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DOE OSTI2024

Energy Systems Integration Facility (ESIF): World-Class Systems Integration Capabilities and Research

The Energy Systems Integration Facility (ESIF), located at the National Renewable Energy Laboratory (NREL) South Table Mountain campus, is a world-renowned user facility for research and development of modern, advanced, and clean energy technologies. ESIF is distinguished by its continuously evolving, highly integrated systems that span throughout the building, connecting research capabilities across multiple laboratories and test areas. The primary ESIF research systems include: [1] data, cyber, and control networks, [2] research electrical distribution buses (REDB), [3] thermal integration infrastructure, and [4] hydrogen systems. The data, cyber, and control networks provide monitoring, control, communication, automation, visualization, and time series data storage and tagging capabilities for research projects and ESIF systems, including facility safety functions. The REDB system consists of four dedicated AC and DC electrical power networks that can connect devices located across the facility through versatile, automatic circuit configuration to support complex power electronics experiments up to the megawatt-scale. The thermal integration infrastructure consists of three temperature-conditioned water loops that provide heating and cooling interfaces and capabilities for thermal energy research. The hydrogen systems provide megawatt-scale hydrogen production, drying, compression, high-pressure storage, and delivery to laboratory end uses, including hydrogen fuel cell vehicle fueling. The ESIF research systems interconnect and extend throughout the various lab areas of the facility to create elaborate networks composed of diverse technologies for cutting-edge research. The ESIF capabilities are operated and stewarded by the ESIF Research Operations group, who also actively upgrade and advance the systems to ensure they remain ahead of anticipated research - enabling the success of many pioneering energy integration projects. The poster, created by members of the ESIF Research Operations team, highlights and summarizes the four core integrated systems at ESIF. The poster was first presented at the internal NREL Energize Forum on May 13th, 2024, and received the "Best Poster" award.

capabilities↗

DOE OSTI2017

Integrity Assessment of Hanford 242-A Evaporator Facility E-A-1 Re-boiler Vessel via Fluorescein Liquid Tracer Test Methods - 17357

The 242-A Evaporator Facility is critical to the United States Department of Energy's (DOE) Hanford Site clean-up mission due to limited space within the existing Double-Shell Tanks (DSTs) used to store nuclear and chemical waste until future processing. The 242-A Evaporator Facility is currently the sole waste volume reduction process used at Hanford, and the E-A-1 Re-boiler is essential to the Evaporator process. Due to the potential for cross-contamination between the Re-boiler tubes through which waste passes and the tube sheets of uncontaminated steam, an assessment of the Re-boiler vessel's integrity is required for continuing operations of the facility. In order to meet these requirements, an independent integrity assessment was designed to use fluorescein liquid tracer (LT) to verify the leak-tightness of the Re-boiler vessel in accordance with Washington River Protection Solutions, LLC (WRPS) tightness test standards, as well as, the ASME Boiler and Pressure Vessel (B and PV) Code, Section III, Division 1, NB-6300. LT test methodologies were evaluated and determined to be appropriate for a vessel with restricted access, such as the E-A-1 Re-boiler, as it provided the needed sensitivity, reliability, and cost; as well as, exceeded the leak-tightness specifications required by both WRPS and ASME B and PV Code standards. The integrity test requires water laced with fluorescein be circulated through the waste processing loop of the 242-A Evaporator and samples of steam condensate be collected and analyzed for traces of fluorescein to determine leak-tightness. Liquid condensate sampling was conducted prior to and during testing and the samples were analyzed for fluorescein tracer to determine the amount of fluorescein that flowed out of the tubes of the Re-boiler into the steam side of the vessel. Given the established criteria for 'leak-tight,' test results determined that the Re-boiler passed the integrity assessment. After further scrutiny of the 2014 test and data results, it was determined that although the Re-boiler was 'leak-tight,' as established by the test criteria, there was concern of future leakage. The DOE and the DOE Office of River Protection (ORP) requested that WRPS repeat the integrity assessment in two and a half years to determine if the potential leak was growing, which could threaten continuing operations of the 242-A Evaporator. The 2017 test has been redesigned using lessons learned from the 2014 test and was modified to account for ergonomic and safety considerations, ease of repeatability, and accuracy of results. The liquid tracer methodology and test plan developed for the Re-boiler will continue to be implemented in 5 year increments to monitor current and future integrity. The method may also prove useful for other aging components across the Hanford Site, where appropriate. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1967

Simultaneous integration of n-bodies by analytic continuation with recursively formed derivatives.

