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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Modeling the Functional Forms of Grid Disturbances

This report introduces a functional form that may be used to quantitatively predict the impacts of new grid tools and changing system qualities on the likelihoods, durations, and depths of various grid disturbances. Each disturbance scenario is modeled to have three component stages—avoidance, reactance and recovery, which together parametrically estimate one disturbance’s impacts. The modeled scenario is then placed and replicated within an analysis period to represent the likelihood or frequency of the scenario and its consequent impacts. Whereas analysts have struggled to define and apply metrics for grid resilience, the functional form introduced by this report shares units of measurement with accepted grid-status measures (e.g., numbers of customers currently experiencing a service outage). Furthermore, the integrated and averaged functional form over an analysis period provides a meaningful normalized performance metric (e.g., customer outage minutes per year) that is ultimately independent of the duration of the period of. The approach may be applied similarly regardless of the severity or frequency of the disturbances that are being analyzed. Because metrics can be chosen to be identical in both the hypothetical future and the actual historical past, the historical past eventually becomes the test of the future predictions, at least in a statistical sense. The authors originally developed this approach to facilitate analysis of the effects of transactive energy (TE) systems effects on electric power grid resilience. TE systems invite energy suppliers and consumers to actively collaborate toward the discovery of, and their responses to, the locational value of energy. The findings from this process are often embodied as energy prices, the dynamics of which indicate the locational value of energy and can further represent important grid service needs. While some academic papers claim to quantify the value of a specific TE system design toward grid resilience, the answer, in general, has been elusive. Not only do multiple and conflicting definitions of resilience and reliability exist, but countless TE systems are being invented. We conclude the following: (1) The ideal analysis should harmonize rather than differentiate resilience and reliability. Therefore, this report uses the more general term disturbance whenever the overloaded terms resilience and reliability can be avoided. (2) The effectiveness of TE systems must be mapped to underlying qualities of a TE system, thereby avoiding presumptions that every TE design offers similar advantages. The authors seek to evaluate the parametric effects of TE system qualities (e.g., spatial granularity, granularity of time steps, length of future prediction horizon) on avoiding, reacting to, and recovering from grid disturbances. Furthermore, any advantages (or disadvantages) must be fairly compared with the many alternative tools, systems, and strategies that might offer comparable benefits.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Interactions between U.S. biofuels policy and the Endangered Species Act

The Renewable Fuel Standard (RFS) is the primary policy governing the use of biofuels in the United States. Following the 2007 enactment of the RFS, there has been substantial expansion in the use of cropland to produce biofuel feedstocks, including corn and soybeans. Both the conversion of land and the ongoing cultivation of these crops can, depending on management practices, lead to negative environmental outcomes including degraded water quality, increased water use, increased greenhouse gas emissions, and loss or degradation of wildlife habitat. These outcomes have the potential to affect threatened and endangered species protected under the U.S. Endangered Species Act (ESA). The ESA requires federal agencies to consult with the U.S. Fish and Wildlife Service or the National Marine Fisheries Service to ensure that an agency's actions are not likely to jeopardize the existence of imperiled species, nor result in the destruction or adverse modification of their habitat. However, formal consultation has not yet been completed between the U.S. Environmental Protection Agency—the agency charged with implementing the RFS—and the wildlife services, thereby hindering mitigation or remediation of potential impacts. This analysis explores the likely effects of the RFS on land use changes and critical habitat, illustrates example pathways by which threatened and endangered species may be affected, and proposes solutions to help redress this harm. The findings suggest a need for further consultation and assessment of the interactions between the RFS and ESA as well as additional research to support the species-conservation and policymaking processes.

09 BIOMASS FUELS↗
DOE OSTI2020

Results for Gamma-Ray Spectroscopy Characterization of Residual Radioactivity on Personal Protective Clothing

In early 2019, Health Physics Services (HPS) personnel put together a test plan to use the shielded gamma-ray spectroscopy instruments in the Health Physics Services Technical Laboratory (HPSTL) to perform a series of measurements on laundered personal protective clothing used in radiological areas at the Savannah River Site (SRS). That test plan describes the methodology used to determine the quantities of laundry to be obtained from operational facilities, the methods for quality control checking the instruments throughout the measurement period, and the physical arrangement of samples in the counting shields. The test plan is documented in SRNS-J6700-2019-00037 (Reference 1).

