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DOE OSTI2021

Design for Remanufacturing

The objective of this project was to develop relationships between published scholarship, industry experience, and remanufacturing design rules and identify a clear path for integrating remanufacturing design rules into CAD tools and design practices. To accomplish this, remanufacturing knowledge was compiled, and then the relationships between this knowledge and a prioritized set of product design guidelines was developed. Next, a process to create rules out of guidelines was developed by first defining life extension as a primary function, and remanufacturing as effective tasks to control the failure modes that would restrict the product life. The reliability centered maintenance (RCM) process was used to identify proactive tasks and default actions to mitigate the effects of failure modes. These tasks were developed into expert system rules. The impact of design on remanufacturing was then validated through implementing a prioritized set of design rules for a Heavy Duty Off-Road (HDOR) techno-economic case study. Finally, detailed steps on how to define, develop, and integrate these rules into CAD were created.

42 ENGINEERING↗

DOE OSTI2023

Codes and standards for ceramic composite core materials for High Temperature Reactor applications

Fiber-reinforced ceramic matrix composites are attractive for high-temperature nuclear applications due to excellent thermal and mechanical properties as well as reasonable-to-outstanding radiation resistance. Over the past 20 years, the use of ceramic matrix composite applications expanded to many commercial non-nuclear industries as fabrication and application of the technologies mature. The ASME Boiler Pressure Vessel Code, under Section III Division 5, provides the design and construction rules for High Temperature Reactor components. It published the first rules for ceramic matrix composites to be used for reactor core components. The rules lay out the quality requirements together with the design and materials criteria for the use and application of silicon carbide- and carbon-based matrix material technologies. As with the established graphite rules, the ceramic composite material rules are structured in Subsection HH (from Section III), that addresses the criteria for class SN nonmetallic core components. The code rules rely heavily on the development and publication of standards for composite specification, classification, and testing of mechanical, thermal, and other properties. These test methods are developed in ASTM Committee C28 on Advanced Ceramics, with a current focus on ceramic composite tubes. This article describes the detail of the composites code, the design methodology and similarities to the graphite code, the guidance for the development of specifications for ceramic composites (for nuclear applications) including recent standard developments, and it mentions the next steps to support licensing aspects by validating the code with benchmarking data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Creep-fatigue Behavior and Damage Accumulation of a Candidate Structural Material for Concentrating Solar Power Solar Thermal Receiver (Final Technical Report)

Creep-fatigue deformation is an important consideration for a thermal receiver in Concentrating Solar Power systems due to the constant static stress or pressure, diurnal cycling, and elevated service temperatures required for efficient operation. An accurate description of the creep-fatigue behavior, not available for five of the six candidate materials, is important for assessment of preliminary designs. This project has provided a detailed analysis of the creep-fatigue behavior and damage accumulation of Alloy 740H, a candidate structural material for a CSP solar thermal receiver to address a critical knowledge barrier for receiver designs identified in the CSP Gen3 Demonstration Roadmap. This project was divided in to three tasks, split between two general categories: Experimental and design methodology. Tasks 1 and 3, relating to the collection of data on Alloy 740H plate and sheet forms, respectively, were performed at the Idaho National Laboratory and used as input to Task 2, the development of design methodology performed at Argonne National Laboratory. Experimental work covered limited tensile and creep testing to fill gaps in available data that is currently available and to demonstrate how the plate of Alloy 740H tested in this work compared to historical data. A more substantial testing program for fatigue and creep-fatigue was performed, with particular emphasis on creep-fatigue as there is little available data and it is necessary to understand the creep-fatigue interaction and develop related design models. This effort includes the development of rules for the design of solar receiver components against high temperature creep-fatigue and ratcheting failure modes. The ASME Code rules for high temperature nuclear components was used to the basis of the method but adjustments will be made to reflect the generally shorter, diurnal operating cycles of thermal receivers and the relative consequences of failure, comparing nuclear to solar components. This work has provided guidance for the design of components for concentrating power facilities operating at high temperatures and undergoing high, secondary thermal stresses relative to the applied primary pressure stress. The design rules were developed for the design of Generation 3 CSP tubular receivers manufactured from Alloy 740H, but are generally applicable to a wide range of component types undergoing similar loads. Procedural design rules for components to be used in conjunction with the 2019 edition of the ASME Boiler & Pressure Vessel Code and the corresponding design data for Alloy 740H have been developed. A commentary describing the rationale behind the design rules and the data underlying the design material properties, as well as an extensive set of worked sample problems detailing the application of the rules to CSP components were developed as a part of this project, with a separate report covering these aspects in detail and included in the Appendix of this report.

