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DOE OSTI2021

Sensitivity Calculations for Systems with Polyethylene Reflector Materials Using CLUTCH

The SCALE 6.2.4 code package contains four sequences for calculating $k_{eff}$ sensitivity coefficients. Two of these sequences use deterministic transport solvers: a one-dimensional (1D) capability based on XSDRN, and a two-dimensional (2D) capability based on NEWT. These sequences are restricted to the multigroup (MG) treatment of neutron energy. The three-dimensional (3D) sequences use the KENO V.a or KENO-VI Monte Carlo transport codes and can be used to calculate sensitivity coefficients with either MG or continuous-energy (CE) transport. The 3D sensitivities are ultimately reported in an MG structure, regardless of the method used in the transport calculations. If desired, the sensitivity coefficients can be reported with very fine energy resolution from a CE calculation, but they are calculated only in the MG library structure in the MG mode. CE TSUNAMI methods are available in SCALE starting in SCALE version 6.2. Sensitivity coefficients were generated using the 3D sequences as part of the generation of the SCALE 6.2.2 Validation Report; difficulties encountered when using the CLUTCH method for thick, fissionable-material reflectors were discussed and investigated as documented in a previous paper. This paper discusses the difficulties encountered in generating accurate sensitivity coefficients using the CLUTCH technique for polyethylene reflectors for two fast spectrum benchmarks. Direct perturbation (DP) calculations were performed to confirm the accuracy of the total sensitivity coefficient for important isotopes with large sensitivities in the system. Discrepancies were detected for CLUTCH-calculated sensitivity coefficients in the reflector of a critical experiment with a radial polyethylene reflector. A simple polyethylene-reflected plutonium sphere was then used to further investigate the discrepancy. Calculations performed using the iterated fission probability (IFP) method generated accurate sensitivity coefficients in both cases. The results of this study emphasize the need to confirm CLUTCH sensitivity results with DP calculations. IFP calculations are generally less efficient but more reliable than CLUTCH calculations. Improvements to the CLUTCH methodology that retain the greater efficiency but address identified difficulties are therefore potentially useful to analysts.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Bayesian inference of structured latent spaces from neural population activity with the orthogonal stochastic linear mixing model

The brain produces diverse functions, from perceiving sounds to producing arm reaches, through the collective activity of populations of many neurons. Determining if and how the features of these exogenous variables (e.g., sound frequency, reach angle) are reflected in population neural activity is important for understanding how the brain operates. Often, high-dimensional neural population activity is confined to low-dimensional latent spaces. However, many current methods fail to extract latent spaces that are clearly structured by exogenous variables. This has contributed to a debate about whether or not brains should be thought of as dynamical systems or representational systems. Here, we developed a new latent process Bayesian regression framework, the orthogonal stochastic linear mixing model (OSLMM) which introduces an orthogonality constraint amongst time-varying mixture coefficients, and provide Markov chain Monte Carlo inference procedures. We demonstrate superior performance of OSLMM on latent trajectory recovery in synthetic experiments and show superior computational efficiency and prediction performance on several real-world benchmark data sets. We primarily focus on demonstrating the utility of OSLMM in two neural data sets: μ ECoG recordings from rat auditory cortex during presentation of pure tones and multi-single unit recordings form monkey motor cortex during complex arm reaching. We show that OSLMM achieves superior or comparable predictive accuracy of neural data and decoding of external variables (e.g., reach velocity). Most importantly, in both experimental contexts, we demonstrate that OSLMM latent trajectories directly reflect features of the sounds and reaches, demonstrating that neural dynamics are structured by neural representations. Together, these results demonstrate that OSLMM will be useful for the analysis of diverse, large-scale biological time-series datasets.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Development of Gamma Background Radiation Digital Twin with Machine Learning Algorithms: Application of Unsupervised Machine Learning to Detection of Anomalies and Nuisances in Gamma Background Radiation Environmental Screening Data

