A Hybrid Reliability Model Using Generalized Renewal Processes for Predictive Maintenance in Nuclear Power Plant Circulating Water Systems
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21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
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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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A non-melting additive approach to structural repair of aluminum aircraft fastener holes
The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.
36 MATERIALS SCIENCE↗
Using Additive Manufacturing to Repair Gas Turbine Hot Section Components
Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limtis. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.
99 GENERAL AND MISCELLANEOUS↗
Architecture-Preserving Provable Repair of Deep Neural Networks
Deep neural networks (DNNs) are becoming increasingly important components of software, and are considered the state-of-the-art solution for a number of problems, such as image recognition. However, DNNs are far from infallible, and incorrect behavior of DNNs can have disastrous real-world consequences. This paper addresses the problem of architecture-preserving V-polytope provable repair of DNNs. A V-polytope defines a convex bounded polytope using its vertex representation. V-polytope provable repair guarantees that the repaired DNN satisfies the given specification on the infinite set of points in the given V-polytope. An architecture-preserving repair only modifies the parameters of the DNN, without modifying its architecture. The repair has the flexibility to modify multiple layers of the DNN, and runs in polynomial time. It supports DNNs with activation functions that have some linear pieces, as well as fully-connected, convolutional, pooling and residual layers. To the best our knowledge, this is the first provable repair approach that has all of these features. We implement our approach in a tool called APRNN. Using MNIST, ImageNet, and ACAS Xu DNNs, we show that it has better efficiency, scalability, and generalization compared to PRDNN and REASSURE, prior provable repair methods that are not architecture preserving.
97 MATHEMATICS AND COMPUTING↗
Using Additive Manufacturing to Repair Gas Turbine Hot Section Components
Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.
36 MATERIALS SCIENCE↗
Force reduction of friction stir welding and processing of steel
Friction stir welding and processing (FSW&P) is considered as a new fabrication method for canisters and repair of existing dry cask storage system canisters (generally made of austenitic stainless steel). Low heat input compared to fusion joining processes and grain refinement associated with low-temperature FSW&P result in a material with improved mechanical properties and equivalent generalized corrosion performance relative to the base metal. But FSW&P of austenitic stainless steel requires significant tool forge axis force to produce a weld (or a run). Exploratory runs utilizing forge axis force control were conducted to investigate the minimum force required to achieve defect-free runs. The correlation between forge axis force and resultant plunge depth was also investigated. Furthermore, detailed microstructural characterization was conducted to display the microstructural variation within the nugget zone.
36 MATERIALS SCIENCE↗
Multiple aspects maintenance ontology-based intelligent maintenance optimization framework for safety-critical systems
Abstract Maintenance optimization is a process for improving the efficiency of maintenance strategies and activities, considering various aspects of the target system and components, such as the probabilities of system failures and the cost of repair and replacement of a failed component. The improvement of maintenance optimization algorithms generally requires information from various data sources. For example, it may require the system risk information derived from risk analysis tools or the residual lifetime of a component from fault prognosis tools. The requirements of data acquisition (DAQ) and aggregation pose new challenges for maintenance management systems (MMSs) that implement and use these maintenance optimization algorithms. This paper proposes a multiple aspects maintenance ontology-based framework to facilitate DAQ from MMSs, online monitoring systems, fault detection and discrimination tools, risk assessment tools, decision-making tools, and component identification tools, and accelerate the implementation and verification of contemporary maintenance optimization models and algorithms. The proposed framework consists of a multi-aspect maintenance ontology with critical information for maintenance optimization and application interfaces for collecting information from various data sources, such as fault prognosis tools, online monitoring tools, risk assessment tools, and decision-making algorithms. In addition, this paper proposes a heuristic method for integrating concepts and properties from other existing ontologies into the proposed framework when the existing ontology is not fully compatible with the ontology under construction. Finally, the paper verifies the proposed ontology framework using a feedwater system designed for nuclear power plants with valves and filters as the components under maintenance.
