Development of a Data Management Methodology for a COTS Part Testing Program to Meet the Needs of a Broad Range of Users.
Abstract not provided.
Stork, Christopher↗
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Determining Radiation Response of Aging COTS Parts through Laser Dose-Rate Surveillance (LDRS) Testing
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Gauderon, Casey Rae↗
Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains
Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.
13 HYDRO ENERGY↗
Use of Commercial Off-The-Shelf Parts with 3-D Printed Connectors for Powered Air Purifying Respirators
This report presents preliminary results from the performance evaluation of a powered air purifying respirator (PAPR) assembled from commercial off-the-shelf (COTS) parts. Cost is a major limiting factor to PAPR adoption in healthcare. Moreover, the lack of standardization for filters and batteries poses a challenge for clinics and hospitals. Rapid prototyping of connectors, both mechanical and electrical, offers a possible solution in addressing both issues. We used 3-D printed connectors to assemble COTS components into a prototype PAPR. Large-scale manufacturing of 3-D printed connectors may be accomplished by converting the computer-aided design (CAD) drawings to pressure-injection molds.
42 ENGINEERING↗
Unattended Dual Current Monitor (UDCM)
Researchers at Los Alamos National Laboratory have developed the Unattended Dual Current Monitor (UDCM). The UDCM is an ideal solution for current measurement needs such as ion chamber gamma measurements. This data acquisition system simplifies hardware requirements for current applications, and provides added reliability, flexibility, and compatibility as compared with the legacy Miniature Gamma Ray and Neutron Detector (MiniGRAND) technology. It is lightweight, can be portable or mounted, is manufactured using COTS parts, and features a modern Internet-of-Things (IoT) enabled design.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
COTS Data Analytics Software User Manual: Version 1.0
Large volumes of data are being collected by Sandia National Laboratories as part of an active commercial-off-the-shelf (COTS) part testing and surveillance program. This user manual documents Python-based COTS Data Analytics software that has been developed for standardizing, displaying, visualizing, and analyzing the resulting COTS part testing and surveillance data. It is the objective of these software tools to streamline the analysis of COTS testing and surveillance data and improve the efficiency with which test engineers and data analytics experts can pinpoint possible performance and reliability problems in COTS parts.
42 ENGINEERING↗
Commercial Electronic Part Class Definitions
Electronic parts used in Nuclear Security Enterprise (NSE) applications have varying pedigrees. Understanding the differences among these "part classes" will better enable Kansas City National Security Campus (KCNSC) and Sandia National Laboratories (SNL, or Sandia) to effectively manage factors such as risk, effort, cost, etc. across all functional areas which have a shared interest in the definition and acquisition process. Regardless of the pedigree and complexity, all parts are expected to meet necessary quality and reliability requirements. This activity has been conducted as part of the COTS Transformation Initiative (CTI).
42 ENGINEERING↗
Survey Report on Commercial Off-The-Shelf (COTS) Tracking Tools
Radioactive/nuclear (R/N) materials are integral parts of many business sectors such as medicine, industry, and research. In the United States alone, approximately 3 million packages containing R/N materials are shipped annually via highways, rail, air, and water. These materials are utilized in medical diagnostics and treatments, industrial radiography, and scientific research. The secure and efficient transportation of R/N materials is paramount to public safety and national security. Recent incidents involving the loss of R/N materials during transportation highlight significant security and safety concerns. For instance, in December 2024, a package containing four encapsulated Selenium-75 sources was reported lost in transit from the Czech Republic to Madrid, raising alarms about the security of such shipments. Similarly, a Germanium-68 pin source was reported lost in transit in New Jersey in December 2024, underscoring the risks associated with transporting radioactive materials.
98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
Evaluation of COTS Electronics by Power Spectrum Analysis and Multivariate Data Analysis
Power spectrum analysis (PSA) is a fast, non-destructive, sensitive method for examining commercial off-the-shelf ( COTS ) electronic components. These features make PSA attractive for both component screening and surveillance in support of component reliability efforts. Current analysis methods limit the utility of PSA due to the need to manually examine the results of analysis to identify anomalous parts. This study demonstrates the development and application of a workflow to automate the screening of COTS electronic components. Further, this study demonstrates the use of multivariate algorithms to assess aging of Zener diodes. These workflows can be readily extended to other components, combining the benefits of PSA and multivariate analysis to screen and evaluate COTS electronic components.