14 SOLAR ENERGY↗

DOE OSTI2024

Impacts of Alternative Operations and Renewable Energy Deployment on Columbia River Hydropower

The Columbia River Treaty Tribes in the Pacific Northwest - the Nez Perce, Umatilla, Warm Springs, and Yakama - hold treaty-reserved fishing rights for the Columbia River, one of the world's most productive salmon rivers and a critical resource for these tribes. However, the tribes have expressed that current operating regimes of hydropower dams throughout the Columbia River Basin (CRB) do not fully account for tribal fishing rights and have negatively impacted fish populations. Four tribes acting together through the Columbia River Inter-Tribal Fish Commission (CRITFC)'s 2022 Energy Vision stated that current power system models often do not fully account for the many constraints faced by hydropower facilities in the CRB. As the deployment of variable renewable energy (VRE) like solar and wind continues to increase, power system flexibility will become increasingly important. As a result, there is a growing need to better understand the true capabilities of the hydropower generation fleet while accurately accounting for ecological constraints (Northwest Power and Conservation Council 2022). Understanding hydropower's role in a future grid with a higher share of VRE can inform water resources planning to address ecological needs. The goal of this study is to examine the impacts of alternative hydropower operation rules and weather variability on hydropower generation and grid operations in VRE and transmission infrastructure deployment scenarios. The study evaluates how hydropower scheduling practices can reduce ecological impacts to the region's salmon populations. More specifically, the study examines the impact of today's dam water release rules (called "adjusted base water rules" in this study) and new, ecologically informed water release rules (called "ecosystem water rules" in this study) on two VRE scenarios (current renewable energy levels and higher renewable energy levels) using six weather years for each scenario (2008-2013). CRITFC developed the ecosystem water rules, which capture a portion of the changes they recommend for CRB hydropower operations. These analyses use a water resource planning model (OASIS) and a production cost model (PLEXOS) to simulate CRB reservoir cascade and Western Interconnection power grid operation.

13 HYDRO ENERGY↗

DOE OSTI2020

Systems biology markup language (SBML) level 3 package: multistate, multicomponent and multicompartment species, version 1, release 2

Rule-based modeling is an approach that permits constructing reaction networks based on the specification of rules for molecular interactions and transformations. These rules can encompass details such as the interacting sub-molecular domains and the states and binding status of the involved components. Conceptually, fine-grained spatial information such as locations can also be provided. Through “wildcards” representing component states, entire families of molecule complexes sharing certain properties can be specified as patterns. This can significantly simplify the definition of models involving species with multiple components, multiple states, and multiple compartments. The systems biology markup language (SBML) Level 3 Multi Package Version 1 extends the SBML Level 3 Version 1 core with the “type” concept in the Species and Compartment classes. Therefore, reaction rules may contain species that can be patterns and exist in multiple locations. Multiple software tools such as Simmune and BioNetGen support this standard that thus also becomes a medium for exchanging rule-based models. This document provides the specification for Release 2 of Version 1 of the SBML Level 3 Multi package. No design changes have been made to the description of models between Release 1 and Release 2; changes are restricted to the correction of errata and the addition of clarifications.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

On triality defects in 2d CFT

We consider the triality fusion category discovered in the c = 1 Kosterlitz-Thouless theory. We analyze this fusion category using the tools from the group theoretical fusion category and compute the simple lines, fusion rules and F-symbols. We then studied the physical implication of this fusion category including deriving the spin selection rule, computing the asymptotic density of states of irreducible representations of the fusion category symmetries, and analyzing its anomaly and constraints under the renormalization group flow. There is another set of F-symbols for the fusion categories with the same fusion rule known in the literature. We find these two solutions are different as they lead to different spin selection rules. This gives a complete list of the fusion categories with the same fusion rule by the classification result in.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Design and analysis of optimal pre-cooling in residential buildings

