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DOE OSTI2026

Mechanical characterization of Bi-2212 composite winding pack samples for high-field superconducting magnet design

Bi₂Sr₂CaCu₂O8−x (Bi-2212) multi-filament round wire is a high-temperature superconductor (HTS) capable of carrying high transport currents, which makes it suitable for high-field magnet applications. However, its weak Ag–Mg sheath leaves it vulnerable to mechanical stress, posing challenges for high-field magnet design. To better understand and improve mechanical stress management in Bi-2212 winding packs, we conducted an experimental study evaluating the axial stress–strain behavior of five winding pack configurations with varying insulation materials, reinforcement strategies, and construction quality. Using uniaxial tensile testing at 77 K, we measured Young’s modulus and Poisson’s ratio for each composition. Our results show that pure alumina braid insulation and co-wind reinforcements significantly enhance stiffness compared to aluminosilicate braids, with more than 2.5 times increased winding pack Young’s modulus. Rule of mixtures analysis further quantified the contribution of non-wire composite components to overall stiffness. These findings highlight the critical role of insulation material selection and reinforcement design in optimizing Bi-2212 coil performance under stress, providing a foundation for improved mechanical models and more reliable high-field HTS magnet designs.

Bi-2212 magnet↗

DOE OSTI2026

A Faster-Than-Real-Time Framework for Reliability-Oriented Simulation of PV Inverters

Physics-of-Failure (PoF) based reliability assessment for photovoltaic (PV) inverters requires long-duration electrical and electrothermal stress histories, yet generating such stress histories with high-fidelity switching models over year long mission profiles is computationally prohibitive. Conventional methods either sacrifice modeling fidelity for speed or require runtimes that are impractical for design iteration and uncertainty studies. To address this bottleneck, this paper presents a High-Performance Computing (HPC) based simulation frame work for faster-than-real-time reliability-oriented simulation. The proposed framework integrates the Average-to-Switching (A2S) method with parallel computing techniques to accelerate switching-level waveform reconstruction. We further introduce optimization strategies, including cluster merging and sensitivity based mission profile screening, to reduce the computational burden. Evaluated using real-world mission profile inputs and a MATLAB/Simulink switching-model reference, the framework reduces the simulation time for a one-year mission from an intractable multi-year duration to approximately 7.3 minutes while maintaining low waveform error. This acceleration provides a practical reliability-oriented simulation engine that can be coupled with component-specific aging models for subsequent PV inverter PoF assessment.

High-performance Computing↗

DOE OSTI2021

The physiological acclimation and growth response of Populus trichocarpa to warming

Plant metabolic acclimation to thermal stress remains underrepresented in current global climate models. Gaps exist in our understanding of how metabolic processes (i.e., photosynthesis, respiration) acclimate over time and how aboveground versus belowground acclimation differs. We measured the thermal acclimation of Populus trichocarpa, comparing aboveground versus belowground physiology over time. Ninety genetically identical ramets were propagated in mesocosms that separated root and microbial components. After establishment at 25°C for 6 weeks, 60 clones were warmed +4 or +8°C and monitored for 10 weeks, measuring photosynthesis (A), leaf respiration (R), soil respiration (R s ), root plus soil respiration (R s+r ), and root respiration (R r ). We observed thermal acclimation in both A and R, with rates initially increasing, then declining as the thermal photosynthetic optimum (T opt ) and the temperature-sensitivity (Q 10 ) of respiration adjusted to warmer conditions. Photosynthetic acclimation was constructive, based on an increase in both T opt and peak A. Belowground, R s+r decreased linearly with warming, while R s rates declined abruptly, then remained constant with additional warming. Plant biomass was greatest at +4°C, with 30% allocated belowground. Rates of mass-based R r were similar among treatments; however, root nitrogen declined at +8°C leading to less mass nitrogen-based R r in that treatment. The Q 10 -temperature relationship of R r was affected by warming, leading to differing values among treatments. Aboveground acclimation exceeded belowground acclimation, and plant nitrogen-use mediated the acclimatory response. Results suggest that moderate climate warming (+4°C) may lead to acclimation and increased plant biomass production but increases in production could be limited with severe warming (+8°C).