42 ENGINEERING↗
Cybersecurity for the Operational Technology Environment (CyOTE) (Final Technical Report)
Electric grids have historically been susceptible to both physical attacks and environmental hazards but the implementation of smart grids, remote management, and self-healing networks, has now made the grid vulnerable to cyber attacks. To address risks introduced by routable connectivity, utilities must establish dynamic solutions to identify, protect, detect, respond to, and recover from cyber security threats and vulnerabilities. In response to the evolving threat landscape U.S. Department of Energy-Office of Cybersecurity, Energy Security, and Emergency Response (DOE CESER) initiated the Cybersecurity for the OT Environment (CyOTE) pilot program, a U.S. Department of Energy (DOE) effort designed to leverage U.S. intelligence capabilities to prevent, detect, or mitigate a cyber attack on utility operational technology (OT) networks. As part of the CyOTE pilot, The Southern Company (Southern Company or Southern) researched, evaluated and deployed emerging Commercial off the Shelf (COTS) technologies and cyber security monitoring architectures to provide previously unrealized network visibility and situational awareness through deep packet inspection and data analytics. This Final Scientific/Technical Report documents the objectives, methodology, lessons learned, and results of Southern Company’s participation in the CyOTE pilot from December 2018 to September 2023.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Low-Cost, Accessible Vaccine Cooler Options
In response to cold chain management requirements for COVID-19 vaccines, Los Alamos National Laboratory has investigated, built, and demonstrated viability for different cryogenic storage options. With ease-of-access and affordability in mind, these cooler units have been built using commercial off-the-shelf (COTS) components. The team was also able to design a testing method for evaluating the performance of the different vaccine cooler options as part of the Technology Evaluation and Demonstration program. The tested cooler units demonstrated compatibility with either dry ice or liquid nitrogen as the cryogen, along with several commercial solvents. This compatibility demonstration would potentially offer sufficient flexibility for temperature control continuity. Next steps are to investigate industry interest in supporting field testing of the cooler units.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
SULI Research Report Paper
The Intelligence and Space Research Group 4 (ISR-4) at the Los Alamos National Laboratory focuses on signal processing and developing space electronics for various national security missions. The Space and Atmospheric Burst Reporting System (SABRS) is a sensing payload designed for nuclear detonation detection. As the sensors from previous payloads become obsolete, the requirement for a novel payload design increases. SABRS Prime is the successor to the previous SABRS payloads and is scheduled for delivery in 2028. As part of the SABRS Prompt Gamma Instrument Interface Board, high frequency signals from silicon photomultiplier tubes need to be split and subsequently transmitted to the Analog to Digital Converter. Prior to developing the Space Grade Instrument Interface Board, evaluation modules with Commercial off-the-shelf (COTS) components are evaluated and tested under rigorous conditions. Verification of power levels and gain specifications are some of the important steps taken during the evaluation stage. Working on the Signal Splitting Board has enabled me to work with various schematic software applications and learn more about the processes behind designing space grade electronic components. In addition, I conducted research on efficiency improvements for space-based power systems. Changes in design approaches were found to be the most significant sources of improvement. Being able to interact with researchers and peers across various scientific disciplines has given me a better insight into my future pursuits. Working in a R&D environment has cemented my decision to work on space applications for Quantum Sensing and pursue a PhD in Electrical Engineering. The SULI internship program at the Los Alamos National Laboratory has helped me develop the skillset of a researcher, understand the rigorous processes behind developing space grade hardware, and improve my critical thinking abilities to support the development of reliable instrumentation for deep space missions.
45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
CROWBAR: Natively Fuzzing Trusted Applications Using ARM CoreSight
Abstract Trusted execution environments (TEE) are deployed on many platforms to provide both confidentiality and integrity, and their extensive use offers a secure environment for privacy-sensitive operations. Despite TEE prevalence in the smartphone and tablet market, vulnerability research into TEE security is relatively rare. This is, in part, due to the strong isolation guarantees provided by its implementation. In this paper, we propose a hardware assisted fuzzing framework, CROWBAR, that bypasses TEE isolation to natively evaluate trusted applications (TAs) on mobile devices by leveraging ARM CoreSight components. CROWBAR performs feedback-driven fuzzing on commercial, closed source TAs while running in a TEE protected environment. We implement CROWBAR on 2 prototype commercial-off-the-shelf (COTS) smartphones and one development board, finding 3 unique crashes in 5 closed source TAs that are previously unreported in the TrustZone fuzzing literature.
