ASME Code Development: Design Rules
ASME Code Development: Design Rules, ASME BPVC, and ASME BPVC HHA-3000, Design Task Group Papers, Presentations, and Memorandums, and records.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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Status Update for the Bearing Test Article Design Development – FY2025
Argonne National Laboratory’s (ANL) Mechanism Engineering Test Loop (METL) team has completed the design of a new Bearing Test Article (BTA) to test mechanical bearings for sodium fast reactor (SFR) mechanism applications. Recognition of the need for further bearing testing arose due to failure of rolling element bearings during testing of components for in-vessel fuel handling machines (FHMs) conducted at ANL in the METL facility. While the initial concept of the BTA arose from a need for bearing testing for FHM applications, the BTA design is configurable to test bearings of various sizes, types, and materials submerged in liquid sodium. Requirements for loading, shaft speed, temperature, and bearing size range were chosen based on requirements for SFR fuel handling. Modular components in the test bearing housings and shaft sleeves allow the design to accommodate a wide range of bearing sizes without modification to the larger assembly. Loading will be applied with screw jacks on the air side of the test article that will be adjusted to apply radial, thrust, or combined loading conditions. Applied force will be measured by load cells in-line with the loading mechanisms. In FY25 we have completed the design of the test article that will be fabricated and undergo testing at the METL facility. Drawing packages for the fabrication of the test article have been drafted and are being reviewed to add part tolerances and we have started ordering off-the-shelf components. The report will summarize the development of the Bearing Test Article design starting with an overview of the entire test article, then a more detailed examination of the bearing test section, loading mechanisms, test article ports and seals, and support structures, including analysis that went into significant design choices.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Overview of design developments for Condensable Vapor Devices for ITER
The Condensable Vapor Devices (CVDs), which are part of the ITER Roughing Pump System (RPS), are designed to separate tritiated water content to protect downstream pumps and transfer the water to Tokamak Exhaust Processing (TEP) systems for further separation. CVDs operate on the principle that a cooling fluid, such as liquid nitrogen, cools the exhaust gas stream (process gas) from the Tokamak, allowing the water present in the process gas to condense and freeze, thereby trapping it in the CVDs. The CVDs once saturated with the ice are then regenerated to release the trapped water molecules, which are sent to the TEP. The present article will describe the technical requirements, challenges, and design progress made so far in the development of the CVDs.
Choukekar, Ketan [ORNL] (ORCID:0009000288016383)↗
Large Scale Granulator Development Designed to Process Reclaimed Feedstock for Sustainable Additive Manufacturing Applications
This CRADA between UT-Battelle, LLC (Contractor) and re:3D Inc. (Participant) aims to develop an affordable large-scale granulator system designed to process reclaimed plastic feedstock suitable for additive manufacturing applications. The 24-month project will focus on testing, prototyping, and optimizing a shredder/granulator system. This project also focuses on the processing steps (e.g. washing and sorting) that can convert waste plastics, like discarded water bottles, into flake/granules which can be 3D printed using re:3D’s Fused Granular Fabrication (FGF) 3D printers. If successful, this could enable more localized 3D printing using recycled plastics, reducing waste and feedstock costs.
Wang, Peter [Oak Ridge National Laboratory (ORNL),↗
Design, development and commissioning of a multi-alkali semiconductor photocathode deposition system for the IUAC Delhi light source photoinjector
A fourth-generation light source, called Delhi Light Source (DLS) based on photocathode-based RF gun has been commissioned at Inter-University Accelerator Centre, New Delhi. Presently, the electron beam is being generated from copper photocathode and the beam is being used for scheduled experiments. Soon, the semiconductor photocathode will be used to produce higher beam current. Here, to develop the semiconductor photocathode, a dedicated photocathode deposition facility was developed in collaboration with Brookhaven national Laboratory (BNL) and has been successfully commissioned and becomes operational at IUAC. This deposition facility is an integrated system with the electron gun and is a unique system as it is capable of producing, preserving (without residual gas poisoning) and in-vacuum transfer of the deposited photocathodes from the deposition chamber up to the RF electron gun. The system is designed to operate under ultra-high vacuum (UHV) and is equipped with load-lock chambers, substrate heating assembly, thickness monitoring via a quartz crystal microbalance (QCM), and an in-situ setup for quantum efficiency (QE) measurements. After testing of all the subsystems and a detailed calibration, the first deposition of a cesium telluride (Cs 2 Te) photocathode was successfully performed on a copper (Cu) substrate. This successful commissioning and initial deposition mark a significant step toward the indigenous photocathode development and lays the groundwork for further research into advanced photo emissive materials at IUAC. This paper will discuss the salient features, installation, commissioning, first semiconductor photocathode deposition and its results.
