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DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗

DOE OSTI2020

Area-Preserving Mapping of 3D Carotid Ultrasound Images Using Density-Equalizing Reference Map

Carotid atherosclerosis is a focal disease at the bifurcations of the carotid artery. To quantitatively monitor the local changes in the vessel-wall-plus-plaque thickness (VWT) and compare the VWT distributions for different patients or for the same patients at different ultrasound scanning sessions, a mapping technique is required to adjust for the geometric variability of different carotid artery models. In this work, we propose a novel method called density-equalizing reference map (DERM) for mapping 3D carotid surfaces to a standardized 2D carotid template, with an emphasis on preserving the local geometry of the carotid surface by minimizing the local area distortion. The initial map was generated by a previously described arc-length scaling (ALS) mapping method, which projects a 3D carotid surface onto a 2D non-convex L-shaped domain. A smooth and area-preserving flattened map was subsequently constructed by deforming the ALS map using the proposed algorithm that combines the density-equalizing map and the reference map techniques. This combination allows, for the first time, one-to-one mapping from a 3D surface to a standardized non-convex planar domain in an area-preserving manner. Evaluations using 20 carotid surface models show that the proposed method reduced the area distortion of the flattening maps by over 80% as compared to the ALS mapping method.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Process-based balance of system cost modeling for offshore wind power plants in the United States

This paper describes the development of a process-based and open-source balance of system cost model that provides the capability to evaluate both existing and novel offshore wind technologies. Individual design and installation steps are represented with bottom-up engineering models that compute times and costs associated with the process; furthermore, operational constraints are assigned to each process so that delays caused by weather and presence of marine mammals may be accounted for in the overall project timeline. The model structure, assumptions, inputs, and results are vetted with industry partners and compared against actual projects for validation. Installation times show reasonable agreement with real data. Project cost sensitivities are investigated to compute the system-level impact of different design choices. First, individual vessel efficiencies are computed for varying numbers of installation vessels and weather time series to show the diminishing returns of more than two feeder barges. Then, array cable capital costs and installation times are determined for a representative project with different turbine sizes. These values quantify the cost-benefit tradeoffs and show a net-cost savings of decreasing numbers of turbines, increased turbine spacing, and fewer turbine terminations. These results demonstrate that the balance of system model features the accuracy, functionality, and accessibility to serve as the foundation for a wide range of analyses to identify cost reduction potentials for offshore wind energy in the United States.

17 WIND ENERGY↗

DOE OSTI2024

A semi-automated algorithm for designing stellarator divertor and limiter plates and application to HSX

We present a semi-automated algorithm for designing three-dimensional divertor or limiter plates targeting low heat loads. The algorithm designs the plates in two stages: firstly, the parallel heat flux distribution is caught on vertically-inclined plates at one or several toroidal locations. Secondly, the power per unit area is reduced by stretching, tilting and bending the plates toroidally. Heat transport is modelled using the EMC3-Lite code, which uses an anisotropic diffusion model. We apply this scheme to HSX, a medium-sized stellarator located at the University of Wisconsin–Madison. Starting from the current machine with an extended vessel wall, we construct plates which are able to effectively catch and spread the heat for three different magnetic configurations. The scheme has a computational cost in the order of tens of CPU-minutes, making it a powerful tool for semi-automated plasma-facing component design in three-dimensional environments.

anisotropic diffusion↗

DOE OSTI2022

Multimodal imaging of hemorrhagic transformation biomarkers in an ischemic stroke model.

Abstract Hemorrhagic transformation of ischemic stroke has devastating consequences, with high mortality and poor functional outcomes. Animal models of ischemic stroke also demonstrate the potential for hemorrhagic transformation, which complicates biochemical characterization, treatment studies, and hinders poststroke functional outcomes in affected subjects. The incidence of hemorrhagic transformation of ischemic stroke in animal model research is not commonly reported. The postmortem brain of such cases presents a complex milieu of biomarkers due to the presence of healthy cells, regions of varying degrees of ischemia, dead and dying cells, dysregulated metabolites, and blood components (especially reactive Fe species released from lysed erythrocytes). To improve the characterization of hemorrhage biomarkers on an ischemic stroke background, we have employed a combination of histology, X-ray fluorescence imaging (XFI), and Fourier transform infrared (FTIR) spectroscopic imaging to assess 122 photothrombotic (ischemic) stroke brains. Rapid freezing preserves brain biomarkers in situ and minimizes metabolic artifacts due to postmortem ischemia. Analysis revealed that 25% of the photothrombotic models had clear signs of hemorrhagic transformation. The XFI and FTIR metabolites provided a quantitative method to differentiate key metabolic regions in these models. Across all hemorrhage cases, it was possible to consistently differentiate otherwise healthy tissue from other metabolically distinct regions, including the ischemic infarct, the ischemic penumbra, blood vessels, sites of hemorrhage, and a region surrounding the hemorrhage core that contained elevated lipid oxidation. Chemical speciation of deposited Fe demonstrates the presence of heme-Fe and accumulation of ferritin.

