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DOE OSTI2022

Effect of tool design and pass strategy on defect elimination and uniform, enhanced tensile properties of friction stir processed high-pressure die-cast A380 alloy

This work reports implementation of friction stir processing (FSP) to locally modify microstructure and create a defect-free processing zone with the aid of different tool designs and altering the passing strategy for two different process parameter combinations. Here, FSP is applied on high pressure die-cast (HPDC) A380 alloy, a widely used Al-Si alloy fabricated in the die casting sector for automotive and aerospace applications. However, the presence of gas and shrinkage porosity, brittle needle-shaped Fe-containing ß-FeSiAl 5 intermetallic compounds, Al-dendrites, coarse and acicular silicon particles, and large second-phase particulates have a detrimental influence on the uniformity of tensile properties across the thickness direction of an HPDC plate. FSP is able to eliminate porosity, refine microstructure and improve tensile properties. An FSP tool design and a passing strategy are identified for the best microstructure consolidation and uniform enhanced tensile properties. This study noted the importance of tool features such as scroll design and flats on tool pin and multiple pass orientation strategy to find best combination of defect-free refined microstructure and uniform tensile strength and ductility across the processing zone of HPDC Al alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Experimental Verification of An Electro-Hydraulic Actuation System Driven by An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and a novel-designed electro-hydraulic unit (EHU) consisting of a fixed-displacement hydraulic gear machine and a variable-speed electric machine. The novel EHU design integrates an electric machine and a hydraulic machine in a single housing, targeting optimal compactness, power density, and component reduction. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. Here, the efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The efficiency of the EHA system based on the measurements on the test rig can reach 54% with up to 20 kN load and 6 kW power level. Furthermore, the EHU is implemented on the reference machine to drive the boom function. Preliminary results on the performance of the EHU show an efficiency of up to 68% under different loading conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Advanced Modeling and Simulation to Characterize Advanced Boiling Water Reactor Source Terms to Support a Regulatory Approval Pathway for Right-Sized Emergency Planning Zone. Advanced Boiling Water Reactor (A-BWR) Project Phase 2

The United States Department of Energy (US DOE) is currently supporting the development of various small modular reactor (SMR), microreactor and advanced reactor designs. These reactors have improved safety features as compared to conventional Large Light Water Reactors (LLWRs), which include features that improve potential reduction of radiological source terms in the event of design and beyond-design basis accidents. Specifically, some reactors feature a relatively smaller containment volume with respect to the available surface area for fission product deposition; these include Integrated Pressurized Water Reactors (iPWRs), such as the NuScale SMR and SMR-type Boiling Water Reactors (BWRs) such as General Electric-Hitachi’s BWRX-300 design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Severe Accident Phenomena: A Comparison Among the NuScale SMR, Other Advanced LWR Designs, and Operating LWRs

During a severe accident in a nuclear reactor, there are a number of phenomenological events which can present a challenge to containment integrity. These include the generation and combustion of hydrogen, energetic fuel-coolant interactions, thermal attack of fission product barriers, core-concrete interactions, direct containment heating, and gradual overpressurization. The advanced design of the NuScale small modular reactor has resulted in the reduced likelihood and severity of severe accident challenges to containment. This paper discusses the features of the NuScale design that reduce the likelihood of occurrence of these severe accident phenomena, and discusses the ability of containment to survive in the unlikely event that they do occur. Here, the impact of severe accident phenomena for the NuScale design is compared and contrasted against other advanced light water reactors, such as AP1000 and ESBWR, as well as the existing fleet, using information from publicly available documents.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Advanced Material Studies for High Intensity Proton Production Targets and Windows

The titanium alloy Ti6Al4V is widely used in accelerator facilities as beam windows, which are exposed to high cycle compressive stress waves from intense pulsed proton beams. Such materials interacting with the beam are subject to various forms of radiation damage, which can adversely affect their endurance limit. However, no fatigue data is currently available for high energy proton irradiated titanium alloy. Due to limitations in proton irradiation facilities, only miniature flat samples can be used for irradiation. To address this issue, we have developed a custom-made bend fatigue tester at Fermilab specifically for testing proton irradiated titanium alloy. In this presentation, we report on the fatigue test results obtained from this custom-fatigue tester using a non-ASTM standard specimen design. We plan to validate these sparse fatigue data with ASTM standard samples using standard fatigue samples. Furthermore, we have modified another commercial bend fatigue tester to accommodate miniature samples, and discuss some inherent deficiencies of the commercial fatigue tester to test miniature samples. To overcome this issue, a new fixture design is presented, which enables satisfactory fatigue testing on miniature samples over long periods. Finally, we present an upgrade to the custom-fatigue tester, featuring this new fixture design.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Advanced Material Studies for High Intensity Proton Production Targets and Windows

