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At least 469 records · Page 26

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DOE OSTI2021

Fracturing process of micro-concrete under uniaxial and triaxial compression: Insights from in-situ X-ray mechanical tests

This paper presents an experimental study of concrete at meso-scale (aggregates, macro-pores and mortar matrix) in order to get a better understanding of the local failure mechanisms known to drive the macroscopic mechanical behaviour of the material. The main originality comes from conducting in-situ X-ray mechanical tests on micro-concrete samples of realistic composition (including cement, sand, aggregates and water), under uniaxial compression and, for the first time, under triaxial compression at 5 MPa, 10 MPa and 15 MPa confining pressures. A timeseries analysis of the set of 3D images coming from each test allows for the measurement of the 3D kinematic fields (displacement and strain fields) throughout the experiments. The different failure patterns observed for each loading path are discussed, along with a quantification of the 3D fracturing processes at the scale of the largest heterogeneities (aggregates and macro-pores). With an increasing level of confinement, the transition from brittle to ductile response is observed, as well as an increase of the strength of the material. The pronounced impact of the meso-scale heterogeneities of concrete on their local failure mechanisms is highlighted. It is shown that strain localisation mainly originates between aggregates and mortar matrix, with the shape and location of the largest aggregates and macro-pores essentially driving the propagation of the cracking network.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Explaining an unusual electromigration behavior—A comprehensive experimental and theoretical analysis using finite element method

In metallic interconnects, it is generally assumed that electromigration (EM) failure location is independent of the applied electrical current and always occurs at the highest-current-density area. Our experiments show otherwise. We designed an Al interconnect that alters its failure location by only varying the applied current density. The failure occurs near the high for a current above 2 × 10 7 A/cm 2 , but at a location with 59% of the maximum for lower current densities. Thermoreflectance thermal imaging is employed to gather time-dependent high-resolution spatial temperature distributions of the Al interconnect during EM. More importantly, we propose a computationally inexpensive 2D finite element method that tracks EM evolution in time and matches well with the observations from different experimental conditions. A detailed analysis covering the major driving forces of EM is carried out to understand the complex physics behind EM. The atomic depletion rate contributed by each force is quantitatively studied. By examining the results from every tested experimental condition, the model reveals that the temperature gradient is the key reason causing atomic depletion near the failure location. Graphical illustrations and qualitative analysis are provided to intuitively show the key findings of our work.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Relationship between Grain Size and Sample Thickness on the Creep-Rupture Performance of Thin Metallic Sheets of INCONEL Alloy 740H

A study was conducted on INCONEL® alloy 740H® to examine the role of grain size and sheet thickness on the alloy’s creep-rupture behavior. Three different starting sheet thicknesses were utilized and multiple heat-treatment conditions anticipated for compact heat exchanger (CHX) manufacturing were applied to produce a range of grain sizes. Creep-rupture testing was conducted at 750 °C for times up to about 6000 h and the results were compared to wrought databases. The data show that both creep strength and ductility were important factors in the overall creep performance of the sheets. Reductions in performance were observed due either to accelerated creep when grain size was fine or loss of rupture ductility when grain sizes approached the sheet thickness. Some combinations of heat-treatment and thickness were able to produce typical expected wrought creep properties. Historically a ‘rule-of-thumb’ requirement for creep testing suggests 3-5 grains per sample minimum dimension to ensure homogeneous behavior. This research shows that to ensure representative wrought creep performance (i.e. no effect of sample size), the sample minimum cross-section should be 10 times the average ASTM grain size. Statistical analysis of the microstructures suggests the population of larger grains as a controlling feature in creep failure.

14 SOLAR ENERGY↗

DOE OSTI2023

Large Local Currents in a Lithium-Ion Battery during Rest after Fast Charging

Increasing electric vehicle (EV) adoption requires lithium-ion batteries that can be charged quickly and safely. Some EV batteries have caught on fire despite being neither charged nor discharged. While the lithium that plates on graphite during fast charging affects battery safety, so do the internal ionic currents that can occur when the battery is at rest after charging. These currents are difficult to quantify; the external current that can readily be measured is zero. Here we study a graphite electrode at rest after 6C fast charging using operando X-ray microtomography. We quantify spatially resolved current density distributions that originate at plated lithium and end in underlithiated graphite particles. The average current densities decrease from 1.5 to 0.5 mA cm -2 in about 20 min after charging is stopped. Surprisingly, the range of the stripping current density is independent of time, with outliers above 20 mA cm -2 . In conclusion, the persistence of outliers provides a clue as to the origin of catastrophic failure in batteries at rest.

