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The 16 T dipole development program for FCC and HE-LHC

A future circular collider (FCC) with a center-of-mass energy of 100 TeV and a circumference of around 100 km, or an energy upgrade of the LHC (HE-LHC) to 27 TeV require bending magnets providing 16 T in a 50-mm aperture. Several development programs for these magnets, based on Nb$_3$Sn technology, are being pursued in Europe and in the U.S. In these programs, cos-theta, block-type, common-coil, and canted-cos-theta magnets are explored; first model magnets are under manufacture; limits on conductor stress levels are studied; and a conductor with enhanced characteristics is developed. This paper summarizes and discusses the status, plans, and preliminary results of these programs.

43 PARTICLE ACCELERATORS↗

Development of spectroscopic tools for nuclear forensics signatures development

The Savannah River National Laboratory (SRNL) has been developing advanced spectroscopic tools for the characterization of plutonium-bearing compounds with the intent to develop material and process signatures for nuclear forensics. Plutonium in a production, refining, or finishing facility will exist in many forms including oxide precursors (PuF4, PuF3, Pu oxalate, etc.), oxide, and metal. The ability to identify plutonium in each of these chemical forms and determine their processing history is crucial for the development of spectroscopic signatures. This presentation will focus on our work to develop and apply spectroscopic tools at SRNL using doubled-walled cells (DWC) to characterize the thermal decomposition of oxalates, calcination chemistry, alpha-decay-induced chemistry, age dating since last calcination, and other signatures related to plutonium processing.

Villa-Aleman, Eliel↗

Important powertrain dynamics for developing models for control of connected and automated electrified vehicles

Connected and Automated Vehicles (CAV) technology presents significant opportunities for energy saving in the transportation sector. CAV technology forecasts vehicle and powertrain power needs under various terrain, ambient, and traffic conditions. Integration of the CAV technology in Hybrid Electric Vehicles (HEVs) provides the opportunity for optimal vehicle operation. Indeed, Hybrid Electric Vehicle powertrains present high degrees of flexibility and possibility for choosing optimum powertrain modes based on the predicted traction power needs. In modeling complex CAV powertrain dynamics, the modeler needs to consider short-time scale powertrain dynamics, such as engine transients, and hysteresis of mode-switching for a multi-mode HEV. Therefore, the powertrain dynamics essential for developing powertrain controllers for a class of connected HEVs is presented. To this end, control-oriented powertrain dynamic models for a test vehicle consisting of full electric, hybrid, and conventional engine operating modes are developed. The resulting powertrain model can forecast vehicle traction torque and energy consumption for the specified prediction horizon of the test vehicle. The model considers different operating modes and associated energy penalty terms for mode switching. Thus, the vehicle controller can determine the optimum powertrain mode, torque, and speed for forecasted vehicle operation via utilizing connectivity data. The powertrain model is validated against the experimental data and shows prediction error of less than 5% for predicting vehicle energy consumption. The model is used to create energy penalty maps that can be used for CAV control, for example fuel penalty map for engine torque changes (10–40 Nm) at each engine speed. The results of model-based optimization show optimum switching delays ranging from 0.4 to 1.4 s to avoid hysteresis in mode switching.

Engineering↗

Development of a medium-duty stoichiometric diesel micro-pilot natural gas engine

Fueling a compression-ignition engine with premixed natural gas offers the potential to combine a clean-burning, low-carbon fuel with a high compression ratio, high-efficiency engine. This work describes the development of a multi-cylinder 6.7 L diesel engine converted to run stoichiometric diesel micro-pilot/ natural gas premix combustion with a maximum diesel contribution target of 5% of the total fuel energy and a three-way catalyst aftertreatment system. Results are given by comparing the stoichiometric combustion to the diesel baseline operation, showing combustion characteristics differences, including the rapid two stage heat release. A high load output of 23 bar brake mean effective pressure was obtained with diesel-like brake thermal efficiency of 41%. This operating condition enabled a brake specific CO 2 emissions reduction of up to 25% when compared to diesel. It was observed that the low load output is limited by combustion stability when operated at stoichiometric condition. The three-way catalyst is observed to run at peak efficiency with an equivalence ratio of 1.01. Injector fouling was observed through the inspection of the nozzle and its internal parts, indicating carbon build-up similar to that seen in injector coking mechanisms. A comparison of the developed engine to other engine technologies is given, showing that the diesel micro-pilot natural gas engine performance is in good standing among other diesel and gas engines in the market.

