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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Reliable, High Power Density Inverters for Heavy Equipment Applications

With this final report, the combined team of the University of Arkansas (UA), University of Illinois, Urbana-Champaign (UIUC), Wolfspeed, Caterpillar, and Ampaire have successfully met all of their project objectives. Noteworthy for the heavy equipment portion of the project with Caterpillar is that the team made its project milestones two years into the project by designing a power dense motor drive for a permanent magnet synchronous machine. Upon finding out that Caterpillar had pivoted to switched-reluctance machines (SRMs), the team subsequently redesigned and implemented the SRM drive with a coolant temperature of 105°C! The other major task that the UA, UIUC, and Wolfspeed teams took on was the design of a PMSM drive for a hybrid aircraft that was flown on Feb. 20, 2023 by Ampaire after extensive testing and evaluation. While there were also technical objectives in thermal management, integrated gate drivers, reliability studies, and high temperature capacitors with integrated bussing, each of these have been fully reported on in quarterly reports. In brief, advances in thermal management and high temperature capacitors were utilized in order to achieve a 105°C motor drive. The integrated gate driver work resulted in a higher density drive with no loss of efficiency. Most of the last year, during a no-cost extension, was spent waiting for the Ampaire motor drive to be tested (outside of our project). Many months passed with the device just sitting in California while the company dealt with battery-related issues. This delayed the integration and testing activities until Fall 2022. Once those began, then the process took about 4-5 months to complete culminating in the test flight in Feb. 2023. By providing technical advances and integration into final platforms, the barrier to economic impact has been lowered. This project benefits the public by overcoming key technical barriers to electrified and hybrid electric heavy equipment and aircraft. This, in turn, leads to lower greenhouse gas emissions and a cleaner environment. This final report summarizes the integrated gate driver work and the Ampaire hybrid electric aircraft integration and test flight efforts. All other information has been previously reported in quarterly reports. A summary of the motor drives created during this project is provided along with a listing of publications.

42 ENGINEERING↗
DOE OSTI2024

Catalytic Upgrading of Renewable Feedstock (Final Technical Report)

The goal of this DOE-funded project was to investigate the fundamental science related to the development of homogeneous (de)hydrogenation catalysts in order to enable energy-relevant transformations of bio-relevant chemical feedstocks including ethanol. The primary focus was to improve the activity of ethanol upgrading catalysts, specifically informed through mechanistic studies, in order to enable rational design optimization strategies. Following in depth mechanistic studies, targeted reaction optimization approaches included ligand redesign to improve catalyst stability, developing new carbon-carbon bond forming reactions using ethanol as a precursor, and examining photochemically-mediated reactions, ultimately to integrate within other reactor designs such as continuous flow reactors. The high modularity of the catalyst components (ligands) has enabled the preparation and analyses of multiple catalyst precursors. These studies uncovered an unexpectedly beneficial substitution pattern of the ligand structure that led to the development of new catalysts that are the best in class for upgrading ethanol to butanol with a turnover number of 155,890 and a turnover frequency of 12,690 h –1 . In addition to upgrading ethanol to butanol, cascade reaction sequences were developed to form new C-C bonds using ethanol as a bio-relevant feedstock, providing access to platform chemicals from renewable sources. As part of the reaction discovery process, new mechanistic details were uncovered that provided insights into: a) catalyst speciation, b) decomposition pathways, c) carbon monoxide releasing pathways, and d) carbon-carbon and carbon hydrogen bond breaking pathways. Most of these outcomes were previously not known; however, they provide important directions for new catalyst design strategies. Finally, use of high throughput and in situ photochemical reaction analyses enabled detailed studies into changes to the catalyst structure upon irradiation. Irradiation was found to improve hydrogen transfer catalysis, by promoting a ligand dissociation event.