Pushie, M. J. (ORCID:0000000174945427)↗

DOE OSTI2025

Resin Testing and Modeling for Optimal Composite Processing

Polymer composites have properties such as high strength and stiffness, low weight, good thermal and chemical stability, as well as impact and abrasion resistance that make them ideal for high-performance applications. The chemistries of these materials are continuously improving, so determining their properties is vital for successfully producing them and achieving the desired results. Multiple methods can be employed to monitor characteristics such as heat flow, weight, dimension, and modulus as a function of time and temperature. By analyzing this information, models can be developed to predict outcomes of parameters not tested for. In one application, materials proposed for wet filament winding and the production of high pressure vessels can be analyzed to verify they will have the necessary low viscosity for good fiber wetting and long pot life for the extended handling inherent to this process. Such data about a prospective system provides valuable information on how that material could ultimately be processed to yield the desired part.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Thermodynamic Analysis of Thermo-vacuum Clothes Drying Operation

Clothes drying accounts for a significant amount of energy consumed in residential and commercial sectors. A thermal vacuum clothes drying technology (TVCD) is proposed as an advanced clothes dryer which can significantly reduce the energy requirements by expediting the drying process. In the conventional convective clothes dryer, hot dry air is introduced into the drum which gets in direct contact to dry the clothes. This process is energy inefficient since the significant amount of heat and the water carried out with the exhaust stream are wasted. In contrast to the conventional convective drying technique, the drying mechanism of TVCD is through nucleate boiling at low temperature due to reduced vessel pressure. The process is not only efficient but also reduces the required time for drying. The objective of this paper is to develop a comprehensive thermodynamic model to predict the transient drying process of TVCD. The three-stage system model including the detail analysis of individual components is capable of simulating the variation of the water content in the textile under various operational conditions. The preliminary results show that the drying time of 3 lb textile from 70% to 2.5% in TVCD is approximately four times less than the time required in the conventional clothes dryer. Parametric studies are carried out to understand the effect of operation conditions and component geometry on the system performance. Energy consumption of the system is also analyzed.

Yang, Cheng-Min↗

DOE OSTI2020

A thermally-limited bubble growth model for the relaxation time of superheated fuels

Here, we propose a novel approach to evaluate the relaxation time of vapor bubble growth in the context of the flash boiling of a superheated liquid. In alternative to the empirical correlation derived from superheated water experiments almost fifty years ago, the new model describes the thermally-dominated growth of vapor bubbles in terms that are dependent on the local Jakob number (the ratio of sensible heat to latent heat during phase change) and the number density of vapor bubbles. The model is tested by plugging the resulting relaxation time into the Homogenous Relaxation Model (HRM). Flash-boiling simulations carried out with HRM are compared with n-pentane (C 5 H 12 ) injection and boil-off experiments conducted with a real-size, axial-hole, transparent gasoline injector discharging into a constant-pressure vessel. The long-distance microscopy images from the experiments, processed to derive the projected liquid volume (PLV) of the spray, provide a unique set of time-resolved validation data for direct fuel injection simulations. At conditions ranging from flaring to mild and minimal flash boiling, we show that switching to the new relaxation time improves the agreement with the measured PLV profiles with respect to the standard empirical model. Particularly at flaring conditions, the predicted increase in gas cooling caused by rapid vapor production is shown to be more consistent with the observed boil-off.

42 ENGINEERING↗

DOE OSTI2022

Study of alkaline carbonate cooling to mitigate Ex-Vessel molten corium accidents