Environmental screening of gamma radiation consists of detecting weak nuisance and anomaly signal in the presence of strong and highly varying background. In a typical scenario, a mobile detector-spectrometer continuously measures gamma radiation spectra in short, e.g., one-second, signal acquisition intervals. The measurement data is a 2D matrix, where one dimension is gamma ray energy, and the other dimension is the number of measurements or total time. In principle, gamma radiation sources can be detected and identified from the measured data by their unique spectral lines. Detecting sources from data measured in a search scenario is difficult due to the highly varying background because of naturally occurring radioactive material (NORM), and low signal-to-noise ratio (S/N) of spectral signal measured during one-second acquisition intervals. The objective of this work is to explore unsupervised machine learning (ML) algorithms for development of a digital twin of gamma radiation background, and for detection and identification of weak nuisances and anomalies events in the presence of highly fluctuating background. In one segment of work, we developed a gamma background estimation model using a Longshort term memory (LSTM) network for one-step CPS time series prediction. The LSTM model was validated with two data sets of measurements from two independent NaI detectors positioned on a mobile platform. The data sets contained background radiation only and no orphan isotope sources. The LSTM model was constructed and tested using data from one of the detectors. Performance of the LSTM model was validate through one-step prediction of CPS time series of another NaI detector without re-training. This approach allows to create a digital twin for nuclear background estimation. Using LSTM, it could be possible to detect a source through subtraction of the estimated counts from the measured background. In another segment of work, we investigated detection of gamma emitting sources in the presence of complex background using unsupervised machine learning. Spectral lines of isotopes are difficult to observe in one-second measurements. Averaging over the entire measurement campaign data set reveals spectral lines of most common background isotopes. Spectral lines of orphan sources, which might appear only in a few measurements during the campaign, will be washed out if averaging is performed over the entire measurement data set. The approach we have explored consists of extracting one-second measurements containing weak spectral features through data clustering. Averaging one-second spectra in a cluster should reveal the presence of anomaly sources. We created two ML models using K-means clustering and Neural Network Self-organizing Map (SOM). Performance of these ML models was benchmarked using search data. One data set contained 137 Cs source, and another dataset contained 131 I source.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Strengthening Technical Safeguards of Fresh Fuel Through International Cooperation

Over time, nuclear fuel designs have shifted towards having higher initial enrichments and a greater number of burnable poison rods. This enables increased burnup for commercial reasons. These changes have made safeguards measurements of the 235 U content in modern fresh fuel more challenging.This is addressed here through a re-evaluation of the UNCL (Uranium Neutron Collar–Light Water Reactor Fuel)poison rod correction factor. Coefficients of the poison rod correction factor were updated by simulating response of AngraII PWR fuel with a wide range of both burnable poison rods and Gd 2 O 3 contentper rod. Benchmark comparisons are made to experiments performed at Resende (Brazil) and CNEN/LASAL in Brazil. By updating these coefficients, while maintaining the same mathematical form to allow INCC to be used without software modification,it was possible to reduce error in experimental 235 U linear density assay by an order of magnitude.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Detection of Anomalies in Gamma Background Radiation Data with K-Means and Self-Organizing Map Clustering Algorithms (Consortium on Nuclear Security Technologies (CONNECT) Q1 Report)

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2022

Coupled Neutronic and Thermal Hydraulic Analysis of a Natural Circulation Based Small Modular Reactor (SMR) Using VERA-CS