Engineering↗

Collaboration on SBIR/TTO Phase II Project for Optical QC Device and Collaboration on SBIR/TTO Phase II-b Project for Advanced Quality Inspection Device Development: Cooperative Research and Development CRADA Number CRD-16-00652 (Final Report)

The overall goal of this program is to develop and commercialize a turnkey quality control solution for the entire PEM fuel cell manufacturing process including membrane, gas diffusion layers, catalyst, and assembled systems. This quality control solution is unique to each customer’s specific needs but includes a suite of in-line quality control systems for roll-to-roll manufacturing that can target thin, transparent membrane as well as opaque membrane, catalyst, and GDLs. The Phase II developed the CPNUVV system for thin, transparent membrane that operates using polarized filters to enhance defect resolution and determine thickness. However, PEM material manufacturers want a complete, turnkey solution for all components of the PEM fuel cell. In the Phase IIB, Mainstream will partner with NREL, and transition reflectance technology NREL developed (US Patent 9,234,843) to operate in real-time on a web-line to develop a total solution to PEM quality control. The device will identify and mark defects as well as monitor materials thickness in real-time to improve line efficiency and to reduce waste. The research performed at NREL under this CRADA increases the basis of knowledge about optical inspection methods, how they perform with regards to fuel cell component materials, and how they can be implemented in in-line, real-time configurations to provide quality inspection for roll-to-roll (R2R) manufacturing. Methods explored were found to be sensitive to catalyst loading in electrodes on both membrane and gas diffusion media substrates and to membrane thickness, across a broad range of thickness. The latter capability is novel and now patented and provides a previously unstudied and undemonstrated capability for R2R manufacturing of membranes.

30 DIRECT ENERGY CONVERSION↗

American Made Challenges Battery Voucher Program Cooperative Research and Development Agreement (Cooperative Research and Development Final Report, CRADA Number CRD-21-17533)

Renewance is a Phase II winner of the U.S. Department of Energy Lithium-ion Battery Recycling Prize. The Prize is designed to incentivize American entrepreneurs to develop and demonstrate processes that, when scaled, have the potential to profitably capture 90% of all discarded or spent lithium-based batteries (LIB) in the Unites States for eventual recovery of key materials for re-introductions into the U.S. supply chain. The objective of this work is to enable a more efficient evaluation of battery sources for second life applications prior to ultimately being recycled, through evaluation of chemistry characteristics, projected battery lifetime, and application history. This work will develop the capability to identify groups of batteries that may be useful for second life and reduce the cost of end-of-life (EOL) LIB evaluation and repurposing. To meet the objective, NREL will use existing and new data to create a refined algorithm that could be used to evaluate batches of batteries for potential reuse based on manufacturing date and historical use characteristics. Based on current battery market prices and compiled literature data, a starting-point estimate of the market value of the batteries for reuse based on expected lifetime will be included in the algorithm. With the projected surge in LIB demand, battery second life is a new area ripe for development and investment from companies like Renewance. With so few large format batteries reaching EOL to date, this is a new market with a variety of areas for optimization and adding value. This work with Renewance is an example of how existing expertise in battery degradation at NREL can be used to reduce the cost of shifting a battery into a second life application. With these cost reductions, this work is also facilitating the development of a battery circular economy in the United States. A robust circular economy can maximize the utilization of critical metals demanded by battery technology such as nickel and cobalt while also reducing the costs of batteries in the marketplace for the many end-uses needed for the green energy transition. The supply of these metals is limited, and we face a supply chain shortage both domestically and globally unless we can ensure they are being used to their maximum potential. This research can improve the economics of a battery circular economy to make it a more likely path for EOL batteries with critical metals. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗

