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All sources NASA NTRS DOE OSTI

DOE OSTI2010

Etching characteristics of organic low-k films interpreted by internal parameters employing a combinatorial plasma process in an inductively coupled H{sub 2}/N{sub 2} plasma

The development of plasma etching technology is being held back due to the use of trial and error methods when scaling down and high integration. Such a continuous development could result in enormous losses in term of cost and time. It is impossible to overcome without a different approach. In this study, we have tried to accumulate a large amount of data on internal parameters and based on database, the etching characteristics could be interpreted with a high reproducibility. In order to realized faster data acquisitions, we developed a combinatorial plasma process (CPP) for obtaining a large amount of data in a single trial from spatially inhomogeneous plasma distribution regarding etching of organic low-k films in H{sub 2}/N{sub 2} plasmas. In addition, synergetic effects of other internal parameters such as vacuum ultraviolet radiation and radicals without ion bombardment were clarified. Finally, the high performance of CPP for faster data acquisitions was shown and the etching characteristics in terms of internal parameters such as ion fluxes and the H/(H+N) radical flux ratio were demonstrated.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Development of a mechanical based system for dry retrieval of single-shell tank waste at Hanford

This study explores the development of a mechanical based system to retrieve single-shell tank waste at the Hanford site, located in Richland, Washington, without the addition of water. Out of 177 tanks at Hanford, there are 149 single-shell tanks (SST) and 28 double-shell tanks (DST). There are currently 67 SSTs that have leaked radioactive waste to the surrounding groundwater in the past or assumed to have questionable tank integrity. Leaking tanks continue to be a major concern as it was recently announced in February 2013 that six SSTs are leaking, even though they were believed to have been stabilized back in 2005. There are also several tanks with significant in-tank obstructions, such as air-lift circulators, where an arm-based retrieval would not be possible. All current methods of waste retrieval deployed involve the addition of significant amounts of water to generate a slurry that can be pumped out of the tank. This water, however, can exacerbate the leak and risk the potential of leaking more waste into the surrounding soil, subsequently contaminating the groundwater. It also reduces available waste storage space in DSTs, and increases the risk of dangerous buoyant displacement gas release events (BDGRE) in the headspace of DSTs. Focusing on leaking tanks, tanks with significant in-tank obstructions, and utilizing existing risers in Hanford's tanks, this study evaluates commercially available dry technologies, such as augers and high-powered vacuums, for feasibility, safety, and efficiency of waste retrieval at Hanford. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

CAT: computer aided triage improving upon the Bayes risk through ε-refusal triage rules

Manual extraction of information from electronic pathology (epath) reports to populate the Surveillance, Epidemiology, and End Result (SEER) database is labor intensive. Systematizing the data extraction automatically using machine-learning (ML) and natural language processing (NLP) is desirable to reduce the human labor required to populate the SEER database and to improve the timeliness of the data. This enables scaling up registry efficiency and collection of new data elements. To ensure the integrity, quality, and continuity of the SEER data, the misclassification error of ML and NPL algorithms needs to be negligible. Current algorithms fail to achieve the precision of human experts who can bring additional information in their assessments. Differences in registry format and the desire to develop a common information extraction platform further complicate the ML/NLP tasks. The purpose of our study is to develop triage rules to partially automate registry workflow to improve the precision of the auto-extracted information. This paper presents a mathematical framework to improve the precision of a classifier beyond that of the Bayes classifier by selectively classifying item that are most likely to be correct. This results in a triage rule that only classifies a subset of the item. We characterize the optimal triage rule and demonstrate its usefulness in the problem of classifying cancer site from electronic pathology reports to achieve a desired precision. From the mathematical formalism, we propose a heuristic estimate for triage rule based on post-processing the soft-max output from standard machine learning algorithms. We show, in test cases, that the triage rule significantly improve the classification accuracy.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Technoeconomic evaluation of recent process improvements in production of sugar and high-value lignin co-products via two-stage Cu-catalyzed alkaline-oxidative pretreatment