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Jet classification using high-level features from anatomy of top jets

Recent advancements in deep learning models have significantly enhanced jet classification performance by analyzing low-level features (LLFs). However, this approach often leads to less interpretable models, emphasizing the need to understand the decision-making process and to identify the high-level features (HLFs) crucial for explaining jet classification. To address this, we consider the top jet tagging problems and introduce an analysis model (AM) that analyzes selected HLFs designed to capture important features of top jets. Our AM mainly consists of the following three modules: a relation network analyzing two-point energy correlations, mathematical morphology and Minkowski functionals for generalizing jet constituent multiplicities, and a recursive neural network analyzing subjet constituent multiplicity to enhance sensitivity to subjet color charges. We demonstrate that our AM achieves performance comparable to the Particle Transformer (ParT) while requiring fewer computational resources in a comparison of top jet tagging using jets simulated at the hadronic calorimeter angular resolution scale. Furthermore, as a more constrained architecture than ParT, the AM exhibits smaller training uncertainties because of the bias-variance tradeoff. We also compare the information content of AM and ParT by decorrelating the features already learned by AM. Lastly, we briefly comment on the results of AM with finer angular resolution inputs.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Verification of the PERSENT Software

Ongoing commercial design activities require a thorough verification of the Argonne Reactor Computation codes be performed. DIF3D is central to this system and substantial work has been done to verify its accuracy on several identified commercial needs. This manuscript details the verification work done on PERSENT which relies upon the DIF3D code for its forward and adjoint flux solution. Previous work identified the PERSENT features required to be verified to support commercial design activities, features of which are generally applicable to hexagonal-Z fast reactor designs. The scope of this verification effort includes verifying PERSENT’s ability to correctly calculate four key quantities: perturbation worth distributions, kinetics parameters, sensitivity coefficients, and cross section uncertainty quantification. This manuscript provides the verification tasks and their results with respect to these quantities needed for commercial design activities. For the perturbation worth distributions, hand calculations are deployed to verify the PERSENT calculated results. Similarly, hand calculation of the PERSENT computed kinetics parameters is also used to verify the PERSENT results. In both of these, the input to PERSENT is manipulated to ensure the hand calculation exactly matches the equations PERSENT is calculating. The sensitivity coefficients involve calculating the derivatives of a parameter (such as reactivity worth), with respect to the cross section data. Direct finite difference calculations with DIF3D are used to verify the PERSENT calculated results. For the uncertainty quantification, manufactured input to PERSENT is used to allow an exact hand calculation to reproduce the PERSENT calculated results. The work detailed in this report verified that significant issues were identified for earlier versions of PERSENT for sensitivity coefficients which were corrected in this work and thus version 12.1.0 of PERSENT must be used to reproduce all of the verified work in this report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Frequency Response Improvement in a Standalone Small Hydropower Plant Using Battery Storage

This paper proposes a control architecture for frequency, current, and voltage control that facilitates using battery storage to improve the response of standalone small hydropower plants. The frequency controller uses rate-of-change of frequency and frequency-Watt-based generations to produce active power commands. The distinctive feature of the controller design is that it nicely integrates response to frequency change with constraints on frequency and state of battery to enable power injections. The current and voltage control scheme allows incorporating the frequency controller. The distinctive feature of this controller is that it incorporates a bounded integral control strategy that guarantees stability. Results on the stability of the hydropower plant with proposed scheme are presented and robust ways to choose the controller gains are investigated via root locus analysis. In conclusion, simulations performed show that: the hydropower plant response is significantly improved with battery storage using the proposed scheme; the load carrying capability of the hydropower plant is significantly improved with battery storage; the proposed scheme has the capability to recharge the battery; and the proposed control scheme gives improved performance.

