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Light Water Reactor Sustainability Program: Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 60%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to grow by about 24% from 2013 to 2040 . At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license, for a total of 60 years of operation (the oldest commercial plants in the United States reached their 40th anniversary in 2009). Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity for 40- and 60-year license periods. If current operating nuclear power plants do not operate beyond 60 years (and new nuclear plants are not built quickly enough to replace them), the total fraction of generated electrical energy from nuclear power will rapidly decline. That decline will be accelerated if plants are shut down before 60 years of operation. Decisions on extended operation ultimately rely on economic factors; however, economics can often be improved through technical advancements. The U.S. Department of Energy Office of Nuclear Energy’s 2010 Research and Development Roadmap (2010 Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: 1. Develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors; 2. Develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration’s energy security and climate change goals; 3. Develop sustainable nuclear fuel cycles; and 4. Understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program’s plans. For the LWRS Program, sustainability is defined as the ability to maintain safe and economic operation of the existing fleet of nuclear power plants for a longer-than-initially-licensed lifetime. It has two facets with respect to long-term operations: (1) manage the aging of plant systems, structures, and components so that nuclear power plant lifetimes can be extended and the plants can continue to operate safely, efficiently, and economically; and (2) provide science-based solutions to the industry to implement technology to exceed the performance of the current labor-intensive business model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Light Water Reactor Sustainability Program Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 60%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to grow by about 24% from 2013 to 2040 . At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license, for a total of 60 years of operation (the oldest commercial plants in the United States reached their 40th anniversary in 2009). Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity for 40- and 60-year license periods. If current operating nuclear power plants do not operate beyond 60 years (and new nuclear plants are not built quickly enough to replace them), the total fraction of generated electrical energy from nuclear power will rapidly decline. That decline will be accelerated if plants are shut down before 60 years of operation. Decisions on extended operation ultimately rely on economic factors; however, economics can often be improved through technical advancements. The U.S. Department of Energy Office of Nuclear Energy’s 2010 Research and Development Roadmap (2010 Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: 1. Develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors. 2. Develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration’s energy security and climate change goals. 3. Develop sustainable nuclear fuel cycles. 4. Understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program’s plans. For the LWRS Program, sustainability is defined as the ability to maintain safe and economic operation of the existing fleet of nuclear power plants for a longer-than-initially-licensed lifetime. It has two facets with respect to long-term operations: (1) manage the aging of plant systems, structures, and components so that nuclear power plant lifetimes can be extended and the plants can continue to operate safely, efficiently, and economically; and (2) provide science-based solutions to the industry to implement technology to exceed the performance of the current labor-intensive business model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Xcel Energy – LBNL ‘Beyond Widgets’ Project. Workstation Specific Lighting with Daylight Dimming Controls System Program Manual

This program manual was developed through a U.S. Department of Energy project to develop streamlined utility program approaches to the deployment of integrated systems in commercial offices. Integrated systems present deep opportunities for energy savings, however by nature these systems have additional levels of complexity and effort required for their design and energy savings assessment, which create barriers for utility incentive programs to develop streamlined cost effective incentive programs to capture these savings. This project worked with Xcel Energy in Colorado and Minnesota to select an integrated system and develop a streamlined approach to its deployment for small and large commercial offices. Xcel Energy worked with LBNL to select a workstation specific lighting system with daylight dimming controls, applied as a retrofit in commercial office spaces. Previous studies indicated a potential lighting annual energy savings of 28-63%, with an average of 47% for this system type, due to reduced fixture LPD and controls only, not including a full fixture replacement from a condition such as T8 to LED. Xcel also had a desire to incorporate this fixture replacement in their integrated system package, and as a result annual energy lighting savings are expected to be higher. FLEXLAB testing of the system for 500 lux minimum output conditions translated into a 94% annual energy savings for this system. Market analysis was developed for large and medium commercial office buildings in Xcel’s Minnesota and Colorado markets showing a potential for 48-295 and 120-672 GWh of energy savings potential for Colorado and Minnesota respectively. Total Resource Costs (TRC) vary by location and technology package used (enterprise versus non-enterprise lighting controls system), and vary from 0.29 to 1.27 and 0.06 and 0.44 for a Retrofit case, and 0.20 to 1.63 and 0.07 to 0.57 for a Replace on Burnout strategy for Colorado and Minnesota respectively. These results indicate good potential for demonstrating a strong technical and economic case for deployment of this system type in Xcel’s Colorado territory, while deployment in the Minnesota market may be advisable as well as part of a portfolio of programs, or as an effort to help shift the market into integrated systems deployment in general. It should be noted that the cost of avoided energy in both markets is significantly low ($0.07/kWh for Minnesota, $0.08/kWh for Colorado), and these TRC values would not be representative of deployment potential in other markets with higher utility rates. In addition, installation costs used for these systems may decrease with time, further enhancing their return on investment. Overall, workstation specific lighting systems with daylight dimming controls present a very strong potential for cost effective lighting energy savings, as demonstrated by the FLEXLAB test results and previous case studies. Further energy savings may be realized from the use of fixture-specific occupancy sensors as well, although this approach was not considered in this study.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of a Liquid-Fueled Molten Salt Reactor Safeguards Model.