Abstract Background A lignocellulose-to-biofuel biorefinery process that enables multiple product streams is recognized as a promising strategy to improve the economics of this biorefinery and to accelerate technology commercialization. We recently identified an innovative pretreatment technology that enables of the production of sugars at high yields while simultaneously generating a high-quality lignin stream that has been demonstrated as both a promising renewable polyol replacement for polyurethane applications and is highly susceptible to depolymerization into monomers. This technology comprises a two-stage pretreatment approach that includes an alkaline pre-extraction followed by a metal-catalyzed alkaline-oxidative pretreatment. Our recent work demonstrated that H 2 O 2 and O 2 act synergistically as co-oxidants during the alkaline-oxidative pretreatment and could significantly reduce the pretreatment chemical input while maintaining high sugar yields (~ 95% glucose and ~ 100% xylose of initial sugar composition), high lignin yields (~ 75% of initial lignin), and improvements in lignin usage. Results This study considers the economic impact of these advances and provides strategies that could lead to additional economic improvements for future commercialization. The results of the technoeconomic analysis (TEA) demonstrated that adding O 2 as a co-oxidant at 50 psig for the alkaline-oxidative pretreatment and reducing the raw material input reduced the minimum fuel selling price from $1.08/L to $0.85/L, assuming recoverable lignin is used as a polyol replacement. If additional lignin can be recovered and sold as more valuable monomers, the minimum fuel selling price (MFSP) can be further reduced to $0.73/L. Conclusions The present work demonstrated that high sugar and lignin yields combined with low raw material inputs and increasing the value of lignin could greatly increase the economic viability of a poplar-based biorefinery. Continued research on integrating sugar production with lignin valorization is thus warranted to confirm this economic potential as the technology matures.

09 BIOMASS FUELS↗

DOE OSTI2021

Chirped laser dispersion spectroscopy for spectroscopic chemical sensing with simultaneous range detection

Spectroscopic chemical detection requires knowledge or determination of an optical path for accurate quantification of path-integrated concentration of species. Continuous- wave-laser-based spectroscopic systems operating in an open integrated-path remote sensing configuration are usually not equipped for optical path determination. Here we demonstrate a measurement technique capable of simultaneous spectroscopic chemical quantification and range finding. Here, the range-finding functionality is implemented with chirped laser dispersion spectroscopy. The methodology is potentially useful for remote chemical sensing in a hard-target LIDAR configuration and for automatic calibration of gas cells with unknown or varying lengths.

03 NATURAL GAS↗

DOE OSTI2014

An Update on Improvements to NiCE Support for RELAP-7

The Multiphysics Object-Oriented Simulation Environment (MOOSE) is a framework that facilitates the development of applications that rely on finite-element analysis to solve a coupled, nonlinear system of partial differential equations. RELAP-7 represents an update to the venerable RELAP-5 simulator that is built upon this framework and attempts to model the balance-of-plant concerns in a full nuclear plant. This report details the continued support and integration of RELAP-7 and the NEAMS Integrated Computational Environment (NiCE). RELAP-7 is fully supported by the NiCE due to on-going work to tightly integrate NiCE with the MOOSE framework, and subsequently the applications built upon it. NiCE development throughout the first quarter of FY15 has focused on improvements, bug fixes, and feature additions to existing MOOSE-based application support. Specifically, this report will focus on improvements to the NiCE MOOSE Model Builder, the MOOSE application job launcher, and the 3D Nuclear Plant Viewer. This report also includes a comprehensive tutorial that guides RELAP-7 users through the basic NiCE workflow: from input generation and 3D Plant modeling, to massively parallel job launch and post-simulation data visualization.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Full Core Multiphysics Simulation with Offline Mesh Deformation

In this report, building on previous reports issued in FY13 we describe our continued efforts to integrate thermal/hydraulics, neutronics, and structural mechanics modeling codes to perform coupled analysis of a representative fast sodium-cooled reactor core. The focus of the present report is a full core simulation with off-line mesh deformation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