13 HYDRO ENERGY↗

DOE OSTI2023

gRNA-SeqRET: a universal tool for targeted and genome-scale gRNA design and sequence extraction for prokaryotes and eukaryotes

High-throughput genetic screening is frequently employed to rapidly associate gene with phenotype and establish sequence-function relationships. With the advent of CRISPR technology, and the ability to functionally interrogate previously genetically recalcitrant organisms, non-model organisms can be investigated using pooled guide RNA (gRNA) libraries and sequencing-based assays to quantitatively assess fitness of every targeted locus in parallel. To aid the construction of pooled gRNA assemblies, we have developed an in silico design workflow for gRNA selection using the gRNA Sequence Region Extraction Tool (gRNA-SeqRET). Built upon the previously developed CCTop, gRNA-SeqRET enables automated, scalable design of gRNA libraries that target user-specified regions or whole genomes of any prokaryote or eukaryote. Additionally, gRNA-SeqRET automates the bulk extraction of any regions of sequence relative to genes or other features, aiding in the design of homology arms for insertion or deletion constructs. We also assess in silico the application of a designed gRNA library to other closely related genomes and demonstrate that for very closely related organisms Average Nucleotide Identity (ANI) > 95% a large fraction of the library may be of relevance. The gRNA-SeqRET web application pipeline can be accessed at https://grna.jgi.doe.gov. The source code is comprised of freely available software tools and customized Python scripts, and is available at https://bitbucket.org/berkeleylab/grnadesigner/src/master/ under a modified BSD open-source license (https://bitbucket.org/berkeleylab/grnadesigner).

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI1992

Nuclear Safety [Vol. 33, No. 4, October-December 1992]

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: 499 Technical Note: Nuclear Regulatory Commission’s Examination Question Bank System, C. L Jensen and N. L. Skinner; 506 Report on the Specialists’ Meeting on Passive and Active Safety Features of Liquid-Metal Fast Breeder Reactors Organized by the International Atomic Energy Agency at Oarai Engineering Centre of Power Reactor and Nuclear Development Corporation, Japan, November 5-7,1991, S. R. Paranjpe; ACCIDENT ANALYSIS: 514 A Review of Hydrogen Production During Melt/Water Interaction in LWRs, D. F. Fletcher, B. D. Turland, and S. P. A. Lawrence; 535 A Review of the U 3 0 8 -Al Reaction as a Potential Heat Source in Research and Test Reactor Accidents, J. L. Snelgrove; CONTROL AND INSTRUMENTATION: 543 Multilevel Interfaces for Power Plant Control Rooms II: A Preliminary Design Space, K. J. Vicente; DESIGN FEATURES: 549 Twenty-Second DOE/NRC Nuclear Air Cleaning and Treatment Conference, R. R. Bellamy, D. W. Moeller, and M. W. First; 562 Book Review: Safety Assessment of Unit 5 (WWER-440/W-213) of the Greifswald Nuclear Power Station, M. H. Fontana; WASTE AND SPENT FUEL MANAGEMENT: 576 Activities Related to Waste and Spent Fuel Management, M. D. Muhlheim and E. G. Silver; OPERATING EXPERIENCES: 586 Analysis of Corrective Actions Applied to Nuclear Power Plant Operations, A. E. Cross; 593 Reactor Shutdown Experience, Compiled by J. W. Cletcher; 596 Operating U.S. Power Reactors, Compiled by M. D. Muhlheim and E. G. Silver; 609 Non-Commercial Power Operating Experience; 614 World Nuclear Performance, Compiled by M. D. Muhlheim; RECENT DEVELOPMENTS: 623 General Administrative Activities, Compiled by M. D. Muhlheim and E. G. Silver; 635 Reports, Standards, and Safety Guides, D. S. Queener; 639 Proposed Rule Changes as of June 30, 1992; ANNOUNCEMENTS: 513 Fourth International Conference on Nuclear Fuel Reprocessing and Waste Management RECOD '94; 585 International Topical Meeting on Advanced Reactors Safety; 622 International Workshop on Implementation of ALARA at Nuclear Power Plants; 648 Short Course on Nuclear Criticality Safety; 648 8th Topical Meeting on Problems in Reactor Physics MEPhi-VOLGA-93; 643 The Authors; 646 Reviewers of Nuclear Safety, Vol. 33

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Conceptual design of a high reactive-power ferroelectric fast reactive tuner