Recursion formulae to generate Taylor series expansion for motion of n-point masses subject to gravitational attractions

Hartwell, J. G.↗

DOE OSTI2013

LEVERAGING AGING MATERIALS DATA TO SUPPORT EXTENSION OF TRANSPORTATION SHIPPING PACKAGES SERVICE LIFE

Nuclear material inventories are increasingly being transferred to interim storage locations where they may reside for extended periods of time. Use of a shipping package to store nuclear materials after the transfer has become more common for a variety of reasons. Shipping packages are robust and have a qualified pedigree for performance in normal operation and accident conditions but are only certified over an approved transportation window. The continued use of shipping packages to contain nuclear material during interim storage will result in reduced overall costs and reduced exposure to workers. However, the shipping package materials of construction must maintain integrity as specified by the safety basis of the storage facility throughout the storage period, which is typically well beyond the certified transportation window. In many ways, the certification processes required for interim storage of nuclear materials in shipping packages is similar to life extension programs required for dry cask storage systems for commercial nuclear fuels. The storage of spent nuclear fuel in dry cask storage systems is federally-regulated, and over 1500 individual dry casks have been in successful service up to 20 years in the US. The uncertainty in final disposition will likely require extended storage of this fuel well beyond initial license periods and perhaps multiple re-licenses may be needed. Thus, both the shipping packages and the dry cask storage systems require materials integrity assessments and assurance of continued satisfactory materials performance over times not considered in the original evaluation processes. Test programs for the shipping packages have been established to obtain aging data on materials of construction to demonstrate continued system integrity. The collective data may be coupled with similar data for the dry cask storage systems and used to support extending the service life of shipping packages in both transportation and storage.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Photonic crystal for graphene plasmons

Photonic crystals are commonly implemented in media with periodically varying optical properties. Photonic crystals enable exquisite control of light propagation in integrated optical circuits, and also emulate advanced physical concepts. However, common photonic crystals are unfit for in-operando on/off controls. We overcome this limitation and demonstrate a broadly tunable two-dimensional photonic crystal for surface plasmon polaritons. Our platform consists of a continuous graphene monolayer integrated in a back-gated platform with nano-structured gate insulators. Infrared nano-imaging reveals the formation of a photonic bandgap and strong modulation of the local plasmonic density of states that can be turned on/off or gradually tuned by the applied gate voltage. We also implement an artificial domain wall which supports highly confined one-dimensional plasmonic modes. Our electrostaticallytunable photonic crystals are derived from standard metal oxide semiconductor field effect transistor technology and pave a way for practical on-chip light manipulation.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

Characterization of a Fast-Framing X-Ray Camera With Wide Dynamic Range for High-Energy Imaging

We present first characterization results, with a focus on high-flux measurements, of a fast-framing, wide-dynamic-range x-ray camera intended for high-energy imaging. The MM-PAD-2.1 uses an integrating pixel front-end with a charge removal architecture and in-pixel counter to extend the pixel well depth while maintaining low read noise across the full dynamic range. The charge-removal mechanism is dead-time-less (i.e., incoming signal continues to be integrated by the front-end while charge removal is taking place). The purpose of the highflux characterization was to determine the maximum sustained incident flux that could be measured while still exhibiting linear behavior. To this end, a 16 x 16 pixel prototype was tested at the Advanced Photon Source at Argonne National Laboratory using 10 keV photons generated by an undulator source. The intensity of the incident beam was varied over 3 orders of magnitude using a series of attenuators, and the signal integrated by the MM-PAD-2.1 prototype was compared to that measured by a He-filled ion chamber directly upstream. Initial results indicate linear performance up to ca. 10(10) ph/s in a spot spanning approximately 2 x 1.5 pixels (FWHM). The onset of transient radiation damage was observed during these measurements, characterized primarily by failure of digital readout from the detector ASIC. These effects were observed to reverse after annealing at 30 degrees C for several hours, with full recovery of the detector readout.