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2025

High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling

Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.

36 MATERIALS SCIENCE↗
DOE OSTI2021

FAST-1.0.1 User Installation and Verification Guide

The purpose of this document is to provide the user information about the installation of FAST-1.0.1 on their computers or servers. General information about the code and supported operating systems is described in Section 1.0.1. Self-service oriented FAST-1.0.1 software licensing steps are described in Section 2.0. An installation verification test suite is provided with FAST-1.0.1 and described in Section 3.0. A convenience script for converting FRAPCON to FAST inputs is discussed in Section 4.0. FAST-1.0.1 was developed and released under a software quality assurance program based upon NQA-1-2017. FAST-1.0.1 is the latest baseline code and the result of a bug fixes to FAST-1.0 with other software and methodology developments. The installation verification test suite contains both steady state and transient Anticipated Operation Occurrences (AOOs). Capability to model accident conditions, such as Reactivity Initiated Accidents (RIAs) and Loss Of Coolant Accidents (LOCAs), are targeted for a later release of FAST. FRAPTRAN-2.0 will continue to be used for accident conditions until the release of FAST with accident condition modeling capabilities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

A multi-objective optimization model for cropland design considering profit, biodiversity, and ecosystem services

More sustainable agricultural methods are needed to alleviate the decreases in biodiversity and ecosystem services that have occurred because of industrial agriculture. One such method is the inclusion of alternative crops into croplands that can support biodiversity, reduce erosion and chemical runoff, and sequester carbon in the soil. However, the question of where such crops should be planted to balance competing economic and environmental objectives remains open. To this end, we develop a mixed-integer quadratically constrained program to optimize the layout of a cropland considering economic, biodiversity, greenhouse gas emissions, and water quality objectives. We include spatially varying fertilization as a decision variable in addition to crop establishment location. We further include the effect of core area and edges between different crops on biodiversity. To demonstrate the applicability of the model, we apply it to an example field, showing how the optimal cropland design changes as a decision-maker prioritizes different objectives and as edges have different impacts on biodiversity.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Association Between Dispatch Complaint and Critical Prehospital Time Intervals in Suspected Stroke 911 Activations in the National Emergency Medical Services Information System, 2012–2016

Emergency Medical Services can help improve stroke outcomes by recognizing stroke symptoms, establishing response priority for 911 calls, and minimizing prehospital delays. This study examines 911 stroke events and evaluates associations between events dispatched as stroke and critical EMS time intervals. Data from the National Emergency Medical Services Information System, 2012 to 2016, were analyzed. Activations from 911 calls with a primary or secondary provider impression of stroke were included for adult patients transported to a hospital destination. Three prehospital time intervals were evaluated: (1) response time (RT) ≤8 min, (2) on-scene time (OST) ≤15 min, and (3) transport time (TT) ≤12 min. Associations between stroke dispatch complaint and prehospital time intervals were assessed using multivariate regression to estimate adjusted risk ratios (ARR) and 95% confidence intervals (CIs). Approximately 37% of stroke dispatch complaints were identified by EMS as a suspected stroke. Compared to stroke events without a stroke dispatch complaint, median OST was shorter for events with a stroke dispatch (16 min vs. 14 min, respectively). In adjusted analyses, events dispatched as stroke were more likely to meet the EMS time benchmark for OST ≤15 min (OST, 1.20 [1.20–1.21]), but not RT or TT (RT, [1.00–1.01]; TT, 0.95 [0.94–0.95]). Furthermore, our results indicate that dispatcher recognition of stroke symptoms reduces the time spent on-scene by EMS personnel. These findings can inform future EMS stroke education and quality improvement efforts to emphasize dispatcher recognition of stroke signs and symptoms, as EMS dispatchers play a crucial role in optimizing the prehospital response.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Satellite remote sensing for environmental sustainable development goals: A review of applications for terrestrial and marine protected areas

