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DOE OSTI2025

Determination of Scale Bar for AGHCF Metallography Data

The DOE Nuclear Energy Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) has supported the development of several databases containing information on the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data represents one of the most critical types of post-irradiation examination (PIE) data being collected, organized, and archived in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Metallic Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three principal sets of metallography data. The first set comprises metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins examined in the Hot Fuel Examination Facility (HFEF). The second set consists of metallography data from EBR-II irradiated fuel pins examined in the Alpha-Gamma Hot Cell Facility (AGHCF). The third set includes metallography data from transient-tested fuel pins (including both out-of-pile furnace tests and TREAT tests) examined in AGHCF. Since both the second and third sets were generated in AGHCF, they are governed by identical specifications. The metallography data in the databases consist of digital images scanned from either positive or negative photographic films. To analyze the microstructure of a fuel pin, a series of preparatory steps are required, including sectioning, epoxy mounting, mechanical grinding and polishing, and etching. Following sample preparation, specimens are transferred for metallographic examination. The AGHCF and HFEF metallography data were generated using optical microscopes manufactured by Leitz and Bausch and Lomb (B&L). Images were recorded on Polaroid film at preset magnifications. Magnification verification for the Leitz and B&L metallographs was conducted every two months prior to 1989 and at least every six months from 1989 through the conclusion of the IFR program. Magnifications determined from imaging of microslide standards were compared to the instrument settings for magnifications ranging from 50× to 500×. If the magnifications determined from standards deviated from the instrument settings, adjustments were made to the bellows extension until agreement was achieved. The specifications for AGHCF and HFEF legacy metallography data have been established based on available hard-copy and digital records, most of which have been incorporated into the data repositories associated with FIPD, OPTD, and TREXR. Detailed specifications including hard-copy records, digitized records, cutting diagrams and sectioning schemes, high-magnification photographs, photomosaics (composites), information tags, scale bars, and magnification verification procedures can be found in a separate report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

A Comparative Study on Representativeness and Stochastic Efficacy of Miniature Tensile Specimen Testing

Here, in this article, a miniature dog bone tensile coupon design was tested against the existing ASTM standard specimen design. Specimens were prepared from commercially sourced austenitic stainless steel 304 alloy, and a defect-ridden additively manufactured 304L alloy was studied. By utilizing a tensile specimen design that is 1/230th volume of the smallest ASTM E8-04(2016), Standard Test Methods for Tension Testing of Metallic Materials, dog bone specimen, coupled to a digital image correlation (DIC) setup, case studies were performed to compare tensile property measurements and strain field evolution. Whereas yield strength measurements were observed to be similar, post-yield, the ultimate strength measurements and ductility measurements from the miniature specimens were observed to be higher than the ASTM specimen design. Although the strength measurements were comparable, the strain evolution was found to differ in the miniature specimens. Studies to assess effects of varying thickness and defect population were also pursued on the miniature tensile specimen. From the DIC strain field estimations, the peak local strain values at ultimate tensile strength were observed to be increasing with reducing specimen thickness. Testing of defect ridden stainless steel revealed the sensitivity to failure through strain localization and the influence of defect size was captured in the strength measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Summary of Methodology for Mitigating Risks Associated with Licensing and Qualifying AM Nuclear Materials

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program focuses on accelerating the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Laser powder bed fusion (LPBF) is one of the most popular additive manufacturing (AM) processes for fabricating components with intrinsically complex geometries. LPBF was extensively explored for nuclear applications under the previous Transformational Challenge Reactor program. Additionally, Oak Ridge National Laboratory developed and licensed the Peregrine software and larger digital platform that couples machine learning and in situ data collection during AM to detect anomalies and any evolved defects. The digital platform will be critical to (1) the qualification of AM components for nuclear applications that link location-specific data to macroscopic properties and (2) predict final component performance. Current in situ process monitoring tools are valuable for observing the formation of stochastic flaws, but additional data are needed to predict the resulting microstructures and associated material performance. Rapid cooling rates and large thermal gradients have caused large heterogeneities in the microstructure, which cause anisotropy in mechanical performance. The AMMT program is evaluating the best approaches for addressing these heterogeneities and their effect on component performance using a combination of multiscale modeling, enhanced in situ process monitoring, and high throughput experimental testing. This report summarizes strategies for mitigating the risks associated with qualifying AM components, including developing new sensing capabilities for in situ process monitoring and characterizing melt pool solidification and residual stresses to inform multiscale modeling efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