New Methods in Non-Perturbative QCD

In this work, we investigate the properties of quantum chromodynamics (QCD), by using newly developing mathematics and physics formalisms. Almost all of the mass in the visible universe emerges from a quantum chromodynamics (QCD), which has a completely negligible microscopic mass content. An intimately related issue in QCD is the quark confinement problem. Answers to non-perturbative questions in QCD remained largely elusive despite much effort over the years. It is also believed that the usual perturbation theory is inadequate to address these kinds of problems. Perturbation theory gives a divergent asymptotic series (even when the theory is properly renormalized), and there are non-perturbative phenomena which never appear at any order in perturbation theory. Recently, a fascinating bridge between perturbation theory and non-perturbative effects has been found: a formalism called resurgence theory in mathematics tells us that perturbative data and non-perturbative data are intimately related. Translating this to the language of quantum field theory, it turns out that non-perturbative information is present in a coded form in perturbation theory and it can be decoded. We take advantage of this feature, which is particularly useful to understand some unresolved mysteries of QCD from first principles. In particular, we use: a) Circle compactifications which provide a semi-classical window to study confinement and mass gap problems, and calculable prototypes of the deconfinement phase transition; b) Resurgence theory and transseries which provide a unified framework for perturbative and non-perturbative expansion; c) Analytic continuation of path integrals and Lefschetz thimbles which may be useful to address sign problem in QCD at finite density.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2017

Steam Oxidation Testing in the Severe Accident Test Station

After the March 2011 accident at Fukushima Daiichi, Oak Ridge National Laboratory (ORNL) began conducting high temperature steam oxidation testing of candidate materials for accident tolerant fuel (ATF) cladding in August 2011 [1-11]. The ATF concept is to enhance safety margins in light water reactors (LWR) during severe accident scenarios by identifying materials with 100× slower steam oxidation rates compared to current Zr-based alloys. In 2012, the ORNL laboratory equipment was expanded and made available to the entire ATF community as the Severe Accident Test Station (SATS) [4,12]. Compared to the current UO2/Zr-based alloy fuel system, an ATF alternative would significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident [13-14]. The steam oxidation behavior of candidate materials is a key metric in the evaluation of ATF concepts and also an important input into models [15-17]. However, initial modeling work of FeCrAl cladding has used incomplete information on the physical properties of FeCrAl. Also, the steam oxidation data being collected at 1200°-1700°C is unique as no prior work has considered steam oxidation of alloys at such high temperatures. Also, because many accident scenarios include steadily increasing temperatures, the required data are not traditional isothermal exposures but exposures with varying “ramp” rates. In some cases, the steam oxidation behavior has been surprising and difficult to interpret. Thus, more fundamental information continues to be collected. In addition, more work continues to focus on commercially-manufactured tube material. This report summarizes recent work to characterize the behavior of candidate alloys exposed to high temperature steam, evaluate steam oxidation behavior in various ramp scenarios and continue to collect integral data on FeCrAl compared to conventional Zr-based cladding.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Abstract - Cooperative Research and Development Agreement between SIOX and National Energy Technology Laboratory

DOE’s Fossil Energy Program has made significant scientific advancements and provided technology solutions over the years ensuring energy security in the United States. This project highly leverages both past and current technology development efforts and utilizes the expertise of the National Energy Technology Laboratory (NETL) in a collaborative effort with SIOX. The proposed effort involves conversion of a steel manufacturing byproduct, iron oxide hematite (Fe2O3), and transforms it into a salable magnetite product applicable to a number of markets. SIOX managers have experience operating a magnetite production facility based on a rotary kiln reactor process. Unfortunately, that process is both costly and inefficient, making it difficult to achieve desired economies, purity, and throughput levels. Recent NETL innovations in multi-phase fluidization technology would allow for successful development of a continuous, fully-integrated process capable of producing synthetic magnetite products. The reactor is based upon a spouting bed technology (patent pending) that allows for the even mixing of the ultrafine hematite which normally packs with all of the reacting gas bypassing the solid particles.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2022

