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DOE OSTI2025

Low Temperature Cyclic Deformation Behavior of Ultrafine-grained Pure Magnesium (Final Technical Report)

The primary goal of the project is to explore the fundamental deformation and fatigue failure mechanisms for magnesium with a hexagonal close packed (HCP) crystal structure. It is important to perform the project for several reasons. Firstly, magnesium is the lightest structural metal and its application in various structural components can reduce the final component weight.

36 MATERIALS SCIENCE↗

DOE OSTI2025

BOILER Experiment Material Characterization and HFIR Irradiation Status

Pre-oxidized alumina-forming austenitic (AFA) steels have been previously identified as candidate alloys for structural components in lead-cooled fast reactors (LFRs). They offer compatibility with liquid Pb, high-temperature strength, formability, and cost advantages. However, variations in Ni content can affect the formation and stability of the Al 2 O 3 layer, influencing compatibility with liquid Pb. The effect of fast neutron irradiation on Al 2 O 3 stability in liquid Pb also requires evaluation. Therefore, understanding how Ni concentrations impacts pre-oxidized AFAs under combined extremes of irradiation and liquid metal corrosion is essential before safe deployment. The Behavior Of In-situ Lead Environments & Radiation (BOILER) experiment was developed under the Nuclear Science User Facilities (NSUF) program to integrate alloy development, irradiation experiment design, and irradiated materials characterization. In this effort, two pre-oxidized AFA steels with 20 wt% and 25 wt% Ni, hereinafter referred to as GA05-20Ni and GA05-25Ni, were produced. An irradiation experiment was then planned for the High Flux Isotope Reactor (HFIR), designed for passive heating of irradiation rabbit capsules from gamma heating in the HFIR flux trap (1 × 10 15 n/cm 2 ·s, >0.1 MeV). This heating melts Pb and exposes the pre-oxidized AFA steel specimens to nominal temperatures of 400 and 650°C. Detailed neutronics and thermal analyses were performed, though based on nominal design rather than as-built, as-irradiated conditions. This report documents further characterization of the pre-oxidized AFAs in the unirradiated condition. It also includes as-built thermal analysis using measured component dimensions, updated fill gas concentrations, and actual HFIR irradiation positions. Finally, the report summarizes capsule fabrication, current irradiation status, projected completion, estimated damage accumulation, and initial plans for post-irradiation examination plans.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Parametric Optimization of Nanostructured Alumina Forming Austenitic Alloys

Alumina-forming austenitic (AFA) alloys provide excellent oxidation resistance through the formation of a stable alumina scale, but their relatively high Ni content might limit application in core structural components because of helium generation and swelling under irradiation. Increasing the density of nanoscale features in the microstructure is a promising route to improve sink strength and mitigate these effects. Conventional oxide dispersion–strengthened (ODS) steels achieve this through mechanical alloying (MA), but the approach is costly and difficult to scale. In this milestone, additive manufacturing was applied as an alternative pathway to fabricate nanostructured AFA (NAFA) alloys with dual precipitation of oxides and nitrides enabled by reactive atmosphere processing. In FY25, two compositions, NAFA-1 (AFA-05) and NAFA-2, were produced and compared. Both alloys achieved densities above 99% of theoretical values, but NAFA-2 exhibited microcracking associated with Nb-rich intermetallic formation, indicating the need for further chemistry optimization. Nitrogen and oxygen uptake was confirmed on selected builds, demonstrating the intended dual-precipitate dispersion. Mechanical testing showed that AM-processed NAFA alloys exceed conventionally produced ODS steels in high-temperature tensile strength and fracture toughness. Preliminary Cu ion irradiation results further suggest improved resistance compared to wrought austenitic alloys. While the current alloys are promising for their compatibility in high-temperature air or liquid Pb environments, modifications to composition will be required for long-term operation in high-temperature impure sodium systems. Future work will focus on refining alloy chemistry to suppress laser powder bed fusion–induced cracking and scaling production to reactor-relevant dimensions using directed energy deposition as a pathway toward net-shape cladding fabrication.

