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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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At least 19 records

ORNL Analysis of Leach-Burn-Leach Round-Robin Test Samples

An international round-robin test to examine the consistency in leach-burn-leach (LBL) analysis of tristructural-isotropic- (TRISO-) coated particle fuel was conducted by three research organizations from the Generation IV International Forum member countries of the People’s Republic of China, the Republic of Korea, and the United States of America. Two sets of round-robin test samples were exchanged for analysis. One set of samples consisted of a series of nonuranium-bearing, TRISO-coated zirconium dioxide particles seeded with up to four depleted uranium-bearing, TRISO-coated uranium dioxide (UO 2 ) particles, which had intentionally damaged coating layers to simulate either particles with either exposed-kernel defects (i.e., particles with a cracked TRISO coating that should be detected during preburn leaching) or particles with silicon carbide (SiC) defects (i.e., particles with an intact pyrocarbon coating and a hole in the SiC layer that should be detected during postburn leaching). These simulated samples also contained added powder with known quantities of impurities from a coal standard. The other sample set consisted of representative sublots of UO 2 -TRISO particles fabricated in a production-scale coater, except they all contained depleted uranium instead of enriched uranium. In this report, the methodology used at Oak Ridge National Laboratory to conduct LBL analysis of the round-robin samples is presented, and the general results are summarized.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Summary of Leach-Burn-Leach Round-Robin Test Results

Tristructural isotropic (TRISO) coated particle fuel is of interest to multiple member states associated with the Generation IV International Forum (GIF). Qualification and acceptance testing of TRISO fuel includes the determination of particle defect fractions and impurities in the as-fabricated TRISO fuel particle and/or composited fuel form, which are typically determined using burn-leach (BL) or leach-burn-leach (LBL) analysis methods. A round-robin test focusing on LBL analysis was undertaken by the GIF Very High Temperature Reactor System Fuel and Fuel Cycle Project Management Board. Participating in this LBL round-robin test were research staff from the Institute of Nuclear and New Energy Technology (INET) in the People’s Republic of China, the Korean Atomic Energy Research Institute (KAERI) in the Republic of Korea, and Oak Ridge National Laboratory (ORNL) in the United States of America. The motivation of this LBL benchmarking exercise was to explore consistency in results generated by LBL and to elucidate the potential influence of variations in the procedures used by the participating members on the accurate determination of the measured fuel properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Anion-exchange membrane water electrolysis: insights from round-robin testing

As research and industrial interest in anion-exchange membrane water electrolysis (AEMWE) grows, there is an increasing need for reliable baselines and cross-lab validation of results. The wide variety of material sets and operating conditions under consideration for AEMWE has thus far limited efforts for standardization. In this study, round-robin testing was conducted in deionized water and KOH-based supporting electrolyte by 5 institutions from academia, national laboratories, and industry to provide baseline performance data and identify sources of cross-lab variability. Baseline membrane electrode assemblies were fabricated with commercial catalysts, membranes, and transport layers using standard techniques and tested using reagent-grade electrolytes, aiming for accessibility rather than state-of-the-art performance. From all tests, the average voltage at 1 A/cm 2 was 2.72 ± 0.17 V and 1.87 ± 0.03 V in deionized water and 0.1 M KOH, respectively. The maximum in-house and cross-lab variations at this current density were 118 mV and 476 mV in water and 60 and 88 mV in 0.1 M KOH. The KOH purity, station contamination, and temperature control were identified as possible factors affecting performance between labs, with in-house specific variation attributed to sample-to-sample differences in fabrication, cell assembly, and station contamination. This work provides a commercial baseline for the field and highlights the need for improved standardization and reproducibility in AEMWE research.