With few years left to achieve the vital United Nations Sustainable Development Goals (SDGs), member nations must urgently leverage technological advancements in environmental monitoring to succeed. Remote sensing now provides decades of global observations at a variety of spatio-temporal scales and a litany of data products to guide comprehensive measures for climate action, and aquatic and terrestrial biota preservation. Protected areas, such as national parks and wildlife preserves, represent largely untapped resources for both applying robust conservation measures and testing ambitious new approaches to sustainable development that could jumpstart the much-needed adoption of strategies to efficiently pursue global sustainability. This review summarizes recent demonstrated utilities of remotely sensed data applied to protected areas for research related to SDG goals 13, 14, and 15: “Climate Action”, “Life below Water”, and “Life on Land”. We identify successful uses of such data for each SDG, identify areas for improvement, and provide recommendations from the literature on how to expand what others have done to achieve lofty goals with global impact. We demonstrate that remote sensing provides a valuable tool for achieving SDGs as it facilitates monitoring vegetation health, water quality and condition, and climate variables at large spatial and fine temporal scales, while also evaluating the effectiveness of management and conservation practices. Issues remain, however, in that there is currently no reference from which to relate goal progress to human livelihoods. Further, the current relationship between remotely sensed indices and ecological services that determine sustainable development omit steps that would establish this connection.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Electric Mobility Opportunities for Brooklyn Park, Minnesota

This report will support Brooklyn Park as it navigates changes in mobility technologies and approaches to best serve the transportation needs of its communities. The content details the advantages of electric mobility, reviews electric mobility options that meet diverse needs and constraints, and maps the benefits and limitations of these options in terms of available technologies, their uses, and incentives that aim to improve accessibility and affordability. Although personal EVs provide both individual and collective advantages to residents - from lowering the total cost of ownership over the lifetime of a vehicle to improving air quality in the surrounding environment by reducing tailpipe emissions - they may still be unaffordable and/or inaccessible to some households in Brooklyn Park. Therefore, this report provides an overview of other accessible and affordable electric mobility options, including electric carshares, e-micromobility (i.e., e-scooters, e-bikes), and on-demand services, as enabled by web-connected technologies and the proliferation of smartphones.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Analysis and design of DC-link capacitor in cascaded H-bridge multilevel active front-end converter

Medium-voltage grid-tied systems often use a cascaded H-bridge multi-level active front-end. In this converter, dc link bus capacitors play an important role in stabilizing the converter and enabling both active and reactive power injections. The present work provides analytical expressions for the capacitor current, which are essential for optimizing system design (especially capacitor size vs. lifetime). Then, the expression is incorporated into the grid connected bidirectional power system model. Consequently, this work contributes to the guiding principles to choose accurate dc link capacitor ratings against grid-side power delivery requirements. DC-link capacitors come with an expiration date which is dependent on the operating power and voltage values. Lack of information about the lifetime of the dc-link capacitor creates uncertainty in the duration of online operation of the converter, thus increasing the probability of a contingency outage. The lifetime of the capacitor can range from only a few seconds of online operation of the station due to under-sizing, to a compromised quality of power flowing through other solid state devices which may not have been designed for the transients that are caused by over-sizing of the dc-link capacitor. A better estimate of the lifetime of these capacitors can help maximize usage and maintain scheduled outages more efficiently, without disruption in service.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Impacts of Experimentally Obtained Harmonic Spectrums of Residential Appliances on Distribution Feeder

Owing to the increased use of power electronic based appliances and energy-efficient home equipment such as modern lighting loads, the percentage of nonlinear loads has increased in the distribution system, which can impact system performance, loss, and stability. Thus a comprehensive knowledge of their power quality and harmonic analysis is essential to improve the load models, voltage stability assessment, determination of possible interactions at harmonic frequencies, protection planning, and the effect of system impedance. This paper focuses on harmonic load flow analysis for multiple residential load types to determine the expected impacts on an modeled distribution secondary. For this study, the household appliances include lighting, power electronic, resistive, and motor loads with a nominal supply voltage of 120 V single-phase or 240 V split phase at a nominal frequency of 60 Hz. The harmonic spectrums, as obtained from the experimental evaluation of real loads, are used to inform the harmonic load flow for a detailed secondary network, including the distribution service transformer extracted from a real distribution feeder's model. Additionally, the impact of voltage harmonics on a three-phase test load is presented with experimental results. The harmonic data of the transformer terminal voltage, as obtained from the former load flow study, are scaled to generate the source voltage for the three-phase configuration of the grid simulator to make the test setup very similar to a typical secondary design in the U.S.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
DOE OSTI2021