Shanks, Katherine S.↗

DOE OSTI2017

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2017

Achieving fusion energy presents a formidable challenge to the field of materials science, to provide a suite of suitable materials in close integration to the plasma physics and other applied technologies. The technological challenge presented by the planned fusion power systems is the inability of current materials and components to withstand the harsh fusion nuclear environment. The overarching goal of the ORNL fusion materials program is to provide the applied materials science support and materials understanding to underpin the ongoing DOE Office of Science fusion energy program in parallel with developing materials for fusion power systems. In this effort the program continues to be integrated both with the larger U.S. and international fusion materials communities and with the international fusion design and technology communities. This long-running ORNL program continues to pursue development of low activation structural materials such as the Reduced Activation Ferritic/Martensitic Steels, higher strength/higher creep resistant/coolant compatible/radiation tolerant advanced steels, and Silicon Carbide Composites. Focus tasks within the steels portfolio are development of Castable Nanostructured Alloys, exploratory work on Bainitic steels and liquid metal compatibility evaluations. Parallel to this is the increased emphasis on radiation effects, high heat flux testing and the development of refractory metals. This includes the use of an ORNL Plasma Arc Lamp facility adapted for the thermal testing of irradiated materials, the development and evaluation of new tungsten materials, and the study and understanding of the irradiation performance of tungsten. In each case the materials are being developed in a design-informed fashion where properties improvements are led by fusion-relevant design studies and directed at advancing the Technology Readiness Level of the material systems.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Model Based Mission Assurance: NASA's Assurance Future

Model Based Systems Engineering (MBSE) is seeing increased application in planning and design of NASA’s missions. This suggests the question: what will be the corresponding practice of Model Based Mission Assurance (MBMA)? Contemporaneously, NASA’s Office of Safety and Mission Assurance (OSMA) is evaluating a new objectives based approach to standards to ensure that the Safety and Mission Assurance disciplines and programs are addressing the challenges of NASA’s changing missions, acquisition and engineering practices, and technology. MBSE is a prominent example of a changing engineering practice. We use NASA’s objectives-based strategy for Reliability and Maintainability as a means to examine how MBSE will affect assurance. We surveyed MBSE literature to look specifically for these affects, and find a variety of them discussed (some are anticipated, some are reported from applications to date). Predominantly these apply to the early stages of design, although there are also extrapolations of how MBSE practices will have benefits for testing phases. As the effort to develop MBMA continues, it will need to clearly and unambiguously establish the roles of uncertainty and risk in the system model. This will enable a variety of uncertainty-based analyses to be performed much more rapidly than ever before and has the promise to increase the integration of CRM (Continuous Risk Management) and PRA (Probabilistic Risk Analyses) even more fully into the project development life cycle. Various views and viewpoints will be required for assurance disciplines, and an over-arching viewpoint will then be able to more completely characterize the state of the project/program as well as (possibly) enabling the safety case approach for overall risk awareness and communication.

Evans, John↗

DOE OSTI2010

Integrated Vehicle Thermal Management for Advanced Vehicle Propulsion Technologies

A critical element to the success of new propulsion technologies that enable reductions in fuel use is the integration of component thermal management technologies within a viable vehicle package. Vehicle operation requires vehicle thermal management systems capable of balancing the needs of multiple vehicle systems that may require heat for operation, require cooling to reject heat, or require operation within specified temperature ranges. As vehicle propulsion transitions away from a single form of vehicle propulsion based solely on conventional internal combustion engines (ICEs) toward a wider array of choices including more electrically dominant systems such as plug-in hybrid electric vehicles (PHEVs), new challenges arise associated with vehicle thermal management. As the number of components that require active thermal management increase, so do the costs in terms of dollars, weight, and size. Integrated vehicle thermal management is one pathway to address the cost, weight, and size challenges. The integration of the power electronics and electric machine (PEEM) thermal management with other existing vehicle systems is one path for reducing the cost of electric drive systems. This work demonstrates techniques for evaluating and quantifying the integrated transient and continuous heat loads of combined systems incorporating electric drive systems that operate primarily under transient duty cycles, but the approach can be extended to include additional steady-state duty cycles typical for designing vehicle thermal management systems of conventional vehicles. The work compares opportunities to create an integrated low temperature coolant loop combining the power electronics and electric machine with the air conditioning system in contrast to a high temperature system integrated with the ICE cooling system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1983

Day and night models of the Venus thermosphere

A model atmosphere of Venus for altitudes between 100 and 178 km is presented for the dayside and nightside. Densities of CO2, CO, O, N2, He, and O2 on the dayside, for 0800 and 1600 hours local time, are obtained by simultaneous solution of continuity equations. These equations couple ionospheric and neutral chemistry and the transport processes of molecular and eddy diffusion. Photodissociation and photoionization J coefficients are presented to facilitate the incorporation of chemistry into circulation models of the Venus atmosphere. Midnight densities of CO2 CO, O, N2, He, and N are derived from integration of the continuity equations, subject to specified fluxes. The nightside densities and fluxes are consistent with the observed airglow of NO and O2(1 Delta). The homopause of Venus is located near 133 km on both the dayside and nightside.