08 HYDROGEN↗

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

Round-robin weathering test of various polymeric back-sheets for PV modules with different ultraviolet irradiation and sample temperatures

Durability assessment of materials exposed to natural weathering with expected service lifetimes of more than 20 years requires accelerated testing of the UV stability, especially for polymeric materials. Fraunhofer ISE organized an interlaboratory comparison for testing different back-sheets in various test laboratories using different UV sources. The five participating test laboratories used three different types of UV sources. The interaction of the UV radiation with the polymers used in PV modules is main subject of this round-robin. Laminates were produced by using solar glass and a suitable EVA encapsulant combined with 10 different back-sheets. The simultaneous usage of different optical filters allowed to investigate roughly the spectral sensitivity and the intensity impact. The degradation was followed by spectral reflectance and transmittance measurements and calculation of the yellowness index as degradation indicator. Clear differences in the degradation behavior of the different products were found.

14 SOLAR ENERGY↗

Ion beam analysis of fusion plasma-facing materials and components: facilities and research challenges

Following the IAEA Technical Meeting on 'Advanced Methodologies for the Analysis of Materials in Energy Applications Using Ion Beam Accelerators', our work reviews the current status of ion beam analysis (IBA) techniques and some aspects of ion-induced radiation damage in materials for the field of materials relevant to fusion. Available facilities, apparatus development, future research options and challenges are presented and discussed. The analysis of beryllium and radioactivity-containing samples from future experiments in JET or ITER represents not only an analytical but also a technical challenge. A comprehensive list of the facilities, their current status, and analytical capabilities comes alongside detailed descriptions of the labs. A discussion of future issues of sample handling and the current status of facilities at JET complete the technical section. To prepare the international IBA community for these challenges, the IAEA technical meeting finalizes the necessity for determining new nuclear reaction cross-sections and improving the inter-laboratory comparability by defining international standards and testing these via a round-robin test.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Angle of Incidence Characterization of Six Laminated Solar Cells for 2020 DTU Fotonik Inter-Laboratory Comparison Study

Photovoltaic energy prediction models include functions or modifiers to account for sun angle reflection losses. These functions may be known interchangeably as Angle of Incidence (AOI) or Incident Angle Modifier (IAM). While standards exist, there is no universally accepted single best practice for developing these functions. They can be generated through characterization of representative modules or single cells, in natural sunlight or indoors using simulated light sources. Repeatability of measurements and the viability of cross-laboratory comparisons are critical to confidence in validation of both methods. To investigate the differences between methods and labs, The Technical University of Denmark (DTU) initiated an international round-robin test comparison between several key test labs with AOI measurement capability. A total of six minimodules were provided in three different cell/interconnect/backsheet combinations. Sandia characterized these minimodules using methods developed over two decades specifically for the outdoor characterization of full-size photovoltaic modules. This report documents the characterization results, summarizes key observations and tabulates the processed data for comparison to results provided by other characterization labs.

14 SOLAR ENERGY↗

An International Round-Robin Study on Thermoelectric Module Testing and Development of Standard Power Generation Modules

An international round-robin study on thermoelectric power generation modules was conducted with nine participating laboratories. Two types of commercially available bismuth telluride modules, 30 mm × 30 mm and 40 mm × 40 mm, were used. A test protocol was followed with five temperature set points from 50°C to 150°C. Graphite sheets were used as thermal interface materials with test pressure at 100 psi (0.69 MPa). The results showed large lab-to-lab variations and the key source of uncertainty for module efficiency was identified as the heat flux measurement. In the meantime, significant uncertainty was also found in maximum electrical power (P max ) measurements. As a result of the round-robin, a “standard module” with 4 × 4 legs on a 20 mm × 20 mm platform was suggested. A skutterudite module and a half-Heusler module were produced with identical geometry and 4 mm × 4 mm × 8 mm legs. All transport properties to calculate the figure-of-merit, zT, were measured from ambient temperature to 500°C. Module performance was measured by two laboratories. Two finite-element-analysis (FEA)-based models were developed independently to simulate and predict the module performance. In conclusion, the standard modules eliminated significant test uncertainties and are aimed at assisting device design and achieving more accurate performance predictions.