Damage Detection and Electrical Performance Impact of Flat-Flexible Circuits

Flat-flexible circuits or ‘flex circuits’ have varied applications in electronics and in explosive detonation systems. They pose advantages over conventional coaxial cables in their ability to fit into small mechanical envelopes and routings. A typical flex circuit is composed of a laminated assembly of multiple layers of conductor and dielectric materials. Copper, because of its high electrical conductivity, is one of the primary materials used in flex circuit conductors. The conductor must maintain structural integrity and electrical continuity when the flexible circuit is bent during processing or to fit an application envelope. Under some strain conditions a cable may have degraded electrical performance even though visible damage may not be evident. Dislocation density can increase by mechanisms such as dislocation forest hardening, where gliding dislocations in primary slip planes get pinned at obstacles and form Frank-Read sources. Dislocation density increases within the conductor layers may impact electrical resistivity but would not necessarily result in visible mechanical failure. In some detonation applications, such as for building implosion for demolition, the time for signal transmission and voltage used for firing detonators can be critical. If the resistance in a single flex cable within a building demolition array is too high, the resultant demolition shape may be asymmetric, leading to unplanned damage to nearby structures and potential hazards to public safety. This study will apply non-destructive evaluation techniques to evaluate the detectability of damage accumulation in flat, flexible copper-conductor cables and discuss potential implications to their practical use.

42 ENGINEERING↗

DOE OSTI2023

Fusion Materials Research at Oak Ridge National Laboratory in FY22

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Fusion Materials Research at Oak Ridge National Laboratory in Fiscal Year 2023

The materials science challenge of providing a suite of suitable materials to satisfy the technology to achieve fusion energy is addressed in this ORNL program. The inability of currently available materials and components to withstand the harsh fusion nuclear environment requires development of new materials, and an understanding of their response to the fusion 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 Sciences program, in parallel with developing the 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 U.S. and international fusion design and technology communities. The excitement of this program comes from the priorities given to this subject in the two recent fusion reviews, by the FESAC and NAS committees. An important element of those recommendations is the support for pivoting the national R&D emphasis to the Fusion Materials and Technologies (FM&T), the long-advocated Fusion Prototypic Neutron Source, and for the Fusion Pilot Plant study that will help focus program direction and efforts. Furthermore, the surge of venture capital investment into the private fusion industry start-ups over the last few years is anticipated to help accelerate all aspects of the fusion energy development. This twelfth annual report of the ORNL (Oak Ridge National Laboratory) Fusion Reactor Materials Program summarizes the accomplishments in Fiscal Year 2023 (FY2023). The year was the first to return to full post-COVID-restriction operations, with students and international assignees no longer impacted by COVID restrictions, as in FY20-21-22. Following the pattern of planning used in this program, work for the year FY2023 focused on having the data and productivity to support a strong presence at the International Conference on Fusion Reactor Materials (ICFRM) 21, organized by Spain and occurred in October 2023. Twenty-nine ORNL-led abstracts were submitted, with all accepted. Four were invited presentations, nine contributed oral, fourteen posters, and two withdrawn due to unforeseen circumstances. Additionally, nine external abstracts with ORNL contributing authors were presented. These will be reported in the FY24 report next year.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Proof Of Concept of Integrated Load Measurement in 3D Printed Structures

Currently, research on structural health monitoring systems is focused on direct integration of the system into a component or structure. The latter results in a so-called smart structure. One example of a smart structure is a component with integrated strain sensing for continuous load monitoring. Additive manufacturing, or 3D printing, now also enables such integration of functions inside components. As a proof-of-concept, the Fused Deposition Modeling (FDM) technique was used to integrate a strain sensing element inside polymer (ABS) tensile test samples. The strain sensing element consisted of a closed capillary filled with a fluid and connected to an externally mounted pressure sensor. The volumetric deformation of the integrated capillary resulted in pressure changes in the fluid. The obtained pressure measurements during tensile testing are reported in this paper and compared to state-of-the-art extensometer measurements. The sensitivity of the 3D printed pressure-based strain sensor is primarily a function of the compressibility of the capillary fluid. Air- and watertightness are of critical importance for the proper functioning of the 3D printed pressure-based strain sensor. Therefore, the best after-treatment procedure was selected on basis of a comparative analysis. The obtained pressure measurements are linear with respect to the extensometer readings, and the uncertainty on the strain measurement of a capillary filled with water (incompressible fluid) is ±3.1 µstrain, which is approximately three times less sensitive than conventional strain gauges (±1 µstrain), but 32 times more sensitive than the same sensor based on air (compressible fluid) (±101 µstrain).