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Wear of Wave Energy Converters Mooring Lines Belts

Using a belt as a replacement for a rope on a rotary power take-offs (PTOs) system has become more common for wave energy converters, improving cyclic bend over sheave performance with a smaller bending thickness for belts. However, the service life predictions of PTOs are a major concern in design, because belt performance under harsh underwater environments is largely less studied. Here, in this work, the effect of fleet and twist angles on wear life is being investigated both experimentally and numerically. Two three-dimensional equivalent static finite element models are constructed to evaluate the complex stress state of polyurethane-steel belts around steel drums. The first is to capture the response of the experimental investigation performed on the wear life, and the second to predict the wear life of an existing functional PTO. The results show a significant effect for fleet and twist angles on stress concentrations and estimated service life.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

LARGE PARTICLE SEPARATION FROM NON-NEWTONIAN SLURRIES USING BUMP ARRAYS

Here we evaluate the performance of bump arrays to separate large particles from non-Newtonian slurries with Bingham and Cross rheology. Bump arrays in deterministic lateral displacement devices separate large particles from small particles using arrays of staggered posts. Large particles, defined as those with radii larger than the distance between the edge of a post and the stagnation streamline from the next downstream post, must bump toward one side of the device, whereas particles smaller than this distance slalom from entrance to exit. Although these devices have been used to separate a wide variety of large particles from blood cells to sand, partition of large particles from non-Newtonian fluids remains unexplored. Yet, an important set of modestly concentrated slurries, including Hanford nuclear waste, displays non-Newtonian rheology. Here we evaluate the influence of non-Newtonian rheology on the large-small particle size cutoff in bump arrays using a model that explores the influence of yield stresses, ratios of zero and infinite shear viscosities, and Cross’s exponent under strictly laminar well-developed conditions. Surprisingly, we find that viscosity ratios and Cross’s exponent make no significant difference on the particle cutoffs between large particles that bump and small particles that slalom around the posts from entrance to exit. In contrast, we find that yield stresses do significantly affect the size cutoff. As the yield stress increases, the velocity profiles become more plug like lowering the size cutoff. For nuclear waste separations where removing large particles is a priority, increasing yield stresses is conservative.

slurry, solids removal, deterministic later displa↗

DOE OSTI2023

Parallel Implicit Hydrodynamics with Material Strength for High Explosive Burn Calculations

High explosives are almost always evolving in some form of metal containment vessel. This fact requires that a materials model for the evolution of the metal containment vessel be part of any simulation of the HE. Since the actual form of the strength model to be used is an open question, we incorporate the material strength properties in a relatively agnostic fashion, which will accommodate many strength models. The only restriction is that the stress components be a function of density, specific internal energy and velocities. In addition, the timescales and rates of the chemical reactions in the HE vary between thousands of seconds and nanoseconds. A hydrodynamics capable of operating in anticipation of the eventual violent release of energy via these chemical reactions is a necessity. The central issue in creating a hydrodynamics capable of spanning these timescales is to forgo the use of a Courant time step control necessary in an explicit hydrodynamics. The Courant time-step arises because of characteristic velocities associated with the material, such as the sound speed or, in materials with strength, characteristic longitudinal and transverse speeds associated with compression and shear. The method used to circumvent the need for a Courant time-step limit is to develop an implicit calculation of the advanced particle pressure and shear modulus derived from the conservation laws of mass, momentum and specific internal energy. This process creates the implicit hydrodynamics needed for the HE calculations of interest to this study.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Time-Temperature-Stress Superposition of PBX 9502 Compressive Creep Data for Lifetime Predictions