09 BIOMASS FUELS↗
DOE OSTI2024

Multiphysics Design Optimization and Additive Manufacturing of Nuclear Components (Final CRADA Report - Executive Summary)

Westinghouse Electric Company (WEC) actively participated in the advancement of the nuclear fuel and reactor design space and requested the help of Oak Ridge National Laboratory (ORNL) in the creation of a new design tool set. This report details the creation of a collection of software tool sets that are linked together to collectively assist WEC design engineers in developing novel ideas outside the normal scope of traditional nuclear fuel and reactor design formulas. Specifically, Siemens HEEDS, a design space exploration and parametric optimization software, monitored and changed parameters in a collection of softwares to meet the team’s objective. The HEEDS parametric optimization method, SHERPA, was developed to control the Siemens NX CAD platform to adjust the native CAD of a hexahedral spacer grid. This new geometry can be used to execute a topological design optimization by the NX Topology software add-in. The resulting geometry is additively manufacturable. This topological optimization occurred twice—once on the spacer grid’s spring, and once on the dimple geometry. These new geometries were imported by Siemens’ STAR-CCM+, a multiphysics structural and fluid dynamic computational solver in which the spring geometry is deflected to match the rod insertion configuration. Along with the dimple geometry, this new deflected spring was used to complete a hydraulic assessment of a single-unit cell comprising one rod, one spring, and two dimples. The HEEDS SHERPA algorithm ranks the design based on the final mass of the unit cell and the hydraulic pressure drop performance. The ORNL team demonstrated the ability to use this software and provided engineering judgement to apply modern aerospace aerodynamic design. The effort has been focused on thinking outside the conventional design space and redesigning a spacer grid to perform beyond the WEC set objectives. Furthermore, the ORNL team also demonstrated that the HEEDS optimization routine can independently develop a design that meets the WEC design goals. Although these designs were at a low technology readiness level, their demonstration confirmed the team’s capability to create novel advanced nuclear concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Developing socially and economically generative, resilient PV-energy systems for low- and moderate-income communities: Applications for Puerto Rico (Final Technical Report)

The nexus of energy and poverty is one of the most significant long-term challenges facing the energy and electricity sectors, with negative feedback loops between energy-related costs, risks, and insecurities, on the one hand, and diverse other social and economic insecurities, on the other, helping to undermine health, wellbeing, and resilience in low- and moderate-income communities around the US and the world (Biswas et al. 2022). The transition of energy systems to clean energy alternatives offers a potential opportunity to redesign future energy arrangements in ways that, instead, create beneficial social value for communities, reverses the energy-poverty nexus, and enhances community wellbeing (Biswas et al. 2020; Miller et al. 2018). The promise of clean energy transitions to address the energy-poverty nexus is especially significant when designed using principles of just energy transitions. To leverage just clean energy transitions to accomplish a reversal of the energy-poverty nexus requires improvement in three capabilities: (1) Understanding and mapping the community-scale dynamics and variability of the energy-poverty nexus, which vary considerably from community to community; (2) Evaluating the technical, social, and economic potential for different clean energy system designs to deliver social value to specific communities; and (3) Working collaboratively with communities to imagine and design clean energy systems solutions that meet their needs, fit their capabilities and contexts, and deliver multiple forms of community-desired social value/benefits that help reverse key facets of the energy-poverty nexus. This project developed a portfolio of novel tools, methodological approaches, and collaborative partnerships with four communities in Puerto Rico that further the objective of building these three capabilities.

14 SOLAR ENERGY↗
DOE OSTI2024

Integrated Biomass Supply Analysis and Logistics Model (IBSAL) 2.0

The Integrated Biomass Supply Analysis and Logistics (IBSAL) 2.0 models a feedstock supply shed's harvest and transport process to estimate the cost of delivered feedstock. The model sets up a supply shed of fields, harvests the fields using a series of sequential harvest operations with different crew types, and transports the harvested feedstock to a storage facility or refinery. The model reports many metrics; the most important ones include the crew resources required for harvest and transport operations, equipment utilization, fuel usage, amount of dry mass harvested, the cost for each operation, and the expected time to complete the harvest with the provided resources. IBSAL 2.0 is a complete redesign around the ExtendSim database, and it is faster and easier to reapply the model to different feedstocks.

09 BIOMASS FUELS↗
DOE OSTI2024

Environmental Validation of Materials and Design Concepts to Enable Operational Flexibility of Existing Coal Power Plants

Increasingly, coal-fired power plants are required to balance power grids by compensating for the variable electricity supply from renewable energy sources. Fossil-fueled power plants, originally designed to be base loaded, will increasingly need to operate on a load following or cyclic basis. This demanding requirement for operational flexibility will need to be evaluated for resilience to frequent start-ups, meeting major and rapid load changes, and providing frequency control duties. Our research objective was to evaluate and improve flexibility of existing power plants by improving and redesigning components and defining new operational strategies, with acceptable impacts on component life, efficiency and emissions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Integrated Energy Systems

Leveraging the synergies among different energy technologies, Integrated Energy Systems (IES) can achieve greater efficiency, higher flexibility, and better CO2 removal concurrently. However, system integration in reality faces various challenges and difficulties. To integrate with other components, off-the-shelf equipment needs case-by-case modifications and redesigns. This presentation will use two integrated systems as examples to reveal the challenges in system integration.

