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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2015

Literature Review: Assessment of DWPF Melter and Melter Off-gas System Lifetime

A glass melter for use in processing radioactive waste is a challenging environment for the materials of construction (MOC) resulting from a combination of high temperatures, chemical attack, and erosion/corrosion; therefore, highly engineered materials must be selected for this application. The focus of this report is to review the testing and evaluations used in the selection of the Defense Waste Processing Facility (DWPF), glass contact MOC specifically the Monofrax ® K-3 refractory and Inconel ® 690 alloy. The degradation or corrosion mechanisms of these materials during pilot scale testing and in-service operation were analyzed over a range of oxidizing and reducing flowsheets; however, DWPF has primarily processed a reducing flowsheet (i.e., Fe 2+ /ΣFe of 0.09 to 0.33) since the start of radioactive operations. This report also discusses the materials selection for the DWPF off-gas system and the corrosion evaluation of these materials during pilot scale testing and non-radioactive operations of DWPF Melter #1. Inspection of the off-gas components has not been performed during radioactive operations with the exception of maintenance because of plugging.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Literature Review: Assessment of DWPF Melter and Melter Off-gas System Lifetime

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

36 MATERIALS SCIENCE↗

DOE OSTI2013

FLYSUB-Consortium Tracking and RICH Performance Evaluation

This is a technical scope of work (TSW) between the Fermi National Accelerator Laboratory (Fermilab) and the experiments of FLYSUB-Consortium who have committed to participate in beam tests to be carried out during the 2013-2014 Fermilab Test Beam Facility program. The ultimate goal of this test-beam effort is to test and verify the performance of the individual components according to their expectation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2016

Alternative Chemical Cleaning Methods for High Level Waste Tanks: Actual Waste Testing with SRS Tank 5F Sludge

Solubility testing with actual High Level Waste tank sludge has been conducted in order to evaluate several alternative chemical cleaning technologies for the dissolution of sludge residuals remaining in the tanks after the exhaustion of mechanical cleaning and sludge sluicing efforts. Tests were conducted with archived Savannah River Site (SRS) radioactive sludge solids that had been retrieved from Tank 5F in order to determine the effectiveness of an optimized, dilute oxalic/nitric acid cleaning reagent toward dissolving the bulk non-radioactive waste components. Solubility tests were performed by direct sludge contact with the oxalic/nitric acid reagent and with sludge that had been pretreated and acidified with dilute nitric acid. For comparison purposes, separate samples were also contacted with pure, concentrated oxalic acid following current baseline tank chemical cleaning methods. One goal of testing with the optimized reagent was to compare the total amounts of oxalic acid and water required for sludge dissolution using the baseline and optimized cleaning methods. A second objective was to compare the two methods with regard to the dissolution of actinide species known to be drivers for SRS tank closure Performance Assessments (PA). Additionally, solubility tests were conducted with Tank 5 sludge using acidic and caustic permanganate-based methods focused on the “targeted” dissolution of actinide species.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Biosecurity through Public Health System Design.

We applied modeling and simulation to examine the real-world tradeoffs between developingcountry public-health improvement and the need to improve the identification, tracking, and security of agents with bio-weapons potential. Traditionally, the international community has applied facility-focused strategies for improving biosecurity and biosafety. This work examines how system-level assessments and improvements can foster biosecurity and biosafety. We modeled medical laboratory resources and capabilities to identify scenarios where biosurveillance goals are transparently aligned with public health needs, and resource are distributed in a way that maximizes their ability to serve patients while minimizing security a nd safety risks. Our modeling platform simulates key processes involved in healthcare system operation, such as sample collection, transport, and analysis at medical laboratories. The research reported here extends the prior art by provided two key compone nts for comparative performance assessment: a model of patient interaction dynamics, and the capability to perform uncertainty quantification. In addition, we have outlined a process for incorporating quantitative biosecurity and biosafety risk measures. Two test problems were used to exercise these research products examine (a) Systemic effects of technological innovation and (b) Right -sizing of laboratory networks.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

Experimental and numerical investigation of reactive shock-accelerated flows

The main goal of this program was to establish a qualitative and quantitative connection, based on the appropriate dimensionless parameters and scaling laws, between shock-induced distortion of astrophysical plasma density clumps and their earthbound analog in a shock tube. These objectives were pursued by carrying out laboratory experiments and numerical simulations to study the evolution of two gas bubbles accelerated by planar shock waves and compare the results to available astrophysical observations. The experiments were carried out in an vertical, downward-firing shock tube, 9.2 m long, with square internal cross section (25×25 cm 2 ). Specific goals were to quantify the effect of the shock strength (Mach number, M) and the density contrast between the bubble gas and its surroundings (usually quantified by the Atwood number, i.e. the dimensionless density difference between the two gases) upon some of the most important flow features (e.g. macroscopic properties; turbulence and mixing rates). The computational component of the work performed through this program was aimed at (a) studying the physics of multi-phase compressible flows in the context of astrophysics plasmas and (b) providing a computational connection between laboratory experiments and the astrophysical application of shock-bubble interactions. Throughout the study, we used the FLASH4.2 code to run hydrodynamical and magnetohydrodynamical simulations of shock bubble interactions on an adaptive mesh.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2017