SQUID With Integral Flux Concentrator

In improved superconducting quantum interference device (SQUID), change in size and shape of superconducting ring improves coupling to external signal coil and eases coil-positioning tolerances. More rugged and easier to manufacture than conventional SQUID's with comparable electrical characteristics. Thin-film superconducting flux concentrator utilizes Meissner effect to deflect magnetic field of signal coil into central hole of SQUID. Used in magnetometers, ammeters, analog-to-digital converters, and related electronic applications in which high signal-to-noise ratios required.

Peters, Palmer N.↗

DOE OSTI2022

GELINA DU-Mo Rotating Target Assembly Fabrication [Slides]

This presentation provides a timeline and delivery schedule for the GELINA DU-Mo Rotating Target, including drawing digitization and translation, fabrication, and assembly.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

36 MATERIALS SCIENCE↗

DOE OSTI2020

Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing

In this study, we aim to advance the structural analysis of wire and arc additive manufacturing (WAAM) by considering the thermomechanical features inherent in direct energy deposition. Simulation approaches including the iterative substructure method (ISM), dynamic mesh refining method (DMRM), and graphics processing unit (GPU) based explicit finite element method (FEM) were developed for accelerating additive manufacturing stress analysis that is very time consuming by conventional numerical methods. ISM and DMRM take advantage of the strong nonlinearity phenomenon near the moving heat source by reducing the global iterations and refining the local mesh, respectively. In addition to the use of GPUs, the explicit FEM is accelerated by a time scaling technique based on the inherent strain concept. The residual stress and distortion of two large builds were analyzed, showing very consistent numerical results and good agreement with experiments. Compared with the commercial software Abaqus, the novel approaches reduced the computational cost substantially without compromising accuracy. The GPU code showed the highest computational efficiency (30~70×), while DMRM and ISM had acceleration factors of 9× and 3×, respectively. Finally, such high-fidelity modeling approaches will be very useful for building up a digital twin of WAAM to reduce development time and cost.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Basic Research of Intrinsic Tamper Indication Markings and Patterns Defined by Pulsed Laser Irradiation (Final Report)

Pulsed laser irradiation has been used to create complex, intrinsic markings that can be used as unique identifiers for authentication and asset protection. Markings have been made on the surface of various materials by rapidly scanning a focused laser beam across a designated area as large as several square inches. Markings include macro-scale patterns, such as barcodes, that contain encrypted information. More complex markings are comprised of macro-scale patterns and embedded, unique micro-scale features. Micro-scale features form spontaneously during scanned laser irradiation and have different shapes, spacings, color and other characteristics that are virtually impossible to recreate. The macro-scale patterns can be interrogated rapidly in the field using a digital camera, while the embedded micro-scale features are best evaluated in the laboratory using microscopy or related optical techniques. Interrogated markings are compared with archived maps of the original patterns (obtained at the time of their manufacture) to determine component authenticity. The majority of experiments have involved marking planar solids. A new instrument that marks non-planar substrates is described for future work.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Data from "What regulates decomposition in agroecosystems? Insights from reading the tea leaves"

Litter decomposition is a critical Earth process, recycling nutrients and setting a portion of plant tissue on a path toward soil organic matter. Despite this importance, we still lack a good understanding of local factors that regulate decomposition, especially in agroecosystems where management plays an outsized role. To help understand these factors, 1308 tea bags containing green and rooibos tea leaves were buried in 109 plots being exposed to a variety of management practices. This dataset contains the decomposition measurements (mass) of those tea bags that were collected 6 times during the 2018 growing season at 9 long-term experimental farms in Iowa, USA. Additionally, the dataset contains a variety of soil and crop measurements to support the understanding of the soils and the decomposition measurements. Files are presented in .csv format.