Final Report on Development of Microwave Resonant Cavity Transducer for Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have developed a continuum electromechanics model of the microwave resonant cavity transducer performance. The deflection of the membrane is calculated using equations from the theory of plates and shells for deflection of radially constrained thin circular disk under uniform load. The microwave frequency shift is calculated using the equations from the microwave cavity perturbation theory. The transducer model was validated with proof-of-concept experimental data of water flow sensing with a Brass 360 right circular cylinder with 22.2mm diameter and 203µm thick wall. The cavity was excited through a subwavelength hole in TE 011 mode with resonant frequency f ≈ 17.8GHz. Subsequently, we have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. For this test, we have developed a cylindrical resonator with the same dimensions as for the Brass 360 cavity. The resonator for high temperature liquid sodium test was machined from stainless steel 316 and electroplated with silver on the interior surfaces. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. The sodium flow sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred kHz was observed. The transducer was removed after 70 days of testing. No visual damage was observed, and the electromagnetic response remained the same. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Water flow sensing was performed before and after liquid sodium test. The responses in both cases are similar and agree with COMSOL computer simulations. Because long-term (multi-year) experimental tests of transducer resilience to harsh environment are not practical, we have developed a probabilistic model of creep to estimate transducer resilience to the harsh environment. The probabilistic model considers diffusion creep under the condition of high temperature and low stress, where the stress and temperature are allowed to be random variables with Gaussian distributions. Using the probabilistic model, we estimate inelastic membrane deflections due to creep for several temperature ranges. We conclude that for temperatures less than 650°C, creep has negligible long-term effect on the transducer performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Research Development and Partnership Pilot (RDPP): Developing plans and partnerships for incorporating tree reproduction to understand Earth system change

The goals for this Research Development and Partnership Pilot (RDPP) proposal were to i) learn about Department of Energy (DOE) research and use the PI’s expertise on patterns and environmental drivers of tree reproduction as a basis to make connections with individuals and research groups at DOE National Laboratories, and ii) to develop plans and form partnerships that will both enhance the PI’s research. The objectives of the proj ect were for the PI to i) participate in the Department of Energy's Office of Science program in Biological and Environmental Research training and outreach activities, ii) conduct directed fact-finding on Earth and Environmental Systems Sciences Division (EESSD) research projects and new partnerships with individuals and groups at National Laboratories, ii) conduct meetings with potential collaborators at National Laboratories to discuss EESSD-relevant research ideas, and iv) to develop a plan for future research efforts. During the period of the award, the objectives of the proposal were met, as the PI attended Environmental System Sciences meetings, American Geophysical Union meetings, SPRUCE experiment meetings, and visited the Oak Ridge National Lab. These activities led to increased understanding of the research being conducted by DOE scientists and the PI had meetings with potential collaborators to develop future research plans that leverage expertise at DOE and the research interests of the PI to increase understanding of the role of tree reproduction in future carbon allocation and in tree regeneration models in boreal ecosystems.

54 ENVIRONMENTAL SCIENCES↗

Investigating Core Gaps and the Development of Subcomponent Validation Methods for Wind Turbine Blades: Preprint

Core gaps are a common manufacturing defect observed in wind blade composite sandwich constructions, which occur when sheets of core material are not properly butted up against each other in the mold. The aim of this study was to characterize core gaps in composite sandwich constructions at the coupon scale. This was to gain an initial understanding of the defect before developing appropriate methodologies for more complex subcomponents as part of a much broader wind blade structural validation and damage tolerance program. Long beam flexure in 4-point-bending was chosen as the most appropriate loading scenario. Beam specimens were characterized with and without 10 mm core gaps in fiberglass/balsa sandwich beams. The core gaps were characterized with two separate resin systems; a Hexion epoxy and Arkema's Elium resins system (a novel, infusible thermoplastic). Results showed that the Elium beams without the core gaps were had a 15% lower static strength than their epoxy counterparts. The introduction of the core gap to the epoxy beams reduced their static strength by 35%. The Elium beams, however, exhibited negligible strength reductions with the inclusion of the core gap. Overall, this characterization study provided pertinent information with regards to core gaps as a manufacturing defect to allow for continued development of damage tolerance and subcomponent validation methodologies with the inclusion of manufacturing defects.