An Aerosol Mobility Imager for Rapid Size Distribution Measurement (Final Report)

Brookhaven and Aerosol Dynamics Inc. (ADI) will collaborate to couple the condensation growth cell of the Aerosol Mobility imager (AMI) constructed by ADI to the Brookhaven mobility column and detector components, and characterize its performance including counting efficiency, measurement accuracy, and speed.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2017

State-of-the-Art for Hygrothermal Simulation Tools

The hygrothermal (heat and moisture) performance of buildings can be assessed by utilizing simulation tools. There are currently a number of available hygrothermal calculation tools available which vary in their degree of sophistication and runtime requirements. This report investigates three of the most commonly used models (WUFI, HAMT, and EMPD) to assess their limitations and potential to generate physically realistic results to prioritize improvements for EnergyPlus (which uses HAMT and EMPD). The outcome of the study shows that, out of these three tools, WUFI has the greatest hygrothermal capabilities. Limitations of these tools were also assessed including: WUFI’s inability to properly account for air leakage and transfer at surface boundaries; HAMT’s inability to handle air leakage, precipitationrelated moisture problems, or condensation problems from high relative humidity; and multiple limitations for EMPD as a simplified method to estimate indoor temperature and humidity levels and generally not used to estimate the hygrothermal performance of the building envelope materials. In conclusion, out of the three investigated simulation tools, HAMT has the greatest modeling potential, is open source, and we have prioritized specific features that can enable EnergyPlus to model all relevant heat and moisture transfer mechanisms that impact the performance of building envelope components.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

Dual-Particle Imaging System with Neutron Spectroscopy for Safeguard Applications

A dual-particle imager (DPI) has been designed that is capable of detecting gamma-ray and neutron signatures from shielded SNM. The system combines liquid organic and NaI(Tl) scintillators to form a combined Compton and neutron scatter camera. Effective image reconstruction of detected particles is a crucial component for maximizing the performance of the system; however, a key deficiency exists in the widely used iterative list-mode maximum-likelihood estimation-maximization (MLEM) image reconstruction technique. For MLEM a stopping condition is required to achieve a good quality solution but these conditions fail to achieve maximum image quality. Stochastic origin ensembles (SOE) imaging is a good candidate to address this problem as it uses Markov chain Monte Carlo to reach a stochastic steady-state solution. The application of SOE to the DPI is presented in this work.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

Embedded 100 Gbps Photonic Components

This innovation to fiber optic component technology increases the performance, reduces the size and reduces the power consumption of optical communications within dense network systems, such as advanced distributed computing systems and data centers. VCSEL technology is enabling short-reach (< 100 m) and >100 Gbps optical interconnections over multi-mode fiber in commercial applications.

42 ENGINEERING↗

DOE OSTI2020

Modeling Failure of Electrical Transformers due to Effects of a HEMP Event

Understanding the effect of a high-altitude electromagnetic pulse (HEMP) on the equipment in the United States electrical power grid is important to national security. A present challenge to this understanding is evaluating the vulnerability of transformers to a HEMP. Evaluating vulnerability by direct testing is cost-prohibitive, due to the wide variation in transformers, their high cost, and the large number of tests required to establish vulnerability with confidence. Alternatively, material and component testing can be performed to quantify a model for transformer failure, and the model can be used to assess vulnerability of a wide variety of transformers. This project develops a model of the probability of equipment failure due to effects of a HEMP. Potential failure modes are cataloged, and a model structure is presented which can be quantified by the results of small-scale coupon tests.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

A Bezier Curve Informed Melt Pool Geometry to Model Additive Manufacturing Microstructures Using SPPARKS

Additive manufacturing is a transformative technology with the potential to manufacture designs which traditional subtractive machining methods cannot. Additive manufacturing offers fast builds at near final desired geometry; however, material properties and variability from part to part remain a challenge for certification and qualification of metallic components. AM induced metallic microstructures are spatially heterogeneous and highly process dependent. Engineering properties such as strength and toughness are significantly affected by microstructure morphologies resulting from the manufacturing process Linking process parameters to microstructures and ultimately to the dynamic response of AM materials is critical to certifying and qualifying AM built parts and components and improving the performance of AM materials. The AM fabrication process is characterized by building parts layer by layer using a selective laser melt process guided by a computer. A laser selectively scans and melts metal according to a designated geometry. As the laser scans, metal melts, fuses, and solidifies forming the final geometry in a layerwise fashion. As the laser heat source moves away, the metal cools and solidifies forming metallic microstructures. This work describes a microstructure modeling application implemented in the SPPARKS kinetic Monte Carlo computational framework for simulating the resulting microstructures. The application uses Bzier curves and surfaces to model the melt pool surface and spatial temperature profile induced by moving the laser heat source; it simulates the melting and fusing of metal at the laser hot spot and microstructure formation and evolution when the laser moves away. The geometry of the melt pool is quite flexible and we explore effects of variances in model parameters on simulated microstructures.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Generic Pressurized Water Reactor Model for SAPHIRE

