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Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion environment. The overarching goal of the ORNL Fusion Materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science—Fusion Energy Sciences program, in parallel with developing the materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Physical and Hydraulic Properties of RCRA Borehole Samples from the Hanford Site : Final Report, Fiscal Years 2023-2024

Sediment from 44 core samples collected from Resource Conservation and Recovery Act (RCRA) boreholes drilled in the 200 East and 200 West areas of the Hanford Site were characterized for physical and hydraulic properties (Table S.1). Characterization data included gravimetric water contents and matric potentials, grain-size distributions, saturated hydraulic conductivity, water retention characteristics, and unsaturated hydraulic conductivity. These properties provide site-specific data and parameters that can be used in subsurface flow and contaminant transport models to assess the transport and fate of contaminants in the vadose zone and underlying aquifer systems. The analyzed core samples come from specific areas and depth intervals at the Hanford Site that were targeted for sampling to address data gaps identified by site contractors (Khaleel 2020). X-ray computed tomography (XCT) was used to evaluate the general textural characteristics of the samples and to determine which samples to use for further physical and hydraulic property characterization. Subsequent sample selection was determined by consensus after review of the XCT images by Pacific Northwest National Laboratory, Central Plateau Cleanup Company, and INTERA staff.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Results for the October 2023 Semiannual Salt Waste Processing Facility Decontaminated Salt Solution Sample

In this Technical Report, the chemical and radionuclide contaminant results from the October 2023 Semiannual sample of the Salt Waste Processing Facility (SWPF) Decontaminated Salt Solution (DSS) salt solution are presented in tabulated form. The information from this characterization will be used by Savannah River Mission Completion (SRMC) for the transfer of aqueous waste from SWPF to the Saltstone Production Facility (SPF) where the waste will be treated and disposed in the Saltstone Disposal Facility. This Technical Report compares results, where applicable, to SPF Waste Acceptance Criteria (WAC) LIMITS and TARGETS that were established at the time the SWPF DSS sample was obtained. The October 2023 Semiannual sample of the SWPF DSS is a composite from the six months of SWPF processing during the Third Quarter Fiscal Year 2023 (3QFY2023) and the Fourth Quarter Fiscal Year 2023 (4QFY2023).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Fiscal Year 2024 Software Quality Assurance Activities for the ARC Software

The continued goal of the ARC SQA project in the Advanced Reactor Technologies program of DOE is to resolve the QA gaps for the ARC software that limit, or prevent, commercialization of the software for industry users. This project started in earnest in fiscal year 2023 which saw the entire code system moved from a SVN repository to a GitLab repository and an associated software quality assurance plan (SQAP) developed and ratified. Most of the QA gaps in the ARC software were identified in collaboration with industry partners and work begin in fiscal year 2023 and continued in 2024. The primary documentation that is missing includes user manuals, user guides, software verification reports, and code coverage assessments. The SUMMAR manual was completed this fiscal year and work was started on creating manuals for SE2ANL, SE2RCT, and DASSH. Software verification work was carried out for DIF3D and REBUS in a previous program and the current fiscal year saw the completion of software verification reports for GAMSOR, GAMSRC, VARPOW, EvaluateFlux, and SUMMAR. The goal for the next fiscal year is to complete the PERSENT software verification work and begin planning the software verification work for DASSH, SE2ANL, and SE2RCT. The code coverage reports for DIF3D and MC2-3 were completed in the previous fiscal year and the goal is to generate code coverage reports for REBUS, GAMSOR, PERSENT, and DASSH in the coming fiscal year. A considerable amount of effort was spent in the current fiscal year working on the continuous integration capability for automated regression testing in GitLab. The first version of the testing was created in the previous fiscal year and applied to DIF3D and its utility programs. That testing was extended this year to cover GAMSOR, REBUS, and PERSENT. To accomplish this, the first version of the new testing methodology had to be updated to make a single output checking methodology viable for all of the ARC software. This will result in a single document to detail the automated regression testing methodology and minor documents to detail the tolerance settings that have been applied to the output for each ARC code. The previous methodology put into place with SVN would have required a separate document for each ARC code to detail the output checking methodology and the tolerance settings for the output from each code. Because some of our industry partners are providing funds to add new capabilities to the ARC software to meet their needs, all of which must be reviewed and approved by the SQA program funded by this project, a summary of that development work is detailed in this report. Overall progress on resolving the QA gaps has been good this year with the most impactful improvement for our industry partners in capability being the creation of a threaded version of DIF3D-VARIANT that allows the DIF3D, REBUS, and GAMSOR run times to be reduced by a factor of 4-6. The most impactful QA gap that was resolved was the software verification of GAMSRC and VARPOW.