The plastic-bonded explosive (PBX) 9502 is a viscoelastic, high-solids loaded polymer bound composite comprised of 95 weight% (wt%) TATB explosive crystals and 5 wt% FK-800 polymer binder. The uniaxial quasi-static mechanical properties have been studied and characterized extensively over 25+ years, including creep. Creep is the strain evolution over time as a result of an asymmetric load typically at temperatures above ambient. Creep measurements to failure can take excessively long periods of time depending on various factors including applied stress, temperature, and loading rate that render a single test to failure impossible. Using the principles of time-temperature-stress superposition (TTSSP), short-term creep tests at various applied stresses and temperatures can be used for long-term creep predictions. The TTSSP model shifts short-term test data using two factors, one for temperature and stress, creating a master curve at a reference test condition. The master curve can be shifted to predict the creep response at any desired test condition. PBX 9502 compression specimens were tested at three temperatures and various applied stresses. This work discusses the TTSSP analysis of PBX 9502 compressive creep data to create a single comprehensive master curve.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Kinetics of HCP-BCC Phase Transition Boundary in Magnesium at High Pressure

Under high pressures, many crystalline metals undergo solid–solid phase transformations. In order to accurately model the behavior of materials under extreme loading conditions, it is essential to understand the kinetics of phase transition. Using molecular dynamics simulations, this work demonstrates the feasibility of characterizing the speeds of a moving phase boundary using atomistic simulations employing a suitable empirical potential for single-crystal magnesium. The model can provide temperature- and tensorial stress-dependent velocity of a moving phase boundary as a rate-limiting contribution to the kinetics of phase transformation in continuum codes. Results demonstrate that a nonlinear interaction exists between plasticity and phase transition, facilitating a jump in the velocity of a moving phase boundary, facilitated by activated plastic deformation mechanisms.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Learnings from the Marcellus Shale Energy and Environmental Lab (MSEEL) Using Fiber Optic Tools and Geomechanical Modeling

The study focuses on the MIP and Boggess pads of the MSEEL (Marcellus Shale Energy and Environmental Laboratory), a public-private partnership with a mandate to publicly release data for scientists and engineers to engage with. Multiple diagnostic tools are used to characterize the formation and monitor fracture treatment and propagation. Geomechanical modeling is used to understand the insitu stresses, microseismic to describe half-lengths and heights, and fiber optics to characterize offset well. Fracture Driven Interactions (FDI’s) and interstage communication. Recent publications covering the MSEEL MIP-3H and MIP-5H wells are reviewed and discussed. A preview of the findings from the Boggess pad (first production in November 2019) is also shared here

03 NATURAL GAS↗

DOE OSTI2022

Graphite Oxidation Modeling

Oxidation modeling importance ASME consideration Effect on graphite properties Model Overview Numerical Model Oxidation Diffusion Reaction Kinetics Model Parameterization Example problems Editing the model Simple problem example Conclusions Coupling to stress analysis Oxidation result analysis

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Update on the Current R&D Activity in the U.S.

This presentation is to fulfil DOE commitment to GIF VHTR Materials PMB. Notched creep rupture testing: Weldment V-notch specimen test finished. 800C 60MPa, 15,716 hour rupture life. Two double V-notch specimen tests have finished. Crack growth tests: System modification was required for creep and creep-fatigue testing, Epsilon 3548COD Extensometer has been ordered, to allow load-line displacement measurements, to be paired with direct current potential drop already used to measure crack length, Sample redesigned in accordance to ASTM E2760 and E1457 to allow for both creep and creep-fatigue crack growth rate testing. Alloy 800H Weldments (1/2) and Alloy 800H Weldments (2/2), Variable Fatigue Testing, and Multi=axial Stress Relaxation. Continue work to finish 800H model, examine ?universal? constitutive model form.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Modeling of surface mechanical behaviors of soft elastic solids: theory and examples