Existing pre-cooling strategies provide a means of shifting or reducing the peak demand and/or energy cost in residential buildings. However, majority of them are rule-based and therefore may not be optimal in terms of cost saving, leaving room for improvement. In this paper, an integer linear programming problem that accounts for the thermal properties of a specific home, HVAC system capacity, utility rate structure, and weather conditions and makes use of a home thermal model is formulated. This problem determines the HVAC on/off control signal that minimizes the 24-h energy cost while maintaining thermal comfort and calculates the corresponding optimal indoor air temperature. The model is constructed using home thermal properties identified via data training in real-time. Through simulation, the energy performance of the proposed optimal pre-cooling strategy is investigated and compared with three rule-based operation strategies from the literature. It is found that the optimal strategy requires the least energy consumption without sacrificing thermal comfort. The superb energy performance of the optimal strategy is attributed to a longer runtime of the HVAC system in cool outdoor air conditions and to the elimination of deadband in HVAC operation, which is required by the rule-based strategies, to allow the indoor air temperature to stay near the thermal comfort upper bound as much as possible. In terms of energy cost, the rule-based operation strategies require 3.52, 1.90, and 2.79, respectively, while the optimal strategy only requires 1.52. These figures represent a saving of 56.82%, 20.00%, and 45.52%, respectively. The results suggest that the optimal strategy is indeed significantly more effective than the existing rule-based operation strategies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Field-based AFDD for refrigerant undercharge in residential HVAC systems: enhancing reliability through false alarm mitigation

This study evaluated rule-based and machine learning (ML) based automated fault detection and diagnostics (AFDD) algorithms for detecting refrigerant undercharge faults in residential heating, ventilation, and air conditioning (HVAC) systems, using actual building data and a minimal set of features. The ML-based algorithms included Decision Tree (DT) and K-Nearest Neighbors (KNN). Both the rule-based and ML-based algorithms demonstrated the capability to detect refrigerant undercharge faults of -30% or more. Both types of algorithms exhibited false alarms before the implementation of a false alarm mitigation algorithm, which motivated the development of such a mitigation strategy. After applying the mitigation, false alarms were substantially reduced, with the rule-based algorithm decreasing to 0.6% and the ML-based algorithms reaching 0%, while maintaining strong detection performance. Although the rule-based algorithm initially showed lower performance compared to the ML-based algorithms, its detection accuracy improved after mitigation to a level comparable to the ML-based algorithms. These results confirm that combining false alarm mitigation with both rule-based and ML-based AFDD algorithms significantly enhances practical reliability while preserving robust fault detection capabilities. Furthermore, the findings demonstrate the potential for field deployment of these algorithms in residential HVAC systems and highlight the importance of minimizing false alarms.

False Alarm↗

DOE OSTI2026

Impact of new physics on the JUNO-long-baseline synergy in the neutrino mass ordering determination

The determination of the neutrino mass ordering is one of the flagship goals in particle physics. A well-known and powerful synergy emerges when combining high-precision measurements of the effective atmospheric mass-squared splitting from electron antineutrino disappearance in reactor experiments with that from muon (anti)neutrino disappearance in accelerator-based long-baseline experiments. To fully exploit this synergy, percent-level precision in the atmospheric mass splitting is required—a target that JUNO is expected to achieve within a few months of data taking. This motivated the formulation of a mass ordering sum rule for neutrino disappearance channels, which shows that by combining data from T2K and NOvA with JUNO after one year of operation, the neutrino mass ordering can be determined at the 3⁢𝜎 confidence level. Since JUNO has recently started taking data, it is timely to ask whether this sum rule remains robust in the presence of new physics. We identify the necessary conditions for new physics to affect the sum rule and demonstrate that, in some cases, such effects could lead to an incorrect inference of the mass ordering. As concrete examples, we consider scalar nonstandard interactions (SNSI) and neutrinos coupled to an ultralight scalar field. We find that, for SNSI, current constraints render any modification of the sum rule negligible, whereas in the latter case, the inference of the ordering requires caution. Nevertheless, these effects can be disentangled, illustrating how the sum rule can also be used to search for new physics.