17 WIND ENERGY↗

Development and Demonstration of a Class 6 Range-Extended Electric Vehicle for Commercial Pickup and Delivery Operation: Preprint

Range-extended hybrids are an attractive option for medium- and heavy-duty commercial vehicle fleets because they offer the efficiency of an electrified powertrain with the driving range of a conventional diesel powertrain. The vehicle essentially operates as if it was purely electric for most trips, while ensuring that all commercial routes can be completed in any weather conditions or geographic terrain. Fuel use and point-source emissions can be significantly reduced, and in some cases eliminated, as many shorter routes can be fully electrified with this architecture. Under a U.S. Department of Energy (DOE)-funded project for Medium- and Heavy-Duty Vehicle Powertrain Electrification, Cummins has developed a plug-in hybrid electric Class 6 truck with a range-extending engine designed for pickup and delivery application. The National Renewable Energy Laboratory (NREL) assisted by developing representative workday drive cycles for Class 6 operation and an adapted cycle to enable vehicle track testing. A novel, automated driving system was utilized by Southwest Research Institute (SwRI) to improve the repeatability of the track testing conducted to quantify vehicle energy consumption. Cummins used a drivetrain model to design the hybrid control system for increased fuel savings. The control system functionality and fuel savings objective of 50% or more were confirmed by track testing described in this paper.

ADVANCED PROPULSION SYSTEMS↗

Grid Application and Controls Development for Medium-Voltage SiC-Based Grid Interconnects

This paper studies, the grid-interconnection requirements of directly connected medium-voltage (MV) Silicon Carbide-based (SiC-based) converters and details the necessary control implementations. These power electronic converters follow the interconnection standard IEEE 1547-2018, but can also have additional controls supported by the microgrid standards in IEEE 2030.7, which is demonstrated in this work. Additionally, this paper defines the grid applications realized by these directly connected medium-voltage power electronic converters at the distribution scale and demonstrates results. The controls for the studied grid applications are then developed and implemented on the controller. The paper also includes details of the control algorithm development and validations of the control algorithm through hardware-in-the-loop results.

28 EE - Advanced Manufacturing Office (EE-5A)↗

WE-H-201-04: Models for Developing Medical Physics Educators and Education Programs in the Developing Countries and the Potential Role of US Universities and Individual Medical Physicists