25 ENERGY STORAGE↗

DOE OSTI2022

Final Report for US DOE Grant DE-FG02-99ER54527

The failure of the NSTX-U coil in 2016 resulted in a redirection of UCLA’s NSTX-U research program. At that time UCLA had two functioning fluctuation reflectometer systems installed on the tokamak and was in the process of installing the new DBS/CPS system. These projects were placed on hold due to the NSTX-U recovery effort. UCLA in consultation with DOE OFES began a program of utilizing the equipment installed at NSTX-U in order to maximize the science output. In these discussion it was decided to move the V-band 50-75 GHz and the W-band 83-88 GHz multifrequency fluctuation reflectometer systems to the DIII-D tokamak. This would achieve two goals – to continue to provide important scientific input the US fusion research program and to test the new W-band system in a fusion research relevant plasma.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Bounding Radionuclide Release Estimates for a Hypothetical Power Reactor Accident

The object of this study is to provide an estimate of bounding radionuclide releases from a nuclear power plant accident. The time frame of interest is the release phase from the initiating event through 30 days. The maximum credible initiating event includes an initial failure of the containment function with a primary system leak. All estimates include a complete loss-of-onsite power and no successful mitigative actions. The active safety injection systems are also assumed failed. The review considers the following commonly deployed reactor designs in the following order of interest: RBMK 1000, VVER-440, VVER-1000, 1000 MWe PWR, 1000 MWe BWR, BN-800, and the 600 MWe CANDU/PHWR. The review also considers spent fuel pool accident scenarios.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Dynamic Probabilistic Safety Assessment Studies for Advanced Reactor Using RAVEN

Probabilistic Safety Assessment (PSA) is used extensively to evaluate the risks associated with complex engineering systems like Nuclear Power Plants (NPPs). Current PSA models are based on the Event-Tree/Fault-Tree (ET/FT) methodology. ET and FT models are static and are based on Boolean logic approaches. In the past, concerns have been raised in the literature regarding the capability of the traditional static modelling approaches to adequately account for the impact of process, hardware, software, firmware and human interactions on the stochastic system behaviour. To overcome the limitations of the traditional approach to PSA, several dynamic PSA methodologies have been proposed. One of the dynamic PSA methodologies used for dynamic evaluations is Dynamic Event Tree (DET) framework which can be used to assess the impact of the parameter variability and scenario dynamics on the PSA model for the initiating event. The DET framework couples the stochastic model (number of component/trains that start on demand, operator action timing, etc.) with a Thermal-Hydraulic (TH) model of the plant. This paper explores the use of DET along with a case study on advanced reactor. The initiating event selected for the study was Class IV power supply failure event. The TH analysis considering uncertainty in various parameters was performed using RELAP5 and Reactor Analysis and Virtual control ENvironment (RAVEN) tool. Based on the uncertainty analysis, it is concluded that the peak clad temperatures (PCT) are within the limits in all the code runs implying a high-degree of safety margin. However, variation in time to reach the PCT was observed among the code runs and the mean time to reach the PCT was found to be around 8590sec (approximately 2.4 hours). Hence, sufficient time margin is available for human intervention and the operator might have a relatively stress-free state during such an accident scenario. Due to the static nature of the traditional PSA models, the safety margin available was lesser, whereas, with the help of dynamic PSA models, one can demonstrate that the actual available safety margin is more in the present case study and is valuable input from the design point of view.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications

A bottom-up multi-scale modeling approach is used to develop an Integrated Computational Materials Engineering (ICME) framework for carbon fiber reinforced polymer (CFRP) composites, which has the potential to reduce development to deployment lead time for structural applications in lightweight vehicles. In this work, we develop and integrate computational models comprising of four size scales to fully describe and characterize three types of CFRP composites. In detail, the properties of the interphase region are determined by an analytical gradient model and molecular dynamics analysis at the nano-scale, which is then incorporated into micro-scale unidirectional (UD) representative volume element (RVE) models to characterize the failure strengths and envelopes of UD CFRP composites. Then, the results are leveraged to propose an elasto-plastic-damage constitutive law for UD composites to study the fiber tows of woven composites as well as the chips of sheet molding compound (SMC) composites. Subsequently, the failure mechanisms and failure strengths of woven and SMC composites are predicted by the meso-scale RVE models. Finally, building upon the models and results from lower scales, we show that a homogenized macro-scale model can capture the mechanical performance of a hat-section-shaped part under four-point bending. Along with the model integration, we will also demonstrate that the computational results are in good agreement with experiments conducted at different scales. The present work illustrates the potential and significance of integrated multi-scale computational modeling tools that can virtually evaluate the performance of CFRP composites and provide design guidance for CFRP composites used in structural applications.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Development of an Innovative Inspection Tool for Superheater Tubes in Fossil Fuel Power Plants

Fossil fuel power plants are complex systems containing multiple components that require periodic health monitoring. Failures in these systems can lead to increased downtime for the plant, reduction of power, and significant cost for repairs. Inspections of the plant’s superheater tubes are typically manual, laborious, and extremely time-consuming. This is due to their small diameter size (between 1.3 and 7.6 cm) and the coiled structure of the tubing. In addition, the tubes are often stacked close to each other, limiting access for external inspection. This paper presents the development and testing of an electrically powered pipe crawler that can navigate inside 5 cm diameter tubes and provide an assessment of their health. The crawler utilizes peristaltic motion within the tubes via interconnected modules for gripping and extending. The modular nature of the system allows it to traverse through straight sections and multiple 90° and 180° bends. Additional modules in the system include an ultrasonic sensor for tube thickness measurements, as well as environmental sensors, a light detecting and ranging (LiDAR) sensor, and camera. Furthermore, these modules utilize a gear system that allows for 360° rotation and provides a means to inspect the entire internal circumference of the tubes.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Enhanced Design of Radiation Tolerant High-Temperature Structural Health Monitoring Sensors

Acoustic emission sensors are vital in the nuclear industry for real-time structural health monitoring and early detection of material degradation. By capturing high-frequency stress waves emitted from defects like cracks, corrosion, or fatigue, acoustic emission sensors enable non-invasive monitoring of critical components such as reactor vessels, piping, and containment structures. This technology supports predictive maintenance, enhances safety, and ensures regulatory compliance by providing early warnings of potential failures. It is also instrumental in research, particularly in material testing reactors, where it is used to monitor the behavior of fuels and materials under irradiation, by allowing the detection of cracking or other acoustic signals in real time. This enables the evaluation of performance and accident behavior of advanced fuel concepts.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2020

A method to determine the electric field of liquid argon time projection chambers using a UV laser system and its application in MicroBooNE

Liquid argon time projection chambers (LArTPCs) are now a standard detector technology for making accelerator neutrino measurements, due to their high material density, precise tracking, and calorimetric capabilities. An electric field (E-field) is required in such detectors to 2020 JINST 15 P07010 drift ionization electrons to the anode where they are collected. The E-field of a TPC is often approximated to be uniform between the anode and the cathode planes. However, significant distortions can appear from effects such as mechanical deformations, electrode failures, or the accumulation of space charge generated by cosmic rays. The latter effect is particularly relevant for detectors placed near the Earth’s surface and with large drift distances and long drift time. To determine the E-field in situ, an ultraviolet (UV) laser system is installed in the MicroBooNE experiment at Fermi National Accelerator Laboratory. The purpose of this system is to provide precise measurements of the E-field, and to make it possible to correct for 3D spatial distortions due to E-field non-uniformities. Here we describe the methodology developed for deriving spatial distortions, the drift velocity and the E-field from UV-laser measurements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

High-speed synchrotron X-ray phase-contrast imaging for evaluating microscale damage mechanisms and tracking cracking behaviors inside cross-ply GFRCs