Zhou, Nana↗
DOE OSTI2024

Fermilab s Transition to Token Authentication

Fermilab is the first High Energy Physics institution to transition from X.509 user certificates to authentication tokens in production systems. All of the experiments that Fermilab hosts are now using JSON Web Token (JWT) access tokens in their grid jobs. Many software components have been either updated or created for this transition, and most of the software is available to others as open source. The tokens are defined using the WLCG Common JWT Profile. Token attributes for all the tokens are stored in the Fermilab FERRY system which generates the configuration for the CILogon token issuer. High security-value refresh tokens are stored in Hashicorp Vault configured by htvault-config, and JWT access tokens are requested by the htgettoken client through its integration with HTCondor. The Fermilab job submission system jobsub was redesigned to be a lightweight wrapper around HTCondor. For automated job submissions a managed tokens service was created to reduce duplication of effort and knowledge of how to securely keep tokens active. The existing Fermilab file transfer tool ifdh was updated to work seamlessly with tokens, as well as the Fermilab POMS (Production Operations Management System) which is used to manage automatic job submission and the RCDS (Rapid Code Distribution System) which is used to distribute analysis code via the CernVM FileSystem. The dCache storage system was reconfigured to accept tokens for authentication in place of X.509 proxy certificates. As some services and sites have not yet implemented token support, proxy certificates are still sent with jobs for backwards compatibility but some experiments are beginning to transition to stop using them. There have been some glitches and learning curve issues but in general the system has been performing well and is being improved as operational problems are addressed.

Dykstra, David↗
DOE OSTI2024

Mechanical Engineering Safety Note 1012910313-AA: CEA LTIC Structural Integrity

The LRU Target Insert Cryostat (LTIC) is the end effector of the NIF Cryogenic Target Positioner (CryoTarpos), which houses a cooling system to support cryogenic target experiments at NIF. The LTIC maintains a target at micron level positional stability and millikelvin level temperature stability during a NIF shot and is also subject to a portion of the blast load governed by the solid angle subtended by the blast shield at the front of the system. This MESN evaluates loading of the CEA LTIC, a redesigned LTIC to be fielded at Laser Megajoule (LMJ) in France, which has been designed to lay out requirements agreed upon between LLNL and CEA personnel. The LMJ version of CryoTarpos is referred to as the PCC. A high-level system overview of the LTIC on the PCC is shown.

42 ENGINEERING↗
DOE OSTI2024

Sierra/SD – Verification Test Manual – 5.22

Verification and validation (V&V) of scientific computing programs are important at Sandia National Labs due to the expanding role of computational simulation in managing the United States nuclear stockpile. The complexities of structural response calculations used to analyze physical problems, the varieties of codes applied to the calculations, and the importance of accurate predictions when assessing field conditions demand confidence in the consistency and accuracy of computer codes. Confidence in the accuracy of the predictions arising from computer simulations must ultimately be gained through verification and validation. The Sierra salinas structural dynamics analysis code, Sierra/SD, is used at the DOE Laboratories, and in several DOD projects. The roles of Sierra/SD in the qualification of weapon systems and components for normal and hostile environments throughout the Stockpile-to-Target Sequence include to, • Redesign weapon components. • Certify weapon components and systems for target environments such as hypersonic vehicles. • Certify that components will survive the thermal mechanical shock loads associated with hostile environments. • Evaluate current stockpile issues, including issues associated with uncertainty quantification. • Address many other problems that are encountered in stockpile management. The Sierra/SD verification plan is described, and an evolving set of key verification tests are described in detail. The verification tests ensure the correctness of the mathematics and numerical algorithms associated with functionality describing engineering phenomena. Development is in accordance with a set of tailored Software Quality Engineering (SQE) practices. SQE practices guide the overall verification and validation effort.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Wholly Sustainable, Cost-Effective Carbon Fiber-Nylon Compounds CRADA 592 (Final Report)