To mitigate adverse effects from molten corium following a reactor pressure vessel failure (RPVF), some new reactor designs employ a core catcher and a sacrificial material (SM), such as ceramic or concrete, to stabilize the molten corium and avoid containment breach. Existing reactors cannot easily be modified to include these SMs but could be modified to allow injectable cooling materials. Current reactor designs are limited to using water to stabilize the corium, but this can create other issues such as reaction of water with the concrete forming hydrogen gas. Here the novel SM proposed is a granular carbonate mineral that can be used in existing light water reactor plants. The granular carbonate will decompose when exposed to heat, inducing an endothermic reaction to quickly solidify the corium in place and producing a mineral oxide and carbon dioxide. Corium spreading is a complex process strongly influenced by coupled chemical reactions, including decay heat from the corium, phase change, and reactions between the concrete containment and available water. A recently completed Sandia National Laboratories laboratory directed research and development (LDRD) project focused on two research areas: experiments to demonstrate the feasibility of the novel SM concept, and modeling activities to determine the potential applications of the concept to actual nuclear plants. Small-scale experiments using lead oxide (PbO) as a surrogate for molten corium demonstrate that the reaction of the SM with molten PbO results in a fast solidification of the melt due to the endothermic carbonate decomposition reaction and the formation of open pore structures in the solidified PbO from CO 2 released during the decomposition. A simplified carbonate decomposition model was developed to predict thermal decomposition of carbonate mineral in contact with corium. This model was incorporated into MELCOR, a severe accident nuclear reactor code. A full-plant MELCOR simulation suggests that by the introduction of SM to the reactor cavity prior to RPVF ex-vessel accident progression, e.g., core-concrete interaction and core spreading on the containment floor, could be delayed by at least 15 h; this may be enough for additional accident management to be implemented to alleviate the situation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Evaluating the Influence of Hemorheological Parameters on Circulating Tumor Cell Trajectory and Simulation Time

Extravasation of circulating tumor cells (CTCs) occurs primarily in the microvasculature, where flow and cell interactions significantly affect the blood rheology. Capturing cell trajectory at this scale requires the coupling of several interaction models, leading to increased computational cost that scales as more cells are added or the domain size is increased. In this work, we focus on micro-scale vessels and study the influence of certain hemorheological factors, including the presence of red blood cell aggregation, hematocrit level, microvessel size, and shear rate, on the trajectory of a circulating tumor cell. We determine which of the aforementioned factors significantly affect CTC motion and identify those which can potentially be disregarded, thus reducing simulation time. We measure the effect of these elements by studying the radial CTC movement and runtime at various combinations of these hemorheological parameters. To accurately capture blood flow dynamics and single cell movement, we perform high-fidelity hemodynamic simulations at a sub-micron resolution using our in-house fluid dynamics solver, HARVEY. We find that increasing hematocrit increases the likelihood of tumor cell margination, which is exacerbated by the presence of red blood cell aggregation. As microvessel diameter increases, there is no major CTC movement towards the wall; however, including aggregation causes the CTC to marginate quicker as the vessel size increases. Finally, as the shear rate is increased, the presence of aggregation has a diminished effect on tumor cell margination.

Roychowdhury, Sayan↗

DOE OSTI2021

Operational and Mission Highlights: A Monthly Summary of Top Achievements September 2021

Laboratory personnel working on a years-long Confinement Vessel Disposition (CVD) Project at the Chemistry and Metallurgy Research (CMR) facility recently shipped its first vessel after closing the emptying and dispositioning portion of the project in 2020. During the 1970s and 1980s, the Laboratory conducted experiments that produced data used in computer modeling. Scientists used these models to evaluate the performance of nuclear weapons.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Implementation of a feature selection algorithm in FARM to identify important state variables and time-invariant matrices

The FARM (Feasible Actuator Range Modifier) software module is a component of the RAVEN-based FORCE framework for analysis of Integrated Energy Systems (IES). FARM aids the HERON software module in the evaluation of the optimal dispatch for the different IES components. Set-point trajectories are required to meet limits on both production variables (i.e., the variables to be optimized such as the electrical power, the hydrogen production rate, etc.) and process variables tied to the service life of equipment (e.g., steam flowrate, vessel pressure, turbine firing temperature, etc.). To evaluate the feasibility of HERON generated set-points and to do so in an acceptable time, FARM employs reduced order models to represent the dynamic behavior of the systems to be dispatched. These surrogate models take the form of a linear dynamic system with sets of Linear Parameter Varying (LPV) matrices that are mapped to the system operating space. These matrices are derived from the trajectories of system state variables and system output variables during transients. The accuracy of LPV matrices depends on the selection of state variables. In previous reports, state variables were selected by adopting a complicated workflow requiring multiple software licenses and an advanced level of user expertise. In this report, a new workflow that automates the state variable selection process is presented. It significantly reduces the frequency of user interventions and does not require multiple software licenses. Each module in the new workflow is described in detail, and the input / output examples in each step of the workflow are provided. It was demonstrated that this workflow can greatly reduce the complexity of the state variable selection process, and that the updated FARM-Gamma and FARM-Delta validators can benefit from this workflow when solving the power dispatch problem of a representative IES test case. Finally, some code improvements that can further enhance the efficiency are suggested.