This work describes the ongoing work to develop a molten salt reactor (MSR) model and associated tools for safeguards analysis. A new flowsheet was developed in collaboration with Oak Ridge National Laboratory (ORNL) for the Molten Salt Demonstration Reactor (MSDR). This design was chosen by ORNL as a generic baseline design that could be used for safeguards research. The model has simple chemical processing that is less extensive than the two-fluid flowsheet developed in the last year. A detailed TRITON reactor physics model, provided by ORNL, was implemented into the process model. The process model now includes reactor parameters such as K-eff and decay heat, which could be used as part of an advanced safeguards approach. Finally, a set of generic safeguards tools based on current safeguards approaches were developed. These tools are flexible and can be used with most MSR flowsheets. ACKNOWLEDGEMENTS This work was funded by the Materials Protection Accounting and Control Technologies (MPACT) working group as part of the Fuel Cycle Technologies Program under the U.S. Department of Energy, Office of Nuclear Energy. The authors would also like to acknowledge Ben Betz ler for his work on the reactor physics models that were incorporated into the work and the continued collaboration with ORNL staff.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

ASCR@40: Four Decades of Department of Energy Leadership in Advanced Scientific Computing Research

Throughout its long history, the Office of Advanced Scientific Computing Research (ASCR) has built the critical technologies to ensure U.S. leadership in energy science and national security. It has made its parent agency, the Department of Energy (DOE) and its Office of Science, the world’s recognized leader in computational science. ASCR’s stated mission is “to discover, develop, and deploy computational and networking capabilities to analyze, model, simulate, and predict complex phenomena important to the DOE.” To accomplish this goal, ASCR oversees a large complex of computing and networking facilities and is responsible for procuring, deploying and operating high-performance computing (HPC), networking and storage resources; conducting basic research in mathematics and computer science; developing and sustaining a large body of software; and collaborating with other Office of Science programs, academia and industry. ASCR’s computational science leadership has a long history, predating even DOE’s inception. Applied mathematics and advanced computing were both elements of the Manhattan Project’s Theoretical Division. In the 1950s, DOE’s predecessor, the Atomic Energy Commission, created a mathematics program to develop and apply digital computing by supporting researchers at universities and AEC laboratories. Several organizational and name changes later, this program would grow and become ASCR.

97 MATHEMATICS AND COMPUTING↗

Thermal Energy Storage Model Development within the Integrated Energy Systems Hybrid Repository