Round-robin↗

How accurate is a machine learning-based wind speed extrapolation under a round-robin approach?

As the size of commercial wind turbines keeps increasing, having accurate ways to vertically extrapolate wind speed is essential to obtain a precise characterization of the wind resource for wind energy production. Recently, machine learning has been proposed and applied to extrapolate wind speed to hub heights. However, previous studies trained and tested the machine learning methods at the same site, giving them an unfair advantage over the conventional extrapolation techniques, which are instead more universal. Here, we use data from four sites in Oklahoma to test a round-robin validation approach for machine learning, under which we train a random forest at a site, and test it at a different site, where the model has no prior knowledge of the wind resource. We quantify how the accuracy of this technique varies with distance from the training site, and we find that it outperforms conventional techniques for wind extrapolation at all the considered spatial separations. We then assess how the accuracy of the machine-learning based approach varies when it is used to predict wind speed in a wind farm far wake. Finally, we explore as case study the performance of the random forest in extrapolating winds during a low-level jet event.

17 WIND ENERGY↗

Guidelines for IAEA Small Specimen Test Techniques Master Curve Fracture Toughness Testing

Under the auspices of International Atomic Energy Agency (IAEA), a coordinated research project (CRP) entitled “Towards the Standardization of Small Specimen Test Techniques for Fusion Applications” has started since 2017. The overall objective of the project is to provide a set of guidelines for small specimen test techniques (SSTT) based on commonly agreed best practices on main test techniques including tensile, creep, low cycle fatigue, fracture toughness, and fatigue crack growth rate. This will act as the first step of a full standardization of the SSTT. Fusion structural materials, i.e., reduced activation ferritic/martensitic (RAFM) steels, are used for testing. In addition, the project will create a comprehensive mechanical property database of RAFM steels tested by SSTT. For the fracture toughness task of the CRP, three testing methods including Master Curve, local approach for ductile crack growth and cleavage fracture, and ductile approach at room temperature will be evaluated. This report focuses on developing guidelines for the round-robin Master Curve testing based on the ASTM standard E1921-19b “Standard Test Method for Determination of Reference Temperature, T 0 , for Ferritic Steels in the Transition Range” and commonly agreed best practice from researchers at Oak Ridge National Laboratory (ORNL), Centre for Energy, Environment and Technology (CIEMAT), and UK Atomic Energy Authority (UKAEA).

36 MATERIALS SCIENCE↗

Advanced Graphite Creep Uncertainty Analysis

Radiation damage estimation is an important component of the post irradiation analysis of the Advanced Graphite Creep (AGC) experiment. It depends primarily on the fast fluence, which is determined using well established methods of spectral adjustment. These are based on best estimates from models such as Monte Carlo N-Particle (MCNP), input cross-sections, and measured activities from flux wires in the experiment. Each of these parameters can propagate uncertainties which will affect the uncertainty in the calculated dose levels for AGC, or any experiment irradiated within a reactor. While the methods of propagating uncertainty are well-established, the final uncertainty estimates they provide are only as good as the estimates of uncertainty in the inputs on which they are based. The purpose of this work is to outline some deficiencies in the ways these input uncertainties are presently estimated, and to outline a methodology by which they can be improved. The fast fluence and radiation damage received by graphite specimens irradiated in the Advanced Graphite Creep (AGC) experiments is presently estimated using spectral adjustment methods that are based on both flux wire activity measurements, and MCNP model predictions. This work describes an ongoing effort to quantify and propagate uncertainties in inputs to the spectral adjustment process, and thereby quantify the resultant error in radiation damage (dpa) estimates. The effort is multi-faceted, and we consider the impacts of both the set of flux wires selected, and the counting process. An expanded set of flux wires is identified that provides a more comprehensive data set on the fast spectrum. To address the counting process itself, a series of round-robin measurements in several reactor metrology laboratories across the Department of Energy (DOE) complex and nuclear industry are being undertaken to refine the American Society for Testing and Materials (ASTM) standards for flux wire measurements. To address the contribution of uncertainty in the MCNP model predictions, an uncertainty quantification (UQ) tool has been developed that statistically samples the model input parameters, runs a series of cases, and assimilates the results to provide an overall uncertainty. The impact of the MCNP UQ tool results is demonstrated by re-analyzing previous AGC flux wire and irradiation data. While the expanded flux wire set obviously cannot be added to these experiments retroactively, plans for future graphite irradiations are outlined.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Materials & Manufacturing Technology (AMMT): Process understanding for qualifying LPBF 316H SS

