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DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Organic Direct-Bonded-Copper-Based Rapid Prototyping for Silicon Carbide Power Module Packaging

Silicon carbide (SiC) power devices are playing ever- growing roles in high-power-density power electronics converters by offering benefits such as high voltage rating, fast transients, and high thermal performance. Organic direct-bonded copper (ODBC)-based packaging, due to its ductility and ease of han- dling, allows the possibility of a more flexible layout design that may better tap the potential of SiC benefits. In this work, an ODBC-based prototyping routine is developed that accelerates the iterations of packaging layout design with low cost. The properties of ODBC and its handling are briefly introduced, and tools and fabrication steps are explained. Following this routine, a 1.2-kV SiC half-bridge power module is designed and fabricated with the focus on sub-nanohenry ultra-low loop inductance. Simulation and experimental validation are also conducted.

25 ENERGY STORAGE↗

DOE OSTI2025

Next Generation Sensor Development (CRADA Final Report)

B. Project Scope This was a collaborative effort between Lawrence Livermore National Security, LLC (LLNS), as manager and operator of Lawrence Livermore National Laboratory (LLNL) and The Federal Reserve Bank of San Francisco ("FRBSF" or "Participant"), to research and develop advanced processing techniques to measure the fitness and authenticity of U.S. currency. The FRBSF previously partnered with LLNL to evaluate end-of-life predictions, review sensor requirements, develop communications protocols, and perform thermal analysis. These Strategic Partnership Projects (SPP) included SPP No. L20960 - Federal Reserve Currency Technology Office Studies, SPP No. L15900 - Development of a Common Detector Interface (CDI 2.0) Specification and Hardware Simulators, and SPP No. L15610 - Limited Design Review of a Second-Generation E-Material Authentication Sensor (EMAS2).

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2025

IER-620 Pulsed-Neutron Die-Away (PNDA) with Oil Targets, CED3a

The Pulsed-Neutron Die-Away (PNDA) Testbed has previously been used to perform thermal scattering law validation measurements on HDPE and Lucite (IER-501) and water (IER-580). This experimental campaign expands the tests to include three additional hydrogenous materials relevant to various machining operations with fissionable materials. As such, it will use much of the same processes and equipment from the previous PNDA experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

IER-620 Pulsed-Neutron Die-Away (PNDA) with Oil Targets, CED3a

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Optimization of wall assembly for DOE Efficient New Homes Program in HUD’s Climate Zones 2 and 3

Manufactured homes provide affordable housing for over 20 million Americans. The U.S. Department of Energy’s Efficient New Homes (ENH) program has introduced new energy certification requirements that manufacturers can optionally target to ensure outstanding levels of energy savings, comfort, health, and durability. In collaboration with Clayton Homes (under User Agreement (NN-23-1469)), Oak Ridge National Laboratory evaluated multiple wall assembly options to meet ENH requirements in HUD Climate Zones 2 and 3, with a target maximum cost premium of 5%. After analyzing thermal performance, cost, and manufacturability, insulated structural sheathing was identified as the most practical and effective solution. A full-scale manufactured home prototype demonstrated that this approach meets energy performance goals with minimal disruption to existing manufacturing processes and a cost premium of less than 10% with a path to further lower costs, offering a promising path forward for more efficient manufactured housing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI1989

Nuclear Safety [Vol. 30, No. 3, July-September 1989]