42 ENGINEERING↗

DOE OSTI2019

Methylated Poly(ethylene)imine Modified Capacitive Micromachined Ultrasonic Transducer for Measurements of CO2 and SO2 in Their Mixtures

A gravimetric gas detection device based on surface functionalized Capacitive Micromachined Ultrasound Transducers (CMUTs) was designed, fabricated and tested for detection of carbon dioxide (CO2) and sulfur dioxide (SO2) mixtures in nitrogen. The created measurement setup of continuous data collection, integrated with an in-situ Fourier Transform Infrared (FT-IR) spectroscopy, allows for better understanding of the mechanisms and molecular interactions with the sensing layer (methylated poly(ethylene)imine) and its need of surface functionalization for multiple gas detection. During experimentation with CO2 gases, weak molecular interactions were observed in spectroscopy data. Linear sensor response to frequency shift was observed with CO2 concentrations ranging from 0.16 vol % to 1 vol %. Moreover, the Raman and FT-IR spectroscopy data showed much stronger SO2 and the polymer interactions, molecules were bound by stronger forces and irreversibly changed the polymer film properties. However, the sensor change in resonance frequency in the tested region of 1 vol % to 5 vol % SO2 showed a linear response. This effect changed not only the device resonance frequency but also affected the magnitude of electroacoustic impedance which was used for differentiating the gas mixture of CO2, SO2, in dry N2.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2011

Explicit modeling of organic chemistry and secondary organic aerosol partitioning for Mexico City and its outflow plume

The evolution of organic aerosols (OA) in Mexico City and its outflow is investigated with the nearly explicit gas phase photochemistry model GECKO-A (Generator of Explicit Chemistry and Kinetics of Organics in the Atmosphere), wherein precursor hydrocarbons are oxidized to numerous intermediate species for which vapor pressures are computed and used to determine gas/particle partitioning in a chemical box model. Precursor emissions included observed C3-10 alkanes, alkenes, and light aromatics, as well as larger n-alkanes (up to C25) not directly observed but estimated by scaling to particulate emissions according to their volatility. Conditions were selected for comparison with observations made in March 2006 (MILAGRO). The model successfully reproduces the magnitude and diurnal shape for both primary (POA) and secondary (SOA) organic aerosols, with POA peaking in the early morning at 15-20 ug m-3, and SOA peaking at 10-15 μg m-3 during mid-day. The majority (> 75%) of the model SOA stems from the large n-alkanes, with the remainder mostly from the light aromatics. Simulated OA elemental composition reproduces observed H/C and O/C ratios reasonably well, although modeled ratios develop more slowly than observations suggest. SOA chemical composition is initially dominated by *- hydroxy ketones and nitrates from the large alkanes, with contributions from peroxy acyl nitrates and, at later times when NOx is lower, organic hydroperoxides. The simulated plume-integrated OA mass continues to increase for several days downwind despite dilution-induced particle evaporation, since oxidation chemistry leading to SOA formation remains strong. In this model, the plume SOA burden several days downwind exceeds that leaving the city by a factor of >3. These results suggest significant regional radiative impacts of SOA.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1974

A note on the effect of bending stiffness of stringers attached to a plate with a crack

An infinite stringer partially bonded to a plate through a layer of adhesive is considered. The stringer had bending as well as longitudinal stiffness. The effect of the stringer's bending rigidity on the stress intensity factor at the tip of the crack is illustrated. Shear stress distribution between the plate and the stringer and the stress intensity factors are obtained from the solution of a system of Fredholm integral equations. The continuity of displacements along the line of bond is represented by the equations.

Arin, K.↗