We present a novel design of a ferroelectric fast reactive tuner (FE-FRT) capable of modulating mega-VAR reactive power on a submicrosecond timescale. The high reactive power capability of our design extends the range of applications of reactive tuners to numerous applications. We present a detailed analytical model of the performance of a megawatt-class reactive power device and benchmark it against finite-element method eigenmode and frequency domain electromagnetic simulations. We introduce new features, including an annulus design for the ferroelectric capacitors and capacitive window coupling to the cavity. We consider thermal design issues and nonlinear effects in the ferroelectric. The model covers several configurations, allowing control of the frequency of superconducting and normal-conducting cavities in a variety of applications and frequencies. We calculate that the FE-FRT designed should be capable of handling around 0.45 MVAR of reactive power with around 3 kW of resistive losses, providing a frequency tuning range of 8 kHz in an example of 400 MHz cavity geometry. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

The Low-Beta Quadrupoles for the High-Luminosity Large Hadron Collider: enabling higher luminosity by using Nb_3Sn conductor

The large-aperture, high-gradient Low Beta Quadrupoles for the High Luminosity Large Hadron Collider at CERN are the cornerstones of this collider. They are first-of-the-kind accelerator magnets bringing Nb_3Sn conductor to High Energy Physics colliders. In the US they are being fabricated and tested by the HL-LHC Accelerator Upgrade Project (AUP), and in Europe by CERN. The design was developed by AUP and CERN in close collaboration. The Q1/Q3 cryo-assemblies contain two 4.2 m long magnets (MQXFA) fabricated and by AUP. They are tested vertically before use in a cry-assembly. In this paper we are going to present the main features of the MQXFA design, results of vertical tests, and main lessons learned. We will also discuss lessons learned for future use of Nb_3Sn magnets in HEP colliders.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Mechanical, Microstructural, and Electrochemical Characterization of NaSICON Sodium Ion Conductors [Poster]

The DOE Office of Electricity views sodium batteries as a priority in pursuing a safe, resilient, and reliable grid. Improvements in solid-state electrolytes are key to realizing the potential of these large-scale batteries. NaSICON structure consists of SiO 4 or PO 4 tetrahedra sharing common corners with ZrO 6 octahedra. Structure forms “tunnels” in three dimensions that can transport interstitial sodium ion. 3D structure provides higher ionic conductivity than other conductors (β’’-alumina), particularly at low temperature. Lower temperature (cheaper) processing compared to β’’-alumina. Our objective was to identify fundamental structure-processing-property relationships in NaSICON solid electrolytes to inform design for use in sodium batteries. In this work, the mechanical properties of NaSICON sodium ion conductors are affected by sodium conduction. Electrochemical cycling can alter modulus and hardness in NaSICON. Excessive cycling can lead to secondary phases and/or dendrite formation that change mechanical properties in NaSICON. Mechanical and electrochemical properties can be correlated with topographical features to further inform design decisions

25 ENERGY STORAGE↗

DOE OSTI2025

Harnessing ionic complexity: A modeling approach for hierarchical ionic circuit design

Since the 1950s, soft ionic devices have evolved from individual components to an expanding library of sensors, actuators, signal transmitters, and processors. However, integrating these components into complex, multifunctional systems remains challenging due to the nonintuitive and nonlinear interactions between ionic elements. In this work, we address these fundamental challenges by developing a lumped element model that enables interrogation of the physics that governs ionic circuits, as well as rapid design and optimization. Our model captures features specific to ionic charge carriers, while preserving the hierarchical design flexibility and computational efficiency of traditional circuit modeling. We demonstrate that our model can not only fit individual device behavior but also accurately predict the behavior of larger circuits formed by combining those devices. Additionally, we show how our tool utilizes the intrinsic nonlinearities of ionic systems to enable extended functionality, revealing how factors such as ion enrichment, ion leakage, and polymer charge density influence performance. Lastly, we present a fully ionic power supply, sensor, control system, and actuator for a soft robot that adapts its motion in response to environmental salt, illustrating the tool’s potential to accelerate advancements in chemical sensing, biointerfacing, biomimetic systems, and adaptive materials.