This publication details newly created energy storage models developed within the HYBRID Modelica repository as part of the Department of Energy Office of Nuclear Energy (DOE-NE) Integrated Energy Systems (IES) program, led by Idaho National Laboratory (INL). Model development to-date includes creation of dynamic systems-level models of concrete, latent heat, and packed-bed thermocline energy storage technologies for deployment in the IES-based HYBRID repository. Models are developed using the latest publicly available data and incorporate the possibility of control strategy inclusion for use with the existing IES modeling, analysis, and optimization toolset. Simulations showcase the abilities of each technology to cyclically charge and discharge when exposed to time-varying boundary conditions. In addition, low-level surrogate models for some of the thermal energy storage technologies were created using Python. These lower order Python files are much cheaper to run (i.e., computationally faster) and thus operate well when incorporated within the stochastic optimization problems run for the IES program. Moreover, economic data was collected for use within the INL-developed Framework for Optimization of ResourCes and Economics (FORCE). This information is incorporated within the FORCE platform. This work has resulted in creation of systems-level models for concrete, latent heat, and thermocline thermal energy storage systems with associated control systems. Now that these models are available, they can be utilized within different integrated energy park concepts to understand optimal system operation, control, and dispatching. Moreover, given the generic nature of the models, industrial partner technologies (e.g., Storworks Power, EnergyNest) can be quickly added to the repository using the existing models as a basis. Additional dynamic models for thermal energy storage concepts can be developed and added to the HYBRID repository as needed.

25 ENERGY STORAGE↗

Building Life-Cycle Analysis with the GREET Building Module: Methodology, Data, and Case Studies

To holistically address building sustainability, Argonne National Laboratory has expanded its Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET) life-cycle model with a new GREET Building Module. This report documents life-cycle analysis (LCA) methodology and foreground data that Argonne National Laboratory compiles and develops to address embodied greenhouse gas (GHG) emissions and energy impacts of a wide range of envelope and structural building materials for new construction and retrofits. The methodology and data form the backbone of the GREET Building Module. This research effort focuses on developing consistent LCA methodology that conforms to building LCA standards such as the EN 15978 to address embodied GHG emissions and energy impacts of building materials/technologies. We document detailed foreground data for selected building materials and building components that are common for building construction. To test the LCA methodology and the GREET Building Module, this report includes case studies of insulation materials and wall panels for residential building retrofit. We have developed a separate document as a User Guide for understanding and applying the GREET Building Module to conduct detailed, process-level LCA of embodied carbon and energy impacts of emerging building materials and technology solutions that of interest to the Building Technologies Office (BTO) of the US Department of Energy, researchers, and industry stakeholders.

42 ENGINEERING↗

Optimal Reconfiguaration and Resilient Control Framework for Real-Time Photopholtaic Dispatch to Manage Critical Infrastructure (ReDis-PV)

The consortium is conducting cutting-edge collaborative research that will allow advancing solar energy’s role in strengthening the resilience of the U.S. electricity grid. The U.S Department of Energy Solar Technologies Office (SETO) has awarded 4.6 million to Professor Sukumar Kamalasadan (The University of North Carolina at Charlotte) for the project “Optimal Reconfiguration and Resilient Control Framework for Real-Time Photovoltaic Dispatch to Manage Critical Infrastructure (ReDis-PV)”. The project developed a grid management tool that detects cyber and physical threats and forms dynamic clusters to manage photovoltaic and energy optimally. The project collaborating team includes the University of North Carolina at Charlotte, Clemson University, New Mexico State University, Florida International University, Argonne National Laboratory, Idaho National Laboratory, OPAL-RT Corporation, and Duke Energy.

14 SOLAR ENERGY↗

Interpretation of Ion Irradiation and Neutron Irradiation Damage in Additively Manufactured 316 Stainless Steel using Multiscale Modeling

The accelerated adoption of nuclear energy necessitates advanced manufacturing technologies, such as additive manufacturing, to meet heightened supply chain requirements and support innovative reactor technologies. Due to the unique microstructural characteristics of additively manufactured materials under distinct solidification conditions, comprehensive evaluation of their performance in reactor environments is essential. The Advanced Materials and Manufacturing Technologies program under the Department of Energy's Office of Nuclear Energy focuses on understanding the irradiation performance and damage evolution of laser powder bed fusion 316 stainless steel, with an emphasis on integrating ion and neutron irradiation data to accelerate the development and qualification of materials for advanced nuclear reactor applications. While ion irradiation is a cost- and time-effective method, modeling and simulation are required to interpret the data for the broader range of irradiation conditions encountered in advanced reactors. In fiscal year 2025, integrated multiscale modeling and simulations were conducted to assess irradiation damage in additively manufactured 316 stainless steel. Key outcomes include predictions of chromium enrichment at grain boundaries, nickel enrichment at dislocation cell walls and void surfaces, and heterogeneous void evolution under ion and neutron irradiation conditions. Cluster dynamics simulations revealed the coarsening of voids at high irradiation temperatures and the suppression of void growth by high network dislocation density, while also demonstrating significant growth and coarsening of voids and self-interstitial atom loops at low dose rates. Machine learning-accelerated atomistic simulations highlighted the impact of the local environment and chromium concentration on vacancy diffusivity, providing key insights on the influence of composition on void swelling and radiation-induced segregation. Additionally, molecular dynamics simulations demonstrated the presence of defect production bias and a significant effect of carbon content on defect cluster behavior. These combined efforts aim to predict the performance of additively manufactured materials under various reactor conditions, supporting their qualification for nuclear reactor applications by interpreting ion irradiation data. This report underscores the potential of integrated multiscale modeling to analyze ion irradiation data in the effort to accelerate the qualification of additively manufactured materials for nuclear reactor components.