Argonne Leadership Computing Facility: 2021 Operational Assessment Report

This Operational Assessment Report describes how the Argonne Leadership Computing Facility (ALCF) met or exceeded every one of its goals for calendar year (CY) 2021 as an advanced scientific computing center. In CY 2021, the ALCF operated its production resource, Theta, an Intel-based Cray XC40 system (11.7-petaflops) augmented with 24 NVIDIA DGX A100-based nodes (3.9-petaflops) that supports diverse workloads, integrating data analytics with artificial intelligence (AI) training and learning in a single platform. In 2021, we began deploying Polaris, our newest 40- petaflops system, and augmented this powerful testbed system with an additional 28 nodes to support the integration of real-time experiments and HPC resources. We also deployed our two largest storage systems yet, named Grand and Eagle, that will bring new services to our users and will power data-driven research for years to come. Last year, Theta delivered a total of 20.8 million node-hours to 16 Innovative and Novel Computational Impact on Theory and Experiment (INCITE) projects and 7.2 million node-hours to ASCR Leadership Computing Challenge (ALCC) projects (32 awarded during the 2020–2021 ALCC year and 17 awarded during the 2021–2022 ALCC year), as well as substantial support to Director’s Discretionary (DD) projects (5.5 million node-hours). As Table ES.1 shows, Theta performed exceptionally well in terms of overall availability (95.1 percent), scheduled availability (99.4 percent), and utilization (98.1 percent; Table 2.1). As of the submission date of this document, ALCF’s user community has published 249 papers in high-quality, peer-reviewed journals and technical proceedings. At the 2021 International Conference for High Performance Computing, Networking, Storage and Analysis (SC’21), Argonne researchers won two HPCwire Readers’ Choice Awards and were part of a Gordon Bell Prize finalist team recognized for developing an AI-enabled, multi-resolution simulation framework for studying complex biomolecular machines. Their framework was used to observe the SARS-CoV-2 replication-transcription machinery in action, by directly integrating experimental data. ALCF also provided a comprehensive program of high-performance computing (HPC) support services to help our community make productive use of the facility’s diverse and growing collection of resources. We are now entering the exascale era, with exascale machines being planned for national laboratories across the country, including Aurora at Argonne National Laboratory (Argonne) in 2023. ALCF researchers have been leading and guiding numerous strategic activities that will push the boundaries of what’s possible in computational science and engineering and allow us to deliver science on day one.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

An overview of data tools for representing and managing building information and performance data

Building information modeling (BIM) has been widely adopted for representing and exchanging building data across disciplines during building design and construction. However, BIM's use in the building operation phase is limited. With the increasing deployment of low-cost sensors and meters, as well as affordable digital storage and computing technologies, growing volumes of data have been collected from buildings, their energy services systems, and occupants. Such data are crucial to help decision makers understand what, how, and when energy is consumed in buildings—a critical step to improving building performance for energy efficiency, demand flexibility, and resilience. However, practical analyses and use of the collected data are very limited due to various reasons, including poor data quality, ad-hoc representation of data, and lack of data science skills. To unlock value from building data, there is a strong need for a toolchain to curate and represent building information and performance data in common standardized terminologies and schemas, to enable interoperability between tools and applications. This study selected and reviewed 24 data tools based on common use cases of data across the building life cycle, from design to construction, commissioning, operation, and retrofits. The selected data tools are grouped into three categories: (1) data dictionary or terminology, (2) data ontology and schemas, and (3) data platforms. The data are grouped into ten typologies covering most types of data collected in buildings. This study resulted in five main findings: (1) most data representation tools can represent their intended data typologies well, such as Green Button for smart meter data and Brick schema for metadata of sensors in buildings and HVAC systems, but none of the tools cover all ten types of data; (2) there is a need for data schemas to represent the basis of design data and metadata of occupant data; (3) standard terminologies such as those defined in BEDES are only adopted in a few data tools; (4) integrating data across various stages in the building life cycle remains a challenge; and (5) most data tools were developed and maintained by different parties for different purposes, their flexibility and interoperability can be improved to support broader use cases. Finally, recommendations for future research on building data tools are provided for the data and buildings community based on the FAIR principles to make data Findable, Accessible, Interoperable, and Reusable.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

