameters. Each input parameter distribution is stochastically sampled and the resulting dose consequence calculation is repeated many times to develop a dose consequence distribution. The resulting distribution provides more information for the decision maker to rely upon when determining the need for safety SSCs. The SODA application was developed using MATLAB and it incorporates the use of Monte Carlo techniques as well as a graphical user interface (GUI). The application includes user selection of the governing distribution for parameters such as the MAR, DR, ARF, RF, LPF,χ/Q, BR, and DCF. While MATLAB was used for the development work, the application is distributed as a self-contained executable program. Features of the application include pull down menus with available distributions for the various parameters. The user has the option to plot the input parameter distribution that results from the random sampling process. The resulting dose consequence distribution is automatically analyzed to determine its similarity to well know distributions. This was done using the Bayesian Information Criterion method. If the resulting distribution is sufficiently similar to a well-known distribution, the application provides information about the distributions such as the mean value and other parameters. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

CASL COBRA-TF improvements for PWR DNB analysis

COBRA-TF (CTF) is a thermal hydraulic (T/H) subchannel code using either three-dimensional (3D) Cartesian or subchannel coordinate formulations for two-phase fluid flow and heat transfer solutions. CTF has been improved under the Consortium for Advanced Simulation of Light Water Reactors (CASL) program for Pressurized Water Reactor (PWR) applications, including software optimization, new closure models, pre- and post-processing and parallelization for modeling full reactor core T/H responses under normal operating and accident conditions. As a result of collaboration among CASL partners including the Westinghouse Electric Company, the Oak Ridge National Laboratory (ORNL), and the Sandia National Laboratories, additional modeling improvements were made to CTF specifically for PWR Departure from Nucleate Boiling (DNB) analysis, including a code option to evaluate fuel thermal margin in terms of DNB Ratio (DNBR) and an axial shape factor to account for effect of non-uniform axial power distribution on DNB. Multiple DNB correlations are now linked with CTF for different applications, including the Westinghouse proprietary WRB-1 correlation for fuel designs containing mixing vane grid spacers. The improved CTF code with the WRB-1 correlation (CTF/WRB-1) was validated using the DNB data from the PWR Subchannel Bundle Tests (PSBT). In addition to the comparison with the test data, the CTF/WRB-1 DNBR results and the associated local fluid conditions were compared to the results of the Westinghouse T/H design code, VIPRE-W, which is an enhanced version of the VIPRE-01 code originally developed by the Electric Power Research Institute (EPRI). The comparisons showed that CTF/WRB-1 DNBR predictions are in good agreement with the VIPRE-W results within the applicable range of the DNB correlation. A model sensitivity study was performed to confirm that the CTF void drift model had an insignificant effect on DNBR under the steam line break (SLB) low pressure condition. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Investigation of dynamics of ELM crashes and their mitigation techniques

The accurate prediction of H-mode pedestal dynamics is critical for planning experiments in existing tokamaks and in the design of future tokamaks such as ITER and DEMO. The main objective of the proposed research is to advance the understanding of the physics of H-mode pedestal. Through advances in coupled kinetic-MHD simulations, a new model for H-mode pedestal and ELM crashes as well as an improved model for the bootstrap current will be developed. ELMmitigation techniques will also be investigated. The proposed research will help design efficient confinement scenarios and reduce transient heat loads on the divertor and plasma facing components. During the last two years, the principal investigator (PI) of this proposal actively participated in physics studies related to the DOE Joint Research Targets. These studies include the modeling of divertor heat load in the DIII-D, Alcator C-Mod, and NSTX tokamaks in 2010, and the modeling of H-mode pedestal structure in the DIII-D tokamak in 2011. It is proposed that this close collaboration with experimentalists from major US tokamaks continue during the next funding period. Verification and validation will be a strong component of the proposed research. During the course of the project, advances will be made in the following areas; Dynamics of the H-mode pedestal buildup and recovery after ELM crashes – The effects of neutral fueling, particle and thermal pinches will be explored; Dynamics of ELM crashes in realistic tokamak geometries – Heat loads associated with ELM crashes will be validated against experimental measurements. An improved model for ELM crashes will be developed; ELM mitigation – The effect of resonant magnetic perturbations on ELMs stability and their evolution will be investigated; Development of a new bootstrap current model – A reduced model for will be developed through careful verification of existing models for bootstrap current against first-principle kinetic neoclassical simulations. The primary focus here will be on plasma regimes where the existing reduced models deviate from each other, such as high-beta and low aspect ratio plasmas; and Results will be verified against analytical models and simulation results from other codes. Simulation results will be compared with diagnostic experimental data such as Thomson measurements (HRTC) or flux measurements if available. We have arrangements with experimentalists from DIII-D and JET to use diagnostic edge data for this validation. In summary, we propose to study the H-mode pedestal buildup, the stability and evolution of ELMs using a model that will account for dynamically evolving neoclassical sources.

