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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 667 records · Page 37

Next Steps [PowerPoint, AM Beams Project]

Three goals are identified as next steps: Goal 1: Finalize DSPI codes. Goal 2: Obtain effective properties of AM beams. Goal 3: Obtain preliminary evidence for being able to fully define internal structure from surface DSPI.

36 MATERIALS SCIENCE↗

Demonstration of Integrated PostIrradiation Process Steps forMultikilogram Amounts of Low- and High-Burnup Used Nuclear Fuels

sponsored research and development (R&D) on the advanced, closed nuclear fuel cycle, including post-irradiation processing of used fuels, recovery of separated components, and preparation of recycle nuclear fuels. During the period 2007–2010, kilogram-scale demonstrations of the integrated processing steps were performed for actual light water reactor (LWR) used nuclear fuels (UNF). These integrated processing demonstrations were called “the Coupled-End-to-End” (CETE) campaigns and were associated with the Global Nuclear Energy Partnership program, which ran concurrently. The demonstrations were carried out in the shielded hot cells and associated gloveboxes located in the Irradiated Fuels Examination Laboratory (IFEL) and the Radiochemical Engineering Development Center (REDC) at the Oak Ridge National Laboratory (ORNL). Limited circulation program reports and a few technical papers were issued. The subject document provides a comprehensive summary of results, technical comparisons, and conclusions obtained from the demonstration campaigns and subsequent associated R&D.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Narrow Slot Gasket Grooves And Step Changes In Width

We provide corrections to the slot capacitance and inverse inductance per unit length for slot gasket groove geometries using an approximate conformal mapping approach. We also provide corrections for abrupt step changes in slot width along with boundary discontinuity conditions for implementation in the various slot models.

42 ENGINEERING↗

A Step Toward Working with Untrusted Ground Stations

We are witnessing a shift toward outsourcing satellite and ground station services to third-party commercial entities. As with any enterprise, these third parties can be vulnerable to cyber compromise, including image tampering and deepfake injection. The multimedia community is beginning to establish standards and technology to enable authenticity verification of multimedia created and edited by others. While appealing to the remote sensing domain, the nature of raw satellite imagery is incompatible with the proposed change verification tools, resulting in the need for a means to validate updates made to image products. We present a simple method for verifying a specific class of algorithms. Our inverse processing approach eliminates the need to see the original image as the reversed data can be checked against an original digital signature. We demonstrate our approach on basic image restoration routines and conclude with a discussion on open challenges and next steps.

97 MATHEMATICS AND COMPUTING↗

A New 1-step Arrhenius Decomposition Model for PBX 9501: Calibration with Isochoric-Adiabatic High-Activation-Energy Asymptotics and Uncertainty Quantification

Here we present a new 1-step Arrhenius thermal decomposition model of PBX 9501. As opposed to previous studies, we use high-energy asymptotic theory, and previously published equations of state to parameterize the model to experimental critical-time data. The model parameters were fit to experimental data using a bootstrapping procedure to capture the effects of experimental uncertainty. Subsequent implementation of the model in a chemicalkinetics ODE solver shows good agreement of times to ignition vs initial temperature in isochoric thermal explosion calculations with the results of the high-energy asymptotic theory. We also compare the resultant ZND structures to those of one of our previously calibrated burn models.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗

Steady Laminar Flame for 1-Step Thermal Decomposition Model of PBX 9501

We have recently developed a new 1-step thermal decomposition model of PBX 9501 high explosive. In this report, we examine the behavior of the model in 1-D steady laminar flame calculations. In particular, the dependencies of the steady laminar flame velocity on initial pressure, thermal conductivies and parameters of the thermal decomposition model are investigated. The results of our numerical calculations are compared to available experimental data.

42 ENGINEERING↗

Ultra-high Q cavity-based search for the Dark Photon: new exclusion limit from Dark SRF phase 1 and step forward for phase 2

We present here the first results of Dark SRF, a light-shining-through-wall (LSW) experiment that leverages ultra-high quality factor superconducting radio frequency (SRF) cavities to search for dark photons. The use of Nb SRF cavities combined with a strict calibration and measurement protocol increased sensitivity to dark photons by several orders of magnitude compared to other LSW experiments, as demonstrated by our new limit that excluded a broad range of previously unstudied dark photon mass and mixing angle.In addition to the results of the search conducted in liquid helium using 1.3GHz SRF cavities, we also present the first steps of the second phase of the experiment, which will take place in a dilution refrigerator using 2.6GHz SRF cavities. These experiments are part of a wider effort of the Superconducting Quantum Materials and Systems (SQMS) Center to employ ultra-high Q SRF cavities to search for Beyond the SM particles and wavelike dark matter.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

