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At least 577 records · Page 32

Milestone 1.2.10: Steady-state H 2 “roll over” point data for aluminum alloys 1100 and 6061

Extended (> 50 years) dry storage is being evaluated by the U.S. Department of Energy (DOE) for the disposition of ~ 18 metric tons of aluminum-clad spent nuclear fuel (ASNF). Transition of the current ASNF inventory into dry storage—using the standard DOE canister—necessitates a rigorous, predictive understanding of the long-term physical and chemical factors that may influence the integrity of the proposed storage canister, including radiolytic molecular hydrogen (H 2 ) generation. Current model predictions employ initial radiolytic yields of H 2 , the values of which change as the cladding’s H 2 -precursor inventory is depleted and H 2 itself becomes progressively more involved in radiolytic and surface dissociation processes. Consequently, the absorbed radiation dose that this steady-state H 2 yield corresponds to is essential for the evaluation and improvement of model predictions. Here, we report our findings on the long-term generation of H 2 from the gamma irradiation (≤ 36 MGy) of corroded AA1100 and AA6061 coupons in helium environments at ambient temperature and ~ 50% RH. Our findings show that AA1100 systems reached steady-state by ~ 36 MGy, while higher doses were necessary for AA6061 systems. This discrepancy was attributed to the AA6061 coupons developing a thicker corrosion layer that led to the trapping of H 2 and its precursors, and potentially additional chemistries, ultimately delaying the depletion of H 2 precursors and the system’s “roll over” point. Further, current model predictions—based on previous AA1100 data—do not show steady-state attainment until above 120 MGy, which is not the case for the AA1100 data collected here. Consequently, the new alloy dependent data presented here are important for the continued improvement of predictive computer models for evaluating the feasibility of extended storage of ASNF in helium backfilled canisters.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Radon Photoionization: Project Technical Report

In most low-background physics experiments, radon is a significant and problematic source of background radiation because it is inert and sufficiently long-lived to pervade laboratory spaces. It may be possible to manipulate (and thus mitigate) radon electromagnetically by taking advantage of its relatively low first ionization energy. When considering ambient-temperature gas phases, only iodine is comparable. The other noble gases, and the most important constituents of breathable air (nitrogen and oxygen), all have higher ionization energies; so it may be possible to selectively manipulate radon in a variety of gas streams by ionizing it with an appropriately low-energy source of photons. Radon’s first ionization energy is in the vacuum UV part of the electromagnetic spectrum, which can be produced using a deuterium lamp. In this report, we present our attempts to manipulate radon via UV photoionization in a laboratory setting. This approach has the potential to increase radon removal efficiency from gases and/or to improve the efficiency of radon detectors. Unfortunately, our experiments suggest that either the life-time of a photoionized radon ion (before it re-neutralizes) is too short to be of much practical use and/or that our low-cost UV-photon source was not sufficiently energetic for efficient photoionization of radon.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Bio-fuel effects and seasonal fuel property variations related to abnormal combustion occurrences observed in the field

Since 2015, the automotive industry has regularly observed sharp increases in customer complaints of poor driveability and increased warranty claims during the months of September and October. These persistent seasonal complaint increases have been tracked to occur from increased abnormal combustion events that coincide with the seasonal transition from summer to winter fuel volatility, beginning on September 15th annually. The Reid Vapor Pressure (RVP) of gasoline during this seasonal transition has been found to be the primary property attributed to this annual issue. It’s hypothesized that an increase in volatile butanes and pentanes from advanced petroleum recovery techniques and hydrofracking production has hastened the transition from summer to winter fuel volatility in the marketplace, rather than the gradual increase of the RVP over time as historically intended. At worst, mid-winter fuel, with an RVP ranging from 12 to 16 psi, depending on location in the U.S., enters the market while ambient temperatures can still be above average for the winter season. This combination of high volatility fuel with unseasonably warm weather will increase fuel system flash boiling, injector spray cavitation, and spray collapse inside the engine’s combustion chamber, ultimately linking fuel property variations to abnormal engine combustion processes. This CRADA program will investigate these known knowledge gaps by coupling with two national laboratories, Oak Ridge National Laboratory, and the National Renewable Energy Laboratory to employ both unique tools and expertise throughout the industry to provide the insight, knowledge, and data critical to understand the observed interactions. Overall findings of this work are that fuel wall retention increased SPI proportionally, and fuels with an increased distillation (i.e. energy fraction) above the wall temperature increased fuel retention. Likewise fuels with increased enthalpy of vaporization (HoV) increased fuel retention proportional to the temperature reduction from the HoV (~13K reduction in this work). Thus, fuel with increased HoV and increased fuel distillation above the linear temperature also exhibited increased SPI rates. Fuel with high RVP did exhibit increased fuel spray collapse form spray imaging measurements, but in SPI testing the high volatility of these fuels at the tested conditions did not necessarily increase SPI rates despite exhibiting increased spray collapse in injector imaging and increased spray-wall impingement measured in fired engine testing. It was also found that spray imaging showed collapse was possible at throttled conditions, but this was not relevant to high boost pressures relevant to SPI conditions, however, under transient load and or speed encountered in real-world operation fuel spray collapse could affect fuel retention and real-world SPI that were not probed in the automated high load test sequence of this work.