Nuclear Safety is a review journal that covers significant developments in the field of nuclear safety. Its scope includes the analysis and control of hazards associated with nuclear energy, operations involving fissionable materials, and the products of nuclear fission and their effects on the environment. Primary emphasis is on safety in reactor design, construction, and operation; however, the safety aspects of the entire fuel cycle, including fuel fabrication, spent-fuel processing, nuclear waste disposal, handling of radioisotopes, and environmental effects of these operations, are also treated. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 325 Safety of Framatome Advanced Nuclear Steam Supply Systems Designs by J. A. Charles and D. Lange, 333 Book Review of Nuclear Accidents: Intervention Levels for the Protection of the Public by H. B. Piper; ACCIDENT ANALYSIS: 335 Living PRA Computer Systems by S. C. Dinsmore and H.-P. Balfanz, 343 Summary of ICAP Assessments of RELAP5/MOD2 by W. E. Driskell and R. G. Hanson; CONTROL AND INSTRUMENTATION: 352 Thermal Performance Monitoring System at Maanshan Nuclear Power Plant by H.-J. Chao, Y.-P. Lin, G.-H. Jou, L.-Y. Liao, and Y.-B. Chen; DESIGN FEATURES: 358 Warning Systems for Nuclear Power Plant Emergencies by J. H. Sorensen and D. S. Mileti; WASTE AND SPENT FUEL MANAGEMENT: 371 Activities Related to Waste Management Compiled by E G. Silver; OPERATING EXPERIENCES: 382 Steam Generator Tube Performance: Experience with Water-Cooled Nuclear Power Reactors During 1985 by O. S. Tatone and R. L. Tapping, 400 Systems Interaction Analyses: Concepts and Techniques (Part II) by M. D. Muhlheim and G. A. Murphy, 413 Reactor Shutdown Experience Compiled by J. W. Cletcher, 416 Operating U.S. Power Reactors Compiled by E G. Silver; RECENT DEVELOPMENTS: 440 General Administrative Activities Compiled by E G. Silver, 460 Reports, Standards, and Safety Guides by D. S. Queener, 466 Status of Power-Reactor Licensing Activities Compiled by E G. Silver, 470 Proposed Rule Changes as of Mar. 31, 1989; ANNOUNCEMENTS: 334 Proceedings Published, 351 CEC Seminar on Methods and Codes for Assessing the Off-Site Consequences of Nuclear Accidents, 357 Short Course on Multiphase Flow and Heat Transfer: Bases and Applications in A: The Nuclear Power Industry B: The Process Industries, 357 International Conference on Probabilistic Safety Assessment and Management, 478 International Topical Meeting on the Safety, Status, and Future of Non-Commercial Reactors and Irradiation Facilities, 475 The Authors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Enhancing Even Gas Distribution in Porous Media with Radial Flow

Packed beds, such as those used in thermal energy storage (TES) systems, typically use flow from one end to the other. This axial flow configuration leads to inefficiencies due to dispersion effects and high pressure drop. Instead of axial flow, this work proposes radial flow in packed beds, where a central tube provides flow that transports fluid from the center to the bed’s wall. Radial flow could be a promising solution to increase the efficiency of charging/discharging processes in TES systems. For instance, studies have been conducted on the thermal behavior during the charging process using radial flow and axial flow, and it was found that radial flow is better than axial flow in terms of thermal performance, where more energy can be stored in the storage tank during the charging process. However, the design of the radial pipe should be optimized to improve even flow distribution. In this work, numerical investigations on different designs were analyzed to enhance even flow gas distribution in the porous media when using this radial technique. This work shows the impact of different parameters on the even flow distribution into the packed bed for two different designs: 1) one radial tube at the center to provide the radial flow along with an annular tube at the wall to receive the flow, and 2) one radial tube at the center and four radial tubes at the wall. Air was used as fluid and 6 mm alumina beads as packing materials. Computational fluid dynamics (CFD) models in COMSOL Multiphysics were used to simulate the behavior of air flow through the piping and packed bed. It was found that the flow into the bed from the radial tube can be affected by different parameters: space between the holes, size/diameter of the holes, number of segments/zones, number of the holes in each zone and the length of each zone.

Beck, David M.↗

DOE OSTI2026

Genome collection processing for “Conserved upper thermal limits and small safety margins in soil copiotrophic bacteria”