Investigations were conducted in fiscal years (FY) 2023 and 2024 to gather relevant data sets addressing challenges related to qualifying 316H stainless steel (SS) for use in future nuclear reactors. This work was a collaborative effort involving researchers from Idaho National Laboratory (INL), Argonne National Laboratory (ANL), and Oak Ridge National Laboratory (ORNL). Key outcomes included: • Development of process-structure-property data sets to better understand the relationships between manufacturing processes, material structure, and performance characteristics. • Establishment of an in-situ monitoring system to link these various data sets together. • Detailed characterization of the raw material feedstock to further strengthen the understanding of process-structure and process-property relationships. Building on this foundation, in FY25 there was interest in exploring the behavior of additively manufactured 316H SS under different test conditions to support the overall material qualification process. Los Alamos National Laboratory (LANL) was tasked with providing specimen samples to the collaborating labs, who then conducted a round-robin study examining factors like selective heat treatment, low-cycle fatigue (LCF), and tensile-creep (T-C) properties. Additionally, high-temperature differential scanning calorimetry (DSC) was performed by LANL to better understand how the material's thermal characteristics change as it is heated up to the melting point. This provided a more comprehensive understanding of the material's behavior. The combined results from these investigations could potentially be used to support the inclusion of 316H stainless steel in Section III, Division 5 of the relevant codes and standards, allowing its use in future nuclear reactor applications.

36 MATERIALS SCIENCE↗

High-Throughput Optical Mapping for Accelerated Stress Testing of PV Module Materials

The study will provide guidance towards the design and application of larger and/or outdoor-use intended instruments. Measurement capability will be benchmarked against existing specimens, examined in a round-robin study using conventional spectrophotometer instruments. Data acquisition and storage will be integrated into the DuraMAT DataHub network along with data visualization tool, facilitating sharing of information.

14 SOLAR ENERGY↗

A Custom High-Throughput Optical Mapping Instrument (OMI) for Accelerated Stress Testing of PV Module Materials

The performance and integrity of photovoltaic (PV) modules and materials may be assessed through optical characterizations. We have developed a custom Optical Mapping Instrument (OMI) to improve measurement throughput time, facilitate automated measurements, and obtain spatial information relative to commercial benchtop spectrophotometer instruments. Both the key components and the methods used to improve the measurements are described. The measurement precision for the OMI is benchmarked for hemispherical transmittance relative to a previous round-robin study for commercial spectrophotometers. Example mapping measurements and their implications are given for specimens from other studies, including: (1) the depletion of the UV absorber is revealed for specimens beyond a certain size after standardized artificial ultraviolet (UV) weathering, (2) an optical degradation by internal haze formation is confirmed following Damp Heat (85°C/85% relative humidity) testing, (3) the better uniformity of the wear pattern for falling sand abrasion is used to select the DIN 52348 fixture over the ASTM D968 fixture, and (4) the local (millimeter-scale) heterogeneity of surface contamination in the soiling-prone location of Dubai relative to Kuwait. The results of the UV study have already been used to improve the standardized weathering of encapsulants. The example for Damp Heat testing is given to increase awareness of a degradation believed to be ubiquitously occurring in safety and design-type qualification testing of PV modules.