47 OTHER INSTRUMENTATION↗
Wave energy in season: a comparative approach to feasibility of seasonal deployments for remote coastal communities
Remote coastal communities, which could be early adopters of wave energy projects, have concerns over costs, conflicts, and potential risks of development. Designers and developers are challenged to address these community concerns as they continue to develop wave energy technologies. One potential means of reducing costs, conflicts, and risks, especially for demonstration and pilot-scale projects, could be planning a deployment that operates for only a portion of the year—a seasonal deployment. Here, in this paper, we examine the impacts of a seasonal deployment in terms of cost, electricity production, operations and maintenance, environmental impacts, and community benefits. We take a holistic, comparative approach to feasibility that can be replicated for other comparative studies. We estimate electricity production using a point absorber WEC modeled near Sitka, AK, USA and optimized for the given sea conditions. We determine that, for remote community sized projects, seasonal deployments could result in small cost savings (less than 10 %), but larger decreases in annual energy production (around 30 % for our case study area). Seasonal deployments could be preferable in places with seasonal energy needs, if failures and device access become a major hindrance to wave energy technology development, or as a cautionary approach to introducing new technology to the oceans. We also determine that a highly seasonal wave resource is not necessarily a requirement for seasonal deployments to be considered. Seasonal deployments are an alternative to year-round deployments that can be considered in places where marine spatial conflict is a seasonal concern.
WEC optimizations↗
Design and Development of the Handling Frame Assembly Table for the NIF Sustainment Project (Draft)
The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The NIF Sustainment project's goal is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, design analysis and validation, and final design. Future work will focus on building and commissioning the system.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields
The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.
42 ENGINEERING↗
Design and Development of the Handling Frame Assembly Table for the National Ignition Facility Blast Shields
The Handling Frame Assembly Table is a custom designed piece of equipment developed to support the NIF Sustainment Project. The goal of the NIF Sustainment Project is to refurbish the National Ignition Facility (NIF), the world’s largest and most energetic laser, so it can continue advancing research in fusion energy, national security, and high energy density physics. A key aspect of this effort involves replacing all 1,728 blast shields on the NIF, which requires specialized equipment such as the Handling Frame Assembly Table to support the production of new blast shields. This project follows a systems engineering approach that guides the design sequence. This report documents the design process from initial concept through final design, including stakeholder analysis, requirements development, conceptual design, final design, and design validation. Future work will focus on building and commissioning the system.
42 ENGINEERING↗
Design and Development of the PIP-II Stripline Beam Position Monitor
• Designed a stripline Beam Position Monitor (BPM) for the PIP-II accelerator to ensure precise proton beam alignment under ultra-high vacuum (UHV) conditions • Developed a mechanically robust and manufacturable assembly, including a cylindrical housing, electrodes, flange interfaces, and internal supports • Achieved high safety margins under pressure loading, using finite element analysis (FEA), while
Avalos Angel, Alejandro [Northern Illinois U.]↗
Design and Development of the PIP-II Stripline Beam Position Monitor
NIU 2026 Senior Design Showcase
Avalos Angel, Alejandro [Northern Illinois U.]↗
Benchmark Study Matrix for Microreactor Geometries Relevant to Multiple Developers
A benchmark study was developed that include design, development, manufacturing, and performance measurement of agnostic reactor relevant geometries to support industry’s adoption of advanced manufacturing in a variety of structures. A matrix of five microreactor component geometries, specifically based on the recent feasibility study on a Marvel microreactor liner, was developed and the Pacific Northwest National Laboratory team initiated one material/process combination, namely 316H using laser powder directed energy deposition (DED). Although the benchmark starts initially with simplistic cubical and cylindrical forms, it builds up to a mock-up of a non-proprietary design that can demonstrate a variety of features potentially useful for presenting knowledge to specific designers of microreactors and for the matter also for other reactor type designers. The initial cubical and cylindrical forms are initial steps to obtain surface features and dimensional responses to the identified process parameters to be used in the non-proprietary design mockup.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Operando X-Ray Diffraction During High Temperature Electrolysis
This work presents the design, development, and deployment of an operando X-ray diffraction (XRD) system for high-temperature electrolysis (HTE), enabling real-time characterization of solid oxide electrolysis cells (SOECs) under true operational conditions. The integration of an HTE test stand within a synchrotron radiation environment, mimicking the conditions of a laboratory setup, aims to enhance our understanding of the degradation processes affecting the performance and longevity of SOECs. Utilizing a custom furnace and a high precision motor stack assembly at the Stanford Synchrotron Radiation Lightsource (SSRL), the system revealed unparalleled insights into the structural evolution of SOEC components through various operational stages, including initial heat ramp, cell reduction, fuel ramp, and wet electrolysis. Initial results demonstrate the significant impact of the initial heating and cooling on secondary phase formation within the SOEC, highlighting the utility of operando XRD for developing more efficient and durable hydrogen production technologies.