Diao, Xiaoxu (ORCID:0000000346726352)↗
Identification of recG genetic interactions in Escherichia coli by transposon sequencing
ABSTRACT Maintaining the integrity of the genome is of utmost importance for cell division and propagation. In Escherichia coli , the RecG protein has been implicated in processing branched recombination intermediates during DNA repair processes, but the primary cellular role(s) of RecG and the repair pathways in which it acts have been difficult to define. To gain additional insight into RecG function, we employed transposon sequencing to identify recG genetic interactions and reveal complementary or redundant functions. The strongest hits from the screen were the dam , uvrD , rnhA , radA , and rep genes. The conditional importance of these five genes in cells lacking recG was confirmed using a plasmid-based assay, revealing synthetic lethal interactions for most double deletion strains. Several of the synthetic lethal gene combinations (with uvrD, rep, and radA , but not rnhA or dam ) were suppressed by deletion of recF or recO , indicating that their genetic relationships involved roles in post-replication gap repair. Additionally, loss of the RecG/SSB interaction phenocopied a recG deletion when combined with dam , uvrD , radA , or rnhA deletions but not with rep . The results reinforce the idea of RecG as a general genome guardian. RecG has at least two functions. It plays an important role in the resolution of joint molecules behind the fork, formed during post-replication gap repair. RecG is also required to suppress genome over-replication caused by unscheduled replication initiation at R-loops, at double-strand breaks caused by dam inactivation, and during replication termination. IMPORTANCE DNA damage and subsequent DNA repair processes are mutagenic in nature and an important driver of evolution in prokaryotes, including antibiotic resistance development. Genetic screening approaches, such as transposon sequencing (Tn-seq), have provided important new insights into gene function and genetic relationships. Here, we employed Tn-seq to gain insight into the function of the recG gene, which renders Escherichia coli cells moderately sensitive to a variety of DNA-damaging agents when they are absent. The reported recG genetic interactions can be used in combination with future screens to aid in a more complete reconstruction of DNA repair pathways in bacteria.
59 BASIC BIOLOGICAL SCIENCES↗
A General Overview of Cathodic Protection in Reinforced Concrete
Corrosion of reinforcement steel in concrete is a prevalent issue in infrastructures worldwide, with the direct costs of repair estimated to be $1 trillion annually. Treatment options are complicated by the concrete’s role in the corrosion process. Ordinary, modern-day cement is so alkaline that it maintains a thick passive layer on the steel surface, reducing corrosion to inconsequential rates. However, environmental contaminants in the form of carbon dioxide or chlorides may cause a breakdown in the passive layer, exposing the steel surface to corrosion. Galvanic cells will be free to form due to potential differences along the rebar, and anode sites will create dissolved iron ions that cannot travel far through the still concrete. Thus, rust products will accumulate directly onto the steel/concrete interface. Iron oxides have a much higher volume relative to steel, and even a miniscule amount of rust can produce enough volumetric stress to cause cracking, spalling and delamination of the surrounding concrete, increasing the risk of structural failure. Safeguards and inhibiting technology exist to limit the chances of corrosion initiation by either species, but cracking of the concrete cover and gradual accumulation of contaminants means that corrosion is unavoidable in certain environments and will initiate, given enough time.