42 ENGINEERING↗

DOE OSTI2025

Design Overview of a High-Pressure Helium Flow Visualization Apparatus for Blanket Cooling Studies

Cooling of the fusion blanket first wall remains a significant challenge given the adverse conditions of heat and particle flux encountered near the plasma. Helium emerges as an attractive cooling candidate because of its chemical and neutronic inertness and separability from hydrogenic species (e.g. tritium). Because of the low thermal mass of helium, optimization of these coolant channels is warranted to provide high heat transfer performance at low pumping costs. Increasingly, computational fluid dynamics (CFD) simulations are employed to model and optimize these flow channels, and accompanying experimental data are needed to validate the predictions of these models. To provide the aforementioned experimental data, a high-pressure helium flow visualization upgrade has been designed for the Helium Flow Loop Experiment facility. This apparatus was built to American Society of Mechanical Engineers boiler and pressure vessel standards to withstand operating pressure of 4 MPa and mated to high-pressure glass windows. Seedless flow visualization is performed via high-speed background oriented schlieren (BOS), with image correlation used for time-resolved two-dimensional velocimetry at frequencies in excess of 60 kHz. Rectangular flow channel test articles are additively manufactured via laser powder bed fusion and installed into this visualization apparatus, with one-sided heating supplied by resistive heaters. In conclusion, the chosen test geometries were informed by prior CFD simulations, and the helium flow structures observed via BOS (detachment, recirculation, etc.) will be used for the validation of these accompanying models, in support of the design and optimization of blanket cooling channel configurations.

Helium flow↗

DOE OSTI2025

Report on the Integration of Experimental and Modeling Data for Initial Equivalence Study of Mechanical Performance in Irradiated LPBF 316 Stainless Steel

To ensure the rapid development, deployment, and use of advanced nuclear technologies, faster qualification approaches are needed. Typically, the primary pathway uses traditional data packages consistent with the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, which does not consider the environmental effects the material will experience such as corrosion and radiation damage. Examining radiation effects requires a significant amount of space in US facilities at the Advanced Test Reactor and the High Flux Isotope Reactor (HFIR) and suffers from natural gradients in temperature and neutron flux profiles. Ion irradiation may enable rapid assessment of radiation-induced damage to a material and is proposed as part of an accelerated materials qualification framework through the Advanced Materials and Manufacturing Technologies program. To enhance the utility of ion irradiation as an examination tool, this report provides the initial assessment of engineering-relevant properties of microstructures produced from ion irradiation in the near-surface volume. Nanoindentation, Vickers hardness, and known tensile properties were brought together with simple mathematical models and experimental data for an initial equivalence study of the mechanical performance of irradiated laser powder bed fusion (LPBF) 316 stainless steels across length scales. Direct observation of the calculated ion irradiation yield stress and measured neutron irradiation yield stress at 2 dpa showed that both datasets exhibit the same trend with irradiation temperature and overlap within an acceptable band of stress values. Ion irradiations at 10 dpa serve as a prediction of properties to compare to postirradiation examination of HFIR-irradiated LPBF 316H further in the program. This work is a significant demonstration of the Licensing Approach with Ions and Neutrons, which uses ion irradiations to generate mechanical property information more rapidly than through neutron irradiations.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Reducing Southern Ocean Shortwave Radiation Errors in the ERA5 Reanalysis with Machine Learning and 25 Years of Surface Observations

Earth system models struggle to simulate clouds and their radiative effects over the Southern Ocean, partly due to a lack of measurements and targeted cloud microphysics knowledge. We have evaluated biases of downwelling shortwave radiation in the ERA5 climate reanalysis using 25 years (1995–2019) of summertime surface measurements, collected on the Research and Supply Vessel (RSV) Aurora Australis, the Research Vessel (R/V) Investigator, and at Macquarie Island. During October–March daylight hours, the ERA5 simulation of SW down exhibited large errors (mean bias = 54 W m -2 , mean absolute error = 82 W m -2 , root-mean-square error = 132 W m -2 , and R 2 = 0.71). To determine whether we could improve these statistics, we bypassed ERA5’s radiative transfer model for SW down with machine learning–based models using a number of ERA5’s gridscale meteorological variables as predictors. These models were trained and tested with the surface measurements of SW down using a 10-fold shuffle split. An extreme gradient boosting (XGBoost) and a random forest–based model setup had the best performance relative to ERA5, both with a near complete reduction of the mean bias error, a decrease in the mean absolute error and root-mean-square error by 25% ± 3%, and an increase in the R 2 value of 5% ± 1% over the 10 splits. Large improvements occurred at higher latitudes and cyclone cold sectors, where ERA5 performed most poorly. We further interpret our methods using Shapley additive explanations. Our results indicate that data-driven techniques could have an important role in simulating surface radiation fluxes and in improving reanalysis products.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Fiberboard Properties and Degradation Rates for Storage of 9975 Shipping Package in KAC (2020 Status Report)