316 stainless steel↗

Pilot land data system

During the fall of 1983, the Information Systems Office of NASA's Office of Space Science and Applications assembled a Working Group to develop initial plans for a Pilot Land Data System (PLDS). Workshops coordinated planning and concept development activities between land-related and computer science disciplines, and examined land research requirements, information science technology requirements, PLDS architecture, and methodologies for system evaluation. The PLDS will be a limited-scale distributed information system to explore scientific, technical and management approaches to satisfy land science research needs. PLDS will pave the way for a Land Data System to improve data access, processing, transfer and analysis, fostering an environment in which land science information synthesis can occur on a scale not previously possible owing to limits to data assembly and access and efficiency of processing.

Cressy, P. J.↗

Requirement Metrics for Risk Identification

The Software Assurance Technology Center (SATC) is part of the Office of Mission Assurance of the Goddard Space Flight Center (GSFC). The SATC's mission is to assist National Aeronautics and Space Administration (NASA) projects to improve the quality of software which they acquire or develop. The SATC's efforts are currently focused on the development and use of metric methodologies and tools that identify and assess risks associated with software performance and scheduled delivery. This starts at the requirements phase, where the SATC, in conjunction with software projects at GSFC and other NASA centers is working to identify tools and metric methodologies to assist project managers in identifying and mitigating risks. This paper discusses requirement metrics currently being used at NASA in a collaborative effort between the SATC and the Quality Assurance Office at GSFC to utilize the information available through the application of requirements management tools.

Hammer, Theodore↗

Light Controller

Artificial lighting is designed to provide the light intensity necessary if there were no other source of illumination. But many rooms, particularly those in large-windowed office buildings, get a substantial amount of sunlight during the day. An automatic system which considers available sunlight and adjusts the artificial lighting level accordingly can trim energy costs appreciably. Such a system was developed by NASA's Kennedy Space Center. International Technology Corporation, Satellite Beach, Florida, obtained a NASA patent license for the technology, refined the design, and is now producing commercially an improved version known as the Automatic Lighting Controller.

Source record↗

NASA Plan for Increasing Access to the Results of Scientific Research

This plan is issued in response to the Executive Office of the President's February 22, 2013, Office of Science and Technology Policy (OSTP) Memorandum for the Heads of Executive Departments and Agencies, "Increasing Access to the Results of Federally Funded Scientific Research." Through this memorandum, OSTP directed all agencies with more than $100 million in annual research and development expenditures to prepare a plan for improving the public's access to the results of federally funded research. The National Aeronautics and Space Administration (NASA) invests on the order of $3 billion annually in fundamental and applied research and technology development1 across a broad range of topics, including space and Earth sciences, life and physical sciences, human health, aeronautics, and technology. Promoting the full and open sharing of data with research communities, private industry, academia, and the general public is one of NASA's longstanding core values. For example, NASA's space and suborbital mission personnel routinely process, archive, and distribute their data to researchers around the globe. This plan expands the breadth of NASA's open-access culture to include data and publications for all of the scientific research that the Agency sponsors.

