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DOE OSTI2023

Property-Graded Stainless Steel 316L by Selective Laser Melting: Characterization & Design

Abstract The purpose of this research work is to characterize and inform the design of (mechanical) property-graded bulk structures made from a single metallic alloy via a laser powder bed fusion (LPBF) process, with an end goal of creating repeatable/reproducible functionally-graded additively manufactured (FGAM) parts. This paper specifically investigates the manufacture of stainless steel (SS) 316L structures via a pulsed selective laser melting (SLM) process, and the underlying causes of property variations (within a functionally-acceptable range) through various material characterization techniques. For this, a design of experiments spanning the volumetric energy density (VED) based process parameter design space was utilized to investigate the range of functionally-acceptable physical/mechanical properties achievable in SS 316L. Five sample conditions (made via different process parameter combinations) were down-selected for in-depth microstructure analysis and mechanical/physical property characterization; these were suitably selected to impart a wide and controllable property range (209–318 HV hardness, 90–99.9% relative density, and 154–211 GPa modulus). It was observed that property variations resulted from combinations of porosity types/amounts, martensitic phase fractions, and grain sizes. Based on these findings, property-graded standard test specimens were designed and manufactured for further investigation—tensile specimens having a monotonic hardness change along its gauge length, four-point bending specimens with varying elastic moduli as a function of the distance from the neutral axis, and Moore’s rotating beam fatigue specimens with moduli variations based on the distance from the center. Altogether, this work lays the foundation for understanding and designing the local and global mechanical performance of FGAM bulk structures.

Engineering↗

DOE OSTI2023

The National Criticality Experiments Research Center and its role in support of advanced reactor design

The National Criticality Experiments Research Center (NCERC) located at the Nevada National Security Site (NNSS) in the Device Assembly Facility (DAF) and operated by Los Alamos National Laboratory (LANL) is the only general purpose critical experiments facility in the United States. Experiments from subcritical to critical and above prompt critical are carried out at NCERC on a regular basis. In recent years, NCERC has become more involved in experiments related to nuclear energy, including the Kilopower/KRUSTY demonstration and the recent Hypatia experiment. Multiple nuclear energy related projects are currently ongoing at NCERC. This paper discusses NCERC’s role in advanced reactor design and how that role may change in the future.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Material Plasma Exposure eXperiment High Heat Flux Microwave Absorber Design, Manufacture, and Articles Test

The Material Plasma Exposure eXperiment (MPEX) at Oak Ridge National Laboratory is in the final design phase. MPEX will be capable of exposing neutron-irradiated materials to plasmas for the study of plasma-material interaction. This facility will provide information about the complex effects of plasmas on materials and contribute to examining new materials that can withstand high heat fluxes and high ion fluences for future fusion devices. MPEX plasma is heated by 70-GHz or 105-GHz electron Bernstein wave/electron cyclotron heating (ECH), and the high-frequency microwaves are prone to scattering microwave power, which can have detrimental effects, especially on diagnostic components. A large portion of the injected ECH power is expected to be absorbed by plasma, but the remainder requires that microwave absorbers be placed immediately upstream and downstream of the ECH launcher to minimize stray microwaves leaving the ECH region. These microwaves can inadvertently heat components that cannot be shielded or otherwise protected. The microwave absorber design is based on an array of pyramid-shaped ceramic tiles brazed to a water-cooled explosion-bonded heat sink and a stainless steel plate to produce one tile module. Computational fluid dynamics and structural analyses were performed to optimize and validate the design. Multiple test coupons were produced to validate the process for brazing the two different tile materials to the Glidcop AL-15 baseplate. The articles were tested to evaluate the reliability and thermal performance through exposure to an electron beam with a heat flux of up to 1.5 MW/m2. Nondestructive testing was performed before and after testing to identify voids or separations that may have been introduced by the high heat flux. This paper discusses the details of high heat flux microwave absorber design, manufacturing details and associated challenges, and test results, demonstrating the effectiveness of the proposed design.