42 ENGINEERING↗

DOE OSTI2021

Design Guidelines for Deployable Wind Turbines for Military Operational Energy Applications

This document aims to provide guidance on the design and operation of deployable wind systems that provide maximum value to missions in defense and disaster relief. Common characteristics of these missions are shorter planning and execution time horizons and a global scope of potential locations. Compared to conventional wind turbine applications, defense and disaster response applications place a premium on rapid shipping and installation, short-duration operation (days to months), and quick teardown upon mission completion. Furthermore, defense and disaster response applications are less concerned with cost of energy than conventional wind turbine applications. These factors impart design drivers that depart from the features found in conventional distributed wind turbines, thus necessitating unique design guidance. The supporting information for this guidance comes from available relevant references, technical analyses, and input from industry and military stakeholders. This document is not intended to be a comprehensive, prescriptive design specification. This document is intended to serve as a written record of an ongoing discussion of stakeholders about the best currently available design guidance for deployable wind turbines to help facilitate the effective development and acquisition of technology solutions to support mission success. The document is generally organized to provide high-level, focused guidance in the main body, with more extensive supporting details available in the referenced appendices. Section 2 begins with a brief qualitative description of the design guidelines being considered for the deployable wind turbines. Section 3 provides an overview of the characteristics of the mobile power systems commonly used in U.S. military missions. Section 4 covers current military and industry standards and specifications that are relevant to a deployable wind turbine design. Section 5 presents the deployable turbine design guidelines for the application cases.

17 WIND ENERGY↗

DOE OSTI2025

A Computational Framework to design 3D stiffness gradient acoustic metamaterials for impedance matching

Acoustic waves play a crucial role in various applications, including medical imaging, non-destructive testing, and sonar systems. One of the significant challenges in these applications is impedance matching, which is essential for minimizing reflections and maximizing the transfer of acoustic energy between different media. Acoustic metamaterials offer a promising solution to this challenge. In addition to impedance control, gradient stiffness can enhance structural efficiency and enable spatial control of wave propagation, making it a valuable feature in acoustic metamaterial design. In this pa- per, we present our developed computational method to design 3D stiffness gradient acoustic metamaterials for impedance matching. The key steps in our approach include generating initial designs using a periodic covariance function to provide unit cells that are both periodic on the boundaries and randomly formed inside the unit cell. Furthermore, we integrated manufacturing constraints into the design process, ensuring that the structures are interconnected for fabrication. We propose two computational optimization algorithms: GenUnit, based on a non-dominated sorting genetic algorithm (NSGA-II), and MLMatch, which leverages differentiable machine learning. The two approaches are not separate contributions but complementary com- ponents of a unified framework. GenUnit requires no training data and directly interfaces with physics-based simulations, making it highly accurate but slower for large-scale exploration. In contrast, MLMatch is data-hungry during training but, once trained, enables near-instantaneous inference and broad design-space coverage. Together, they form a hybrid strategy: ML- Match rapidly explores the global design space, and GenUnit provides local refinement with high-fidelity accuracy. This balance between training cost, inference time, and precision is the motivation for including both methods in the same study. We applied this dual-algorithm framework to generate two metallic-based metamaterial designs that match the acoustic impedance of water while exhibiting a controlled gradient in stiffness (from stiff to soft). The stiffness gradient is particularly advantageous in applications where one side of the structure must interface with soft or sensitive surfaces, such as human tissue or delicate components. Here, this work paves the way for improved materials in various acoustic applications, particularly in ultrasound devices, by providing better impedance.

Metamaterial↗

DOE OSTI2023

Book Chapter: Small Modular Reactors

Small Modular Reactors (SMRs) have been a very promising development in nuclear power over the last two decades. SMRs are defined as nuclear reactors with a power output of less than 300 MWe. This is in comparison to gigawatt-size reactors, which can have electrical output of 1000–1500 MWe or more. This chapter will consist of two major sections. The first will be a detailed summary of the small modular reactor designs being proposed around the world. This section will focus on those that are the furthest along in their development, but will also include some information about the wide variety of proposed designs that require significant research and development. The second part will be a discussion of the remaining challenges to the adoption of SMRs as a major energy source. SMRs are not a new concept, but they do represent a new vision for an older concept. These reactors have the potential to become a major source of energy in the near future. The development of small, modular designs can help promote the adoption of nuclear energy by reducing upfront costs, reducing the financial risk associated with nuclear power, and the barriers to entry. However, the adoption of SMRs is not without challenges. Regulatory and licensing changes to address the unique benefits and concerns associated with SMRs will continue to be a challenge as regulators adapt to the unique features emerging from the design process. The development of new instrumentation and control systems is an ongoing issue. And economics is possibly the most significant challenge, with high construction costs, cheap natural gas, and government subsidies, combining to result in significant financial risk associated with adopting nuclear generation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