Source record↗

Transforming ENERGY through Computational Excellence

Computational methods underpin advancing the science and engineering of energy efficiency, sustainable transportation, renewable power technologies, and developing a knowledge base to optimize energy systems. Researchers with access to enough computing, and the right type, can focus their ingenuity and creativity on addressing the energy challenges. NREL’s advanced computing influence spans several common themes across the Office of Energy Efficiency and Renewable Energy (EERE), including materials discovery, process modeling, fluid dynamics, resource mapping, and analysis of large-scale systems with real-time optimization.

advanced computing↗

Light Water Reactor Sustainability Program: Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 60%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to grow by about 24% from 2013 to 2040 . At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license, for a total of 60 years of operation (the oldest commercial plants in the United States reached their 40th anniversary in 2009). Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity for 40- and 60-year license periods. If current operating nuclear power plants do not operate beyond 60 years (and new nuclear plants are not built quickly enough to replace them), the total fraction of generated electrical energy from nuclear power will rapidly decline. That decline will be accelerated if plants are shut down before 60 years of operation. Decisions on extended operation ultimately rely on economic factors; however, economics can often be improved through technical advancements. The U.S. Department of Energy Office of Nuclear Energy's 2010 Research and Development Roadmap (2010 Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: 1. Develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors; 2. Develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration's energy security and climate change goals; 3. Develop sustainable nuclear fuel cycles; and 4. Understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program's plans. For the LWRS Program, sustainability is defined as the ability to maintain safe and economic operation of the existing fleet of nuclear power plants for a longer-than-initially-licensed lifetime. It has two facets with respect to long-term operations: (1) manage the aging of plant systems, structures, and components so that nuclear power plant lifetimes can be extended and the plants can continue to operate safely, efficiently, and economically; and (2) provide science-based solutions to the industry to implement technology to exceed the performance of the current labor-intensive business model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Florida International University Research on Soil and Groundwater Contamination at DOE's Hanford and Savannah River Sites - 18547

Nuclear weapons production and other defense-related activities at U.S. Department of Energy (DOE) sites have resulted in radionuclide and heavy metal contamination in surface and subsurface environments nationwide. The DOE Office of Environmental Management (DOE EM) faces a number of environmental challenges that are technically complex and unique to EM with tremendous associated cleanup costs. The success of the DOE EM mission will require development and insertion of innovative approaches and novel technologies to address the significant challenges associated with the remaining cleanup of contaminated sites. A key focus of the applied research portfolio addresses data gaps related to the behavior and chemistry of radionuclides of concern as well as the co-mingling of these contaminants in groundwater at EM sites such as Hanford, Savannah River, Oak Ridge and others. Florida International University (FIU) is conducting research in conjunction with Pacific Northwest National Laboratory (PNNL) and savannah River National Laboratory (SRNL) scientists to support environmental remediation efforts at Hanford and SRS. This research is focused on remediation technologies for contaminated soil and groundwater as well as the assessment of the fate and transport of contaminants in the environment. The overall objective is to reduce contaminant mobility through the development and application of state-of-the-art scientific and environmental remediation technologies. The FIU strategy is to conduct basic science research that fills knowledge gaps and complements work conducted at DOE sites. Support to Hanford includes contributing to the understanding of {sup 99}Tc chemistry and the fate and transport mechanisms of co-mingled contaminants including {sup 99}Tc, U(VI), Cr, and iodine (I). FIU has also provided basic science research that supports a treatability study currently underway at Hanford, which uses ammonia gas injection to manipulate pH and immobilize U(VI) in the subsurface. In addition, support for long-term monitored natural attenuation is provided through geophysical research that monitors subsurface contaminant and microbial responses. Research to evaluate the environmental factors that control the fate and transport of contaminants and co-contaminants in soil and groundwater is being performed for SRS. This research has contributed to the development, design, and deployment of innovative strategies to enhance the natural attenuation processes and to validate novel in situ remediation technologies. The SRS EM test bed demonstrations directly benefit SRS cleanup initiatives. Current investigations focus on natural organic compounds, such as humate, as a potential amendment for the treatment of uranium in groundwater associated with the SRS F-Area Seepage Basins plume, investigates the synergy between humate and silica to optimize the pH adjustment strategy for uranium remediation and investigates the interaction of Tc and I with soil from the Four Mile Branch wetland. Collaborative relationships between FIU and the national laboratories have provided synergy and benefits over the years to FIU, the national laboratories, the DOE complex, and the DOE EM mission. By working closely with the national laboratories, FIU research is not only closely aligned with the cleanup mission priorities at the DOE sites, but complements and supports the work at national laboratories. This coordination and leveraging of research efforts results in time- and cost-savings, and accelerates progress in the DOE EM environmental restoration mission. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Helios: Understanding Solar Evolution Through Text Analytics