We extracted the genomic DNA of 400 randomly selected isolates using a Quick-DNA Microprep Kit (Zymo Research D3020) according to the manufacturer’s protocol. We then submitted the extracted gDNA samples for short-read Illumina sequencing (200 Mbp) at SeqCoast Genomics (Portsmouth, NH, USA). After preprocessing the sequences using Trimmommatic (Bolger et al. 2014), we assembled the genomes using SPADES (Bankevich et al. 2012) and checked the quality of each assembly using QUAST (Gurevich et al. 2013). We processed the genome assemblies using a KBase (v1.4.0) pipeline (Allen et al. 2017; Arkin et al. 2018). Briefly, we used DRAM (v0.1.2) with default settings to annotate the genome assemblies. We then evaluated genome quality and possible contamination levels using CheckM (v1.0.18) (Parks et al. 2015) and retained genomes with completeness above 98% and contamination below 5% (n = 354), following the authors' guidelines. We then obtained taxonomic assignments for all remaining isolates using the Genome Taxonomy Database tool GTDB-Tk (v2.3.2, database version r214) (Chaumeil et al. 2019). We constructed a phylogenetic tree using the tool SpeciesTree (v2.2.0). We then trimmed the tree (using Trim SpeciesTree to GenomeSet- v1.4.0), retaining only tips within our collection with measured thermal performance.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

42 ENGINEERING↗

DOE OSTI2021

Candidate Core Designs for the Transformational Challenge Reactor

Early cycle activities under the Transformational Challenge Reactor (TCR) program focused on analyzing and maturing four reactor core design concepts: two fast-spectrum systems and two thermal-spectrum systems. A rapid, iterative approach has been implemented through which designs can be modified and analyzed and subcomponents can be manufactured in parallel over time frames of weeks rather than months or years. To meet key program initiatives (e.g., timeline, material use), several constraints—including fissile material availability (less than 250 kg of HALEU), component availabilities, materials compatibility, and additive manufacturing capabilities—were factored into the design effort, yielding small (less than one cubic meter in volume) cores with near-term viability. The fast-spectrum designs did not meet the fissile material constraint, so the thermal-spectrum systems became the primary design focus. Since significant progress has been made on advanced moderator materials (YH x ) under the TCR program, gas-cooled thermal-spectrum systems using less than 250 kg of HALEU that occupy less than 1 m 3 are now feasible. The designs for two of these systems have been evolved and matured. In both thermal-spectrum design concepts, bidirectional coolant flow is used. Coolant flows down through YH x moderator elements and is reversed in a bottom manifold and core support structure, and then flows up though or around the fuel elements. The main difference between the two thermal-spectrum design concepts is the fuel elements—one uses traditional UO 2 ceramic fuel, and the other uses UN-bearing TRISO fuel particles embedded inside a SiC matrix. Finally, core neutronics and thermal performance for these systems are assessed and summarized herein.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Improvements in the Sample Space for the Backscattering Silicon Spectrometer (BASIS)

The increase in neutron flux at the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source (SNS), currently operating at 2.0 MW proton beam power, has created new opportunities for higher-throughput neutron scattering experiments while also increasing the importance of minimizing background scattering and optimizing sample-environment operations. To address these challenges on the Backscattering Silicon Spectrometer (BA-SIS), several upgrades were developed and evaluated, including boron carbide (B₄C) masking for flat-plate sample containers, multi-cell sample holders used with a vertically translating sample stick, and an automated helium pump and purge (HPP) system for closed-cycle refrigerators. Neutron diffraction measurements demonstrate that B₄C masks reduce background scattering by 49–67%, outperforming both borated aluminum and boron nitride masks while introducing no additional Bragg reflections within the instrument’s accessible Q-range. Commissioning tests of a double-cell flat-plate sample contain-er showed no measurable crosstalk between adjacent sample compartments and con-firmed stable thermal performance, enabling multiple samples to be measured without re-peated temperature cycling. In addition, the automated HPP system provided reproducible sample-space gas handling with approximately ±1 mbar precision while reducing the need for operator intervention and supporting remote operation. Together, these developments improve signal-to-noise performance, increase experimental throughput, and enhance operational efficiency at BASIS, supporting the instrument’s continued operation under higher neutron flux conditions.