36 MATERIALS SCIENCE↗

DOE OSTI2025

LAROMance Grade 91 Model Integration in NEML2

New reactor designs are targeting higher operating temperatures for increased thermal efficiency when compared to the current fleet of light water reactors. Designing structural components for these high temperature environments with reliable long-term operations requires material models that can accurately capture the deformation mechanisms active in these environments. The LAROMance surrogate material models are based on a database of mechanistic crystal plasticity simulations for high-temperature conditions. Inputs to the LAROMance models reflect the microstructural pedigree of the material, like dislocation densities and precipitate contents. Based on the evolution of these microstructural features, the LAROMance model provides the engineering scale constitutive model response. The LAROMance model was recently parameterized for Grade 91, a high temperature alloy. In the present work, the Grade 91 LAROMance model is implemented in the New Material Model Library, version 2 (NEML2). NEML2 provides a modular way to build material models from smaller blocks and was developed to vectorize the material update to efficiently run on modern computational architectures with graphics processing unit accelerators. NEML2 constitutive models can be used in simulations based on the multiphysics object-oriented simulation environment (MOOSE). This report provides details on the implementation of the Grade 91 LAROMance model in NEML2 and its verification of engineering scale finite element simulations in MOOSE.

42 - ENGINEERING↗

DOE OSTI2026

Low-Cost Highly Recyclable Structural Composites Utilizing Vitrimers and Natural Fibers (Basalt) Manufactured via a Novel Pultrusion Method for High-Volume Applications

The project’s overall goal is to explore and demonstrate as proof-of-concept that a highly recyclable and repairable composite material system, that is reinforced with natural fibers, can be used to produce lightweight structural components using a low-cost manufacturing process for high-volume automotive applications. More specifically, the project’s objectives will focus on vitrimer resins (which are a hybrid polymeric system of thermoplastics and thermosets) reinforced with basalt fibers and manufactured using pultrusion technologies. Pultrusion, as a method, is well-known to be one of the lowest-cost manufacturing processes for high-volume applications. However, to date, the validity and viability of such attractive objectives have not been demonstrated in support of the automotive industry.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Juvenile Salmon and Their Habitats in the Columbia River Estuary: A Review and Synthesis of Knowledge Development 2000–2025

[This is a 90% discussion draft.] This is the third Synthesis Memorandum funded by the U.S. Army Corps of Engineers and developed for the Columbia Estuary Ecosystem Restoration Program (CEERP) on the topic of habitat restoration in the Columbia River Estuary (CRE) from Bonneville Dam to the river mouth. While the first two were developed by PNNL and NOAA without the benefit of stakeholder participation, for the current memo, two key activities were initiated: (1) review, by the Expert Regional Technical Group (ERTG), of status and trends monitoring and action effectiveness monitoring funded by CEERP, and (2) a workshop including representatives of the Bonneville Power Administration and the U.S. Army Corps of Engineers (the action agencies [AAs]), the National Oceanic and Atmospheric Administration (NOAA), major research agencies contributing to CEERP, and sponsors who implement CEERP restoration actions. A systematic literature review was conducted using ClarivateTM Web of ScienceTM database. The topics of interest for CRE relevant research included salmon ecology, physical processes, and wetland habitats, and therefore required the use of broad search terms. Our final search criteria included a combination of Boolean operators and an approach to combine different sets of search terms. The final search result yielded 669 records. The records were classified by groups and assigned to the relevant disciplinary expert for review. The review identified substantive advances in understanding the provision of salmon habitat functions through spatiotemporally dynamic physical and ecological processes, and the use of CRE habitats by numerous stocks of juvenile salmon. It also uncovered heretofore unincorporated historical documentation of riparian habitats across the CRE. The characterization of the structural components of floodplain habitat including plant associations and channel networks has advanced considerably, together with the understanding of seasonal changes and long-term trends. The relative influence of salmon-habitat location in the CRE as compared with temporal factors, mainly season, has been well described, which affects the prioritization of restoration. Stressors on the ecosystem and fish, and the drivers of these stressors, have been more carefully elucidated and predictive models are in various stages of development. The vision, aims, and design of restoration projects have advanced together with methods of data collection, analysis, and modeling that have seen substantial improvements. Experiments intended to inform the design of restoration projects are underway or have been completed. An important outstanding area of research that has lagged behind the advances in fundamental understanding of the ecosystem and salmon habitat functions remains the peer-reviewed documentation of the outcomes of restoration for both habitats and fish functions.