This proof-of-concept project focused on developing, testing, and validating a range of bibliometric, text analytic, and machine-learning based methods to explore the evolution of three photovoltaic (PV) technologies: Cadmium Telluride (CdTe), Dye-Sensitized solar cells (DSSC), and Multi-junction solar cells. The analytical approach to the work was inspired by previous work by the same team to measure and predict the scientific prominence of terms and entities within specific research domains. The goal was to create tools that could assist domain-knowledgeable analysts in investigating the history and path of technological developments in general, with a focus on analyzing step-function changes in performance, or “breakthroughs,” in particular. The text-analytics platform developed during this project was dubbed Helios. The project relied on computational methods for analyzing large corpora of technical documents. For this project we ingested technical documents from the following sources into Helios: Thomson Scientific Web of Science (papers), the U.S. Patent & Trademark Office (patents), the U.S. Department of Energy (technical documents), the U.S. National Science Foundation (project funding summaries), and a hand curated set of full-text documents from Thomson Scientific and other sources.

14 SOLAR ENERGY↗

Assessment of Stirling Technology Has Provided Critical Data Leading Toward Flight Readiness of the Stirling Converter

The NASA Glenn Research Center is supporting the development of a Stirling converter with the Department of Energy (DOE, Germantown, Maryland) for an advanced Stirling Radioisotope Power System (SRPS) to provide spacecraft onboard electric power for NASA space science missions. A key technology assessment completed by Glenn and DOE has led to the SRPS being identified as a high-efficiency power source for such deep space missions as the Europa Orbiter and the Solar Probe. In addition, the Stirling system is now being considered for unmanned Mars rovers, especially where mission profiles may exclude the use of photovoltaic power systems, such as exploration at high Martian latitudes or for missions of long duration. The SRPS efficiency of over 20 percent will reduce the required amount of radioisotope by more than a factor of 3 in comparison to current radioisotope thermoelectric generators. This significantly reduces radioisotope cost, radiological inventory, and system cost, and it provides efficient use of scarce radioisotope resources. In support of this technology assessment, Glenn conducted a series of independent evaluations and tests to determine the technology readiness of a 55-We Stirling converter developed by Stirling Technology Company (Kennewick, Washington) and DOE. Key areas evaluated by Glenn included: 1) Radiation tolerance of materials; 2) Random vibration testing of the Stirling converter in Glenn's Structural Dynamics Lab to simulate operation in the launch environment; 3) Electromagnetic interference and compatibility (EMI/EMC) of the converter operating in Glenn's EMI lab; Independent failure modes, effects, and criticality analysis, and life and reliability 4. Independent failure modes, effects, and criticality analysis, and life and reliability assessment; and 5) SRPS cost estimate. The data from these evaluations were presented to NASA Headquarters and the Jet Propulsion Laboratory mission office by a joint industry/Government team consisting of DOE, Glenn, and Lockheed Martin Astronautics. This team concluded that there are no technical reasons that would rule out using the Stirling converter for deep space missions. As a direct result of the successful testing at Glenn, the DOE/Stirling Technology Company 55-We Stirling converter has been baselined for the SRPS. Glenn is now continuing an in-house project to assist in developing the Stirling converter for readiness for space qualification and mission implementation. As part of this effort, the Stirling converter will be further characterized under launch environment random vibration testing, methods to reduce converter EMI will be developed, and an independent performance verification will be completed. Converter life assessment and permanent magnet aging characterization tasks are also underway. Substitute organic materials for the linear alternator and piston bearing coatings for use in a high-radiation environment have been identified and have now been incorporated in Stirling converters built by Stirling Technology Company for Glenn. Electromagnetic and thermal finite element analyses for the alternator are also being conducted.

Thieme, Lanny G.↗