Agricultural land management↗

NASA NTRS1993

Differential temperature stress measurement employing array sensor with local offset

The instrument has a focal plane array of infrared sensors of the integrating type such as a multiplexed device in which a charge is built up on a capacitor which is proportional to the total number of photons which that sensor is exposed to between read-out cycles. The infrared sensors of the array are manufactured as part of an overall array which is part of a micro-electronic device. The sensor achieves greater sensitivity by applying a local offset to the output of each sensor before it is converted into a digital word. The offset which is applied to each sensor will typically be the sensor's average value so that the digital signal which is periodically read from each sensor of the array corresponds to the portion of the signal which is varying in time. With proper synchronization between the cyclical loading of the test object and the frame rate of the infrared array the output of the A/D converted signal will correspond to the stress field induced temperature variations. A digital lock-in operation may be performed on the output of each sensor in the array. This results in a test instrument which can rapidly form a precise image of the thermoelastic stresses in an object.

Lesniak, Jon R.↗

DOE OSTI2021

Hierarchical porous metals with deterministic 3D morphology and shape via de-alloying of 3D printed alloys

The present disclosure relates to a method for forming a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale pore architectures. The method may involve providing a feedstock able to be applied in an additive manufacturing process, and using an additive manufacturing process to produce a three dimensional (3D) structure using the feedstock. The method may involve further processing the 3D structure through at least a de-alloying operation to form a metallic 3D structure having an engineered, digitally controlled macropore morphology with integrated nanoporosity.

Qi, Zhen↗

NASA NTRS2010

Effects of Hydrocarbon-Based Grease on Rapid Prototype Material Used for Grease Retention Shrouds

Effects of hydrocarbon-based greases on specific rapid prototype (RP) materials used to fabricate grease retention shrouds (GRS) were explored in this study. Grease retention shrouds are being considered as a way to maintain adequate grease lubrication at the gear mesh in a prototype research transmission system. Due to their design and manufacturing flexibility, rapid prototype materials were chosen for the grease retention shrouds. In order to gain a better understanding of the short and long term effects grease pose on RP materials, research was conducted on the interaction of hydrocarbon-based grease with RP materials. The materials used in this study were durable polyamide (nylon), acrylonitrile butadiene styrene (ABS), and WaterClear 10120. Testing was conducted using Mobilgrease 28 and Syn-Tech 3913G grease (gear coupling grease). These greases were selected due to their regular use with mechanical components. To investigate the effect that grease has on RP materials, the following methods were used to obtain qualitative and quantitative data: Fourier transform infrared spectroscopy (FT-IR), interference profilometer measurements, digital camera imaging, physical shape measurement, and visual observations. To record the changes in the RP materials due to contact with the grease, data was taken before and after the grease application. Results showed that the WaterClear 10120 RP material provided the best resistance to grease penetration as compared to nylon and ABS RP materials. The manufacturing process, and thus resulting surface conditions of the RP material, played a key role in the grease penetration properties and resilience of these materials.

Zakrajsek, Andrew J.↗

NASA NTRSDate not supplied

Finite Element Analysis Validation for Stitched, Blade-Stiffened Aerospace Structures

Increased performance and manufacturing rates for aircraft or spacecraft structures may be achieved using stitched and resin infused composite structures. In order to carry out design and analysis of stitched composites, 2-dimensional (2-D) and 3-dimensional (3-D) modeling approaches for stitched and non-stitched carbon fiber vacuum-infused parts were developed. These analysis approaches will be compared with data from previous test specimens tested at the NASA Langley Research Center (LaRC) under tension and bending load conditions. The preliminary results presented herein for the 2-D and 3-D models capture the strain patterns observed in digital image correlation (DIC) data for stitched, blade-stiffened specimens tested in either tension or bending. The analysis method study presented for these specimens is part of a larger analysis development effort planned for stitched composites, with the modeling practices developed here contributing to those that may be applied to a new set of blade- stiffened test specimens that are currently being manufactured for testing as well as the design of a blade stringer pull-off test. These future tests are expected to provide opportunities to validate the developed modeling approaches for predictive purposes, and to provide opportunities for further refinement of the modeling approaches.

HiCAM↗

DOE OSTI2021

Supervisory control and health monitoring framework for large-scale additive manufacturing systems. Final CRADA report

ORNL worked with National Instruments (NI) to develop a large-scale, complex additive manufacturing (AM) systems framework for remote health monitoring and supervisory control. We found the framework, based on the Lincoln Electric Metal AM system located at ORNL’s MDF, capable of controlling the process, leading to improved part quality and digital twin creation.