Savannah River Site (SRS) stores plutonium materials within model 9975 shipping packages in the K-Area Complex (KAC). The 9975 shipping package consists of a 35 gallon stainless steel drum, Celotex fiberboard insulation, lead shield, and primary and secondary containment vessels. The 9975 shipping package design, performance, and analysis for safe transport of radioactive material are described in the Safety Analysis Report for Packaging (SARP). Celotex fiberboard provides three safety functions: thermal insulation to limit internal temperature during a fire, criticality control, and resistance to package crushing. The fiberboard material must retain its dimensions and density within certain ranges to provide the required impact resistance, criticality control, and fire resistance. The SRS Surveillance Program monitors material performance to establish a basis for service life and ensures the continued integrity of 9975 packages. Fiberboard samples, taken from multiple fiberboard assemblies fabricated from cane and softwood fiberboard, have been conditioning in elevated temperature environments since 2005. The samples are periodically examined to monitor thermal, mechanical, and physical properties, and assess degradation trends. Fiberboard properties of interest that are evaluated to demonstrate acceptable long-term performance include dimensional stability, density, compressive strength, thermal conductivity, and specific heat capacity. Duplicate samples from multiple package sources have been tested to identify the range of variability in fiberboard properties and degradation rates. Baseline and long-term testing of fiberboard material properties have been reported previously; reference 6 summarized experimental results of cane and softwood fiberboard through May 2019 and presented degradation models for the measured properties. This report presents the cumulative data collected through June 2020 and the corresponding updated aging models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Ring Model Development and Validation for Prismatic HTGR Core Thermal-hydraulics and Safety Analysis

Because of the complex core geometry, prismatic high temperature gas-cooled reactors (prismatic HTGRs) often exhibit complex thermal fluid behaviors during both normal operating and transient conditions. Most HTGR designs rely on passive safety system for decay heat removal, such as the reactor cavity cooling system (RCCS). During postulated accidents like Pressurized Conduction Cooldown (PCC) event, the decay heat is first radially transferred from the core region to the reactor vessel outer surface, then to the RCCS cooling panels. The peak fuel temperature is controlled by heat transfer mechanisms with two distinctive characteristic length scales, i.e., the core-wise effective heat conduction and local heat conduction in the fuel pellet scale. As both length scales are essential to determine the fuel temperature, from the modeling perspective, computer codes must be able to capture heat transfer in both scales. This is challenging for both computational fluid dynamics (CFD) tools because of extremely large amount of computation resources required, and for system analysis codes because of the challenge to model the complex core geometry. Under the support of DOE-NE’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, efforts have been pursued to support HTGR technology development and its modeling and simulation needs. There is a particular need for advanced modeling and simulation tools to predict thermal-fluid behavior during safety-related transients. In our previous studies, the ring model was adopted in SAM and further developed to simulate the normal operating condition and a PCC event using the MHTGR-350 design of General Atomics as the reference design. This current work represents a continuation of these previous efforts, and the focus is to critically review and examine simplifications and assumptions made to develop the ring model, and to perform code validation using experimental data from an integral-effect test facility, the High Temperature Test Facility (HTTF) at the Oregon State University. In this study, the test PG-27 from the HTTF test suite was selected for code validation purpose. The test PG-27 is a transient test designed to simulate the PCC event of the MHTGR design. Very good agreements between SAM prediction and experimental measurements were found in both coolant and solid structure temperatures during the transient.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Plasma confinement state classification via FPP relevant microwave diagnostics

We present a parsimonious and robust machine learning approach for identifying plasma confinement states in fusion power plants (FPPs) where reliable identification of the low-confinement and high-confinement regimes is critical for safe and efficient operation. Unlike research-oriented devices, FPPs must operate with a severely constrained set of diagnostics. To address this challenge, we demonstrate that a minimalist model, using only electron cyclotron emission (ECE) signals, can achieve accurate and reliable state classification. ECE provides electron temperature profiles without the engineering or survivability issues of in-vessel probes, making it a primary candidate for FPP-relevant diagnostics. Our framework employs ECE as input, extracts features using radial basis functions, and applies a gradient boosting classifier, achieving a test accuracy of 96% (correct predictions). Robustness analysis and feature importance analyzes confirm the approach’s reliability. These results demonstrate that state-of-the-art performance is attainable from a restricted diagnostic set, paving the way for minimalist yet resilient plasma control architectures for FPPs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