09 BIOMASS FUELS↗

Dose Rate Effects on Degradation of Nuclear Power Plant Electrical Cable Insulation at a Common Dose

The intent of this report is to address an identified knowledge gap in relating accelerated aging of nuclear electrical cables to service aging: dose rate effects (DRE). Here, DRE refer to gamma radiation-induced polymer degradation being a function of dose rate in addition to total absorbed dose. The concern raised is that historical qualification conducted at higher dose rates to simulate service lifetime may underestimate insulation degradation that occurs at lower dose rates in service. In the work described herein, common nuclear cable insulation materials—cross-linked polyethylene (XLPE) and ethylene propylene diene elastomer (EPDM)—were subjected to accelerated aging at ambient temperature (26°C) at different gamma dose rates of 100, 200 and 1800 Gy/h for select exposure durations to achieve constant total doses of 170, 210 and 300 kGy to evaluate DRE. First, the cable insulation material types investigated are described. Then, the accelerated aging experimental process involving gamma irradiation applied to the insulation specimens at room temperature and different dose rates is discussed. Then, the experimental characterization techniques used to perform this work are elucidated. These include elongation at break (EAB), mass change, yellowness index (YI), carbonyl index (CI), density, indenter modulus (IM), and relaxation constant (t). Theory of polymer degradation is discussed, and characterization results and discussion are provided. Finally, concluding remarks are made. The findings from this work and cited prior work reveal that DRE are material dependent, even between similar material categories (e.g., XLPE). In the case of the EPDM studied, degradation of ductility was observed to be greater at higher dose rate for the same total dose, indicating accelerated gamma aging to be more conservative than extended aging. Thus, conclusions regarding the conservatism of historical qualification likely require additional consideration for specific materials and conditions in question. The results of this study support the contention that, due to inherent limitations and uncertainties associated with prediction of cable remaining useful life from accelerated aging experiments, trending of installed cable insulation health status will be more practical and useful for safe and efficient cable aging management repair and replace decisions than lifetime prediction from historical qualification. The combination of material robustness demonstrated by the qualification process and ongoing monitoring of cable health status combine to provide confidence in continued safe use of existing nuclear cables. Additional research into effective and efficient condition monitoring methods for non-destructive evaluation of installed cables is needed to support aging cable management, including material studies to inform interpretation of measured results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of an Advanced Hydrogen Energy Storage System using Aerogel in a Cryogenic Flux Capacitor

The Cryogenic Flux Capacitor (CFC) is a cold, dense fluid storage core with integrated design features that afford the designer flexibility and provide new possibilities for the storage and discharge of energy. The stored energy, in this case, is represented by hydrogen physically bonded within the nanoscale pores within the aerogel composite blanket material, and the process of bonding or debonding is governed by the principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m 2 /g) allows for storage densities close to, or in some cases exceeding, that of normal boiling point liquids. Its performance easily exceeds what can be achieved via ambient temperature and high-pressure gas storage for an equivalent volume. CFC storage is predicted to be easily scalable, constructed from readily available commercial materials, and lends itself to a range of pressure applications. The project team designed and manufactured the CFC, integrating it into a set of temperature-controlled flow loops. The CFC test setup was validated against existing data from previous NASA work. Tests used bottled hydrogen gas for test validation. A cryogenic fluid, nitrogen, flowed through a metered control system. Hydrogen temperature, pressure, and flow rates, as well as the temperature control targets, provided all necessary control targets. The team analyzed the recorded data and updated the Technology Maturation Plan based on the results of the test, making recommendations for a follow-up test, scale-up, and maturation pathway. For the engineering development and maturation of CFC hydrogen storage technology, a Techno-Economic Assessment (TEA) and Commercialization Plan for the integration of this technology with various power generation assets were produced. A companion analytical model was developed, experimentally validated, compared against performance metric, and used to tune the model and scale up the technology.