41 EE - Solar Energy Technologies Office (EE-4S)↗

A Custom High-Throughput Optical Mapping Instrument for Accelerated Stress Testing of PV Module Materials

The performance and integrity of photovoltaic (PV) modules and materials may be assessed through optical characterizations. We have developed a custom optical mapping instrument (OMI) to improve measurement throughput time, facilitate automated measurements, allow for localized specimen examination, obtain spatial information relative to commercial benchtop spectrophotometer instruments, and provide automated data analysis. Both the key components and the methods used to improve the measurements are described. The measurement precision for the OMI is benchmarked for hemispherical transmittance relative to a previous round-robin study for commercial spectrophotometers. In addition to the unique instrument developed in this study, new insights have emerged from the examination of specimens from previous experiments, including: the depletion of the UV absorber is revealed for specimens beyond a certain size after artificial ultraviolet (UV) weathering; an optical degradation by internal haze formation is confirmed following Damp Heat (85 °C/85% relative humidity) testing; the better uniformity of the wear pattern for falling sand abrasion is used to select the DIN 52348 fixture over the ASTM D968 fixture; and the greater local (in the order of millimeters) heterogeneity of surface contamination in the soiling-prone location of Dubai relative to Kuwait. The results of the UV study have already been used to improve the standardized weathering of encapsulants. The example for Damp Heat testing is given to increase awareness of a degradation believed to be ubiquitously occurring in safety and design-type qualification testing of PV modules.

14 SOLAR ENERGY↗

How Should Machine Learning Be Successfully Used for Wind Speed Vertical Extrapolation?

An accurate characterization of the wind resource available at hub-height is required for an efficient and bankable wind farm project. However, direct measurement of wind speed at the constantly increasing height of the hub of commercial wind turbines is oftentimes challenging and expensive, so that it is common practice to vertically extrapolate the wind resource from lower and more easily accessible levels. Conventional techniques for wind speed vertical extrapolation include the use of a power law and a logarithmic profile. While simple, the limits in accuracy of these methods have been shown in various studies. Recently, machine learning has been proposed as a new method to vertically extrapolate winds. All the published studies on the topic assess the performance of machine learning techniques in vertically extrapolating the wind resource at the same location where the algorithm has been trained. However, in real-world applications, the wind resource is measured at the instrument location, but it then needs to be extrapolated at hub height at the location of the wind turbines within the find farm. To be able to fully recommend the use of machine learning techniques over the simple power law and logarithmic law, the spatial variability of the performance improvements of the machine learning approaches needs to be assessed. Here, we propose a round-robin validation of a machine learning-based method for wind speed extrapolation. We use 20 months of observations at four locations spanning a 100 km wide region at the Southern Great Plains (SGP) atmospheric observatory, in north-central Oklahoma. At each location, we train a random forest to predict 30-min average wind speed at 143 m AGL. We use as input features lidar wind speed at 65 m AGL, time of day, sonic anemometer wind speed at 4 m AGL, turbulent kinetic energy, and Obukhov length. First, we perform a same-site comparison of the performance of the proposed random forest against the conventional techniques for wind speed extrapolation (namely power law and logarithmic profile, with widely accepted stability corrections). We find that the random forest outperforms the power law in vertically extrapolating wind speed in all the considered stability regimes, with a 33% reduction in MAE for stable conditions, and a 31% reduction in unstable conditions. Similar results are found when comparing predictions of extrapolated winds from the logarithmic profile and the random forest with the observed values. Next, we propose a round-robin validation, to use the random forest trained at each site to extrapolate wind speed at the remaining three sites. We find that the performance of the random forest approach degrades when the algorithm is tested at a site different than the training one. However, even under those circumstances, the machine learning-based approach still outperforms the conventional techniques for wind speed extrapolation, with, on average, a reduction in mean absolute error between 15 and 20% over the conventional methods, with the largest benefits obtained under stable conditions.

Monte Carlo↗