Carbon fiber composites have attracted considerable attention due to the potential for substantial mass savings, with many examples now implemented in the low-volume luxury car market. However, migration to higher volume applications has been hindered by: (a) high material cost, (b) high processing times, and (c) perception of low Sustainability. This project will address all three of these barriers: (a) carbon fiber material to replace aluminum in structural components at a cost penalty of no more than $5/Kg-saved (aka weight buy), (b) fitting into high-rate processes for automotive production like injection molding, and (c) end-to-end Sustainable material – based on post industrial waste carbon fiber and nylon 66 and ability to recycle end-of-life auto parts. The opportunity lies in combining DowAksa capabilities in carbon fiber manufacturing, resin chemistry intermediate production with the unique testing capabilities inherent within PNNL. The teams from PNNL and DowAksa held several meetings virtually and in-person in Michigan and at PNNL, including a lab tour at PNNL. Throughout, the teams discussed DowAksa material sources, commercially available recycled base materials, and preliminary material properties. The teams also engaged in multiple discussions and evaluations of potential automotive applications based on the ideas suggested by PNNL. The teams discussed several potential automotive applications in which recycled carbon fiber and recycled PA resin can be used. The PNNL team identified 38 cast aluminum components that can potentially be assessed for redesign using the DowAksa materials system. The PNNL team also identified 27 polyamide components. The teams discussed the lists and narrowed it down to a handful of applications that are exterior and interior to common vehicle architectures. The team also considered semi-structural and structural components and short-listed the highest potential candidates, such as cross-car-beam. The cross-car beam was considered to be highly suitable and potentially viable demonstration applications based on the properties of the materials as well as the weight savings potentials and the reduction in embodied energy by utilizing wholly sustainable materials, since both materials, carbon fiber and resin, were derived from recycled materials. The next step was to reach out to potential OEMs and/or Tier1s who were interested in exploring such technology for future applications. However, the project was terminated, and no further discussions or exchange of information took place. No new data were generated, including no IP and no publications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Cell-free bioelectrocatalytic platform for carbon dioxide reduction (Final Technical Report)

The University of Minnesota (UMN) EcoSynBio Team aimed to develop a cell-free, enzyme-based platform for the electro- biocatalytic conversion of CO2 into formate as a platform chemical for further upgrading. This type of bio electrocatalytic process delivers a clean product stream without the need for extensive separation from the electrolyte as in electrochemical synthesis and microbial processes. The reduction reaction is catalyzed by metal-dependent formate dehydrogenases (mFDHs) that are capable of efficient electrocatalytic CO2 reduction without the need of costly co-factors. The development of an efficient, scalable electrobiocatalytic process with high total turnover numbers and viable space time yields, however, was not without its challenges. The UM team has developed a protein-based scaffolding system that facilitates enzyme stabilization and attachment to electrodes along with electron transfer. Yet, although FDHs are highly promising enzymes for cell-free, electrobiochemical CO2 reduction, they are also greatly understudied and especially for applications in electrocatalysis. The UM team used the best described mFDH from Clostridium as its benchmark system and spent significant time and effort in attempting to replicate published data and finally, redesigned a recombinant production system for proper metal co-factor incorporation. The UM team has also identified a small set of new enzyme homologs from extreme microorganisms with superior stabilities that have yielded initial structural data for further engineering. In addition, a new bioelectrocatalytic reactor system has been developed that can be 3D printed and used for enzyme attachment to electrodes. In summary the project has generated critical basic information for the further development of this class of enzymes for the electricity driven reduction of CO2 into formate as platform chemical for upgrading into various other chemicals, including fuels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

PV Performance Modeling and Stakeholder Engagement (Final Technical Report)