Surfaces of soft solids can have significant surface stress, extensional modulus and bending stiffness. Previous theoretical studies have usually examined cases in which both the surface stress and bending stiffness are constant, assuming small deformation. In this work we consider a general formulation in which the surface can support large deformation and carry both surface stresses and surface bending moments. We show that the large deformation theory can be reduced to the classical linear theory (Shuttleworth equation). We obtain exact solutions for problems of an inflated cylindrical shell and bending of a plate with a finite thickness. Our analysis illustrates the different manners in which surface stiffening and surface bending stabilize these structures. We discuss how the complex surface constitutive behaviors affect the stress field of the bulk. Our calculation provides insights into effects of strain-dependent surface stress and surface bending in the large deformation regime, and can be used as a model to implement surface finite elements to study large deformation of complex structures.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A Bayesian Approach for In-Situ Stress Prediction and Uncertainty Quantification for Subsurface Engineering

Many subsurface engineering applications require accurate knowledge of the in-situ state of stress for their safe design and operation. Existing methods to meet this need primarily include field measurements for estimating one or more of the principal stresses from a borehole, or optimization methods for constructing a 3D geomechanical model in terms of geophysical measurements. These methods, however, often contain considerable uncertainty in estimating the state of stress. Here, in this paper, we build on a Bayesian approach to quantify uncertainty in stress estimations for subsurface engineering applications. This approach can provide an estimate of the 3D distribution of stress throughout the volume of interest and provide an estimate of the uncertainty arising from the stress measurement, the rheology parameters, and a paucity of measurements. The value of this approach is demonstrated using stress measurements from the In Salah carbon storage site, which was one of the world’s first industrial carbon capture and storage projects. This demonstration shows the application of this Bayesian approach for estimating the initial state of stress for In Salah and quantifying the uncertainty in the estimated stress. Also, an assessment of a maximum injection pressure to prevent geomechanical risks from CO 2 injection pressures is provided in terms of the probability distribution of the minimum principal stress quantified by the approach. With the In Salah case study, this paper demonstrates that using the Bayesian approach can provide additional insights for site explorations and/or project operations to make informed-site decisions for subsurface engineering applications.

58 GEOSCIENCES↗

DOE OSTI2021

Genetic Basis of Chromate Adaptation and the Role of the Pre-existing Genetic Divergence during an Experimental Evolution Study with Desulfovibrio vulgaris Populations

Hexavalent chromium [Cr(VI)] is a common environmental pollutant. However, little is known about the genetic basis of microbial evolution under Cr(VI) stress and the influence of the prior evolution histories on the subsequent evolution under Cr(VI) stress. In this study, Desulfovibrio vulgaris Hildenborough (DvH), a model sulfate-reducing bacterium, was experimentally evolved for 600 generations. By evolving the replicate populations of three genetically diverse DvH clones, including ancestor (AN, without prior experimental evolution history), non-stress-evolved EC3-10, and salt stress-evolved ES9-11, the contributions of adaptation, chance, and pre-existing genetic divergence to the evolution under Cr(VI) stress were able to be dissected. Significantly decreased lag phases under Cr(VI) stress were observed in most evolved populations, while increased Cr(VI) reduction rates were primarily observed in populations evolved from EC3-10 and ES9-11. The pre-existing genetic divergence in the starting clones showed strong influences on the changes in lag phases, growth rates, and Cr(VI) reduction rates. Additionally, the genomic mutation spectra in populations evolved from different starting clones were significantly different. A total of 14 newly mutated genes obtained mutations in at least two evolved populations, suggesting their importance in Cr(VI) adaptation. An in-frame deletion mutation of one of these genes, the chromate transporter gene DVU0426, demonstrated that it played an important role in Cr(VI) tolerance. Overall, our study identified potential key functional genes for Cr(VI) tolerance and demonstrated the important role of pre-existing genetic divergence in evolution under Cr(VI) stress conditions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

A finite element formulation for deformation twinning induced strain localization in polycrystal magnesium alloys