In this study, we integrated the high-speed synchrotron X-ray phase-contrast imaging (PCI) with a modified Kolsky compression bar loading platform to visualize the dynamic failure processes of cross-ply glass fiber reinforced composites (GFRCs). Four S-2 glass/SC-15 composite specimens were prepared, having similar thicknesses but different stacking sequences, namely as [0 12 /90 12 ], [90 12 /0 12 ], [0 8 /90 8 /0 8 ], and [90 8 /0 8 /90 8 ]. Three-dimensional synchrotron X-ray computed tomography and scanning electron microscopy (SEM) were employed to examine the microstructures and quantify the fiber volume fractions. Each specimen was notched and subjected to a dynamic three-point flexural loading. The onset of cracking close to the notch tip, crack propagation in 0° or 90° plies and their interface, crack opening, and ultimately failure of the specimen were captured by high-speed synchrotron X-ray PCI. Additional dynamic experiments were performed to determine the average time when the stress wave propagated through the specimen and correlate the X-ray images with the specimen's force-deflection response. Finally, the surface morphology of each specimen after the dynamic loading was imaged by SEM. Comparison between real-time X-ray images and post-fracture SEM images demonstrated the capability of the X-ray method to record damage evolution inside composites. Furthermore, the high spatial and temporal resolutions of the X-ray setup and edge enhancement by PCI enabled the identification of microscale damage features within 1 μs. Two damaging processes were identified, crack growth was quantified, and fracture toughness of the composites was evaluated. The method is deemed useful to reveal microscale damage mechanisms and track cracking behaviors inside cross-ply GFRCs under dynamic loading in real time.

42 ENGINEERING↗

DOE OSTI2020

Correlative acoustic time-of-flight spectroscopy and X-ray imaging to investigate gas-induced delamination in lithium-ion pouch cells during thermal runaway

It remains difficult to detect internal mechanical deformation and gas-induced degradation in lithium-ion batteries, especially outside specialized diagnostics laboratories. In this work, we demonstrate that electrochemical acoustic time-of-flight (EA-ToF) spectroscopy can be used as an insightful and field-deployable diagnostic/prognostic technique to sense the onset of failure. A 210 mAh commercial lithium-ion cell undergoing thermal abuse testing is probed with in situ and operando EA-ToF spectroscopy, together with simultaneous fractional thermal runaway calorimetry (FTRC) and synchrotron X-ray imaging. The combination of X-ray imaging and EA-ToF analysis provides new understanding into the through-plane mechanical deformation in lithium-ion batteries through direct visualisation and the acoustic ToF response. Internal structural changes, such as gas-induced delamination, are identified using EA-ToF spectroscopy due to variations in the attenuation and signal peak shifts. This is corroborated using X-ray imaging, demonstrating EA-ToF spectroscopy as a promising technique for detecting onset of battery failure.

25 ENERGY STORAGE↗

DOE OSTI2025

Reliability Analysis of Power Grids Considering Component Failures of Variable Energy Resources

This paper proposes an improved model for the reliability assessment of power systems considering component failures of variable energy resources (VER). The inherent intermittency of VER such as solar photovoltaic (PV) and wind farms, along with their susceptibility to component failures, present significant challenges to reliable system operation. These issues, combined with power grid operation and network constraints, complicate the reliable operation of VER-integrated power systems. Here, to address these concerns, this paper introduces a reliability assessment framework that considers VER input variability, its impact on component availability, and their resulting impact on overall system reliability. Stochastic models based on discrete Markov processes are developed to incorporate variable irradiance, wind speeds, and their effects on PV and wind component failure rates. A next-event and state transition-based approach is then developed to integrate the stochastic models into a mixed-timing sequential Monte Carlo simulation framework for composite reliability assessment. Case studies on the RTS-GMLC system demonstrate the effectiveness of the proposed model in evaluating the reliability of VER-integrated systems.

Pandit, Dilip [Sandia National Laboratories (SNL-N↗

DOE OSTI2026

A Technical Evaluation of Self-Protection Dose Rates in U.S. Domestic Nuclear Security Policy

U.S. nuclear security policy uses radiation self-protection as a basis for reducing material attractiveness, but existing dose-rate criteria may not reflect the time scales of theft or sabotage. This report evaluates whether the commonly cited 1 Gy/h at 1 m criterion can plausibly cause adversary task failure during short-duration malicious acts.