08 HYDROGEN↗

Evaluation of Technologies for Destruction of LDR Organics in Hanford Tank Waste

Aqueous Hanford tank wastes contain soluble organics and some tanks contain small amounts (<100 mg/L) of organics that are regulated under the Land Disposal Restrictions (LDR) portions of the Resource Conservation and Recovery Act (RCRA). Most of these organics can be removed by evaporation, but some are not. Methods to destroy/remove organics that are regulated by the LDR section of the RCRA and that are not removed by evaporation may be needed if ambient temperature waste treatment processes are used to immobilize aqueous Hanford tank wastes. To identify viable and compatible organic removal or destruction pretreatment methods an evaluation was performed by a team of researchers. The team utilized a Systems Engineering Approach that examines all aspects of the technology, based on information available in the literature and the experience of the team members. That evaluation led to recommendations by the team to perform testing on technologies to determine efficacy in destroying organics in Hanford tank waste liquids. The primary technologies recommended are chemical oxidants, including permanganate, peroxymonosulfate or peroxydisulfate (PMS/PDS), hydrogen peroxide, and ozone. Ultraviolet light irradiation of the stream with a solid catalyst sorbent is also recommended for testing. A generalized description of the test program is also included.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Alternative Materials Literature Review: A Review of Alternative Materials for Xenon Capture in Comparison to AgZ-PAN

A collaborative literature review between Idaho National Laboratory (INL) and Pacific National Laboratory (PNNL) was conducted to research alternative metals/materials for xenon adsorption in gaseous effluents generated from used nuclear fuel (UNF) reprocessing. The review was conducted to research sorbents that could outperform silver mordenite (AgZ) at ambient temperature. The use of silver requires complex and expensive waste disposal processes due to it being an RCRA metal, therefore alternative materials need to be researched and evaluated. The report details two different types of sorbent material: alternative zeolite materials and non-zeolite-based materials (i.e., MOFs, COFs, etc.). This report documents a brief history of the materials, what testing has been conducted on them, and what results suggest the possibility of outperforming the silver-based materials. Sorbent performance characteristics such as durability, capacity, and operating temperatures were evaluated. The simplicity of the sorbents was also evaluated, meaning how they are acquired (synthesized vs. naturally abundant). Recommendations were made for the most promising sorbents based on available research in the subject area and these recommended sorbents will be tested in the upcoming fiscal year. The recommended sorbents that are zeolite based are CHA zeolites, ZIF-69, and Na-ETS-10. The recommended sorbents that are non-zeolite based are SBMOF-1 and CC3.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Alternative Pozzolans for Replacement of Fly Ash in Grout: Literature Review for Continuous Improvement of Cement Waste Forms

The Department of Energy (DOE) is currently responsible for treating radioactive and mixed waste, performing environmental restoration, and closing contaminated tanks and facilities resulting from nuclear weapons production during the Cold War. Cementitious reagents are the most widely used materials for (1) chemically stabilizing and encapsulating radionuclides and hazardous metals and (2) solidifying radioactive wastewater. Cementitious grouts and flowable concretes are also the most widely used materials for tank and facility closures and are used extensively for physical as well as chemical stabilization in environmental restoration projects. Ambient temperature radioactive waste cementation is a widely used technology for producing waste forms for final disposal. The current practice of designing and testing waste forms is based on a mid to late 20th century technology approach (i.e., materials, characterization, and test methods) for generating parameters for risk assessments. DOE technology development is needed to address both current, long-term, and emerging issues in this area as new waste streams come online and as regulations, performance knowledge, and risk assessment methodology continue to evolve. Consequently, the use of cementation as a means of treating chemically challenging radioactive liquid waste streams and reactive debris requires an enduring effort.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Isolated Single Metal Atoms Supported on Silica for One Step Non-Oxidative Methane Upgrading to Hydrogen and Value-Added Hydrocarbons

Natural gas in the United States offers substantial economic opportunities due to its abundance but its transportation is challenging because its primary component, methane (CH 4 ), does not liquefy at ambient temperature and typical pressures. As a result, a significant portion of natural gas is either used for heat, flared in remote locations, or remains unutilized, presenting a lost economic opportunity and an environmental harm. Converting natural gas to larger hydrocarbons in an economically competitive manner would enable transportation of products and further boost the economy and reduce environmental footprint. Our research goal is to enable efficient non-oxidative methane conversion (NMC) via catalyst innovation to convert CH 4 in one-step to olefins and aromatics and hydrogen (H 2 ) co-product. The catalysts are made of supported single metal atoms and operated at medium-high temperatures. The single metal atoms achieve methane activation by heterogeneous surface dehydrogenation to generate a hydrocarbon pool and importantly limit coke formation. The integration of novel single atom catalysts in a short contact time microreactor enable unprecedented NMC performance that could lead to economically-feasible, distributed natural gas upgrading by advanced manufacturing and process intensification. Our innovated catalyst and reactor technology promise to tap into previously uneconomic natural gas resources, such as stranded, vented, and flared methane.