Shan, Haoqi↗
Microhole drilling technology utilizing a golden section search algorithm
A fundamental issue in microhole drilling is that delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes necessary to realize the envisioned cost savings An optimization algorithm called a golden section search (GSS) was used to systematically identify the preferred WOB for a given set of conditions. This research focused on implementing and evaluating two low WOB drilling technologies for microhole drilling: - Laser-assisted mechanical drill, which was tested in the laboratory - Lightly modified commercial off-the-shelf (COTS) percussive hammer, which was tested in a limited field test. Data were collected for microhole GSS using WOB optimization via simulation as well as at the Blue Canyon Dome Site in Socorro, NM. Information on the attached files and folders are as follows: - the .tdms files are LabView data files, which can be opened within Excel using a .tdms add-in or using a Matlab .tdms converter - the .tdms_index files are part of the .tdms file structure - sampling rate, column headers, and length data within the .tdms files follow SOP when utilizing Excel and/or Matlab as described above
15 GEOTHERMAL ENERGY↗
Savannah River Site H-Canyon Advancing Technologies for Remote Inspections - 20345
In 2017, the DOE Environmental Management Office of Technology Development (DOE-EM TD) sponsored the H-Canyon Advanced Technology Demonstration (ATD) to demonstrate to DOE facilities the value of using new commercial-off-the-shelf (COTS) and near-ready technologies to solve difficult problems and enhance worker safety. The DOE Savannah River Site (SRS) H-Canyon Air Exhaust Tunnel (HCAEX) inspection task was identified as representative of the hazardous, human denied environments which could benefit from advanced technologies. The HCAEX underground concrete tunnel is visually inspected biannually using a camera mounted on a remotely operated vehicle (ROV) designed and built by SRNL. While tunnel images have provided valuable visual information, it is desirable to have a higher order of understanding of the environment to support a more thorough structural integrity (SI) analysis and for long term planning purposes. As part of the ATD, the Concrete Integrated Product Team (CIPT) was formed to identify and evaluate available sensors and methods mature enough to remotely obtain tunnel concrete characterization data of high value and with a high probability of success. The team included SMEs and H-Canyon stakeholders in the field of concrete, nondestructive examination (NDE), structural integrity, sensors and remote systems from SRNL, SRNS, LANL, DOE-SR and the Army Corps of Engineering. The CIPT completed an in-depth identification of customer concrete inspection needs and potential technology solutions. Sensors and methods were evaluated on performance, data usefulness, cost and the feasibility of a successful deployment given the unique tunnel access challenges and environment. Two technologies were identified as promising by the CIPT for near term demonstration and evaluation: Lidar (Light Detection and Ranging) 3-dimensional (3D) mapping and remote robotic deployment of NDE instrumentation. Laser spectroscopy to characterize tunnel surface chemical changes was also of interest, but presently cost prohibitive. This paper will include a discussion of the two efforts underway to evaluate and implement the CIPT recommendations. First, the status of the November 2019 deployment of Lidar at a single location into the tunnel is presented. This initial deployment provided the team a learning curve and lessons learned on the challenges of tunnel deployment to include remote operation and data collection, stabilization of the sensor in high air flow (∼30 mph), ability to achieve a tolerance accuracy of 0.25-inches, and the probability to identify change in tunnel dimensions over time. Secondly, a discussion on the development of the Robotic Arm Concrete Inspection Test Bed capable of deploying NDE instruments to examine custom concrete forms will be presented. Concrete forms simulating the rough concrete surfaces, strength, composition and potential structural defects that can be found at our DOE EM facilities have been designed and built for the test bed. Two state-of-the art concrete NDE instruments have been identified as having potential to work on rough concrete walls, they are being tested and characterized as to their ability to provide desired structural integrity data to include wall thickness and defect identification on the developed test beams. Lastly, lessons learned, and the path forward will be presented. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Advancement of Commercial Intumescent Expanding Foams for Deactivation and Decommissioning in the Nuclear Sector - 20198