97 MATHEMATICS AND COMPUTING↗

Fiscal Year 2025 Software Quality Assurance Activities for the ARC Software

The continued goal of the ARC SQA project in the Advanced Reactor Technologies program of DOE is to resolve the QA gaps for the ARC software that limit, or prevent, commercialization of the software for industry users. This project started in earnest in fiscal year 2023 which saw the entire code system moved from a SVN repository to a GitLab repository and an associated software quality assurance plan (SQAP) developed and ratified. Most of the QA gaps in the ARC software were identified in collaboration with industry partners and work begin in fiscal year 2023 and continued through 2024 and 2025. The continuous integration testing was extended to RCT, DASSH, and SE2ANL. Minor changes were required to the original continuous integration methodology to make this happen. When full confidence in the methodology is complete, a report will be created to detail the automated regression testing methodology and minor reports will be created to detail the tolerance settings that have been applied to the output for each ARC code. The primary documentation that is missing includes user manuals, user guides, software verification reports, and code coverage assessments. The DASSH, SE2ANL, and SE2RCT manuals were completed this fiscal year. A review of the SE2ANL software identified that it is unrealistic to include updated correlations or different geometry models and it was scheduled for deprecation in favor of DASSH. The SE2ANL manual is essential for SE2RCT as they are similar but quite different in purpose. The only piece of software missing a manual consistent with the source code is NUBOW-3D which is a focus of the coming year. The code coverage report for DIF3D was updated and code coverage reports were created for REBUS, RCT, PERSENT, GAMSRC, and DASSH. Minor coverage issues were identified for all of these pieces of software which did not prevent the work done to transition them to the OneAPI compiler. Because SE2ANL was scheduled for deprecation, it was not transitioned, but it was successfully tested with the OneAPI compiler. This leaves SE2RCT and NUBOW-3D as the only pieces of software not transitioned to OneAPI and further work is required to get SE2RCT to work properly. The SE2RCT software transition will begin early next year while the NUBOW-3D software requires a manual before it can begin. Software verification work has been completed for DIF3D, REBUS, GAMSOR, GAMSRC, VARPOW, EvaluateFlux, and SUMMAR. The PERSENT software verification work was completed this year which was somewhat delayed because of unexpected bugs in the software. The PERSENT manual was updated to detail some of the issues and discuss the bowing reactivity worth feature added in the previous fiscal year. The RCT, DASSH, SE2RCT, and NUBOW-3D software are the only maintained pieces of software without verification reports. The software verification work for DASSH will be a focus in the upcoming fiscal year and it is hoped that some of the test cases created can serve as verification tests for SE2RCT. The NUBOW-3D work will begin when the manual and requirements report are completed. Only minor industry partner software development funds were provided this year. The DASSH software was updated to handle general axial geometry for each assembly and the NUBOW-3D software was updated to incorporate a new input format and better output. Overall progress on resolving the QA gaps has been good this year.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fiscal Year 2025 Software Quality Assurance Activities for the ARC Software

The continued goal of the ARC SQA project in the Advanced Reactor Technologies program of DOE is to resolve the QA gaps for the ARC software that limit, or prevent, commercialization of the software for industry users. This project started in earnest in fiscal year 2023 which saw the entire code system moved from a SVN repository to a GitLab repository and an associated software quality assurance plan (SQAP) developed and ratified. Most of the QA gaps in the ARC software were identified in collaboration with industry partners and work begin in fiscal year 2023 and continued through 2024 and 2025. The continuous integration testing was extended to RCT, DASSH, and SE2ANL. Minor changes were required to the original continuous integration methodology to make this happen. When full confidence in the methodology is complete, a report will be created to detail the automated regression testing methodology and minor reports will be created to detail the tolerance settings that have been applied to the output for each ARC code. The primary documentation that is missing includes user manuals, user guides, software verification reports, and code coverage assessments. The DASSH, SE2ANL, and SE2RCT manuals were completed this fiscal year. A review of the SE2ANL software identified that it is unrealistic to include updated correlations or different geometry models and it was scheduled for deprecation in favor of DASSH. The SE2ANL manual is essential for SE2RCT as they are similar but quite different in purpose. The only piece of software missing a manual consistent with the source code is NUBOW-3D which is a focus of the coming year. The code coverage report for DIF3D was updated and code coverage reports were created for REBUS, RCT, PERSENT, GAMSRC, and DASSH. Minor coverage issues were identified for all of these pieces of software which did not prevent the work done to transition them to the OneAPI compiler. Because SE2ANL was scheduled for deprecation, it was not transitioned, but it was successfully tested with the OneAPI compiler. This leaves SE2RCT and NUBOW-3D as the only pieces of software not transitioned to OneAPI and further work is required to get SE2RCT to work properly. The SE2RCT software transition will begin early next year while the NUBOW-3D software requires a manual before it can begin. Software verification work has been completed for DIF3D, REBUS, GAMSOR, GAMSRC, VARPOW, EvaluateFlux, and SUMMAR. The PERSENT software verification work was completed this year which was somewhat delayed because of unexpected bugs in the software. The PERSENT manual was updated to detail some of the issues and discuss the bowing reactivity worth feature added in the previous fiscal year. The RCT, DASSH, SE2RCT, and NUBOW-3D software are the only maintained pieces of software without verification reports. The software verification work for DASSH will be a focus in the upcoming fiscal year and it is hoped that some of the test cases created can serve as verification tests for SE2RCT. The NUBOW-3D work will begin when the manual and requirements report are completed. Only minor industry partner software development funds were provided this year. The DASSH software was updated to handle general axial geometry for each assembly and the NUBOW-3D software was updated to incorporate a new input format and better output. Overall progress on resolving the QA gaps has been good this year.