Massie, S. T.↗

DOE OSTI2025

DeepLynx Ecosystem 2025

Poor data integration and governance continue to plague complex engineering projects, resulting in missed cost, schedule, and performance targets. Departments operate in isolated systems with manual data exchange, creating fragmented information that compounds errors and leads to significant delays and cost overruns. The DeepLynx ecosystem addresses these challenges through an open-source, modular data management platform that transforms fragmented project data into an integrated digital thread. Built on a federated microservice architecture, the ecosystem comprises seven specialized tools centered around DeepLynx Nexus, a unified data catalog with hierarchical organization and graph-based navigation capabilities. The ecosystem includes: DeepLynx Stream for real-time timeseries data ingestion from industrial sources; DeepLynx Ingest for governed data uploads with formal review workflows; DeepLynx Lattice for ontology-based entity and relationship extraction; DeepLynx Run for workflow orchestration and secure AI/ML compute; DeepLynx Visualize for 3D digital twin visualization; and DeepLynx Insight for AI-assisted document analysis with traceable, grounded responses. Deployable in cloud, on-premise, or hybrid environments using containerized Docker applications and Helm charts, the DeepLynx ecosystem provides flexible infrastructure that adapts to organizational requirements. By consolidating project data into a unified data lake with role-based access controls and OAuth2 authentication, DeepLynx enables digital thread and digital twin capabilities that improve decision-making, reduce risk, and support complex engineering workflows throughout the project lifecycle.

42 - ENGINEERING↗

NASA NTRS1982

An iterative finite element-integral technique for predicting sound radiation from turbofan inlets in steady flight

A new iterative solution technique for predicting the sound field radiated from a turbofan inlet in steady flight is presented. The sound field is divided into two regions: the sound field within and near the inlet which is computed using the finite element method and the radiation field beyond the inlet which is calculated using an integral solution technique. A continuous solution is obtained by matching the finite element and integral solutions at the interface between the two regions. The applicability of the iterative technique is demonstrated by comparison of experimental results with the theoretical results for several different inlet configurations with and without flow. These examples show that good agreement between experiment and theory is obtained within five iterations.

Horowitz, S. J.↗

NASA NTRS1983

Optimization of acoustic liners by the hybrid finite element-integral approach

An iterative solution technique for predicting the sound field radiated from a turbofan inlet is used to predict the optimum inlet acoustic liner. The analytical approach divides the sound field into two regions: the sound field within and near the inlet which is computed using the finite element method and the radiation field beyond the inlet which is calculated using an integral solution technique. A continuous solution is obtained by matching the finite element and integral solutions at the interface between the two regions. Using a trial and error scheme, this analytical procedure is used to calculate the impedance value of the duct liner which will produce a minimum sound pressure level in the far field. Several examples of straight and non-uniform ducts with and without flow are presented.