Jalarvo, Niina [ORNL] (ORCID:0000000306446866)↗

DOE OSTI2022

Ignition of Carbon Burning from Nuclear Fission in Compact Stars

Abstract Type Ia supernovae (SN Ia) are powerful stellar explosions that provide important distance indicators in cosmology. Recently, we proposed a new SN Ia mechanism that involves a nuclear fission chain reaction in an isolated white dwarf (WD). The first solids that form as a WD starts to freeze are actinide rich and potentially support a fission chain reaction. In this Letter, we explore thermonuclear ignition from fission heating. We perform thermal diffusion simulations and find at high densities, above about 7 × 10 8 g cm −3 , that fission heating can ignite carbon burning. This could produce an SN Ia or another kind of astrophysical transient.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Heat Transfer of an Integrated Counterflow Ceramic Heat Exchanger

The ceramic-based heat exchanger is one of the leading contenders for high-efficiency concentrating solar power plants using a molten salt heat transfer fluid and a supercritical carbon dioxide Brayton power cycle operating at temperatures above 700 °C due to the excellent resistance of ceramics to corrosion, oxidation, erosion, creep, and fouling. In the present study, the thermal performance of a ceramic silicon carbide prototype heat exchanger, with semi-elliptical heat transfer channels, integrated header channels, and a counterflow configuration fabricated by using binder jetting additive manufacturing, was experimentally investigated. Experimental heat transfer tests of the prototype were conducted at high temperatures and under various test fluid flow rates and inlet temperatures. The experimental heat transfer rates compared favorably with simulation predictions.

Yu, Wenhua (ORCID:0000000219457014)↗

DOE OSTI2020

Dielectrics for Power Electronics Applications

This presentation discusses the role of dielectric materials in power electronic packages. Two dielectric technologies - a dielectric material film-based substrate for insulation and a dielectric coolant - are discussed. The thermal performance benefits of dielectric film-based substrate in comparison with traditional direct-bond-copper substrates are studied through finite element analysis. Also, a novel cooling concept based on dielectric liquids that can contact electrically active surfaces are presented.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Numerical study of heat transfer enhancement in laminar and turbulent flow in enhanced tubes with uniform and non-uniform thermal boundary conditions

Various types of tube enhancements have been proposed in order to increase heat transfer while minimizing any associated increases in pressure drop. This paper presents a numerical study of two different types of enhanced tubes: the relatively common twisted tape insert tube, and a novel tube with airfoil shaped pins on the inner surface. Each tube is studied in both the laminar and turbulent flow regime. In addition to the typical constant temperature and constant flux boundary conditions, a non-constant heat flux boundary condition is applied on one half of the tube, a situation which may be encountered when absorbing solar radiation. In general, each type of enhanced tube offers a thermal performance factor greater than unity at certain Re. In addition, the non-uniform heat flux boundary condition appears to function similarly as the uniform heat flux boundary condition.

Sandlin, Matthew J.↗

DOE OSTI2020

Thermal Insulation for a High Temperature Molten Salt Storage Tank in a CSP Plant: Preprint

A ternary molten chloride has been suggested as a high temperature (550-720 °C) sensible heat storage medium for a two-tank system. An effective thermal insulation is proposed to provide an opportunity for the fabrication of both the hot and cold storage tanks from lower cost metals, e.g. A240-347H, by maintaining the tank wall below 500 °C. To achieve this, the hot storage tank mainly comprises of inner shell (11.4 cm of a refractory brick as liner (KX-99 ®), 30 cm of insulation brick) and outer metal shell, where 5 cm of frozen layer of PCM800 (NaCl), and 5 cm of ceramic wool fill the annular space between the shells. Another layer of ceramic wool was introduced at the outer side of the metal shell to keep the temperature lower than 60 °C. ANSYS Fluent was used for the numerical study of the cool down behavior of the system during idle period when tank is quarter-filled. The heat transfer modes were considered as radiation and natural convection heat transfer from the hot molten salt at 720 °C, conduction through the solid layers and convection heat transfer from the outer shell to the environment at 15 °C. The results showed that the proposed insulation system including a frozen layer of PCM800 maintains the temperature at the metal wall lower than 500 °C, and lower than 60 °C at the outer side of the tank. Apart from the insulation property of the frozen layer of PCM800, it absorbs any leak of hot molten salt, acting as a barrier between salt and the metal shell. The thermal performance analysis provide an insight into the benefits of the multilayer insulation.

41 EE - Solar Energy Technologies Office (EE-4S)↗