03 NATURAL GAS↗

Electrocatalytic nitrate reduction: controlling adsorbate affinity to tailor reaction products

Every year, Haber-Bosch nitrogen fixation to form ammonia releases immense volumes of CO2. At the same time, nitrate contamination from untreated wastewater threatens human health across the US. Development of circular processes to efficiently upgrade waste nitrate for reuse is critical to sustainably address this growing environmental hazard. Electrochemical reduction of nitrate operates at ambient temperatures and pressures, and can leverage distributed renewable energy sources and water as a hydrogen source for ammonia production. However, current catalysts lack electron efficiency in reducing nitrate versus water, lack selectivity in forming ammonia as a product, or rely on expensive rare metals, making widespread implementation unfeasible. To overcome these limitations, this proposal seeks a mechanistic understanding of nitrate electrochemical reduction on earth abundant metals and their alloys, with the goal of identifying active-site properties that improve both Faradaic efficiency and product selectivity. This insight will extend to other electrocatalytic reductive process that compete with water reduction.

30 DIRECT ENERGY CONVERSION↗

Nitrate and Nitrite at Hanford – From Tanks to Natural Attenuation

Washington River Protection Solutions, LLC (WRPS) contracted Pacific Northwest National Laboratory (PNNL) in support of their maturation testing and analysis to develop and deploy an ambient temperature solidification/stabilization process for low-activity waste (LAW) (referred to as “grout” in this report). The intent of this effort is to support a sample-and-send regulatory and processing strategy in the Hanford 200 West Area, specifically considering grout waste forms disposal at Hanford in the Integrated Disposal Facility (IDF). Currently the disposal of grouted LAW is not an option because the IDF is not permitted to receive this waste form. The material presented in this report is intended to help inform the U.S. Department of Energy (DOE), the site operating contractors, regulatory agencies, and stakeholders of the future implications of IDF disposal of a grouted LAW waste form, specifically for the behavior of nitrate (NO 3 - ) and nitrite (NO 2 - ) at the Hanford. The only calculation of nitrate release from a hypothetical grouted LAW inventory in the IDF showed that the overall release was slightly above the compliance limit of 45 mg/L nitrate and 3.32 mg/L nitrate after 1000 years (Asmussen et al. 2019). As such, uncertainty around the impact of nitrate and nitrite release from the IDF was identified in the recent National Academies of Sciences study of Hanford supplemental LAW by both the national laboratory team and Hanford stakeholders (Bates et al. 2023). However, these calculations (and others for the IDF involving secondary waste grout) may be conservative as no nitrate and nitrite retention in the grout waste form was assumed, nor any attenuation in the subsurface. There is evidence from the literature of processes that can attenuate nitrate migration both in the waste form and in the Hanford subsurface. If found to be technically defensible and likely to occur in the IDF and associated subsurface, then these processes should be included in modeling of the IDF to represent the behavior of nitrate and nitrite more accurately. Doing so would remove unnecessary conservatism in the modeling projections and reduce the uncertainty in assessments of facility compliance of a grouted LAW waste form in the IDF.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Electrocatalytic Oxidation of Ammonia for Energy Conversion and Storage (Final Report)

Ammonia is one of the most promising candidates to be a major renewable fuel. Ammonia is synthesized from H 2 and N 2 , which is the most abundant gas in the Earth’s atmosphere, using the Haber-Bosch (HB) process in the largest scale production of a chemical commodity. Using H 2 generated from renewable resources would result in a scalable, carbon-free, high energy density liquid fuel. The HB reaction is almost thermoneutral, which means hydrogen’s intrinsic energy is largely retained in the ammonia product, making NH 3 possibly the best candidate for storing and transporting H 2 . The conversion of NH 3 to energy has received very little attention, however. As part of this project we demonstrated the first example of a well-defined complex capable of driving electrocatalytic ammonia oxidation to N 2 , protons and electrons. We further thoroughly investigated the mechanistic underpinnings of the electrocatalytic reactions. We have also developed new chemistry to synthesize transition metal complexes aimed at increasing the efficiency and activity of electrocatalysts for the conversion of NH 3 to H 2 and N 2 at ambient temperatures.