97 MATHEMATICS AND COMPUTING↗

2023 LDRD Annual Report

This summary report provides an overview of all LDRD projects at Argonne National Laboratory that concluded in Fiscal Year 2023. Many projects are funded for multiple years, the initial fiscal year for each project is indicated by the first four digits of the LDRD project number.

99 GENERAL AND MISCELLANEOUS↗

Progress Towards NQA-1 for Cardinal in FY25

Cardinal is a wrapping of the GPU-oriented spectral element Computational Fluid Dynamics (CFD) code NekRS and the Monte Carlo particle transport code OpenMC within the Multiphysics Object-Oriented Simulation Environment (MOOSE). Cardinal provides high-resolution thermal-hydraulics and/or radiation transport feedback to MOOSE multiphysics simulations. Multiphysics feedback is implemented in a geometry-agnostic manner which eliminates the need for rigid one-to-one mappings. A generic data transfer implementation also allows NekRS and OpenMC to couple to any MOOSE application, enabling a broad set of multiphysics capabilities. Cardinal simulations can also leverage combinations of MPI, OpenMP, and GPU resources. Cardinal continuous development and improvement efforts have led to the software being considered as a high-fidelity design and licensing tool for key areas of nuclear reactor relevant physics, including neutron transport, fluid flow, heat transfer, and mechanical processes. The fast development and expansion of the software from a pure R&D framework towards its application in the nuclear industry and regulation require a focus on developing, enhancing,and maintaining Cardinal’s software quality through strict adherence to a Software Quality Assurance (SQA) framework and SQA program. To facilitate compliance with SQA standards, the Cardinal SQA Program was initiated during Fiscal Year 2023 (FY23). During the development of the Cardinal SQA Program, multiple gaps have been identified. These gaps are primarily related to model verification and code pedigree as they relate to the use of Cardinal as an analysis tool. These gaps were captured in a report published in 2023. A second report highlighted the progress made during Fiscal Year 2024 (FY24) and described Argonne’s effort to document and integrate software verification within Cardinal’s software development process. This report documents the progress made towards NQA-1 for Cardinal in the Fiscal Year 2025 (FY25). All cases in the expanded Continuous Integration (CI) suite of NekRS are included in this report which test the solvers and modules available in NekRS exhaustively. The NekRS tests are integrated with the Cardinal CI suite and made available in publicly accessible Github documentation. Following the CI practice permits integrating of source code changes frequently and ensuring that the integrated codebase clears the verification testing for the software. Also in this report is a brief overview of the development of the Cardinal Software Quality Assurance Plan (SQAP) that was done in FY25, though it should be noted that the rest of the documentation for the SQA program needs to be developed in a future step of this task.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Software Quality Assurance for the MOOSE-Based Open-Source Multiphysics Code Cardinal - An Expanded CI Testing Suite