As part of the work supported by a US Department of Energy (DOE) Office of Nuclear Energy Gateway for Accelerated Innovation in Nuclear FY 2020 Voucher, Holtec International subsidiary SMR LLC (hereinafter referred to as Holtec) and Oak Ridge National Laboratory entered into a cooperative research and development agreement (CRADA) to develop coupled multiphysics core models of the Holtec developed small modular reactor (SMR), SMR-160. The scope of the 1 year project was to use the DOE–developed tool set, VERA, to analyze several aspects of a representative SMR-160 core design. The goals of the project were to perform the code-to-code benchmarking and to provide Holtec with a confirmatory calculations to compare against the results with the codes used in the SMR-160 design, identify and resolve areas of discrepancy between the two models to give Holtec a basis for selecting certain tool and model options, and develop a workflow so that the VERA model could be adapted easily to any future changes in the design of the SMR-160 core. The work proceeded in four phases: 1. Developing the initial VERA model based on Holtec-provided core design information; 2. Comparing VERA results with Holtec-provided calculations for the first five cycles; 3. Developing a VERA transient model based on the prior model; and 4. Training Holtec personnel on VERA and hand-off the developed models. This report summarizes at a high level the completed tasks. Details of the tasks and results are reserved for the full report, which will not be publicly released for 5 years per the terms of the CRADA. The report is titled “Coupled Neutronic and Thermal Hydraulic Analysis of a Natural Circulation Based Small Modular Reactor (SMR) using VERA-CS” and has the ORNL technical report number ORNL/TM 2021/2303 (NFE-20-08305)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Thermodynamically Stable, Plasmonic Transition Metal Oxide Nanoparticle Solar Selective Absorbers towards 95% Optical-to-Thermal Conversion Efficiency at 750 °C

Generation 3 (Gen) concentrating solar power (CSP) systems requires a high operation temperature ≥750°C to increase the power-cycle efficiency towards ≥50%. However, such a high operation temperature poses a notable challenge to high temperature materials. On the receiver side, a critical challenge is the lack of solar selective absorbers that demonstrate both high optical-to-thermal energy conversion efficiency η therm approaching 95% and long-term thermal stability at >750°C in air. Existing solar absorbers either have limited η therm ≤89% or deteriorate significantly within 500 h at 750°C; some of these also require costly vacuum deposition for stringent thickness control. Therefore, it is highly desirable to simultaneously achieve η therm ~95% AND high thermal stability at 750°C for future generations of CSP receivers. This project has investigated and developed low-cost, highly scalable spray-coated transition metal oxide nanoparticle (NP) pigmented solar selective coatings on various types of Inconel alloy tube sections that are thermodynamically stable at 750-800°C in air, maintaining η therm >94.3%(93.2%) under a solar concentration ratio of C=1000 after 60 simulated day-night cycles at 750ºC (800ºC) (1 cycle=12 h at 750 or 800°C and 12h ramping down to 25°C). We have also coated up to 48 inches long receiver tubes for preliminary solar testing under Norwich Technology’s parabolic trough systems, demonstrating notably improved performance in solar heating compared to benchmark Pyromark 2500 coatings. Two key innovations have been developed in this project: (1) We achieved an unprecedented high thermal efficiency >94% by optimizing the d-band optical absorption spectra of transition metal ions, engineering their valences and stoichiometry; (2) We were able to maintain or even slightly increase the efficiency when operating at 750°C in air by engineering the interdiffusion of transition metal ions between the coating and the Inconel substrate to our advantage. Featuring high-temperature solar spectral selectivity and thermodynamic stability in air, as well as low-cost, highly scalable solution-chemical synthesis and spray coating techniques, this innovation in solar selective absorber technology alone accounts for nearly 40% of the targeted reduction in the levelized cost of electricity (LCOE) from the receiver, thermal energy storage, and operation & maintenance combined by 2030, as proposed by the U.S. Department of Energy. For a 110 MWe CSP power plant, this LCOE reduction from the solar selective coating alone transfers to ~$\$ $1.9 M increase in annual profit based on a sales price of 10¢/kWh (or an annual sale of $50 M/year). The high solar absorptance (~98%) NP pigment materials developed in this project are equally applicable to volumetric receivers either as a coating or as bigger ceramic microspheres after sintering, potentially benefiting Gen3 falling particle CSP technologies. All these contributions facilitate the larger scale deployment of CSP systems with energy storage capability to address the intermittency issue of solar energy towards dispatchable solar electricity, bridging the temporal gap between peak solar electricity production and peak electricity consumption. The collaboration with Norwich Technologies and Brayton Energy in this project will also facilitate the future commercialization of this new solar selective coating technology developed in this SIPS project.