Hussain, Aftab↗

DOE OSTI2025

An Experiment with LLMs as Database Design Tutors: Persistent Equity and Fairness Challenges in Online Learning

As large language models (LLMs) continue to evolve, their capacity to replace humans as their surrogates is also improving. As increasing numbers of intelligent tutoring systems (ITSs) are embracing the integration of LLMs for digital tutoring, questions are arising as to how effective they are and if their hallucinatory behaviors diminish their perceived advantages. One critical question that is seldom asked if the availability, plurality, and relative weaknesses in the reasoning process of LLMs are contributing to the much discussed digital divide and equity and fairness in online learning. In this paper, we present an experiment with database design theory assignments and demonstrate that while their capacity to reason logically is improving, LLMs are still prone to serious errors. We demonstrate that in online learning and in the absence of a human instructor, LLMs could introduce inequity in the form of “wrongful” tutoring that could be devastatingly harmful for learners, which we call ignorant bias, in increasingly popular digital learning. We also show that significant challenges remain for STEM subjects, especially for subjects for which sound and free online tutoring systems exist. Based on the set of use cases, we formulate a possible direction for an effective ITS for online database learning classes of the future.

Jamil, Hasan M. (ORCID:0000000231243780)↗

DOE OSTI2023

Design of UO 2 -BeO Critical Experiment at Sandia [Poster]

The purpose of this proposal is to design a new integral critical experiment to investigate the effects of beryllium oxide and high assay low-enriched uranium fuels. this proposal considers using several existing resources at Sandia: (1) the Critical Experiments (SCX) facility and water tank, (2) spare UO 2 -BeO fuel for the Annular Core Research Reactor (ACRR), and 7uPCX fuel rods from previous benchmark experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Shock-induced transformation of nitinol shape memory alloy: Effect of stress state on transformation

Due to its numerous practical applications and intriguing phase transformation behavior, shape memory alloys (SMAs) have garnered significant research and development interests. In the past, most studies on the mechanical behavior of SMAs have been conducted under uniaxial stress loadings. Limited research on SMAs under shock loading has not provided conclusive results regarding their transformation behavior and transformation stress under such loading. Additionally, there is a lack of comprehensive understanding regarding the effects of different stress states on transformation behavior. The main objectives of this study are to address these issues. To achieve these objectives, a series of shock wave experiments were designed and conducted. Additionally, quasi-static and dynamic uniaxial stress experiments were carried out to establish a baseline for comparison. The results revealed that the transformation stress under dynamic uniaxial strain shock loading was approximately 1.92 GPa in contrast to 0.5 GPa (quasi-static) to 0.8 GPa (dynamic) observed in uniaxial stress loading. The transformation behavior exhibited noticeable rate sensitivity for both types of loading. There appeared to be a critical strain rate above which the austenite phase was driven to a metastable state. This estimated critical axial strain rate along the loading direction was approximately 2 × 10 3 /s–4 × 10 3 /s for uniaxial stress loading and approximately 2 × 10 6 /s for uniaxial strain loading. The apparent high transformation stress for uniaxial strain loading can likely be attributed to a combination of high-pressure confinement and high strain rate. Furthermore, determining their relative contributions remains an open issue.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Intelligent Sampling for Surrogate Modeling, Hyperparameter Optimization, and Data Analysis

Sampling techniques are used in many fields, including design of experiments, image processing, and graphics. The techniques in each field are designed to meet the constraints specific to that field such as uniform coverage of the range of each dimension or random samples that are at least a certain distance apart from each other. When an application imposes new constraints, for example, by requiring samples in a non-rectangular domain or the addition of new samples to an existing set, a common solution is to modify the algorithm currently in use, often with less than satisfactory results. As an alternative, we propose the concept of intelligent sampling, where we devise algorithms specifically tailored to meet our sampling needs, either by creating new algorithms or by modifying suitable algorithms from other fields. Surprisingly, both qualitative and quantitative comparisons indicate that some relatively simple algorithms can be easily modified to meet the many sampling requirements of surrogate modeling, hyperparameter optimization, and data analysis; these algorithms outperform their more sophisticated counterparts currently in use, resulting in better use of time and computer resources.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

MITR DDE End Fitting Structural Rigidity Analysis

As a part of the design of the MITR Design Demonstration Element (DDE), a new design for the end fittings must be considered to meet specific experiment needs, e.g., compatibility with the geometrical restrictions of the DDE testing location (BR2 test reactor located in Mol, Belgium), and to allow for proper inspection of these test elements during the experiments. The design of the MITR DDE end fittings is substantially different from the design of the end fittings of the MITR LEU fuel elements, with the DDE end fittings considerably smaller in overall size and weight. Consequently, the stiffness of the end fittings as well as of the entire fuel element is affected. The end fittings in the MITR LEU fuel element are designed primarily for proper handling and flow distribution. The stiffness of the end fittings also constitutes a fraction of the total stiffness of the entire fuel element. It is debatable to what extent the end fittings provide the structural rigidity necessary for the fuel element to properly respond to potential loadings. It is presumed that the bulk of the overall stiffness of the element is derived from swaging multiple fuel plates into the side plates. However, the contribution of stiffness from various components of the MITR LEU fuel element and MITR DDE has not been determined so far. The primary objective of the work presented in this report was to assess the extent to which the stiffness of the end fitting in the MITR DDE contributes to the stiffness of the entire fuel element, and how it compares to the equivalent stiffness of the end fitting in the MITR LEU fuel element. Several simplified load cases were analyzed for that purpose using the geometries of the MITR LEU fuel element, MITR DDE, as well as that of the MITR DDE without the top end fitting.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Neutron Noise Analysis of the Neptunium Subcritical Observation (NESO) Experiment