42 ENGINEERING↗

DOE OSTI2017

Arc Parameter Modeling (Arc Breakdown Experiments and Modeling: Confined Geometries and Alternate Gap Materials)

Sandia Nationa.l Laboratories (SNL) and The Boeing Company (Boeing) collaborated on this PTS to develop the capability to predict thermal and electrical characteristics of short arcs that may appear in equipment subjected to transient currents of hundreds or thousands of amperes. The final tasks of this CRADA included experiments and computer simulations used to investigate the effect of an arc breakdown between two planar electrodes and confined by various potting materials. The arc is generated by a current waveform with a rise of 8 μs and a 20 μs fall time. Voltage, current and light emissions are recorded. The developing shock wave is observed with an optical fiber embedded in the potting material and recorded using a photonic Doppler velocimetry (PDV) diagnostic system. The experiments were modeled using the ALEGRA-MHD simulation code and comparisons are made between the experiments and simulations. This product contains Protected CRADA Information which was produced December 2015 under CRADA No. 1651. l 5 and is not to be further disclosed for a period of 5 years from the date it was produced except as expressly provided for in the CRADA. Further dissemination only as authorized by the originating partners: the Boeing Company and Sandia National Laboratories Radiation Sciences Center, or higher U.S. Department of Energy programmatic authority. Please note that the project leads from both SNL and Boeing have all retired or left for other reasons at the time of the creation of this document. The final project manager collected information for this document from the final proposal and the final report.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Evolve CAPP Final Report

The Evolve Central Appalachia (Evolve CAPP) project is investigating the rare earth and critical mineral resource potential of the Central Appalachian basin, spanning Virginia, West Virginia, Kentucky, and Tennessee. This initiative aims to advance clean energy technologies, strengthen sustainable industries critical to national security, and foster economic growth through downstream value-added industries. Innovative policy incentives, stakeholder collaboration, and responsible sourcing practices are identified as pivotal to overcoming barriers. The project seeks to align environmental stewardship with economic imperatives. These efforts aim to position the Central Appalachian region as a leader in responsible critical mineral sourcing, contributing to a resilient, secure, and future-ready supply chain for critical minerals.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

NSR&D Program Fiscal Year 2015 Funded Research Stochastic Modeling of Radioactive Material Releases Final Report

Nonreactor nuclear facilities operating under the approval authority of the U.S. Department of Energy use unmitigated hazard evaluations to determine if potential radiological doses associated with design basis events challenge or exceed dose evaluation guidelines. Unmitigated design basis events that sufficiently challenge dose evaluation guidelines or exceed the guidelines for members of the public or workers, merit selection of safety structures, systems, or components or other controls to prevent or mitigate the hazard. Idaho State University, in collaboration with Idaho National Laboratory, has developed a portable and simple to use software application called SODA (Stochastic Objective Decision-Aide) that stochastically calculates the radiation dose distribution associated with hypothetical radiological material release scenarios. Rather than producing a point estimate of the dose, SODA produces a dose distribution result to allow a deeper understanding of the dose potential. SODA allows users to select the distribution type and parameter values for all of the input variables used to perform the dose calculation. Users can also specify custom distributions through a user defined distribution option. SODA then randomly samples each distribution input variable and calculates the overall resulting dose distribution. In cases where an input variable distribution is unknown, a traditional single point value can be used. SODA, developed using the MATLAB coding framework, has a graphical user interface and can be installed on both Windows and Mac computers. SODA is a standalone software application and does not require MATLAB to function. SODA provides improved risk understanding leading to better informed decision making associated with establishing nuclear facility material-at-risk limits and safety structure, system, or component selection. It is important to note that SODA does not replace or compete with codes such as MACCS or RSAC; rather it is viewed as an easy to use supplemental tool to help improve risk understanding and support better informed decisions. The SODA development project was funded through a grant from the DOE Nuclear Safety Research and Development Program.

42 ENGINEERING↗

DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

14 SOLAR ENERGY↗

DOE OSTI2026

Facilitating Data Collection of Maintenance Events to Populate the Hydrogen Component Reliability Database (HyCReD)

The Hydrogen Component Reliability Database (HyCReD) is a collaborative project between the National Renewable Energy Laboratory, the University of Maryland, and hydrogen stakeholders to improve safety and reliability for hydrogen facilities by implementing component reliability data taxonomies that support hydrogen infrastructure failure rate analysis. The project aims to quantify failure rates of hydrogen components through high-quality data collection and analysis on root causes and maintenance needed. HyCReD provides a common database for cataloging hydrogen component failures which exists for reliability research in many other mature industries [2]. The database fills a gap for the hydrogen community by providing a scientifically rigorous approach to quantitative risk assessment (QRA), prognostic health management (PHM), and reliability-centered maintenance (RCM) analysis. High level results will be aggregated and anonymized to protect company sensitive information; detailed results will be used to help address issues of hydrogen components. These advanced analytics will support accelerated deployment of hydrogen infrastructure by enabling better: design and safety of projects (safety codes and standards development), infrastructure reliability and cost (component failure rates, maintenance protocols), and component R&D needs (robust supply chain). A key to a successful HyCReD implementation is facilitating the ease of reporting and data quality in the database that can be used for analysis. Maintenance data was a previously identified gap in initial efforts to populate and validate the database taxonomies [3]. Collection of maintenance data will be instrumental in identifying failure modes and rates, identifying incipient component failures or reduced performance, cataloging best practices for maintenance routines and methods for prognostic health management, and quantifying the risk and effect of different failure modes. Several key priorities are identified for streamlined data collection to achieve quality and detailed failure data: Applicability, Ease of Use, Accessibility, and Information Security. The HyCReD team has now begun deployment of the database to several companies and groups that have signed non-disclosure agreements to facilitate the data collection of failures in industry hydrogen refueling station infrastructure. This paper will provide an update into the process of HyCReD deployment including the development of a coding guide for facility personnel to reference and ensure data quality and consistency from one station to another as well as implementation of contextually dependent data fields of system taxonomy and formatted entries to provide ease of use. The goal is to communicate the lessons learned from the roll-out to technicians and engineers in the field, and the addition of need for high level of security to protect all stakeholders.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