14 SOLAR ENERGY↗

DOE OSTI2022

Representative-cell-based Modeling of HTTF in SAM

Although the current nuclear power market is primarily occupied by the light water reactors (LWRs), the TRISO-fueled helium-cooled graphite-moderated high temperature gas reactors (HTGRs) are drawing growing attention as the nuclear power industry marches towards more advanced systems. Compared to that of conventional LWRs, the thermal hydraulics of HTGR cores show extra complexity from their multi-scale heat transfer mechanisms with varying importance during different operation modes or transient stages. The modeling of HTGR cores for the system analysis purpose therefore faces the challenge of reaching reasonable fidelity and accuracy while maintaining sufficient simplicity. Previous development and validation efforts have demonstrated that a “2-D ring model” with reasonable performance can be implemented in the System Analysis Module (SAM) for prismatic HTGR cores. In the current project, an alternative modeling methodology based on “representative cells” is proposed for the typical prismatic core of HTGRs. Different from the previous ring model approach, the proposed methodology first separately models and then combines the small- and large-scale thermal conductions, by connecting representative local heat transfer units (cells) with effective core- wise thermal resistance. A modeling practice for an integral high-temperature test facility (HTTF) elaborates the modeling details. Steady-state validation of the resultant candidate model is performed against a higher-resolution benchmark from a 3D-1D coupled simulation, which shows satisfactory prediction with reasonably captured global parameters and well-represented temperature fields. A postulated pressurized conduction cooldown (PCC) is also simulated and analyzed, demonstrating the model’s capability of transient prediction with physically captured phenomena resolved in both small and large temporal and spatial scales. In general, the current work achieves a preliminary success in proposing a methodology using representative cells to model prismatic HTGR cores in SAM. Future efforts are envisioned with more validation activities and with potential modeling improvements to eventually achieve the high confidence on a high-fidelity robust modeling methodology with reasonable accuracy.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Recent Advances of PyROS: A Pyomo Solver for Nonconvex Two-Stage Robust Optimization in Process Systems Engineering

This poster highlights uncertainty and technical risk reduction capabilities in CCSI2, with a focus on robust optimization. It presents recent advances of the two-stage robust optimization (RO) solver PyROS and applications to advanced energy systems optimization. To demonstrate the computational performance and reliability of PyROS, a benchmarking study on a library of over 8,500 small-scale RO problems is presented. Further, PyROS is used to obtain robust system designs of a MEA-based CO2 absorber under uncertainty in the thermodynamic property models for a variety of CO2 capture rate threshold requirements. Overall, the results demonstrate that the PyROS solver, including recent extensions to multi-stage RO settings, provides a reliable avenue to optimize the design and operation of advanced energy systems subject to various sources of parametric uncertainty.

Sherman, Jason↗

DOE OSTI2024

Recent Advances of PyROS: A Pyomo Solver for Nonconvex Two-Stage Robust Optimization in Process Systems Engineering

Sherman, Jason↗

DOE OSTI2025

CRCNS22 Learning Rules in the Hippocampus and their Mapping to Neuromorphic Systems (Final Technical Report)