This core capability project’s objective is to increase the value of photovoltaic (PV) performance models by improving their functionality, demonstrating, and quantifying their validity, and offering a wide range of stakeholder engagement opportunities. In FY22-24, we developed new and improved modeling algorithms and functions to represent PV performance more accurately in a variety of environments and conditions. The “Model parameter toolkit” was developed and includes functions to translate between different module temperature models, incidence angle modifier models, and single-diode models. A new modeling capability named “PV Atlas” was also developed leveraging Sandia’s High Performance Computing resources. This capability allows us to investigate several questions and provide climate-specific best practices and geographic data files; all these are hosted on an interactive website on Sandia’s GitHub and can be used for training, system optimization, or to provide best practices for uncertainty reduction. For model validation, we published high-quality PV performance, and weather data; these data are well documented, filtered, and processed for quality and include examples on how to run PV simulations. We also developed well documented, standardized methods for validating PV models and ran independent model validation and 2 blind modeling intercomparisons engaging with 49 organizations from 17 countries. We co-led and contributed to a growing, well documented and maintained suite of open-source functions for PV modeling (i.e., the pvlib-python) and we outreached to the PV modeling stakeholders via the PVPMC workshops and web resources. In addition, this project supported US representation and leadership for the International Energy Agency (IEA) PVPS Task 13; specifically, members of our team led and supported 3 subtasks on: 1) Best practices for the optimization of bifacial photovoltaic tracking, 2) Extreme weather events and their multiple impact on PV power plants: Risks, failure mechanisms and mitigation strategies, and 3) Best practice guidelines for the use of economic and technical Key Performance Indicators (KPIs). This project resulted in the publications of 14 peer reviewed journal papers, 37 conference presentations, 6 SAND reports, 5 public datasets and 6 new webpages on the PVPMC website. It supported the release of 13 pvlib-python versions where 28 enhancements were from this PV Performance Modeling project. We co-organized 5 PVPMC workshops in FY22-24 with the participation of 214 unique institutions and around 700 participants. The PVPMC website was redesigned, and its reliability was improved; it receives over 50,000 visitors/year from 202 unique countries.

14 SOLAR ENERGY↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE-20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ̊C.This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Spallation Neutron Source Proton Power Upgrade (PPU) Project: Lessons Learned for CD-4

The SNS PPU project goals were to design, build, install and test the equipment necessary to double the accelerator power from 1.4 MW to 2.8 MW and to deliver a 2.0 MW qualified target. PPU also included the provision of a stub-out in the SNS accumulator-ring-to-target tunnel to facilitate a rapid connection to a new proton beamline for the Second Target Station (STS) project. The power capability was doubled by increasing the proton beam energy by 33% and the peak beam current by 50%, relative to pre-PPU accelerator performance. The project also included modifications to some buildings and services. The PPU project accomplished the energy upgrade by fabricating and installing new superconducting radiofrequency (RF) cryomodules, with supporting RF equipment, in the existing linac tunnel and klystron gallery, respectively. The High Voltage Converter Modulators (HVCM) and klystrons for some of the existing installed RF equipment were upgraded to handle the higher beam current. The increased beam power of 2 MW on the First Target Station (FTS) was enabled by the addition of a new high-volume gas injection system for pressure pulse and cavitation mitigation in the mercury target and a redesigned mercury target vessel.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Wire Arc Additive Manufacturing of Lightweight High Pressure Die Casting Tooling

Oak Ridge National Laboratory (ORNL) and Mercury Marine partnered to develop and test methods for additively manufactured tooling for aluminum die casting applications under CRADA agreement NFE- 20-08193. Tooling is the largest capital expense for high production casting projects. The lead time for tooling is often measured in months with a typical project taking 9-12 months to realize Production Part Approval Process (PPAP) ready die cast samples. This project demonstrated the technical viability of rapidly produced steel components for high pressure die casting tooling via Wire Arc Additive Manufacturing (WAAM). A 410 stainless steel tool was redesigned and optimized with conformal cooling channels and additively manufactured. The finished tool was tested and used to produce over 4000 parts, which well surpassed expectations. A secondary objective was to evaluate the durability of multi-material additively manufactured (AM) components with conformal cooling. A large multi-material tool (H13 and 410SSNiMo) was manufactured using the same methods showing potential reductions in used material and cost. However, the H13 section sustained material cracking. Further analysis showed that the potential cause was the CTE mismatch of the two materials at higher temperatures. It is also suggested that the material mix can be used if the steel processing temperature does not exceed 600 ˚C. This project has shown high potential for using the WAAM technology for creating AM parts for aluminum dies casting. However, the multi-material approach requires extended study and tests.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Maintainable Fusion Pilot Plant