Sigman, R. K.↗

DOE OSTI2014

Advanced Fuels Campaign FY 2014 Accomplishments Report

The mission of the Advanced Fuels Campaign (AFC) is to perform Research, Development, and Demonstration (RD&D) activities for advanced fuel forms (including cladding) to enhance the performance and safety of the nation’s current and future reactors; enhance proliferation resistance of nuclear fuel; effectively utilize nuclear energy resources; and address the longer-term waste management challenges. This includes development of a state-of-the art Research and Development (R&D) infrastructure to support the use of a “goal-oriented science-based approach.” In support of the Fuel Cycle Research and Development (FCRD) program, AFC is responsible for developing advanced fuels technologies to support the various fuel cycle options defined in the Department of Energy (DOE) Nuclear Energy Research and Development Roadmap, Report to Congress, April 2010. AFC uses a “goal-oriented, science-based approach” aimed at a fundamental understanding of fuel and cladding fabrication methods and performance under irradiation, enabling the pursuit of multiple fuel forms for future fuel cycle options. This approach includes fundamental experiments, theory, and advanced modeling and simulation. The modeling and simulation activities for fuel performance are carried out under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, which is closely coordinated with AFC. In this report, the word “fuel” is used generically to include fuels, targets, and their associated cladding materials. R&D of light water reactor (LWR) fuels with enhanced accident tolerance is also conducted by AFC. These fuel systems are designed to achieve significantly higher fuel and plant performance to allow operation to significantly higher burnup, and to provide enhanced safety during design basis and beyond design basis accident conditions. The overarching goal is to develop advanced nuclear fuels and materials that are robust, have high performance capability, and are more tolerant to accident conditions than traditional fuel systems. AFC management and integration activities included continued support for international collaborations, primarily with France, Japan, the European Union, Republic of Korea, and China, as well as various working group and expert group activities in the Organization for Economic Cooperation and Development Nuclear Energy Agency (OECD-NEA) and the International Atomic Energy Agency (IAEA). Three industry-led Funding Opportunity Announcements (FOAs) and two university-led Integrated Research Projects (IRPs), funded in 2013, made significant progress in fuels and materials development. All are closely integrated with AFC and Accident Tolerant Fuels (ATF) research. Accomplishments made during fiscal year (FY) 2014 are highlighted in this report, which focuses on completed work and results. The process details leading up to the results are not included; however, the lead technical contact is provided for each section.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Plasma etching: Yesterday, today, and tomorrow

The field of plasma etching is reviewed. Plasma etching, a revolutionary extension of the technique of physical sputtering, was introduced to integrated circuit manufacturing as early as the mid 1960s and more widely in the early 1970s, in an effort to reduce liquid waste disposal in manufacturing and achieve selectivities that were difficult to obtain with wet chemistry. Quickly, the ability to anisotropically etch silicon, aluminum, and silicon dioxide in plasmas became the breakthrough that allowed the features in integrated circuits to continue to shrink over the next 40 years. Some of this early history is reviewed, and a discussion of the evolution in plasma reactor design is included. Some basic principles related to plasma etching such as evaporation rates and Langmuir–Hinshelwood adsorption are introduced. Etching mechanisms of selected materials, silicon, silicon dioxide, and low dielectric-constant materials are discussed in detail. A detailed treatment is presented of applications in current silicon integrated circuit fabrication. Finally, some predictions are offered for future needs and advances in plasma etching for silicon and nonsilicon-based devices.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2015

The realization of fusion energy is a formidable challenge with significant achievements resulting from close integration of the plasma physics and applied technology disciplines. Presently, the most significant technological challenge for the near-term experiments such as ITER, and next generation fusion power systems, is the inability of current materials and components to withstand the harsh fusion nuclear environment. The overarching goal of the Oak Ridge National Laboratory (ORNL) fusion materials program is to provide the applied materials science support and understanding to underpin the ongoing Department of Energy (DOE) Office of Science fusion energy program while developing materials for fusion power systems. In doing so the program continues to be integrated both with the larger United States (US) and international fusion materials communities, and with the international fusion design and technology communities.This document provides a summary of Fiscal Year (FY) 2015 activities supporting the Office of Science, Office of Fusion Energy Sciences Materials Research for Magnetic Fusion Energy (AT-60-20-10-0) carried out by ORNL. The organization of this report is mainly by material type, with sections on specific technical activities. Four projects selected in the Funding Opportunity Announcement (FOA) solicitation of late 2011 and funded in FY2012-FY2014 are identified by “FOA” in the titles. This report includes the final funded work of these projects, although ORNL plans to continue some of this work within the base program.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2010

Synchrotron Area X-ray Detectors, Present and Future

X-ray experiments are very frequently detector limited at today's storage ring synchrotron radiation (SR) sources, and will be even more so at future Energy Recovery Linac and X-ray Free Electron Laser sources. Image plate and phosphor-coupled CCD detectors that predominate at present-day sources were outgrowths of technologies initially developed for the medical and astronomical communities, respectively, with resultant limitations for SR. These limitations are enumerated. The growth of commercial silicon foundries and design tools enabling the production of large, customized integrated circuits is beginning to have a profound impact on SR detectors and is ushering in the age of 'designer detectors'. Novel area Pixel Array Detectors (PADs) are starting to appear in which each pixel has dedicated, complex circuitry capable of high speed and, in some cases, significant data processing power for specific applications. PADs now at, or near the horizon will be described. Integrated circuit methods continue to develop at a rapid pace. Implications for future x-ray detectors will be discussed.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2018

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