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ORNL Infrastructure: Status Update on BEA Research Reactor Cask Planning Activities Completed During FY 2025
This report documents Oak Ridge National Laboratory’s (ORNL’s) FY 2025 progress toward establishing readiness to use the Battelle Energy Alliance (BEA) Research Reactor (BRR) shipping cask in support of the Nuclear Science User Facilities (NSUF). The BRR cask will provide a new shared infrastructure capability for transporting irradiated fuels and materials between ORNL and Idaho National Laboratory (INL), thereby supporting NSUF’s mission of enabling user access to advanced nuclear research facilities. In FY 2025, ORNL advanced the regulatory, contractual, safety review, and planning activities necessary to qualify its facilities and staff for BRR cask handling. Although loaded shipments were delayed due to fabrication lead times for Orano Federal Services LLC’s internal basket hardware, the program progressed to the point where an empty cask dry run is scheduled for October 2025. This dry run represents a critical step in demonstrating ORNL’s ability to receive, handle, and return the BRR cask.
National Campaign Development Test Executive Summary
NASA’s vision for Advanced Air Mobility (AAM) is to provide safe, sustainable, accessible, and affordable aviation for transformational local and intraregional missions and includes the transportation of passengers and cargo as well as aerial work missions, such as infrastructure inspection or search and rescue operations. NASA’s technical expertise, intergovernmental relationships, and high level of public trust will help this technology come to market concurrent with infrastructure readiness, public acceptance, and constructive regulation. By advising and integrating disparate AAM efforts across the country and working collaboratively with the FAA, the National Campaign (NC) objective is to motivate industry progress and support the development of policy, regulatory, and technical standards in a manner that best ensures public safety and benefit to the American people. NC began with the Dry Run and Developmental Test (NC-DT), which served as a pathfinder for collaboration and direct involvement with industry partners in integrated simulation exercises and flight tests. NC-DT culminated with an acoustics-gathering flight test in September 2021 with industry partner Joby’s prototype S4 2.0 air vehicle, which delivered the first foundational baseline of noise levels present in Electric Vertical Takeoff and Landing (eVTOL) vehicles. Through the DT phase, the NC team built and tested the airspace and range infrastructure while assessing the readiness level of industry partners leading up to future NC events. The purpose of this paper is to provide an overview of NC-DT.
Investigation of Wear and Friction Properties Under Sliding Conditions of Some Materials Suitable for Cages of Rolling-Contact Bearings
An investigation of wear and friction properties of a number of materials sliding against SAE 52100 steel was conducted. These materials included brass, bronze, beryllium copper, monel, nichrome v, 24s-t aluminum, nodular iron, and gray cast iron. The metals investigated may be useful as possible cage (separator or retainer) materials for rolling-contact bearings of high-speed turbine engines. The ability of materials to form surface films that prevent welding is a most important factor in both dry friction and boundary lubrication. On the basis of wear and resistance to welding only, the cast irons were the most promising materials investigated; they showed the least wear and the least tendency to surface failure when run dry, and when boundary lubricated they showed the highest load capacity. On the basis of mechanical properties, nodular iron is superior to gray cast iron. Bronze had the lowest friction coefficient under dry sliding conditions. The results with brass, beryllium copper, and aluminum were poor and these materials do not appear, with regard to friction and wear, to be suitable for cages.
Sputter sample preparation for ion beam delivery of radium-223 at ATLAS
A radium-223 ion beam was delivered to an experiment from the electron cyclotron resonance ion source, ECR2, at the Argonne Tandem Linac Accelerator System (ATLAS). Here, the radium-223 material was in a nitrate salt form within a vial, prior to being converted to a usable sputter sample. The sputter sample was produced using a new sample preparation method, where the radium nitrate was dissolved into a solution and pipetted onto pressed aluminum powder. This sample was then allowed to dry, distributing the radium-223 material throughout the sputter sample. Ion source operation using the radium sputter sample is described with the operating parameters listed. The intensity and energy requirements for this ion beam were 1 × 10 6 particles/s and 1.07 GeV, respectively. Because the intensity is relatively low compared to most experiments at ATLAS, previously developed accelerator mass spectrometry methods were used Scott et al. to avoid the need for tuning of the low-intensity beam of interest. Handling of the radium material, as well as loading and unloading of the sputter sample from ECR2, required collaboration with Health Physics. Procedures were used and dry runs were carried out before, during, and after the experiment to ensure the safety of the workers. The processes used and lessons learned are described within.