Deformation twinning induces shear strain localization in hexagonal close-packed crystals and is critical for the material’s ductility and failure. Cracks often occur at twin-twin or twin-grain boundary intersections and propagate along twin bands. However, most crystal plasticity models for deformation twinning are based on a “pseudo-slip” approach and do not capture the localized deformation associated with the formation of each discrete twin band. The few exceptions are discrete twin models that involve very complex numerical algorithms and are often compromised in accuracy due to the numerical convergence. These factors make the discrete twin models hard to adopt. This paper proposes a modification to the conventional finite element weak form, to fully incorporate a twin-induced heterogeneous deformation that does not depend on the “pseudo-slip” assumption. The model starts by splitting the deformation gradient into elastic-slip-twinning components. The twin-induced deformation gradient component is computed separately by solving a microstructural evolution problem and then implemented into finite element weak form by constructing a global “twin-force” vector. The constitutive update (e.g., in the user-defined material subroutine, or UMAT, for ABAQUS) therefore avoids dealing with the twinning and recovers to the form of a regular slip-based crystal plasticity model. The results presented here indicate that the twin-induced strain localization and the associated stress-reversal phenomena near the twin band were naturally captured in the model, which was validated against an in-situ synchrotron X-ray micro-diffraction experiment.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Vertical effective stress and temperature as controls of quartz cementation in sandstones: Evidence from North Sea Fulmar and Gulf of Mexico Wilcox sandstones

Here we present quantitative petrographic data, high spatial resolution oxygen isotope analyses of quartz cement, basin modelling and a kinetic model for quartz precipitation for two Paleocene-Eocene Wilcox Group sandstones from Texas and two Jurassic Fulmar Formation sandstones from the Central North Sea. At each location, one sandstone has been buried to ca. 145 °C and one to ca. 185 °C. A key difference between the Wilcox and Fulmar burial histories is that the Wilcox sandstones are currently at higher vertical effective stresses and, from basin modelling studies, have been subjected to generally higher vertical effective stresses through their burial history. The amounts of quartz cement in the Wilcox sandstones are between 12 and 18%, and between 2 and 6% in the Fulmar sandstones. High-spatial-resolution oxygen isotope data obtained from the quartz cements suggest temperature ranges for quartz precipitation from 60 to 80 °C to values approaching maximum burial temperature. Factors such as grain coatings or the timing of petroleum emplacement cannot explain the differences in the amounts of quartz cement. Petrographic data show that most of the silica for quartz cement can be derived from intergranular pressure dissolution. Although the sample set is small, we interpret the results to suggest that the differences in quartz cementation in Fulmar and Wilcox sandstones can be explained better by differences in their vertical effective stress history than their temperature history; in this case, the supply of silica rather than the precipitation of quartz becomes an important control on the rate and extent of cementation.

58 GEOSCIENCES↗

DOE OSTI2023

MHz free electron laser x-ray diffraction and modeling of pulsed laser heated diamond anvil cell

A new diamond anvil cell experimental approach has been implemented at the European x-ray Free Electron Laser, combining pulsed laser heating with MHz x-ray diffraction. In this report we use this setup to determine liquidus temperatures under extreme conditions, based on the determination of time-resolved crystallization. The focus is on a Fe-Si-O ternary system, relevant for planetary cores. This time-resolved diagnostic is complemented by a finite-element model, reproducing temporal temperature profiles measured experimentally using streaked optical pyrometry. This model calculates the temperature and strain fields by including (i) pressure and temperature dependencies of material properties, and (ii) the heat-induced thermal stress, including feedback effect on material parameter variations. Making our model more realistic, these improvements are critical as they give 7000 K temperature differences compared to previous models. Laser intensities are determined by seeking minimal deviation between measured and modeled temperatures. Combining models and streak optical pyrometry data extends temperature determination below detection limit. The presented approach can be used to infer the liquidus temperature by the appearance of SiO 2 diffraction spots. In addition, temperatures obtained by the model agree with crystallization temperatures reported for Fe–Si alloys. Our model reproduces the planetary relevant experimental conditions, providing temperature, pressure, and volume conditions. Those predictions are then used to determine liquidus temperatures at experimental timescales where chemical migration is limited. This synergy of novel time-resolved experiments and finite-element modeling pushes further the interpretation capabilities in diamond anvil cell experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