Alves, Gustavo F. S. [Fermi National Accelerator L↗

DOE OSTI2020

Design of Thermophotovoltaic Cells for Optimal System Efficiency, Accounting for Photon Reuse from Front and Back Contacts

We develop a model showing how reflection from both the front and back contacts of thermophotovoltaic (TPV) cells affects the system efficiency. From this foundation we determine the design rules for front grids for TPV cells, and assess the consequences of those rules on cell design and system performance. We show that these design rules are different and more complex than the corresponding design rules for solar photovoltaic (PV) cells, and can lead to substantially different grid design and system performance than if the simpler solar PV design rules were used.

14 SOLAR ENERGY↗

DOE OSTI2023

Pickaxe: a Python library for the prediction of novel metabolic reactions

Abstract Background Biochemical reaction prediction tools leverage enzymatic promiscuity rules to generate reaction networks containing novel compounds and reactions. The resulting reaction networks can be used for multiple applications such as designing novel biosynthetic pathways and annotating untargeted metabolomics data. It is vital for these tools to provide a robust, user-friendly method to generate networks for a given application. However, existing tools lack the flexibility to easily generate networks that are tailor-fit for a user’s application due to lack of exhaustive reaction rules, restriction to pre-computed networks, and difficulty in using the software due to lack of documentation. Results Here we present Pickaxe, an open-source, flexible software that provides a user-friendly method to generate novel reaction networks. This software iteratively applies reaction rules to a set of metabolites to generate novel reactions. Users can select rules from the prepackaged JN1224min ruleset, derived from MetaCyc, or define their own custom rules. Additionally, filters are provided which allow for the pruning of a network on-the-fly based on compound and reaction properties. The filters include chemical similarity to target molecules, metabolomics, thermodynamics, and reaction feasibility filters. Example applications are given to highlight the capabilities of Pickaxe: the expansion of common biological databases with novel reactions, the generation of industrially useful chemicals from a yeast metabolome database, and the annotation of untargeted metabolomics peaks from an E. coli dataset. Conclusion Pickaxe predicts novel metabolic reactions and compounds, which can be used for a variety of applications. This software is open-source and available as part of the MINE Database python package ( https://pypi.org/project/minedatabase/ ) or on GitHub ( https://github.com/tyo-nu/MINE-Database ). Documentation and examples can be found on Read the Docs ( https://mine-database.readthedocs.io/en/latest/ ). Through its documentation, pre-packaged features, and customizable nature, Pickaxe allows users to generate novel reaction networks tailored to their application.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

R&D GREET Battery Carbon Footprint Calculator

The Battery Carbon Footprint (CF) Calculator was developed to help U.S. battery manufacturers meet the carbon footprint reporting requirements of the EU Battery Regulation (EU) 2023/1542. The calculator incorporates several major battery carbon footprint frameworks, including the Joint Research Centre's Rules for the Calculation of the Carbon Footprint of Electric Vehicle Batteries (CFB-EV), RECHARGE's Product Environmental Footprint Category Rules for High Specific Energy Rechargeable Batteries for Mobile Applications (PEFCR), the Catena-X Product Carbon Footprint Rulebook (CX-PCF Rules), Battery Pass's Battery Carbon Footprint: Rules for Calculating the Carbon Footprint of the "Distribution" and "End-of-Life and Recycling" Life Cycle Stages, the Global Battery Alliance's Greenhouse Gas Rulebook: Generic Rules, Version 2.1, and the Ministry of Economy, Trade and Industry's draft Carbon Footprint Calculation Method for Automotive Batteries. The tool pairs these frameworks with foreground data from Argonne's R&D GREET models and integrates user-supplied background data covering battery manufacturing and supply chain activities. By bringing multiple international methodologies together in a single platform, the calculator enables manufacturers to evaluate product carbon footprints, improve data consistency, and prepare for evolving regulatory compliance and global market reporting requirements.