Large scale biologically-realistic computational models are key to investigating the interplay between structure and function in nervous systems, thus paving the way to new clinical methods and neuro-inspired computing solutions. This project focuses on the hippocampus, in particular the CA3-CA1 regions, due to their role in associative learning and memory, pattern separation and completion, and spatial navigation. Investigations into the neuronal organization and learning rule(s) of this circuit can shed light into how declarative memories are formed, stored, recalled and forgotten and inform computational, experimental and clinical neuroscience work. Our project aims at developing a novel data-driven methodology supported by a broad heterogeneous base of neuroscience experimental knowledge and inspired from advances in computer science and engineering. Specifically, this work will benchmark existing and new learning rules within a full-scale spiking neural network simulation of the CA3-CA1 region. The model will be based on an open-source repository, called the Hippocampome, which contains neuronal morphologies, firing patterns, synapse probabilities, and most other required parameters for all known neuron types in the rodent hippocampal formation. The model will be first trained in a supervised fashion for associative memory tasks using backpropagation through time traditionally used in computer science, enhanced with a new technique called the surrogate gradient method. This optimization method will be used to obtain a global loss minimization, but it is not biologically inspired as it assumes the use of data not locally available to the synapses. However, we propose its use as a benchmarking tool, to compare the training performance of local biologically plausible and hardware-mappable learning rules at scale. New rules or combinations will be proposed and tested as needed, based on the obtained results. Progress in this area will also drive the development of novel hardware-mappable algorithms for continual lifelong learning and categorization of new events from few presented examples. This project goes beyond the existing state-of-the-art by looking at large scale realistic neuronal circuits as networks trainable via global optimization methods such as surrogate gradient descent. The objective function of the brain that supports learning is largely unknown, but it is likely that it operates through local learning rules. Studying network trajectories around local minima as proposed in this work represents a useful strategy for understanding whether a network is training by using a specific (set of) learning rule(s). Starting from a completely untrained network is a challenging test since it is difficult to determine how the learning rule affects the trajectory of the network. This interdisciplinary project will help understand what rule governs learning in these regions or if multiple learning rules are involved. The work will develop a robust methodology to measure if the network is converging to the target solution, oscillating around it, or diverging away.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Improving ProtoDUNE pion cross-section measurements with NuGraph Michel-electron tagging

Understanding hadron-argon interactions is essential for precise neutrino energy reconstruction and final-state interaction modeling in liquid-argon time projection chamber (LArTPC) experiments such as DUNE. In particular, pion absorption and charge-exchange processes constitute significant sources of systematic uncertainty in neutrino oscillation measurements. ProtoDUNE-SP, a large-scale LArTPC prototype operated at the CERN Neutrino Platform and exposed to charged-particle test beams in the few-GeV range, enables direct measurements of these processes. This work focuses on the measurement of differential cross sections for pion absorption and charge exchange using the 2 GeV/c pion beam data from the ProtoDUNE-SP run. A key component of this analysis is the identification of Michel electrons from $\pi \rightarrow \mu \rightarrow e$ decay chains, which helps separate different interaction topologies and improves background rejection. Michel electron identification will also assist in reliably calibrating the electromagnetic response in ProtoDUNE-SP data and for the future DUNE detectors. In this analysis, we apply NuGraph to identify Michel electrons. NuGraph is a graph neural network that models detector hits as nodes connected by spatial and temporal edges for particle and topology classification in LArTPC detectors. We first benchmark NuGraph’s Michel electron classification performance using ICEBERG data, a small-scale LArTPC prototype used for DUNE electronics and reconstruction development, and then transfer the approach to ProtoDUNE-SP. This poster presents the analysis strategy, NuGraph-based classification studies, and discusses how these developments are expected to improve the pion cross-section measurement.

Razafinime, Soamasina Herilala [Cincinnati U.] (OR↗

DOE OSTI2024

Global 1 km land surface parameters for kilometer-scale Earth system modeling

Earth system models (ESMs) are progressively advancing towards the kilometer scale (“k-scale”). However, the surface parameters for land surface models (LSMs) within ESMs running at the k-scale are typically derived from coarse-resolution and outdated datasets. This study aims to develop a new set of global land surface parameters with a resolution of 1 km for multiple years from 2001 to 2020, utilizing the latest and most accurate available datasets. Specifically, the datasets consist of parameters related to land use and land cover, vegetation, soil, and topography. Differences between the newly developed 1 km land surface parameters and conventional parameters emphasize their potential for higher accuracy due to the incorporation of the most advanced and latest data sources. To demonstrate the capability of these new parameters, we conducted 1 km resolution simulations using the E3SM Land Model version 2 (ELM2) over the contiguous United States. Our results demonstrate that land surface parameters contribute to significant spatial heterogeneity in ELM2 simulations of soil moisture, latent heat, emitted longwave radiation, and absorbed shortwave radiation. On average, about 31 % to 54 % of spatial information is lost by upscaling the 1 km ELM2 simulations to a 12 km resolution. Using eXplainable Machine Learning (XML) methods, the influential factors driving the spatial variability and spatial information loss of ELM2 simulations were identified, highlighting the substantial impact of the spatial variability and information loss of various land surface parameters, as well as the mean climate conditions. The comparison against four benchmark datasets indicates that ELM generally performs well in simulating soil moisture and surface energy fluxes. The new land surface parameters are tailored to meet the emerging needs of k-scale LSM and ESM modeling with significant implications for advancing our understanding of water, carbon, and energy cycles under global change. The 1 km land surface parameters are publicly available at https://doi.org/10.5281/zenodo.10815170 (Li et al., 2024).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