08 HYDROGEN↗
Designing Remote Monitoring for Smart Manufacturing Facilities: Hazard Identification and Classification
This study investigates the process of hazard identification in complex manufacturing environments during the design phase, emphasizing the significance of the design process in developing designs that effectively mitigate hazards in contexts with numerous variables, such as a variety of machines, sensors, actuators, and agents. Through a mixed-methods approach, the objective of this work is to understand how the evolution of design outcomes across various stages might influence a designer’s ability to recognize both standard and novel hazards. To achieve this understanding, an experimental design task was conducted with six designers from a national lab specializing in manufacturing technologies. This approach combined qualitative and quantitative data analysis from a one-hour virtual session with participants. Findings suggest that the complexity of identifying hazards in a high-dimensional design space is challenging within a limited time frame and that the identification of hazards is significantly influenced by the stage of the design task and the initial design decisions, indicating the need for extended time and strategic initial planning in the design process to enhance hazard identification.
Ballestas, Caseysimone↗
Innovative Advanced Hydrogen Mobile Fueler (Final Technical Report)
The US Department of Energy (DOE) funded a project to design, develop, deploy and analyze the economic viability of an innovative Advanced Hydrogen Mobile Fueler (AHMF). As part of the design activity the project team defined specifications based upon vehicle requirements and compliance with specific fueling performance criteria. The AHMF was originally designed to fuel 10-20 fuel cell vehicles (FCV) per day, consistent with the requirements of the H70 fueling category. The AHMF is able to operate without remote power connections, is modular for easy transport and deployment, and can provide expanded daily capacity and multi-day operations using delivered gaseous hydrogen. Toward the end of the project, due to request from the hydrogen industry and some necessary modifications of the AHMF, the system is now modified to fuel heavy duty vehicles. The project was conducted over two primary phases, each including several key tasks, subtasks, and project milestones. Phase 1 involved the design, development, and construction of the AHMF, moving from a conceptual design through to completion of assembly and testing. In addition to reviewing several different approaches, the team chose to take a conventional station design and modify it for mobile fueling. There were several innovative components included in the design. The high pressure storage was the first to achieve a US Department of Energy (DOE) Special Permit (SP 20391) to transport high pressure hydrogen (95 MPa) in a composite cylinder. The second novel system was a liquid nitrogen (LIN) cooling system with a compact heat exchanger. Without this change, the cooling system would not be able to fit into the AHMF. Phase 2 demonstrated the AHMF by fueling fuel cell buses at a fleet in Pomona, CA. The site was chosen because a temporary fueling solution was required while a fixed station was being installed. The existing permits for the fixed station and non-public access also was a determining factor. Over two months, the buses were fueled 320 times with over 5000 kg of hydrogen from tube trailers. Existing shore power was used, and the average electrical efficiency was 0.13 kWh/kg. The average liquid nitrogen (LIN) consumption was 90.68 scf/kg. The fueling and consumption data was provided to the National Renewable Energy Laboratory (NREL) for analysis. An economic analysis was performed and will be provided in a separate report. The project was successful, but not without challenges and lessons learned. The DOT special permit led the way for the use of high pressure, composite cylinders and is being by multiple other systems and applications. The pandemic along with time for the DOT special permit approval delayed the project for years. The team also believes that hydrogen mobile fueling has a use for the industry, especially during this upcoming phase of expansion. However, it does have its limitations due to high cost to build and operate, and the same permitting challenges as a fixed station. A fully capable system at the speeds and pressures of the AHMF may not be necessary for most applications and would help reduce the cost and increase storage capacity. The on-board generator can be easily replaced with shore power or the wide range of power generation solutions in the marketplace. One of the major results of the project was the development of new code language in National Fire Protection Agency (NFPA) 2 and the International Fire Code (IFC) for on-demand mobile fueling. This will provide guidance for Authorities Having Jurisdiction (AHJ) and user on how to permit temporary fueling sites across the nation.
08 HYDROGEN↗
Design and development of the magnetic diagnostic systems for the first operational phase of the SMART tokamak
A set of magnetic diagnostics has been designed, manufactured, and calibrated for the first operational phase of the small aspect ratio tokamak. The sensor suite comprises of Rogowski coils; 2D magnetic probes; and poloidal, saddle, and diamagnetic flux loops. Here, a set of continuous Rogowski coils has been manufactured for the measurement of plasma current and induced eddy currents in conductive elements. A set of flux loops and magnetic probes will be used as input for the reconstruction of the magnetohydrodynamic equilibrium. The quantity and position of these sensors have been verified to be sufficient with synthetic equilibrium reconstructions using the equilibrium fitting code and baseline scenarios computed with the Fiesta code. These sensors will also be used as input for the real-time control system, and magnetic probes will be used for the detection of plasma instabilities. The calibration procedure for the magnetic probes is described, and the results are shown. The signal conditioning and data acquisition systems are described.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining
The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.
42 ENGINEERING↗