Generic Pressurized Water Reactor Model for SAPHIRE This report contains a data dump from a SAPHIRE Generic Pressurized Water Reactor (PWR) model. The intent is to have this information reviewed for export control and classification so that the generic model can be used external to INL. The facility model is not applicable to any existing nuclear reactors. The Generic PWR model does not represent any existing power plant and was created to support research and training purposes. Three distinct types of data are used to create a SAPHIRE risk model: - Event trees representing typical PWR sequences - Fault trees representing generic system performance - Basic events (e.g., component failure information) Where possible, we have taken information from publicly available documents and referenced that information tagged to a specific item.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Project 7.3 Characterization of Kevlar®-reinforced Composites for Predictive Simulation

The IACMI 7.3 project between DuPont and Purdue University required the mechanical testing of a 2x2 twill Kevlar® weave with Hexion EPIKOTE resin. The tension, shear, flexure, and compressive behavior of this material system was characterized, and the results can be seen in Table 1. These material properties can now be further evaluated for use in performance simulations of automotive components to represent the properties of composites based on woven materials containing Kevlar. This report will provide details regarding the effort required to arrive at these material properties.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Automated Vulnerability Detection (AVUD) for Compiled Smart Grid Software

This project developed and implemented a system for conducting cybersecurity vulnerability detection of smart grid components and systems by performing static analysis of compiled software (“firmware”). The resulting system for automated vulnerability detection (AVUD) was implemented as part of Oak Ridge National Laboratory’s existing test bed for smart meters, the Sustainable Campus Initiative. The work consisted of two phases: the first phase implemented the necessary software and computational models to perform the analysis, and the second phase demonstrated the system on example firmware in partnership with smart meter manufacturer Sensus USA, Inc. The resulting system won an R&D 100 award and has been successfully commercialized, winning a National Laboratory Consortium Commercialization Award.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

University of Missouri Research Reactor (MURR) LEU Fuel Fluid-Structure Interaction Analysis

The University of Missouri Research Reactor (MURR ® ) is one of five U.S. high performance research reactors (USHPRR), plus one critical facility, that are actively collaborating with the National Nuclear Security Administration (NNSA) Material Management and Minimization (M 3 ) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥ 20 wt.% U-235) to low-enriched uranium (LEU, < 20 wt.% U-235) fuel. A new type of LEU fuel with very high density, based on an alloy of uranium and 10 weight percent molybdenum (U-10Mo), is expected to allow the conversion to LEU of USHPRR that have been found unable to be converted with previously qualified uranium silicide-aluminum (U 3 Si 2 -Al) dispersion fuel. MURR has been working with the USHPRR Reactor Conversion (RC) Pillar at Argonne National Laboratory to perform fuel element design and fuel cycle performance analyses, steady-state thermal hydraulics safety analyses, and accident safety analyses in preparation for the conversion of MURR and to support a preliminary Safety Analysis Report (SAR) for conversion to LEU fuel. In this work, Fluid-structure interaction (FSI) analysis at the fuel element level, as compared to the fuel plate level of the previous work. is performed which models all components of the MURR LEU fuel element, including fuel plates and the supporting structures e.g., side plates, end fittings, and combs. Therefore, the effect of supporting structures on the coolant flow distribution, the fuel plate deflection, and the resulting coolant channel gap reduction can be evaluated. In addition to the nominal element geometry and flow rate, the tolerances in the geometry dimensions of coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are considered in this work. The effect of comb on plate displacement is quantified through two bounding cases: the case assuming a perfect bond between the comb and plates and the case neglecting the comb effect. Note that in this analysis, the FSI has been decoupled from the other structural effects caused by irradiation (e.g., swelling and irradiation creep). Assessment of combined effects is planned for a later stage of this project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

HPE ultralit project (ARPA-E open program 2018) final report 15

The goal of the program was to build a fully integrated optical transceiver with >1 Tb/s and <1.5 pJ/bit operating at 50 ◦ C. Optical transceivers are critical components in high-performance-computers (HPC) and data centers, and the details of their implementation has a big impact on the total power consumption (energy efficiency) of an HPC system. Our proposed transceiver used three key enabling technologies. Firstly, SiGe avalanche photodetectors have record-low sensitivities, meaning that they can reach low bit error rates with very little light input. As a result, we can drive our lasers at a lower drive current, thus saving electrical power. Secondly, we use MOS-based capacitive tuning in our deinterleaver, modulator, and demultiplexer. Capacitive tuning allows for the tuning of photonic elements with zero static power consumption. Thirdly, we use quantum dots as the gain material in our light source. This allows us to efficiently use our light source at temperatures that are typically encountered in an HPCsystem. Our proposed optical transceiver consisted of a quantum dot comb laser as a light source, a booster SOA, MOS-based deinterleavers, MOS based ring modulators, MOS-based ring demultiplexers, and SiGe APDs.

77 NANOSCIENCE AND NANOTECHNOLOGY↗