CLM5 CAMELS Basins Ensemble

Land surface models such as Community Land Model Version 5 (CLM5) are essential tools for simulating the behaviors of the terrestrial system. Despite the extensive application of CLM5, limited attention has been paid to the underlying uncertainties associated with its hydrologic parameters and the implications that these uncertainties have on water resources applications. To address this long-standing issue, we conduct a comprehensive hydrologic parameter uncertainty characterization (UC) of CLM5 over the hydroclimatic gradients of the Conterminous United States using five meteorological datasets. Key datasets produced from the UC experiment include a benchmark dataset of CLM5 default hydrological performance, parameter sensitivity identified for 28 hydrological metrics, and large ensemble outputs for hydrological predictions. The presented datasets can assist CLM5 calibration and to support broad applications such as evaluating vulnerabilities to droughts and floods. The dataset can be used to identify under what hydroclimate conditions parametric uncertainties demonstrate substantial effects on hydrological predictions and clarify where further investigations are needed to understand how land runoff uncertainties interact with other Earth system processes. Please refer to the included README.pdf for a description of the included files. Note that raw CLM5 model outputs for each forcing dataset are hosted on a Globus endpoint: https://app.globus.org/file-manager?destination_id=d22ef858-27b0-11ed-a910-fd3165076336.

Yan, Hongxiang↗

DOE OSTI2023

CLM5 CAMELS Basins Ensemble

Land surface models such as Community Land Model Version 5 (CLM5) are essential tools for simulating the behaviors of the terrestrial system. Despite the extensive application of CLM5, limited attention has been paid to the underlying uncertainties associated with its hydrologic parameters and the implications that these uncertainties have on water resources applications. To address this long-standing issue, we conduct a comprehensive hydrologic parameter uncertainty characterization (UC) of CLM5 over the hydroclimatic gradients of the Conterminous United States using five meteorological datasets. Key datasets produced from the UC experiment include a benchmark dataset of CLM5 default hydrological performance, parameter sensitivity identified for 28 hydrological metrics, and large ensemble outputs for hydrological predictions. The presented datasets can assist CLM5 calibration and to support broad applications such as evaluating vulnerabilities to droughts and floods. The dataset can be used to identify under what hydroclimate conditions parametric uncertainties demonstrate substantial effects on hydrological predictions and clarify where further investigations are needed to understand how land runoff uncertainties interact with other Earth system processes. Please refer to the README.pdf for a description of the included files. Note that raw CLM5 model outputs for each forcing dataset are hosted on a Globus endpoint: https://app.globus.org/file-manager?destination_id=d22ef858-27b0-11ed-a910-fd3165076336.