Zhang, Jingyi↗

DOE OSTI2020

Initial development and verification of a primary load design method based on elastic-perfectly plastic analysis

This report describes a new primary load design method to supplement the current design-by-elastic-analysis rules in Section III, Division 5, Subsection HB, Subpart B of the ASME Boiler and Pressure Vessel Code, covering the design and construction of Class A high temperature nuclear structural components. The main objectives for the new design method are to provide a procedure that can be applied to components with complicated geometries and to simplify the primary load design process by providing rules more compatible with modern finite element analysis. The report includes a complete set of design rules, presented as a draft ASME Code Case, as well as a commentary on the rules and a set of verification problems. The verification design problems demonstrate the new primary load design rules produce safe, efficient components when compared to the current Division 5 approach, while greatly simplifying the design analysis process.

42 ENGINEERING↗

DOE OSTI2020

Status Report on ASME Code Development for Nonmetallic Core Components in 2020

The purpose of this report is to provide a status update on the progress and ongoing activities of the current ASME Boiler Pressure Vessel (BPV) Code Section III, Division 5, on nonmetallic core components and assemblies which includes the design rules for graphite and ceramic composite materials. Section III is concerned with the design and construction of nuclear reactor components and Division 5 focuses on high temperature reactors (HTR). The ASME Section III Committee’s function for nuclear items other than pressure-retaining components, is to establish rules of safety related to structural integrity. The term “construction” refers to the all-inclusive effort comprising of materials, design, fabrication, examination, inspection, testing, certification, and pressure relief. The Department of Energy (DOE) supports industry codes and standards development through focused research providing the technical basis for new or modified codes and standards and the participation of subject matter experts in codes and standards committees. The activities for the nonmetallic core components and assemblies committees are the pursuit of two working groups that meet quarterly during ASME BPV Code Week meetings. The two working groups are General Requirements for Graphite and Ceramic Composite Core Components and Assemblies (GR GCCCCA) and Nonmetallic Design and Materials (NDM). The rules on general requirements for nonmetallic core components are discussed in the articles of Subsection HA subpart B. Ceramic composites were recently incorporated within the rules, and the GR GCCCCA working group is now in the process of aligning the requirements with the subsections and articles of ASME BPV Code Section III NCA, the general requirements for Division 1 and 2 of the code. The NDM working group is concerned with the design rules for graphite and composite materials for core components and assemblies discussed in Subsection HH (Class SN Nonmetallic Core Components) subpart A and subpart B which reference graphite and composite materials respectively. The bulk of the progress and work is done within this working group. A significant undertaking, with discussion that started in 2015, is to gain endorsement of ASME Section III, Division 5, by the U.S. Nuclear Regulatory Commission (NRC). In June 2018, ASME formally recommended endorsement to the NRC. The NRC has since initiated the endorsement review process, which is to be concluded early in 2021. ASME task groups on metallic structures and components, as well as non-metallic core support structures, have been formed to define potential pathways and schedules for NRC endorsement of Division 5. NRC determined to perform a review on the 2017 edition of Section III Division 5 as a baseline. As a result, the use of graphite as nonmetallic core components formed part of the review, but it excluded composite materials (which were first introduced in the 2019 edition). This report documents progress in FY 2020 directed toward ASME’s efforts to develop design codes for graphite and composites. Progress includes a major code review by NRC, the first code enquiry, and its solution, an overhaul of the treatment of Weibull Statistics, and the addition of Nonmandatory Appendices to the composites code relating to carbon-carbon composite materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Identifying Limitations of ASME Section III Division 5 For Advanced SMR Designs