The desperate need for radiotherapy in low and mid-income countries (LMICs) has been well documented. Roughly 60 % of the worldwide incidence of cancer occurs in these resource-limited settings and the international community alongside governmental and non-profit agencies have begun publishing reports and seeking help from qualified volunteers. However, the focus of several reports has been on how dire the situation is and the magnitude of the problem, leaving most to feel overwhelmed and unsure as to how to help and why to get involved. This session will help to explain the specific ways that Medical Physicists can uniquely assist in this grand effort to help bring radiotherapy to grossly-underserved areas. Not only can these experts fulfill an important purpose, they also can benefit professionally, academically, emotionally and socially from the endeavor. By assisting others worldwide with their skillset, Medical Physicists can end up helping themselves. Learning Objectives: Understand the need for radiotherapy in LMICs. Understand which agencies are seeking Medical Physicists for help in LMICs. Understand the potential research funding mechanisms are available to establish academic collaborations with LMIC researchers/physicians. Understand the potential social and emotional benefits for both the physicist and the LMIC partners when collaborations are made. Understand the potential for collaboration with other high-income scientists that can develop as the physicist partners with other large institutions to assist LMICs. Wil Ngwa - A recent United Nations Study reports that in developing countries more people have access to cell phones than toilets. In Africa, only 63% of the population has access to piped water, yet, 93% of Africans have cell phone service. Today, these cell phones, Skype, WhatsApp and other information and communication technologies (ICTs) connect us in unprecedented ways and are increasingly recognized as powerful, indispensable to global health. Thanks to ICTs, there are growing opportunities for Medical Physicists to reach out beyond the bunker and impact the world far beyond, without even having to travel. These growing opportunities in global health for Medical Physicists, powered by ICTs, will be highlighted in this presentation, illustrated by high impact examples/models across the globe that are improving patient safety and healthcare outcomes, saving lives. Learning Objectives: Published definitions of global health and the emerging field of global radiation oncology Learn about the transformative potential of ICTs in global radiation oncology care, research and education with focus on Medical Physics Learn about high impact examples of ICT-powered global radiation oncology and the increasing opportunities for participation by Medical Physicists. Yakov Pipman - The number and scope of volunteer Medical Physics activities in support of low-to-middle income countries has been increasing gradually. This happens through a variety of formal channels and to some extent through less formal but personal initiatives. A good deal of effort is dedicated by many, but many more could be recruited through a structured framework to volunteer. We will look into typical volunteer activities and how they fit with organizations already involved in advancing Medical Physics in LMIC. We will identify the range of these organizational activities and their scope to reveal areas of further need. We will point to a few key features of MPWB ( http://www.mpwb.org ) as a volunteering and collaborating structure and how members can get involved and contribute to these efforts at the grass roots level. The goal is that scarce resources can thus be channeled to complement rather than compete with those already in place. Learning Objectives: Understand the strengths and limitations of various organizations that support Medical Physics efforts in LMIC. Learn about ways to volunteer and contribute to Global Health through a grass roots organization focused on Medical Physics in LMIC. Perry Sprawls - With the growing capability and complexity of medical imaging methods in all countries of the world, the expanding role of medical physicists includes optimizing imaging procedures with respect to image quality, radiation dose, and other conflicting factors. With access to appropriate educational resources local medical physicists in all countries can provide direct clinical support and educational for other medical professionals. This is being supported through the process of Collaborative Teaching that combines the capabilities and experience of medical physicists in countries spanning the spectrum of economic, technological, and clinical development. The supporting resources are on the web at: http://www.sprawls.org/resources . Learning Objectives: Identify the medical physics educational needs to support effective and optimized medical imaging procedures. Use collaborative teaching resources to enhance the role of medical physicists in all countries of the world.

60 APPLIED LIFE SCIENCES↗

Catalyst Development to Overcome Barriers for Commercialization of Synthetic High-Octane Hydrocarbons: Cooperative Research and Development (Final Report)

In recent years, researchers at the National Renewable Energy Laboratory (NREL) and the University of California Berkeley (UC Berkeley) have independently developed catalysts that convert methanol and dimethyl ether into alkylate-like hydrocarbons with a high-octane value, and both have developed intellectual property around these chemical transformations. Both UC Berkeley and NREL wish to see their technologies commercialized to address a number of domestic and international energy challenges. The technologies developed by NREL and UC Berkeley are complimentary but neither have moved beyond the laboratory scale due to remaining challenges with the catalyst activity and selectivity, and/or with the reaction engineering associated with maximizing the yield of the high-value product. NREL and UC Berkeley wish to collaboratively through a shared resources CRADA to solve issues related to the scale-up and process integration of their high-octane hydrocarbon technologies, thus enabling future licensing of the technology to an industry partner.