Yan, Hongxiang↗

DOE OSTI2021

Evaluating Cell Temperature Models and the Effect of Wind Speed in PV System Capacity Testing: Preprint

Capacity testing is a routine procedure for assessing a photovoltaic system's performance relative to expectations. The most common test method involves fitting a regression model that predicts system output power using operating weather conditions including wind speed. Structural modifications to the regression model to incorporate wind in different ways improved the model's ability to fit measured system performance, but the observed improvements were small and unlikely to change the result of a capacity test. However, the results showed that the choice of reporting wind speed and inclusion or exclusion of wind speed in the performance model used as the test benchmark can significantly change the test result.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2021

Closing the Loop on Automotive Carbon Fiber Prepreg Manufacturing Scrap

The project demonstrated how to “close the loop” on carbon fiber by integrating industrial carbon fiber scrap into new functional components in an automotive lightweighting application. The project serves as a validation of discontinuous recycled carbon fiber in a commercial context, while generating comprehensive material data throughout the production chain. To this end, the project exhibited increasing complexity as material evaluation progressed from benchtop to commercial scale through full-scale part production, with key material properties thoroughly characterized throughout the process. Of particular focus was the form of the fiber that was fed into compounding, as recycled fiber has historically been problematic to feed at commercial-scale. Carbon fiber is energy-intensive to manufacture, so reuse of existing fiber material can reduce costs and increase sustainability. Additionally, by integrating recovered short fiber into a thermoplastic, regrind processes can be used to provide feedstock for later generations of product. While regrind plastics are not “infinitely recyclable”, reusing the manufacturing scrap over several generations of products can greatly increase material sustainability and lower the fractional embodied energy of each successive product. As such, this project supports the IACMI technical goals of (1) 25% lower carbon fiber-reinforced polymer (CFRP) cost, (2) 50% reduction in CFRP embodied energy, and (3) 80% composite recyclability into useful products. The initial stage of the project involved down selecting surface treatment (sizing) chemistries. Sizing evaluations were performed on Vartega’s chemically recycled intermediate modulus fiber along with standard modulus dry scrap which was oversized with sizing provided by Michelman. More dramatic improvements from sizing were found on the standard rather than the intermediate modulus fibers. The strength of the chemically recycled individual fibers were evaluated by Michelman and ORNL through single fiber testing and found to be comparable to similarly evaluated virgin fibers. UDRI’s mechanical testing on injection molded test specimens identified similar mechanical properties and fiber distribution relative to benchmark specimens. Additional surface chemistry tests and visualizations were performed by the Colorado School of Mines to confirm close conformance between the benchmark and recycled-fiber specimens. As the mechanical test results exceeded the 80% threshold established as the go/no-go(GNG), the project scale was increased to use commercial-scale equipment that would both better characterize the manufacturing utility of the target product format and allow qualitative assessment of a complex commercial part. An upscaled compounding evaluation was performed with a 27 mm twin-screw compounding extruding using oversized standard modulus fibers that were formatted to improve bulk solids transfer. The project team anticipated that milestone mechanical benchmarks could be achieved given the favorable performance of the sized standard modulus material identified in the initial micro-compounding trials. While the mechanical performance did meet the milestone target for that phase of the project, mechanical properties for this standard modulus-based compound were still less than those of the Ford specification. To compare the performance, the project team oversized intermediate modulus dry fibers and compounded them with the project resin at BASF using a 40 mm compounder. Test specimen mechanical performance exceeded the targets laid out in both the project milestone and the Ford specification. A series of prototype parts were successfully molded, albeit with instances of short shot components due to the high thermal conductivity of the carbon fiber compared to glass fiber for which the prototype tool was designed for. The project demonstrated that recycled carbon fiber is a viable option in fiber reinforced compound, providing greatly increased strength and modulus for applications that require them. The “agglomerated” format that facilitated effective bulk solids transfer of recovered fiber showed promise for industrial application.

36 MATERIALS SCIENCE↗

DOE OSTI2023

The Structural Evaluation Test Unit (SETU) Benchmark Test Results

A series of extensively instrumented tests was performed on the Structural Evaluation Test Unit in the early 1990s. The purpose of these tests was to determine the response of a minimally designed cask to impacts that were more severe than the design basis impact. This test series provides an excellent opportunity for benchmarking explicit dynamic finite element analysis programs for behaviors that may be experienced by casks during regulatory and extra-regulatory impact events. This report provides the results of the four tests that were conducted. It is meant to go along with a companion report that defines the benchmark problem and gives the locations for the instrumentation and inspection points.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