FAST-1.2 User Installation and Verification Guide: Developed Under NQA-1-2017

The purpose of this document is to provide the user information about the installation of Fuel Analysis for Steady state and Transient (FAST)-1.2 on their computers or servers. General information about the code and supported operating systems is described in Section 1.0. Self-service oriented FAST-1.2 software licensing steps are described in Section 2.0. An installation verification test suite is provided with FAST-1.2 and described in Section 3.0. A convenience script for converting Fuel Rod Analysis Program – Constant (FRAPCON) to FAST inputs is discussed in Section 4.0. FAST-1.2 was developed and released under a software quality assurance program based upon NQA-1-2017 at Pacific Northwest National Laboratory (PNNL). FAST-1.2 is the latest baseline code. The installation verification test suite contains both steady state and transient Anticipated Operation Occurrences (AOOs), accident conditions, such as Reactivity Initiated Accidents (RIAs) and Loss of Coolant Accidents (LOCAs).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Reducing Deferrals by Integrating Health Homes with Weatherization

The U.S. Department of Energy’s Weatherization Assistance Program (WAP) improves energy efficiency and household health for low-income families, yet a substantial number of otherwise eligible homes are deferred from due to health and safety concerns in their homes, including mold, moisture damage, or structural deficiencies. These deferred homes are often occupied by marginalized or otherwise vulnerable residents who may be exposed to elevated indoor air pollutant concentration. Integrating Healthy Homes (HH) interventions with weatherization has been proposed as a strategy to reduce deferrals, address environmental justice concerns, and improve health outcomes. However, limited data on the health and economic implications of such integration exist. This study aimed to assess the potential health benefits and savings-to-investment ratio (SIR) associated with integrating Healthy Homes interventions into weatherization programs for homes typically deferred from WAP services. We collected indoor air pollutant data from homes undergoing health home renovations, including fine particulate matter (PM 2.5 ), nitrogen dioxide (NO 2 ), carbon monoxide (CO), and formaldehyde, with sampling times up to one month. Except for fomaldehyde, which was measured using passive UMEx badges, the other metrics were measured using the airQ Pro indoor air quality monitor.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Automated Mobility Platforms: A Framework for Versatile, Energy-Efficient Urban Transportation for the 21st Century: Preprint

This paper presents automated mobility platforms (AMPs) as a framework to deliver high-quality urban mobility. AMPs leverage advances in sensing technology developed from automated roadway vehicles to provide opportunities for efficient movement of people and goods in dense urban environments, campuses, and large facilities like airports. In this paper, we layout the concept of AMPs and how they can serve the mobility needs of the population by providing service at the intersection of micromobility (services such as electric scooters or bikes), personal rapid transit, and moving walkways. Several key attributes and justification for the AMPs concept are described, including improvements to accessibility (inherent in design) covering both socioeconomic and disability equity, safety, energy efficiency, cost-effectiveness, urban land and space management, and scalability. We summarize the results from an ongoing national laboratory-sponsored, faculty-supported, student-led investigation into AMPs that includes stakeholder engagement and technical feasibility assessment.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Optimization of a Welding Procedure for Making Critical Aluminum Welds on the LBNF Absorber Core Block

The LBNF Absorber consists of thirteen 6061-T6 aluminum core blocks. The core blocks are water cooled with de-ionized (DI) water which becomes radioactive during beam operations. The cooling water flows through gun-drilled channels in the core blocks. A weld quality optimization was performed to produce National Aeronautical Standard 1514 Class I quality welds on the aluminum core blocks. This was not successful in all cases. An existing Gas Tungsten Arc Welding Procedure Specification was fine tuned to minimize, in most cases, and eliminate detect-able tungsten inclusions in the welds. All the weld coupons, however passed welding inspection as per the piping code: ASME B31.3 Normal Fluid Service. Tungsten electrode diameter, type, and manufacturer were varied. Some of the samples were pre-heated and others were not. It was observed that larger diameter electrodes, 5/32 in., with pre-heated joints resulted in welds with the least number of tungsten inclusions. It is hypothesized that thinner electrodes breakdown easily and get lodged into the weld pool during the welding process. This breakdown is further enhanced by the large temperature differential between the un-preheated sample and the hot electrode.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