36 MATERIALS SCIENCE↗
Effects of Desiccation and Freezing on Microbial Ionizing Radiation Survivability: Considerations for Mars Sample Return
Increasingly, national space agencies are expanding their goals to include Mars exploration with sample return. To better protect Earth and its biosphere from potential extraterrestrial sources of contamination, as set forth in the Outer Space Treaty of 1967, international efforts to develop planetary protection measures strive to understand the danger of cross-contamination processes in Mars sample return missions. We aim to better understand the impact of the martian surface on microbial dormancy and survivability. Radiation resistance of microbes is a key parameter in considering survivability of microbes over geologic times on the frigid, arid surface of Mars that is bombarded by solar and galactic cosmic radiation. We tested the influence of desiccation and freezing on the ionizing radiation survival of six model microorganisms: vegetative cells of two bacteria (Deinococcus radiodurans, Escherichia coli) and a strain of budding yeast (Saccharomyces cerevisiae); and vegetative cells and endospores of three Bacillus bacteria (B. subtilis, B. megaterium, B. thuringiensis). Desiccation and freezing greatly increased radiation survival of vegetative polyploid microorganisms when applied separately, and when combined, desiccation and freezing increased radiation survival even more so. Thus, the radiation survival threshold of polyploid D. radiodurans cells can be extended from the already high value of 25 kGy in liquid culture to an astonishing 140 kGy when the cells are both desiccated and frozen. However, such synergistic radioprotective effects of desiccation and freezing were not observed in monogenomic or digenomic Bacillus cells and endospores, which are generally sterilized by 12 kGy. This difference is associated with a critical requirement for survivability under radiation, that is, repair of genome damage caused by radiation. Deinococcus radiodurans and S. cerevisiae accumulate similarly high levels of the Mn antioxidants that are required for extreme radiation resistance, as do endospores, though they greatly exceed spores in radioresistance because they contain multiple identical genome copies, which in D. radiodurans are joined by persistent Holliday junctions. We estimate ionizing radiation survival limits of polyploid DNA-based life-forms to be hundreds of millions of years of background radiation while buried in the martian subsurface. Our findings imply that forward contamination of Mars will essentially be permanent, and backward contamination is a possibility if life ever existed on Mars.
59 BASIC BIOLOGICAL SCIENCES↗
Optimizing Rate of Penetration and Tripping Decision-Making using Real-Time Bit Wear Monitoring While Drilling Geothermal Wells
Understanding bit wear while drilling is critical to minimizing non-productive time (NPT) and optimizing rate of penetration (ROP). Lengthening drilling runs with damaged bits does not only lower the ROP, but also elevates the risk of inducing severe bit damage, which could potentially lead to time-consuming fishing operations. When drillers believe the bit has worn off substantially, the bit is tripped out to be replaced. On geothermal wells, tripping can take up to 20% of the overall well construction time, and this is generally acknowledged as an opportunity for improvement. Ideally, a bit run should be terminated before the bit is damaged beyond repair. At the same time, premature bit pulls are to be avoided as well. This study aims to leverage bit and tooth wear metrics that can be obtained in real time to characterize bit condition in order to optimize ROP and determine the optimal time to pull the bit. Two metrics were explored in this study: a bit wear metric that incorporated depth-of-cut, and a tooth wear metric developed by Bourgoyne & Young characterizing the state of bit teeth dull. Both metrics were computed using recorded data from 12¼ inches roller cone insert bit runs in five geothermal wells targeting a granodiorite formation in the western United States. Together with the actual dull grades, determined after the bits were pulled to surface, the metric trends were interpreted to characterize the downhole bit condition and identify the point at which the bit should have optimally been tripped out. The insights from studying the actual dull grades and how they relate to the two metrics were used to establish a reliable bit pull criterion. The bit wear metric trend correctly showed a noticeable departure from baseline for bits experiencing major dulling behavior. Additionally, the tooth wear model predicted the cutter dull within two dull grades for most runs, with better performance in predicting the inner teeth dull. Moreover, the combination of the bit wear and tooth wear metrics was effective in revealing the cause of the bit performance impairment. Proactive tracking of these two metrics in real-time can facilitate geothermal drilling ROP optimization and better-informed tripping decision-making, thereby avoiding wasted time and cost.
Ashari, Rahmat↗
Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing
The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.