Florida International University (FIU), in collaboration with The Department of Energy's Office of Environmental Management (DOE-EM), Savannah River National Laboratory (SRNL), and sites across the Savannah River complex, have identified an operational requirement for a fixative technology that is intended to immobilize and/or isolate residual contamination within a 3-dimensional space. Fixation of radiological contamination can reduce worker risk and mitigate potentially hazardous conditions, however nearly every marketed contamination fixative has been found to be flammable; a significant concern in radiological facilities. Coupled with this, industry fixatives are normally used as a thin coating which can present problems when attempting to stabilize irregular geometry or areas that are difficult to access whilst ensuring full coverage. The technical evaluation and advancement of commercial-off-the-shelf (COTS) polyurethane foams has yielded a down-selected candidate that shows potential in meeting the requirements to support deactivation and decommissioning activities. Several performance criteria have been established and tested to progress the technology readiness level towards an active field demonstration (TRL-7). Such criteria include: mechanical failure limits, adhesive and cohesive properties, thermal/fire resilience, determining thermal behavior, ability to immobilize contamination, and a means of non-destructive evaluation of applications. The test scenario examined was targeted towards an application for decommissioning nuclear pipework, in which the down-selected polyurethane foam would act as a barrier to segregate pipework and mitigate the potential for release during cutting, packaging, and storage operations. Testing carried out at SRNL included: mechanical evaluation of tensile, compressive, and adhesion strength by dynamic mechanical analysis (DMA), as well as thermogravimetric analysis (TGA). FIU examined the foam's fixative properties by utilizing phosphorescent europium-dysprosium doped strontium aluminate powder to investigating the extent to which contamination can be immobilized. FIU has also exploited previous successes in the field of intumescent technologies to assess the down-selected foam's tolerance to an extreme fire scenario, while maintaining the ability to effectively mitigate a contamination release. Parallel to this, extensive thermal investigations were carried out to determine the upper boundary of anticipated heat generation during the curing process as heat generation has the potential to compromise rubber parts of contaminated enclosures. These investigations subsequently yielded a promising method for a non-destructive application evaluation by means of infrared thermography. Utilizing the high sensitivity of modern IR cameras, coupled with the heat generated during the curing process of the polyurethane foam, FIU has been exploring the concept of monitoring the external pipe surface for indications of an irregular or abnormal application, thus informing operational decision making. The testing carried out utilized several current 'best fit' ASTM standards, which serve as helpful guidelines for testing, however, a precise definition of the operational parameters and requirements is still necessary. With continued collaboration with SRNL, FIU aims refine said definitions and develop new standards by which this, and other decommissioning technologies, can be accredited by relevant standards based testing. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
The Impact of Increased Requirements for Verification Measurements of Category III and IV Receipts
As part of the regular nuclear material accounting and control process, sites that have accountable nuclear material regularly perform measurements of the material in their possession. The expectation for the type of measurements and their frequency is set out in Department of Energy (DOE) Order 474.2, and further detailed in each site’s respective material control and accountability (MC&A) plan and associated controlling documents. The measurements of interest in this report are those performed on external (between DOE sites) transfer receipts of Category III or IV accountable materials. In 2020, a revision of DOE Order 474.2 was proposed that would significantly increase the requirement that measurements be performed upon receipt of material, and further, that those measurements be quantitative verification (rather than qualitative confirmatory) measurements. A survey was performed of DOE sites to discuss the impact on their MC&A measurements program if more rigorous verification measurements requirements for Category III and IV receipts were implemented. An assessment of nondestructive assay (NDA) measurement instruments to meet those needs was also performed. Across the board, sites indicated that personnel and budget would cause the largest impact. Sites which are qualified as Category I/II indicated a reduced impact as these sites already have the measurement capabilities and some personnel but would require the acquisition of additional measurement systems. Category III/IV sites indicated a much larger impact as these sites generally have smaller MC&A programs. A few smaller sites stated a measurement program would need to be created to handle the demand. Calorimetry, quantitative gamma spectroscopy and neutron coincidence counting systems were identified as common systems that could meet the verification measurement requirements. The other, and perhaps larger issue is the need for calibration standards for the calorimetry and neutron coincidence counting systems. It is proposed that a comparative study be performed for ISOCS and ISOTOPICS, qualification of a COTS calorimetry system be performed, and development of an AWCC system that uses a neutron generator.
98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