This report provides an overview of the ASME Boiler & Pressure Vessel Section III, Division 5 rules for the design and construction of high temperature nuclear reactor components. The overview focuses on the application of the rules to the design of Small Modular Reactors (SMRs). The discussion covers the general ASME Code rules for base metal design and construction, the rules for designing weldments, and provides an overview of environmental degradation mechanisms affecting reactor structural materials. The analysis includes historical context on the development of the ASME design approach and a description of what actions could be taken to mitigate the gaps identified in the report. The report concludes with a summary of the key gaps identified in the rules, as they apply to SMR, and a list of recommendations on how those gaps might be addressed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Resilience Through Data-Driven, Intelligent Designed Control: A Formal Methods Approach

The PNNL and GTRI team developed a strategy to integrate temporal logic rule specification for detection of cyber-intrusion in the source code and control algorithms of CPS using advanced cyber-data. The GTRI team utilized its capabilities in rule synthesis and temporal logic specifications for software assurance and verification to detect and predict impact of cyber-intrusions and malware in the computational and control algorithms of cyber-physical systems. The team also developed a testing and verification approach that could be used to validate the suggested approach against a realistic use-case CPS showcasing improvements in system impact prediction performance. Temporal logic offers a compact expression of events in absolute and relative time and has a formalized translation to state machines. As such, temporal logic rules can feasibly be synthesized to any system as a rule engine, with the process being formally verified to be correct. The goal here is to utilize temporal logic rules to detect cyber-attacks and manipulations in the computational algorithms and provide real-time software assurance and verification guarantees.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Modeling Approach to Critical in the Upcoming CERBERUS Experiment

The planned Critical Experiment Reflected By coppEr to betteR Understand Scattering (CERBERUS) seeks to maximize sensitivity to elastic neutron scattering in the intermediate energy region (0.625 eV to 100 keV). It will be performed near the end of FY 2023 at the National Criticality Experiments Research Center (NCERC). Very few International Criticality Safety Benchmark Evaluation Project (ICSBEP) benchmarks are sensitive to copper in this region. Creating a benchmark sensitive in this area will make the Zeus benchmark series, an intermediate benchmark evaluation that uses a copper reflector, more useful for code and nuclear data validation. Approaching criticality in a safe manner is of utmost importance to avoid a criticality accident, which would present a safety concern and could cause damage to equipment. The two rules that are followed closely to ensure that a criticality accident does not occur are the 3/4 rule and the 1/2 rule. The 3/4 rule states that no more than 3/4 of a critical mass can be assembled by hand, and the 1/2 rule states that no more than 1/2 of the material expected to reach criticality, or 1/2 the distance needed to reach criticality, can be added before another measurement of the count rate has been taken. This work will discuss the approach to criticality as modeled in MCNP6® 1 particle transport code with the ENDF/B- VIII.0 cross-section library and the .00c data library.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Impact of New Physics on the JUNO-Long-Baseline Synergy in Neutrino Mass Ordering Determination

The determination of the neutrino mass ordering is one of the flagship goals in particle physics. A well-known and powerful synergy emerges when combining high-precision measurements of the effective atmospheric mass-squared splitting from electron antineutrino disappearance in reactor experiments with that from muon (anti)neutrino disappearance in accelerator-based long-baseline experiments. To fully exploit this synergy, percent-level precision in the atmospheric mass splitting is required-a target that JUNO is expected to achieve within a few months of data taking. This motivated the formulation of a mass ordering sum rule for neutrino disappearance channels, which shows that by combining data from T2K and NOvA with JUNO after one year of operation, the neutrino mass ordering can be determined at the $3σ$ confidence level. Since JUNO has recently started taking data, it is timely to ask whether this sum rule remains robust in the presence of new physics. We identify the necessary conditions for new physics to affect the sum rule and demonstrate that, in some cases, such effects could lead to an incorrect inference of the mass ordering. As concrete examples, we consider Scalar Non-Standard Interactions (SNSI) and neutrinos coupled to an ultralight scalar field. We find that, for SNSI, current constraints render any modification of the sum rule negligible, whereas in the latter case, the inference of the ordering requires caution. Nevertheless, these effects can be disentangled, illustrating how the sum rule can also be used to search for new physics.

Alves, Gustavo F.S. [Fermilab; Northwestern U.; Sa↗