36 MATERIALS SCIENCE↗
Novel Cell-Type-Specific Drought-Responsive Proteins in Root Tips of Field-Grown Perennial Switchgrass
The root-tip region of plants, including the root cap, forms the most basal terminal of the root and exhibits a high degree of cellular complexity in terms of morphology, cytological function, and interaction with environmental cues in the soil. Cells in this region follow a developmental trajectory, transitioning from stem cells to meristematic cells, and ultimately to fully differentiated cell types. However, our understanding of root-tip cell-type specific proteomic responses to abiotic stresses, such as drought, particularly under field conditions, remains limited. This study aimed to identify spatially resolved, cell type-specific proteomes in switchgrass (Panicum virgatum) root tips under drought stress. Root tips were collected from seven-year-old, field-grown switchgrass ‘Alamo’ plants excavated under both well-watered and long-term drought conditions. Cell type-specific proteins were identified using laser capture microdissection (LCM) coupled with nanoPOTS (Nanodroplet Processing in One Pot for Trace Samples) and nano-LC-MS proteomics analysis. Five distinct cell types were targeted: (1) cells in the quiescent center and stem cell niche (QuC), (2) protodermal epidermal cells (PEC) in the meristematic zone, (3) epidermal cells in the transition and elongation zones above the root cap (Epi), (4) peripheral root cap cells (PRC), forming 2–3 layers below the PEC and 1–2 layers above the root border cells, and (5) columella root cap cells (Col) comprising of the columella initials and a single underlying layer of cells undergoing active growth. Principal component analysis (PCA) revealed clear separation among the five targeted cell types, confirming distinct proteomic profiles. Proteins predominantly enriched in each cell type were linked to distinct cellular functions, with QuC cells showing involvement in chromosomal behavior, DNA replication, and mitosis—key processes for stem cell niche regulation. Drought stress resulted in alterations of proteostasis, as evidenced by significant decreases in ribosomal proteins and increases in protein synthesis inhibitors. Moreover, drought stress induced unique cell-type–specific proteins involved in phytohormone biosynthesis and signaling pathways, including auxin, cytokinin, and jasmonic acid. In particular, QuC cells were more highly enriched in proteins associated with DNA repair and mitotic processes. Metabolic pathways related to amino acids, carbohydrates, and lipids were differentially affected in a cell-type–dependent manner, whereas general stress-responsive proteins exhibited consistent changes across all five cell types. Overall, this study provides unique spatially resolved, cell-type-specific proteomic profiles in root tips, representing a significant advancement in our understanding of the cellular mechanisms underlying plant responses to drought stress in natural field conditions.
perennial grass↗
SetGo: Metadata Readiness for Scientific AI Datasets
Scientific datasets intended for AI use require both computational readiness for model training and metadata readiness for discovery, sharing, and reuse. The Readiness Engine for Data Integration (REDI) addresses computational readiness, but no corresponding tool evaluates whether a dataset’s metadata are sufficiently complete, governed, and standards-compliant for publication and agent-based consumption. Existing FAIR assessors operate only on published repository records, and no single system covers FAIR compliance, licensing, provenance, governance, reproducibility, and catalog readiness together. We present SetGo, an open-source Python toolkit that assesses and repairs metadata readiness across these six dimensions before a dataset is published or archived. Applied to four scientific corpora, SetGo surfaces deficiencies that general-purpose tools do not detect: ERA5 climate metadata scores 4% on ACDD 1.3 compliance; materials datasets fail OPTIMADE species-definition requirements; and PDB-derived proteomics data carries licensing terms incompatible with standard SPDX identifiers. Guided enrichment raises overall FAIR scores from 52–57% to 81–91%, and a single setgo publish command pushes to Hugging Face Hub, CKAN, or OpenMetadata with ML Commons Croissant 1.0 metadata sidecars. To support interactive and automated workflows, SetGo integrates with coding agents powered by large language models (LLMs) through a /setgo skill that enables natural-language execution of the full assess–enrich–publish loop, with user involvement limited to supplying missing metadata values.
Wilkinson, Sean [ORNL] (ORCID:0000000214437479)↗
C56-14B-Photocured Hydropower Repair Coatings- Phase I-Final Report
Explore the source record for details and available documents.
36 MATERIALS SCIENCE↗
Electrolytes for lithium metal electrodes and rechargeable batteries using same
The present invention is generally related to separators for use in lithium metal batteries, and associated systems and products. Certain embodiments are related to separators that form or are repaired when an electrode is held at a voltage. In some embodiments, an electrochemical cell may comprise an electrolyte that comprises a precursor for the separator.
Chiang, Yet-Ming↗
Lithium metal electrodes and batteries thereof
The present disclosure is generally related to separators for use in lithium metal batteries, and associated systems and products. Certain embodiments are related to separators that form or are repaired when an electrode is held at a voltage. In some embodiments, an electrochemical cell may comprise an electrolyte that comprises a precursor for the separator.
Chiang, Yet-Ming↗