10 SYNTHETIC FUELS↗

ACCELERATING MICROREACTOR DEVELOPMENT AND DEPLOYMENT THROUGH JOINT PUBLIC TEST BEDS AND PRIVATE ADVANCED REACTOR DEVELOPMENT

The United States Department of Energy (DOE) has funded the National Reactor Innovation Center (NRIC) to accelerate the development and commercialization of small modular reactors and other advanced reactor technologies. As part of this effort NIRC is building two strategic assets at the Idaho National Laboratory (INL) to facilitate public-private partnerships for the development and testing of advanced nuclear microreactors and Small Modular Reactors (SMR). One will provide a safe, secure, and affordable location for High-Assay Low Enriched Uranium (HALEU) fueled reactors and a second for Highly Enriched Uranium (HEU) fueled reactors. Together these testbeds fill a nuclear testing infrastructure gap. The availability of such comprehensive testing facilities at the national labs eliminates the significant financial and operational burdens associated with each developer building and licensing their own test facilities. Consequently, this approach will not only accelerate technological innovation and reduce time-to-market for advanced nuclear solutions but it also underscores the DOE's commitment to fostering an ecosystem where nuclear energy will thrive as a clean, reliable, and efficient source of power. The Demonstration of Microreactor Experiments (DOME) and Laboratory for Operations and Testing in the United States (LOTUS) have planned availability in 2026, and 2027 respectively.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

The future of natural gas infrastructure development in the United states

Changes in the natural gas market have spawned the need for pipeline infrastructure planning. Previous studies have analyzed natural gas infrastructure development largely independent of the interactions of the natural gas sector with the broader economy. However, natural gas infrastructure development is strongly influenced by broader domestic and international socioeconomic conditions. We couple a global Human-Earth system model with state-level detail in the United States (GCAM-USA) that provides the broader socioeconomic context for natural gas supply and demand with a natural gas infrastructure investment model (NANGAM) to examine interstate natural gas pipeline infrastructure development in the U.S. under a range of socioeconomic scenarios. Here we show that existing pipeline infrastructure in the U.S. is insufficient to satisfy the increasing demand for natural gas and investments in pipeline capacity will be required. However, the geographic distribution of investments within the U.S. is heterogeneous and depends on the capacity of existing infrastructure as well as the magnitude of increase in demand. Our results also illustrate the risks of under-utilization of pipeline capacity, in particular, under a scenario characterized by long-term systemic transitions toward a low-carbon economy. More broadly, our study highlights the value of integrated approaches to facilitate informed decision-making.

Feijoo, Felipe↗

Development of a Low-Level Ar-37 Calibration Standard

Argon-37 is an important environmental signature of an underground nuclear explosion. Producing and quantifying low-level 37Ar standards is an important step in the development of sensitive field measurement instruments for use during an On-Site Inspection, a key provision of the Comprehensive Nuclear-Test-Ban Treaty. This paper describes progress at Pacific Northwest National Laboratory (PNNL) in the development of a process to generate and quantify low-level 37Ar standard material, which can then be used to calibrate sensitive field systems at activities consistent with soil background levels. The 37Ar used for our work was generated using a laboratory-scale, high-energy neutron source to irradiate powdered samples of calcium carbonate. Small aliquots of 37Ar were then extracted from the head space of the irradiated samples. The specific activity of the head space samples, mixed with P10 (90% stable argon:10% methane by mole fraction) count gas, is then derived using the accepted Length-Compensated Internal-Source Proportional Counting method. Due to the low activity of the samples, a set of three Ultra-Low Background Proportional-Counters designed and fabricated at PNNL from radio-pure electroformed copper was used to make the measurements in PNNL’s shallow underground counting laboratory. Very low background levels (<10 counts/day) have been observed in the spectral region near the 37Ar emission feature at 2.8 keV. Two separate samples from the same irradiation were measured. The first sample was counted for 12 days beginning 28 days after irradiation, the second sample was counted for 24 days beginning 70 days after irradiation (the half-life of 37Ar is 35.0 days). Both sets of measurements were analyzed and yielded very similar results for the starting activity (~0.1 Bq) and activity concentration (0.15 mBq/ccSTP argon) after P10 count gas was added. A detailed uncertainty model was developed based on the ISO Guide to the Expression of Uncertainty in Measurement. This paper presents a discussion of the measurement analysis, along with assumptions and uncertainty estimates.

Absolute radiation measurement↗