Cardinal is a wrapping of the GPU-oriented spectral element Computational Fluid Dynamics (CFD) code NekRS and the Monte Carlo particle transport code OpenMC within the Multiphysics Object-Oriented Simulation Environment (MOOSE). Cardinal provides high-resolution thermal-hydraulics and/or radiation transport feedback to MOOSE multiphysics simulations. Multiphysics feedback is implemented in a geometry-agnostic manner which eliminates the need for rigid one-to-one mappings. A generic data transfer implementation also allows NekRS and OpenMC to couple to any MOOSE application, enabling a broad set of multiphysics capabilities. Cardinal simulations can also leverage combinations of MPI, OpenMP, and GPU resources. Cardinal continuous development and improvement efforts have led to the software being considered as a high-fidelity design and licensing tool for key areas of nuclear reactor relevant physics, including neutron transport, fluid flow, heat transfer, and mechanical processes. The fast development and expansion of the software from a pure R&D framework towards its application in the nuclear industry and regulation require a focus on developing, enhancing and, maintaining Cardinal’s software quality through strict adherence to a Software Quality Assurance (SQA) framework and SQA program. To facilitate compliance with SQA standards, the Cardinal SQA Program has been initiated during Fiscal Year 2023 (FY23). During the development of the Cardinal SQA Program, multiple gaps have been identified. These gaps are primarily related to model verification and code pedigree as they relate to the use of Cardinal as a safety analysis tool. These gaps have been captured in a report published in 2023. A second report highlighted the progress made during Fiscal Year 2024 (FY24) and described Argonne’s effort to document and integrate software verification within Cardinal’s software development process. This report documents a snapshot of the verification test cases currently available for Cardinal and NekRS in their assimilation into a Continuous Integration (CI) platform. Following the CI practice permits the integrating of source code changes frequently and ensuring that the integrated codebase clears the verification testing for the software. It should be noted that the SQA program itself, including the program plans, procedures, configuration management, and testing strategies, need to be developed in a future step of this task.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Annual Summary Report for the Remote-Handled Low-Level Waste Disposal Facility—FY 2023

This Fiscal Year (FY) 2023 annual summary report (ASR) documents the continued adequacy of the performance assessment (PA), the composite analysis (CA) and associated operating disposal-authorization statement (ODAS) technical-basis documents for the Remote-Handled (RH) Low-Level Waste (LLW) Disposal Facility at Idaho National Laboratory. Annual review of the adequacy of the PA and CA for the RHLLW Disposal Facility ensures that conclusions of the analyses remain valid in accordance with requirements of Department of Energy (DOE) Order 435.1, “Radioactive Waste Management.” In FY 2023, no significant operational changes or other activities occurred that would cause deviation from the assumptions in the PA and CA pertaining to disposal geometry, verification of waste characteristics, tracking disposal inventories against total limits, facility-closure design, or institutional controls. Eleven waste canister shipments were received at the RHLLW Disposal Facility, and ten waste canisters were emplaced in disposal vaults.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

U.S. Department of Energy Hydrogen Program: 2023 Annual Merit Review and Peer Evaluation Report; June 6-9, 2023

This document summarizes peer review comments and scores for the fiscal year 2023 U.S. Department of Energy (DOE) Hydrogen Program Annual Merit Review and Peer Evaluation Meeting (AMR), held June 6-9, 2023. This review process provides project- and program-level evaluations of DOE-funded research, development, demonstration, and analysis of hydrogen and fuel cell technologies.

AMR↗

Analysis Program (2023 Annual Progress Report)

This document summarizes the progress of VTO Analysis projects supported during the fiscal year 2023. The VTO Analysis Program supports mission-critical technological, economic, and interdisciplinary analyses to assist in prioritizing VTO technology investments and to inform research portfolio planning. These efforts provide essential vehicle and market data, modeling and simulation, and integrated and applied analyses, using the unique capabilities, analytical tools, and expertise resident in the DOE’s national laboratory system. VTO Analysis projects also demonstrate additional capabilities and expertise provided by research partnerships that may include academia, the private sector, and non-profit organizations.

33 ADVANCED PROPULSION SYSTEMS↗

Technology Integration 2023 Annual Progress Report

This document summarizes the progress of VTO Technology Integration projects supported during the fiscal year 2023. VTO's Technology Integration Program supports a broad technology portfolio that includes alternative fuels, energy efficient mobility systems and technologies, and other efficient advanced technologies that can reduce transportation energy costs for businesses and consumers. The program provides objective, unbiased data and real-world lessons learned to inform future research needs and support local decision making. It also includes projects to disseminate data, information, and insight, as well as online tools and technology assistance to cities and regions working to implement alternative fuels and energy efficient mobility technologies and systems.

33 ADVANCED PROPULSION SYSTEMS↗

Batteries (2023 Annual Progress Report)

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2023. Its R&D focus was on the development of high-energy batteries for PEVs. The electrochemical energy storage roadmap describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability.

25 ENERGY STORAGE↗

Electrification (2023 Annual Progress Report)

This document summarizes the progress of VTO Electrification R&D projects supported during the fiscal year 2023. The Electric Drive Technologies (EDT) program’s mission is to conduct early-stage research and development on transportation electrification technologies that accelerate the development of cost-effective and compact electric traction drive systems that meet or exceed performance and reliability requirements of internal combustion engine (ICE)-based vehicles, thereby enabling electrification across all light-duty vehicle types. The Grid and Charging Infrastructure (G&I) program's mission is to conduct early-stage research and development on transportation electrification technologies that enable reduced petroleum consumption by light, medium, and heavy-duty vehicles. The program identifies and enables the role of vehicles in the future electrical grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