Concept Study of Robotic Camera-Based Foreign Object Detection for EV Wireless Charging
Wireless charging of an electric vehicle (EV) is an emerging charging technology promising convenient, autonomous, and highly efficient EV charging without requiring heavy gauge cables. However, due to the strong electromagnetic field created by this process that surrounds the wireless charger, the presence of foreign objects can detrimentally interact with it, thus affecting wireless power transfer (WPT) performance or leading to harmful and unwanted safety risks. This paper presents the results for a concept study on a robotic camera-based foreign object detection (FOD) system, as a supplement to the industry-existing overlapped FOD coil array method, for EV wireless charging. A Raspberry PI 4 control board and compatible Raspberry PI Camera Module 2 are used to implement camera-based object detection. The FOD program was developed using a state-of-the-art deep learning object detection model with the OpenCV and Pytorch library and is compatible with camera module hardware. A dry-run test with Raspberry PI and a camera module was conducted and the preliminary FOD function was verified. The feasibility assessment is also validated by comparing the performance of five existing state-of-the-art deep learning object detection models for vehicles, animals, persons, and metals subsets, respectively. Satisfactory performance on the benchmark datasets is observed by the tests, but further improvements are needed in future work when detecting small-sized metallic objects. A programable robotic car is also under development as ongoing work for carrying the Raspberry PI and camera module while moving for the maintenance process.
Assessing the New Home Market Opportunity: Case Study and Cost Modeling for Solar and Storage in 2030
Residential solar and storage markets are growing in the United States. With approximately 1 million new homes constructed every year, this represents a significant opportunity for solar and storage installations. Some homebuilders have begun to build new homes with solar and storage included as a standard offering. It is not clear how solar and storage is incorporated into the new construction process and at what cost. Further, it is unclear what barriers or opportunities exist to scale this model nationwide. To fill this gap in the literature, this research conducts a case study of Mandalay Homes' new solar and storage community in Arizona to gather lessons learned. From this foundation, we further generate a set of pathways to reduce install costs and expand solar and storage market penetration in this sector. To model existing and 2030 solar and storage costs, we use the National Renewable Energy Laboratory's (NREL's) bottom-up cost model. This modeling is further informed by 12 interviews conducted with new home builders, solar contractors, and other subject matter expert organizations. Our case study analysis generated three key considerations for other homebuilders including: 1. Educating local permitting, inspection, and in some cases utility officials on solar and storage products, designs, and code compliant building practices may be required. The need for education may decline as more local governments and utilities review and approve solar and storage projects. 2. Incorporating solar and storage systems into the homebuilding process can add complexity and related coordination challenges. This does not need to result in home construction delays, but can result in costly contractor "dry runs" to construction sites. 3. Deploying solar and storage at the time of new construction has significant economies of scale, which can improve the value proposition of the systems. The case study, extant literature, and interviews were used to model both existing and future solar and storage installation costs at time of new construction. Here, we find three key cost reduction opportunities relating to solar and battery storage hardware, customer acquisition, and overhead. If future contractors can maximize the cost reduction opportunities outlined here, residential new construction costs could decline by 8 - 25% by 2030, depending on the modeled scenario. Though we expect costs to decline through 2030, it is unclear which of these scenarios may ultimately appear. Interviewees further identified a variety of barriers across each cost category that could temper the savings shown here. At the same time, interviewees described several pathways to scale the new construction solar and storage market, beyond installation cost savings. Interviewees confirmed that changes in finance, rate design, resilience policies, deployment mandates, and DER aggregation could all support more market adoption than seen today. These findings suggest that there are significant opportunities to expand new construction markets and this research can serve as a baseline to assess progress in this segment through 2030.
29 th International Training Course on the Physical Protection of Nuclear Materials and Nuclear Facilities (Project Summary)
Sandia National Laboratories (Sandia) has hosted the International Training Course on the Physical Protection of Nuclear Materials and Nuclear Facilities since 1978. This course is the flagship training course of the International Atomic Energy Agency (IAEA). On behalf of the National Nuclear Security Administration (NNSA), Sandia manages, develops, and coordinates all course materials, and works closely with the IAEA to arrange all logistical details for the course ITC-29 incorporated some updates to the facility models, based on feedback received in ITC-28 and the ITC-29 dry run. In addition, all the graphics were refreshed after ITC-28 and implemented in the posters, data handbooks, etc. As in ITC-28, the ITC-29 staff worked closely with the IAEA on course materials, including a peer review process to ensure all course materials were aligned with Nuclear Security Series No. 13 and other relevant international guidance documentation from the IAEA. Due to the COVID-19 pandemic, ITC-29 was postponed twice and eventually took place in the late summer/early fall of 2022. Due to ongoing COVID-19 restrictions and safety requirements, the number of participants was reduced by about 31 percent from 59 participants in ITC-28 to 41 in ITC-29. As a result, the number of subgroups also decreased from eight in ITC-28 to six for ITC-29. This enabled the Sandia team to implement more opportunities for social distancing, particularly in the large classrooms. Despite the challenges, ITC-29 still passed a significant milestone, with the one-thousandth participant of the international training course attending during this event. Finally, the ITC staff continued the use of its improved method of evaluation to capture participants’ satisfaction with the updated course and to gather feedback concerning future improvements. This document provides a brief description of ITC-29, including a summary of lessons learned and key recommendations for future development efforts.