42 ENGINEERING↗

DOE OSTI2014

A resonant sensor composed of quartz double ended tuning fork and silicon substrate for digital acceleration measurement

Presented in this paper is a micro-resonant acceleration sensor based on the frequency shift of quartz double ended tuning fork (DETF). The structure is silicon substrate having a proof mass supported by two parallel flexure hinges as doubly sustained cantilever, with a resonating DETF located between the hinges. The acceleration normal to the chip plane induces an axial stress in the DETF beam and, in turn, a proportional shift in the beam resonant frequency. Substrate is manufactured by single-crystal silicon for stable mechanical properties and batch-fabrication processes. Electrodes on the four surfaces of DETF beam excite anti-phase vibration model, to balance inner stress and torque and imply a high quality factor. The sensor is simply packaged and operates unsealed in atmosphere for measurements. The tested natural frequency is 36.9 kHz and the sensitivity is 21 Hz/g on a nominally ±100 g device, which is in good agreement with analytical calculation and finite element simulation. The output frequency drifting is less than 0.5 Hz (0.0014% of steady output) within 1 h. The nonlinearity is 0.0019%FS and hysteresis is 0.0026%FS. The testing results confirm the feasibility of combining quartz DETF and silicon substrate to achieve a micro-resonant sensor based on simple processing for digital acceleration measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Assessment of a Grade 91 Steel Forging and Seamless Pipe Section After 141,000-Hours of Operation in a Superheat Outlet Header

In this work, two unique heats of 9Cr creep strength enhanced ferritic (CSEF) steels extracted from a retired superheat outlet header after 141,000 hours of service were evaluated. These two CSEF steels were a forging manufactured to SA-182 F91 (F91) reducer and a seamless pipe produced to SA-335 P91 (P91) pipe. Their creep deformation and fracture behavior were assessed using a lever arm creep frame integrated with in-situ high-temperature digital image correlation (DIC) system. Critical metallurgical and microstructure factors, including composition, service damage, grain matrix degradation, precipitates, and inclusions were quantitatively characterized to link the performance of the two service aged F91 and P91 CSEF steels. The creep test results show the F91 and P91 steels exhibit a large variation in creep strength and creep ductility. The F91 steel fractured at 572 hours while P91 steel fractured at 1,901 hours when subjected to a test condition of 650 °C and 100 MPa. The nominal creep strains at fracture were 12.5% (F91) and 14.5% (P91), respectively. The high-resolution DIC strain measurements reveal the local creep strain in F91 was about 50% while the local creep strain in P91 was >80%. The characterization results show that the F91 steel possessed pre-existing creep damage from its time in service, a higher fraction of inclusions, and a faster matrix grain coarsening rate. These features contribute to the observed reduction in performance for the F91 steel. The context for these findings, and the importance of metallurgical risk in an integrated life management approach will be emphasized.

Wang, Yiyu↗

DOE OSTI2022

Towards Software Bill of Materials in the Nuclear Industry

Large, modern industrial facilities often incorporate thousands of digital assets in their operational technology. Regulated facilities, such as nuclear power plants (NPPs), maintain robust cybersecurity and configuration management programs that often use bills of materials (BOMs) for these assets, including make, model, and version of hardware, firmware, and software. However, these BOMs typically capture only first- or second-tier information provided by the original equipment manufacturer (OEM). Unfortunately, as indicated by the increasing number and sophistication of software supply chain attacks, this level of detail is insufficient for identifying all the potential vulnerabilities and risks in software applications. Software BOMs (SBOMs) provide detailed enumeration of components and dependencies within the product or devices, including firmware. SBOMs can be combined with vulnerability data sources and vendor vulnerability attestations to improve vulnerability management and enable rapid identification of affected components when new software vulnerabilities are discovered. Ideally, SBOMs are created by the OEM prior to installation. However, since this practice is not yet commonplace and since NPPs are typically slow to adopt new technology, most NPPs do not incorporate SBOMs into their asset or configuration management programs. Fortunately, SBOMs can be generated by NPPs on existing digital assets to provide further insight into risk management decisions. This report provides an overview of the current SBOM ecosystem and recommends guidance on how to get started in a “crawl, walk, run” manner to develop and implement a sustainable SBOM program for digital assets in an NPP.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