08 HYDROGEN↗

Enabling CO 2 Isothermal Compression Using Liquid Piston and Integrated Gas Cooler

This report outlines the development of a near-isothermal liquid piston compressor. Initially, a proof-of-concept experiment was conducted to validate the feasibility and potential of near-isothermal compression. A first-of-its-kind near-isothermal liquid piston compressor was then successfully built and tested. Additionally, a Matlab-based transient model was developed to capture performance trends accurately. These efforts laid the groundwork for developing a second-generation prototype with enhanced efficiency and design. Subsequent field tests at the Helix Innovation Center in Ohio demonstrated a cooling capacity of 2 kW with a COP of 1.64 at an ambient temperature of 25°C. An improved model was also created to suggest different heat exchanger geometries for better compression efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Helium Bubble Physics Experiments

New results from MST-16 indicate that as plutonium ages at close to ambient temperature and helium ingrows, the number density of bubbles increases only slowly, if at all, and their size distribution shifts towards larger diameters. Helium-containing aged plutonium foams when annealed at high temperatures. We attribute these phenomena to a diffusivity large enough that, after a few years of aging, new decay helium diffuses to extant bubbles rather than nucleating new bubbles, and that during annealing larger bubbles grow at the expense of smaller ones (Ostwald ripening). Bulk swelling results from the fact that the Laplace pressure and therefore the helium density are less in larger bubbles. We develop a simple theory and propose to study these phenomena in aluminum alloyed with 10 B in which successive exposure to reactor thermal neutrons produces a stepwise increase in helium content.

36 MATERIALS SCIENCE↗

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗

Evaluation of Hanford Supernatant Waste Evaporation

Storage space within Hanford’s double shell tanks is running low, with only an approximate 4.1 Mgal of space remaining. Construction of additional storage space is not a pursuable option, but treatment of the waste via vacuum evaporation may be used to reduce the waste volume and increase the available amount of free space. However, without proper care and consideration, concentrating the waste may lead to harmful effects such as excessive solids generation, growth in liquid density and ionic concentration, and development of aggressive properties in the solution. OLI Studio was used to simulate a subset of DSTs using BBI ionic concentrations to generate recipes of every tank’s supernatant layer. Vacuum evaporation was performed by taking each simulated solution and bringing it to 50°C under a pressure of 60 Torr, after which the vapor phase was removed from the simulation, and the solution was brought back to ambient temperature and pressure. Several million gallons of space were created, and only about 100-200 kgal of solids were precipitated during evaporation. Minimal changes to the solution’s pitting factor occurred, and no solution is expected to develop aggressive characteristics due to evaporation. Although a theoretical result is provided, it is unique to the specific temperature and pressure value chosen for the simulation, and future transfers of waste are expected to cause changes in waste properties, which would cause the OLI recipes to lose accuracy. Though the results are not anticipated to be used as a target value or a guide, as an exercise, they show that the extent of volume gains could be equivalent to the construction of new DSTs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Neutron Diffraction Residual Stress Characterization of Large-Scale Components by WA-DED

Two large scale 316L stainless steel cylindrical shells were fabricated by wire arc directed energy deposition (WA DED). Residual stresses were measured by neutron diffraction, and the microstructure and mechanical properties of the printed material were characterized. Longitudinal and transverse residual stresses were compressive at the inner diameter, near neutral at mid wall, and tensile at the outer diameter; radial (through thickness) residual stresses were relatively low in magnitude, and peak tensile residual stresses occurred at the outer diameter surface along the longitudinal direction. The printed 316L SS exhibited a heterogeneous microstructure with finely dispersed δ ferrite, and demonstrated high yield and tensile strengths with large elongation and ductile fracture at ambient temperature and at 250 °C. These results indicate that the outer diameter surface and near surface regions—where tensile residual stress is highest—are the most vulnerable to residual stress–sensitive failure modes, such as stress corrosion cracking and fatigue.

36 MATERIALS SCIENCE↗

Cementless Concrete: Advancing Alkali-Activated Slag Composites with Black Liquor

This project explores the use of black liquor, a byproduct of sustainable aviation fuel production, as an alkaline activator for industrial byproducts such as steel slags to produce alkali-activated composites (AACs). The resulting cementless concrete cures at ambient temperature, demonstrates comparable performance to conventional cement, and offers a safer, lower-energy alternative for durable construction materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