estuary↗

DOE OSTI2022

Development, construction and qualification tests of the mechanical structures of the electromagnetic calorimeter of the Mu2e experiment at Fermilab

The “muon-to-electron conversion” (Mu2e) experiment at Fermilab will search for the Charged Lepton Flavour Violating neutrino-less coherent conversion of a muon into an electron in the field of an aluminum nucleus. The observation of this process would be the unambiguous evidence of physics beyond the Standard Model. Mu2e detectors comprise a straw-tracker, an electromagnetic calorimeter and an external veto for cosmic rays. The calorimeter provides excellent electron identification, complementary information to aid pattern recognition and track reconstruction, and a fast calorimetric online trigger. The detector has been designed as a state-of-the-art crystal calorimeter and employs 1340 pure Cesium Iodide (CsI) crystals readout by UV-extended silicon photosensors and fast front-end and digitization electronics. A design consisting of two identical annular matrices (named “disks”) positioned at the relative distance of 70 cm downstream the aluminum target along the muon beamline satisfies the Mu2e physics requirements.The hostile Mu2e operational conditions, in terms of radiation levels (total ionizing dose of 12 krad and a neutron fluence of 5x1010 n/cm2 @ 1 MeVeq (Si)/y), magnetic field intensity (1 T) and vacuum level (10$^{-4}$ Torr) have posed tight constraints on the design of the detector mechanical structures and materials choice. The support structure of the two 670 crystal matrices employs two aluminum hollow rings and parts made of open-cell vacuum-compatible carbon fiber. The photosensors and service front-end electronics for each crystal are assembled in a unique mechanical unit inserted in a machined copper holder. The 670 units are supported by a machined plate made of vacuum-compatible plastic material. The plate also integrates the cooling system made of a network of copper lines flowing a low temperature radiation-hard fluid and placed in thermal contact with the copper holders to constitute a low resistance thermal bridge. The data acquisition electronics is hosted in aluminum custom crates positioned on the external lateral surface of the two disks. The crates also integrate the electronics cooling system as lines running in parallel to the front-end system.The constraints on the calorimeter mechanical structures design, the development from the conceptual design to the specifications of all the structural components, the status of components production and the components quality assurance tests are presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Development of a web-based screening tool for ground source heat pump applications

Ground source heat pump (GSHP) technology has great potential to help the nation meet its energy and decarbonization goals, but several barriers hinder the wide application of GSHP. Important barriers include the lack of a coherent toolset for analyzing the technical feasibility and economic viability of the GSHP application. The current design and analysis methods are ineffective and require significant expertise to apply. Although building energy modeling is increasingly important in designing buildings, the tools for GSHP modeling and simulation are lacking. A web-based free-to-use tool is being developed for quick techno-economic analysis of GSHP applications in nearly any building in the United States. This tool is enabled by improvements in the calculation methodology to allow rapid sizing of borehole configurations that provide significant cost savings. The screening tool currently uses US Department of Energy (DOE) prototype building models and an extended g-function library to size ground heat exchangers and simulate the performance of GSHP systems. The team is integrating with DOE's Oak Ridge National Laboratory's AutoBEM program to automatically create a building model based on user inputs. This paper introduces the structure, components, features, and results of the web-based screening tool for GSHP applications. Future directions for further developing the tool are also discussed.

Liu, Xiaobing↗

DOE OSTI2022

The regulation of the cell wall by glycosylphosphatidylinositol-anchored proteins in Arabidopsis