The Neptunium Subcritical Observation (NeSO) experiment was a subcritical integral benchmark experiment. This experiment was designed in 2017-2018 and was performed at the National Criticality Experiments Research Center (NCERC) in 2019. Eight different subcritical configurations were measured with varying Nickel reflector thickness. For all configurations, a 3 He detection system was used to record neutron events. The focus of this work is to share neutron noise results of the measured data.

3-Helium↗

DOE OSTI2023

Neutron Noise Analysis of the Neptunium Subcritical Observation (NESO) Experiment

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

IER305: Molybdenum Sleeve Experiments in the Sandia Critical Experiments Facility [Slides]

This presentation is on the Molybdenum (Mo) sleeve experiments at the Sandia Critical Experiments Facility. The Institut de Radioprotection et de Sûreté Nucléaire (IRSN) performed the preliminary design of the experiment. IRSN performed the final nuclear design of the experiment. Sandia performed the detailed design of the experiment to make it work in the critical assembly and Sandia also oversaw the fabrication and installation of the hardware. The slides include cutaway and overall views and a look into the results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Optimizing ablator thickness for laser shock experiments

In laser shock experiments, a well-defined, flat-top shock wave at the ablator/sample interface is important for accurately probing material response under uniaxial strain compression. However, the relationship between the ablator thickness and the resulting shock wave characteristics is insufficiently understood, limiting the ability to design optimal experiments. To address this need, we conducted a systematic experimental study using a 100 J laser to shock-compress polyimide ablators to peak stresses ranging from 20.4 to 111.6 GPa. Laser interferometry diagnostics measured the transmitted wave profiles at the ablator/sample interface, consistently showing a single jump followed by a constant peak state before the arrival of release waves. Here, by analyzing shock transit time, flat-top duration, and stress, our results establish a framework for selecting ablator thickness to maximize the flat-top duration, improving the precision and reproducibility of laser shock experiments.

design of experiments↗

DOE OSTI2021

A Unified User-Friendly Instrument Control and Data Acquisition System for the ORNL SANS Instrument Suite

In an effort to upgrade and provide a unified and improved instrument control and data acquisition system for the Oak Ridge National Laboratory (ORNL) small-angle neutron scattering (SANS) instrument suite—biological small-angle neutron scattering instrument (Bio-SANS), the extended q-range small-angle neutron scattering diffractometer (EQ-SANS), the general-purpose small-angle neutron scattering diffractometer (GP-SANS)—beamline scientists and developers teamed up and worked closely together to design and develop a new system. We began with an in-depth analysis of user needs and requirements, covering all perspectives of control and data acquisition based on previous usage data and user feedback. Our design and implementation were guided by the principles from the latest user experience and design research and based on effective practices from our previous projects. In this article, we share details of our design process as well as prominent features of the new instrument control and data acquisition system. The new system provides a sophisticated Q-Range Planner to help scientists and users plan and execute instrument configurations easily and efficiently. The system also provides different user operation interfaces, such as wizard-type tool Panel Scan, a Scripting Tool based on Python Language, and Table Scan, all of which are tailored to different user needs. The new system further captures all the metadata to enable post-experiment data reduction and possibly automatic reduction and provides users with enhanced live displays and additional feedback at the run time. We hope our results will serve as a good example for developing a user-friendly instrument control and data acquisition system at large user facilities.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Shattered pellet injection experiments at JET in support of the ITER disruption mitigation system design

A series of experiments have been executed at JET to assess the efficacy of the newly installed shattered pellet injection (SPI) system in mitigating the effects of disruptions. Issues, important for the ITER disruption mitigation system, such as thermal load mitigation, avoidance of runaway electron (RE) formation, radiation asymmetries during thermal quench mitigation, electromagnetic load control and RE energy dissipation have been addressed over a large parameter range. The efficiency of the mitigation has been examined for the various SPI injection strategies. Here, the paper summarises the results from these JET SPI experiments and discusses their implications for the ITER disruption mitigation scheme.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Integrated Modeling and Optimal Operation of Multi-Energy System for Coastal Community