Safety management of a complex R and D ground operating system
A perspective on safety program management was developed for a complex R&D operating system, such as the NASA-Lewis Research Center. Using a systems approach, hazardous operations are subjected to third-party reviews by designated-area safety committees and are maintained under safety permit controls. To insure personnel alertness, emergency containment forces and employees are trained in dry-run emergency simulation exercises. The keys to real safety effectiveness are top management support and visibility of residual risks.
Safety management of a complex R&D ground operating system
A perspective on safety program management has been developed for a complex R&D operating system, such as the NASA-Lewis Research Center. Using a systems approach, hazardous operations are subjected to third-party reviews by designated area safety committees and are maintained under safety permit controls. To insure personnel alertness, emergency containment forces and employees are trained in dry-run emergency simulation exercises. The keys to real safety effectiveness are top management support and visibility of residual risks.
Development of Advanced Czochralski Growth Process to produce low cost 150 KG silicon ingots from a single crucible for technology readiness
The modified CG2000 crystal grower construction, installation, and machine check-out was completed. The process development check-out proceeded with several dry runs and one growth run. Several machine calibrations and functional problems were discovered and corrected. Several exhaust gas analysis system alternatives were evaluated and an integrated system approved and ordered. A contract presentation was made at the Project Integration Meeting at JPL, including cost-projections using contract projected throughput and machine parameters. Several growth runs on a development CG200 RC grower show that complete neck, crown, and body automated growth can be achieved with only one operator input. Work continued for melt level, melt temperature, and diameter sensor development.
Fabrication and wear test of a continuous fiber/particulate composite total surface hip replacement
Continuous fiber woven E-glass composite femoral shells having the ame elastic properties as bone were fabricated. The shells were then encrusted with filled epoxy wear resistant coatings and run dry against ultrahigh molecular weight polyethylene acetabular cups in 42,000 and 250,000 cycle were tests on a total hip simulator. The tribological characteristics of these shells atriculating with the acetabular cups are comparable to a vitallium bal articulating with an ultrahigh molecular weight polyethylene cup.
Tribological characteristics of a composite total-surface hip replacement
Continuous fiber, woven E glass composite femoral shells having the same elastic properties as bone were fabricated. The shells were then encrusted with filled epoxy wear resistant coatings and run dry against ultrahigh molecular weight polyethylene acetabular cups in 42,000 and 250,000 cycle wear tests on a total hip simulator. The tribological characteristics of these continuous fiber particulate composite femoral shells articulating with ultrahigh molecular weight polyethylene acetabular cups were comparable to those of a vitallium ball articulating with an ultrahigh molecular weight polyethylene acetabular cup.
Development of advanced Czochralski growth process to produce low-cost 150 kG silicon ingots from a single crucible for technology readiness
The modified CG2000 crystal grower construction, installation, and machine check out was completed. The process development check out proceeded with several dry runs and one growth run. Several machine calibrations and functional problems were discovered and corrected. Exhaust gas analysis system alternatives were evaluated and an integrated system approved and ordered. Several growth runs on a development CG2000 RC grower show that complete neck, crown, and body automated growth can be achieved with only one operator input.
Calibration Check For Programmed Welding Robot
Preweld calibration check helps to ensure welding torch on computer-controlled welding robot mounted properly, right gas cup selected, and length of extension of electrode adjusted correctly. Performed by operator just before dry run for each set of parts welded. Procedure takes 2 to 3 minutes and enables correction of errors before parts or equipment damaged.
STS-41 Ulysses TCDT Activities
Live footage shows the crewmembers of STS-41, Commander Richard N. Richards, Pilot Robert D. Cabana, Mission Specialists William M. Shepherd, Bruce E. Melnick, and Thomas D. Akers, participating in Terminal Countdown Demonstration Tests (TCDT). The astronauts are seen participating in many different activities including the traditional breakfast, suit-up, simulated training in the crew module, and a dry run of launch and emergency egress training.
STS-104 Flight Day 9 Highlights
On this ninth day of the STS-104 mission, Mike Gernhardt and Jim Reilly are seen in the newly installed Quest Airlock performing a dry run for flight day ten's spacewalks' preparations. The crews of STS-104 (Commander Steven Lindsey, Pilot Charles Hobaugh, and Mission Specialists Mike Gernhardt, Jim Reilly, and Janet Kavandi) and Expedition 2 (Commander Yuriy Usachev and Flight Engineers James Voss and Susan Helms) answer questions about the STS-104 mission, the next day's spacewalks, and Expedition 2's stay on the International Space Station during an on-orbit interview. An external shot of the Atlantis Orbiter shows a water dump as it leaves the Shuttle and dissipates into space. Commander Lindsey gives a guided video tour of the Quest Airlock, displaying equipment and summarizing its purpose.