The US fusion community has coalesced around the goal of building an FPP as described by the National Academies of Science, Engineering, and Medicine (NASEM). In addition to demonstrating the viability of the technologies necessary to operate such a plant, including demonstration of net energy and electricity production, NASEM found that a “fusion pilot plant will need to demonstrate the ability to efficiently perform remote maintenance and replacement in support of the design of a power plant, taking into account details of the consequences of the fusion environment, such as material activation and tritium retention in components.” Current designs of fusion demonstration reactors do usually foresee a regular exchange of their first wall modules, including the tritium breeding blankets. In the European Power Plant Conceptual Studies, it is assumed that a fusion reactor will need to change its divertor every 2 years and its first wall blanket module every 5 to 6 years to reach acceptable availability. Underlying this capability are remote-handling technologies to keep the outage for the exchange of these components short. There are many uncertainties in the remote-handling schemes, and most schemes are at a preconceptual level at best. In addition, the exchange of these components would either produce an enormous rad-waste stream or would require an enormous refurbishment activity with huge cost-prohibitive hot-cells. Past Fusion Nuclear Science Facility (FNSF) preconceptual studies have led to hot cell dimensions of an unbelievable size, likely costing tens of billions of dollars. Already at The Way (previously International Thermonuclear Experimental Reactor, ITER), hot-cells have become cost-prohibitive, demanding redesigns of the ITER first wall to reduce the toxic rad-waste/inventory. In this in-situ PFC repair project, a concept for a long-life, maintainable first wall module concept is developed and tested. This first wall concept relies on innovative remote handling to repair the first wall modules in-situ, avoiding costly refurbishments outside of the tokamak vessel. This approach was highlighted in the Fusion Energy Sciences Advisory Committee (FESAC) report on Transformative Enabling Capabilities for Efficient Advance Toward Fusion Energy. In general, the damage of the first wall armor is due to particle and radiation exposures. Load conditions vary from one fusion reactor design to another. In tokamaks, first wall Plasma Facing Components (PFCs) are exposed to far-Scrape-Off-Layer plasma fluxes, electromagnetic radiation, energetic CX neutrals, and potentially runaway electron beams. Protecting the first wall to the worst-case load conditions would require the design of a very thick first wall armor. Transient heat and particle fluxes due to disruptions or edge localized modes can lead to excessive heat loads resulting potentially in melting PFCs down to the cooling channel. Catastrophic events like these need to be avoided by appropriate disruption mitigation systems. However, failure of these systems will still put a first wall at an unacceptable risk. Hence, a first wall design needs to accommodate the occasional transient heat loads by introducing sacrificial limiters, which will absorb these transients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Technical Considerations on MURR Control Blade Design Change and Testing using a New Metal Matrix Composite

The University of Missouri Research Reactor (MURR) is one of six research reactors, including a critical facility, that are pursuing conversion as part of a collaboration with the U.S. Department of Energy National Nuclear Security Administration Material Management and Minimization Office of Reactor Conversion and Uranium Supply, under the U.S. High Performance Research Reactors (USHPRR) conversion project. Five of the six USHPRR are planned to convert from highly enriched uranium (HEU) fuel using a low-enriched uranium (LEU) high assay monolithic alloy of uranium-10 wt% molybdenum (U-10Mo). As part of the conversion safety analysis, it is necessary to demonstrate the safety performance of the proposed core fueled with LEU as compared to the current HEU cores. The MURR reactor is planning to switch to a new control blade design that uses a metal matrix composite of boron carbide (B 4 C) and aluminum as the absorber in place of Boral®. Since MURR is expected to adopt the new metal matrix composite control blade design prior to conversion, the impact of the new blade design on the neutronics characteristics of the MURR cores for conversion are analyzed in this work through updates to incorporate the changes to the blade design in conversion models as they directly impact the LEU conversion safety analysis. The quantitative comparison shows that the neutronics and thermal hydraulic behavior of one metal matrix composite blade replacing a Boral blade is comparable for the two example MURR LEU and HEU cores states considered. Geometrical changes in the metal matrix composite blade design, combined with a 4% increase in areal boron density, showed local heating effects up to 20% higher than the Boral design. As expected, the metal matrix composite showed slightly lower heat depositions and absorber region temperatures for the LEU cases compared to HEU. Although this analysis was comparative for a single blade, maximum control blade temperatures for both Boral, metal matrix composite, and HEU/LEU remained below 100 °C, though additional analysis at a core level could differ. A qualitative irradiation behavior assessment concludes that the mechanisms that may drive swelling and blistering in the current Boral design are eased by the adoption of the metal matrix composite design. The work concludes that the two blade designs are essentially equivalent with regards to neutronics, thermal hydraulics, and expected material behavior under irradiation. However, due to the geometrical changes to the blades including redesigned and thinner cladding, new testing and increased surveillance for distortion and swelling are recommended to confirm the performance of the metal matrix composite control blade design. Where testing is completed prior to conversion, the only anticipated impacts on conversion to LEU U-10Mo fuel would be the need for models and safety analysis incorporating the metal matrix composite control blades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