Focusing on remote, isolated, and underserved communities, a multi-energy system is designed in this research which is capable of utilizing different energy sources in a more coordinated and energy-efficient way to support various demands, such as fresh water, electricity, hydrogen, thermal demand, etc. The energy sources considered are renewables (wind, solar, marine) and natural gas. The energy conversion process includes water desalination, gas combustion, water electrolyzation, and different types of storage (hydrogen tank, electricity, thermal, etc.) are designed to serve as buffers in supply-demand balancing. Sets of experiments are designed to demonstrate the effectiveness of the proposed operating model and investigate the impact of uncertainties from renewable generations and demands.

Chen, Yang↗

DOE OSTI2021

Tunable Permanent Magnet Quadrupole Operating at Cryogenic Temperatures for Accelerators

The project objective is to develop a compact and tunable quadrupole using Electron Energy Corporation (EEC)’s PM materials for cryogenic accelerator applications. To achieve this objective, EEC and SLAC National Accelerator Laboratory (SLAC) will collaborate to develop a cost-effective quadrupole and optimize the conventional manufacturing process. Based on previous experience, EEC designed an innovative field adjustment capability using tuning magnets which is able to achieve all the requirements for SLAC’s cold copper collider (C3 ) application. These novel ideas enable us to develop a compact and tunable quadrupole magnet superior to the current designs. Our approach is to leverage EEC's over 50 years of experience in magnet manufacturing and SLAC’s beamline test capabilities.

42 ENGINEERING↗

DOE OSTI2023

Machine-Learning-aided Approach for Predicting the Thermal Expansion Behaviors in Advanced Test Reactor Capsules (NURETH-20 full paper)

Instrumented experiments at test reactors are essential to deploying new advanced reactor systems. Designing new experiments and generating data on specific conditions require both time and cost investment. A high-fidelity model of the experiment environment can be created using finite element analysis software to support the actual experiments, but computation time is still a concern in applying outcomes to real-time usage (e.g., a digital twin). This research proposes a machine-learning-aided approach to temperature and displacement predictions, based on the thickness of the outer gas gap on the experimental capsule used for the in-pile demonstration of a novel thermal conductivity probe in the Advanced Test Reactor. The capsule consisted of U10Zr fuel, a rodlet, sodium, and inner and outer capsules. There were gas gaps between the fuel and rodlet and between the inner and outer capsule. The learning data consisted of an experimental capsule’s radial distributions of temperature and displacement, as obtained from Abaqus and the physical features. For the first step, temperature was predicted using three positional parameters. Then the displacement was predicted using six different positional parameters. Each physical feature was normalized to be both nondimensional and standardized. The temperature and displacement predictions showed good agreement in all cases involving interpolation and extrapolation. Also, data similarity enhancement increased the similarity between training and target data increasing the predictive accuracy of machine-learning models. In some cases of extrapolation, the accuracy of the machine-learning model showed limited performance, but still data similarity enhancement improved the accuracy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Piston Bowl Geometry Effects on Gasoline Compression Ignition in a Heavy-Duty Diesel Engine

A design optimization campaign was conducted to search for improved combustion profiles that enhance gasoline compression ignition in a heavy-duty diesel engine with a geometric compression ratio of 17.3. A large-scale design of experiments approach was used for the optimization, employing three-dimensional computational fluid dynamics simulations. The main parameters explored include geometric features, injector specifications, and swirl motion. Both stepped-lip and re-entrant bowls were included in order to assess their respective performance implications. A total of 256 design candidates were prepared using the software package CAESES for automated and simultaneous geometry generation and combustion recipe perturbation. The design optimization was conducted for three engine loads representing light to medium load conditions. The design candidates were evaluated for fuel efficiency, emissions, fuel-air mixing, and global combustion behavior. Simulation results showed that the optimum designs were all stepped-lip bowls, due to improvements in fuel-air mixing, as well as reduced heat loss and emissions formation. Improvements in indicated specific fuel consumption of up to 3.2% were achieved while meeting engine-out NOx emission targets of 1-1.5 g/kW center dot h. Re-entrant bowls performed worse compared to the baseline design, and significant performance variations occurred across the load points. Specifically, the re-entrant bowls were on par with the stepped-lip bowls under light load conditions, but significant deteriorations occurred under higher load conditions. As a final task, selected optimized designs were then evaluated under full-load conditions.

CFD↗