A polysaccharides-based cell wall covers the plant cell, shaping it and protecting it from the harsh environment. Cellulose microfibrils constitute the cell wall backbone and are embedded in a matrix of pectic and hemicellulosic polysaccharides and glycoproteins. Various environmental and developmental cues can regulate the plant cell wall, and diverse glycosylphosphatidylinositol (GPI)-anchored proteins participate in these regulations. GPI is a common lipid modification on eukaryotic proteins, which covalently tethers the proteins to the membrane lipid bilayer. Catalyzed by a series of enzymic complexes, protein precursors are post-translationally modified at their hydrophobic carboxyl-terminus in the endomembrane system and anchored to the lipid bilayer through an oligosaccharidic GPI modification. Ultimately, mature proteins reach the plasma membrane via the secretory pathway facing toward the apoplast and cell wall in plants. In Arabidopsis, more than three hundred GPI-anchored proteins (GPI-APs) have been predicted, and many are reported to be involved in diverse regulations of the cell wall. In this review, we summarize GPI-APs involved in cell wall regulation. GPI-APs are proposed to act as structural components of the cell wall, organize cellulose microfibrils at the cell surface, and during cell wall integrity signaling transduction. Besides regulating protein trafficking, the GPI modification is potentially governed by a GPI shedding system that cleaves and releases the GPI-anchored proteins from the plasma membrane into the cell wall.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Springtime Drought Shifts Carbon Partitioning of Recent Photosynthates in 10-Year Old Picea mariana Trees, Causing Restricted Canopy Development

Springtime bud-break and shoot development induces substantial carbon (C) costs in trees. Drought stress during shoot development can impede C uptake and translocation. This is therefore a channel through which water shortage can lead to restricted shoot expansion and physiological capacity, which in turn may impact annual canopy C uptake. We studied effects of drought and re-hydration on early season shoot development, C uptake and partitioning in five individual 10-year old Picea mariana [black spruce] trees to identify and quantify dynamics of key morphological/physiological processes. Trees were subjected to one of two treatments: (i) well-watered control or (ii) drought and rehydration. We monitored changes in morphological [shoot volume, leaf mass area (LMA)], biochemical [osmolality, non-structural carbohydrates (NSC)] and physiological [rates of respiration (R d ) and light-saturated photosynthesis ( A sat )] processes during shoot development. Further, to study functional compartmentalization and use of new assimilates, we 13 C-pulse labeled shoots at multiple development stages, and measured isotopic signatures of leaf respiration, NSC pools and structural biomass. Shoot water potential dropped to a minimum of −2.5 MPa in shoots on the droughted trees. Development of the photosynthetic apparatus was delayed, as shoots on well-watered trees broke-even 14 days prior to shoots from trees exposed to water deficit. R d decreased with shoot maturation as growth respiration declined, and was lower in shoots exposed to drought. We found that shoot development was delayed by drought, and while rehydration resulted in recovery of A sat to similar levels as shoots on the well-watered trees, shoot volume remained lower. Water deficit during shoot expansion resulted in longer, yet more compact (i.e., with greater LMA) shoots with greater needle osmolality. The 12 C: 13 C isotopic patterns indicated that internal C partitioning and use was dependent on foliar developmental and hydration status. Shoots on drought-stressed trees prioritized allocating newly fixed C to respiration over structural components. In conclusion, temporary water deficit delayed new shoot development and resulted in greater LMA in black spruce. Since evergreen species such as black spruce retain active foliage for multiple years, impacts of early season drought on net primary productivity could be carried forward into subsequent years.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Development of radiopharmaceuticals for targeted alpha therapy: Where do we stand?

Targeted alpha therapy is an oncological treatment, where cytotoxic doses of alpha radiation are locally delivered to tumor cells, while the surrounding healthy tissue is minimally affected. This therapeutic strategy relies on radiopharmaceuticals made of medically relevant radionuclides chelated by ligands, and conjugated to targeting vectors, which promote the drug accumulation in tumor sites. This review discusses the state-of-the-art in the development of radiopharmaceuticals for targeted alpha therapy, breaking down their key structural components, such as radioisotope, targeting vector, and delivery formulation, and analyzing their pros and cons. Moreover, we discuss current drawbacks that are holding back targeted alpha therapy in the clinic, and identify ongoing strategies in field to overcome those issues, including radioisotope encapsulation in nanoformulations to prevent the release of the daughters. Lastly, we critically discuss potential opportunities the field holds, which may contribute to targeted alpha therapy becoming a gold standard treatment in oncology in the future.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2021

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades).