Fritchie, Jacob Wesley [Sandia National Laboratori↗

DOE OSTI2024

Fatigue and Creep-Fatigue Evaluation of Alloy 709 at 760 and 816°C

A significant research and development effort is underway to support the qualification of Alloy 709 as a Class A construction material in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. This initiative includes a comprehensive Alloy 709 code qualification plan aimed at generating extensive material testing data crucial for compiling the code case data package. The data package is essential in establishing material-specific design parameters for Alloy 709 to be used as Section III, Division 5 Class A construction material for fast reactors, molten salt reactors and gas-cooled reactors. An ASME Section III, Division 5 material code case requires the evaluation of mechanical properties from a minimum of three commercial heats, covering anticipated compositional ranges. A key part of the data package involves fatigue and creep-fatigue testing at elevated temperatures, needed for developing the fatigue design curves and the damage envelope of the creep-fatigue interaction diagram (D-diagram). This paper summarizes the strain-controlled fatigue testing on three commercial heats of Alloy 709 at 760 and 816°C with strain ranges between 0.25% and 3%. The fatigue failure data are used to generate a preliminary fatigue design curve. Additionally, the creep-fatigue testing results at 816°C with tensile hold times of 10, 30, and 60 minutes are presented in support of developing the D-diagram for Alloy 709.

Wang, Yanli↗

DOE OSTI2023

From Hydrometeor Size Distribution Measurements to Projections of Wind Turbine Blade Leading-Edge Erosion

Wind turbine blade leading-edge erosion (LEE) is a cause of increased operation and maintenance costs and decreased annual energy production. Thus, detailed, site-specific quantification of likely erosion conditions are critically needed to inform wind plant owner/operator decisions regarding mitigation strategies. Estimating the damage potential at a wind plant site requires accurate measurement of precipitation intensity, phase, droplet size distributions, wind speeds and their joint statistics. The current work quantifies the effect of disdrometer type on the characterization of LEE potential at a site in the US Southern Great Plains. using observations from three co-located disdrometers (an optical, an impact and a video disdrometer), along with hub-height wind-speed observations from a Doppler lidar and two LEE models: a kinetic energy model and the Springer model. Estimates of total kinetic energy of hydrometeor impacts over the four-year study period vary by as much as 38%, and coating lifetime derived from accumulated distance-to-failure estimates from the Springer model differ by an even greater amount, depending on disdrometer type. Damage potential at this site is concentrated in time, with 50% of impact kinetic energy occurring in 6–12 h per year, depending on which set of disdrometer observations is used. Rotor-speed curtailment during the most erosive 0.1–0.2% of 10 min periods is found to increase blade lifetimes and lead to the lowest levelized cost of energy.

17 WIND ENERGY↗

DOE OSTI2023

A Comprehensive Assessment Tool for Low-TRL Current Energy Converters

Along with a market-competitive levelized cost of energy, a current energy converter technology strongly benefits from an extensive consideration of socioeconomic, environmental, and regulatory factors early in the design process. As part of a technology performance level assessment, a series of assessment questions and guidance are developed and presented to evaluate an early-stage current energy technology on holistic criteria considering the entire device lifecycle. The assessment represents an accumulation of industry and research experience to date and relies on regular updates to ensure alignment with industry best-practices, regulatory requirements, and up-to-date technical understanding. A cradle-to-grave (materials, manufacturing, installation and deployment, operations and maintenance, and end-of-life) assessment of capabilities and functional requirements (i.e., high, medium, and low) performance criteria for current energy converters deployed in tidal, ocean current, and/or river applications. Key considerations related to manufacturing and installation include supply chain robustness, manufacturability and related job creation in the end-user and/or adjacent communities, and the time-to-repayment of the embodied energy debt. During deployment and maintenance operations, the safety of the device and subsystems during disconnect or grid failure, the difficulty and frequency of offshore heavy-lift activities, the avoidance or mitigation of area-use conflicts, the sea-states and weather conditions that permit maintenance access, and the availability of contingency plans (should conditions change unexpectedly) are a portion of the considered assessment criteria. Results include the potential impact of early-stage design decisions on the socioeconomic, environmental, and regulatory performance of a technology that allows developers to increase the product value and probability of success, and minimize costly late-stage design iterations through early and broad consideration of factors affecting overall performance and acceptability.

life cycle analysis↗