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↗

MFiX: Fractional-Step Method Implementation

A comprehensive, multiphase computational fluid dynamics (CFD) simulation solves several coupled transport equations including continuity, momentum, species, and energy. Chemical reactions further couple these equations through heats of reaction and rates of formation of products and rates of destruction of reactants. A fractional-step method separates changes attributed to chemical reactions from transport phenomena like convection and diffusion. When the governing equations are split into the transport and reacting components, efficient and independent methodologies can be exploited to solve the different systems. Specifically, discretization of field variable transport equations results in large, sparse matrices which are loosely coupled. These systems are solved in succession using iterative techniques that take advantage of the matrix structure. In contrast, chemical reactions tightly couple field variables locally within the domain (e.g., within a single computational cell) resulting in low dimensional but dense, nonlinear systems that are better solved using direct integration techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Finding ways to reduce nuclear waste: searching for the unknown one step at a time

In my home country, Venezuela, research has been stagnant. Due to the political turmoil and the crisis, many educated people have left the country in search for a better life. This has caused a deficit in any technological and scientific advances, making Venezuela one of the first South American countries to have its rate of publications decline by 29% in 2013. Currently, Venezuela lacks the infrastructure and the means to keep up with the research progress as compared to other countries in South America, such as Brazil. Since coming to the United States (US), and currently working for a national laboratory, the active research environment endorses a wide range of careers and engineering programs that allow researchers to thrive at any given field. Researchers have access to funds and tools to succeed in developing materials for the future. There are 17 national laboratories in the US, and all of these have a different research focus/objective. As examples, Los Alamos National Laboratory and Sandia National Laboratory focus is on national homeland security, weapon science, radiation effects, among others. Argonne National Laboratory focuses on nuclear energy, energy storage, high performance computing, etc. At Idaho National Laboratory (INL) the research focuses on innovating nuclear energy and clean energy resources, critical infrastructure materials, along with fuel cycle solutions to manage, dispose and find ways to recycle current and future radiological waste. Compared to other national laboratories, INL focuses slightly more on applied processes and how nuclear energy can be innovated to next reactor design and technologies. The research being conducted at INL made me apply for a Seaborg distinguished postdoctoral position. For the position itself, the researcher must submit a proposal related to actinide chemistry on a research field area. In this position, 50% of my time will be focused on my own proposal. The proposal that I am working on is focused on the innovation of nuclear energy and fuel cycle recycling, which is why I was mainly interested on working at this national laboratory. To give a bit more context of what my proposal is about, a little bit of background is necessary: After the nuclear fuel (UO2) is used in a reactor, the fuel matrix is then characterized by various fission products (FP). Among these FP (including rare earth elements, alkali/alkaline earths, and actinides), many can potentially be recovered through nuclear reprocessing technologies. In pyroprocessing, the used nuclear fuel undergoes electrochemical dissolution into a molten chloride salt mixture in an electrorefiner. Initially, uranium is reduced onto an inert cathode by applied potentials. However, numerous remaining FPs accumulate in the melt and pose challenges for recovery by an inert electrode, particularly the rare earth elements (e.g., Nd, Gd, Pr, Sm) due to their multivalent oxidation states and tendencies toward side reactions, leading to their dissolution in the electrolyte. These recovery challenges result in inefficiencies and necessitate the continual discarding of the molten chloride salt, thereby generating additional waste. Furthermore, the presence of rare earth elements and other fission products in the molten salt electrolyte alters its physical and chemical properties, affecting both uranium recovery efficiency and the longevity of the molten chloride salt. To improve the recovery efficiency of the FP, specifically rare earth elements, I am investigating the fundamental interactions between rare earth elements in the molten chloride salt and their metallic form. The kinetic pathways and the chemical reactions of these elements will give insights on how the recovery efficiency can be improved. The interactions and speciation of these elements are being studied by spectro-electrochemistry at high temperature environments in quartz and other ceramic materials (e.g., alumina crucibles). Some of the challenges I am facing specifically relates the reactivity of some of these elements with different glass and crucible materials. Although my research focuses on fundamental science, it will benefit the applied process by generating new scientific knowledge and closing the gap for an efficient recycling of the waste: one step at a time.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Chapter 8: Looking Forward and Next Steps

U.S. Department of Energy. 2024. “Chapter 8: Looking Forward and Next Steps.” In 2023 Billion‐Ton Report. M. H. Langholtz (Lead). Oak Ridge, TN: Oak Ridge National Laboratory. doi: 10.23720/BT2023/2316179.

BT23↗