36 MATERIALS SCIENCE↗

DOE OSTI2022

Stress-Controlled Creep–Fatigue of an Advanced Austenitic Stainless Steel at Elevated Temperatures

Creep–fatigue interaction occurs in many structural components of high-temperature systems operating under cyclic and steady-state service conditions, such as in nuclear power plants, aerospace, naval, and other industrial applications. Thus, understanding micromechanisms governing high-temperature creep–fatigue behavior is essential for safety and design considerations. In this work, stress-controlled creep–fatigue tests of advanced austenitic stainless steel (Alloy 709) were performed at a 400 MPa stress range and 750 °C with tensile hold times of 0, 60, 600, 1800, and 3600 s, followed by microstructural examinations. The creep–fatigue lifetime of the Alloy 709 was found to decrease with increasing hold time until reaching a saturation level where the number of cycles to failure did not exhibit a significant decrease. Softening behavior was observed at the beginning of the test, possibly due to the recovery of entangled dislocations and de-twining. In addition, hysteresis loops showed ratcheting behavior, although the mean stress was zero during creep–fatigue cycling, which was attributed to activity of partial dislocations. Microstructural examination of the fracture surfaces showed that fatigue failure dominated at small hold times where the cracks initiated at the surface of the sample. Larger creep cracks were found for longer hold times with a lower probability of dimpled cavities, indicating the dominance of creep deformation. The results were compared with other commonly used stainless steels, and plausible reasons for the observed responses were described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

The Chemodynamics of the Stellar Populations in M31 from APOGEE Integrated-light Spectroscopy

We present an analysis of nearly 1000 near-infrared, integrated-light spectra from APOGEE in the inner ~7 kpc of M31. We utilize full-spectrum fitting with A-LIST simple stellar population spectral templates that represent a population of stars with the same age, [M/H], and [α/M]. With this, we determine the mean kinematics, metallicities, α abundances, and ages of the stellar populations of M31's bar, bulge, and inner disk (~4–7 kpc). We find a nonaxisymmetric velocity field in M31 resulting from the presence of a bar. The bulge of M31 is less metal-rich (mean [M/H] = $0.149$$^{+0.067}_{-0.081}$ dex) than the disk, features minima in metallicity on either side of the bar ([M/H] ~ -0.2), and is enhanced in α abundance (mean [α/M] = $0.281$$^{+0.035}_{-0.038}$). The disk of M31 within ~7 kpc is enhanced in both metallicity ([M/H] = $-0.023$$^{+0.050}_{-0.052}$) and α abundance ([α/M] = $0.274$$^{+0.020}_{-0.025}$). Both of these structural components are uniformly old at ≃12 Gyr. We find the mean metallicity increases with distance from the center of M31, with the steepest gradient along the disk major axis (0.043 ± 0.021 dex kpc -1 ). This gradient is the result of changing light contributions from the bulge and disk. The chemodynamics of stellar populations encodes information about a galaxy's chemical enrichment, star formation history, and merger history, allowing us to discuss new constraints on M31's formation. Our results provide a stepping stone between our understanding of the Milky Way and other external galaxies.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Novel, Simplified Air Delivery System Design Gets Commercialized

Typical air delivery systems require contractors to design systems that are complex, difficult to integrate into the framing and structural components of a home, and often do not meet the optimization demands of newer energy-efficient homes. This complex process can be a burden to already strained construction labor costs. However, a new technology simplifies duct system design to improve comfort and eliminate sources of installation error for residential air delivery systems.

Building America↗

DOE OSTI2020

Novel, Simplified Air Delivery System Design Gets Commercialized

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Fast Modular Reactor Nuclear Design Parameters of Fuel Cycle and Power Distributions

This paper describes conceptual design of a 112 MW thermal (50 MW electric) Fast Modular Reactor (FMR) system operating at 7 MPa with inlet/outlet temperatures of 509/800 ºC. The reactor system includes the reactor core, fuel assemblies, fuel rods, reactor internals, reflector, neutron control system, flow control, and structural components. The nuclear design and analysis were conducted to search for a baseline core with a cycle length greater than 8-year and the power peaking factor less than 1.5 by adjusting the fuel assembly, reactor core, and reflector configurations. The neutronics calculations of the baseline core showed that a refueling interval of 9-year is achieved with a total peaking factor of 1.47 and a fuel rod average linear power of 3.6 kW/m.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