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DOE OSTI2020

Revisiting the first Sandia Fracture Challenge with transient deformation heating and strain localization considerations

In this study, we present a systematic experimental study and accompanying theoretical analysis of the dependence of ductile fracture on strain localization, strain hardening rates, deformation-induced thermal softening, and transient heat conduction under spatially uniform as well as spatially heterogeneous deformation. Spatially uniform cases are studied via standard dogbone shaped specimens subject to uniaxial tension. Spatially heterogeneous deformation is studied via the so-called Sandia Fracture Challenge (SFC) specimen, which is a standard compact tension specimen modified with three machined holes in front of a blunt notch. We utilize the same precipitation hardened martensitic stainless steel used in the first SFC experiments, i.e. 15-5 PH with an H1075 heat treatment. We also study 15-5 PH in Condition A and with the H900 heat treatment, each of which has a different hardening behavior and ductility. We find that the ductility does not correlate with the deformation to first crack initiation in the SFC specimen. Instead, hardening rates are better correlated. Moreover, a re-examination finds that an accurate calibration of the hardening rates is strongly correlated with accurate blind predictions of ductile fracture in the SFC specimens. Given that thermal softening can greatly affect hardening rates, we provided a thermographic analysis of deformation-induced heating and transient heat transfer in both the dogbone shaped samples and the SFC specimens. Transient heating in stainless steels is found to have first-order effects on the strain at the onset of necking, strain to fracture, as well as strain localization and ductile fracture in complex geometries even under so-called quasi-static loading rates.

42 ENGINEERING↗

DOE OSTI2021

Shear Strength and Release of Large Cryogenic Pellets from the Barrel of a Shattered Pellet Injector for Disruption Mitigation

Shattered pellet injection (SPI) has been chosen as the baseline disruption mitigation system on ITER due to its ability to rapidly inject material deep into the plasma to greatly increase the plasma density and radiate the thermal energy. SPI utilizes a mechanical punch or high-pressure gas to release and accelerate a pellet that has been cryogenically desublimated in the barrel of a pipe gun. Various material injection combinations could possibly be implemented during different phases of a disruption event to radiate plasma energy, reduce electromagnetic loads on machine components, avoid the formation of runaway electrons, or to dissipate runaway electrons that form. Each injection phase could possibly utilize combinations of deuterium, neon, or argon. In this paper we outline experimental measurements of pellet material shear strength at SPI operating temperatures to understand the force needed to release SPI pellets. Deuterium, neon, argon, and deuterium-neon mixture pellets with diameters of 8.5, 12.5, and 15.7 mm are formed at a range of relevant gas pressures and temperatures and dislodged from the cold zone with a slow-moving piston driven by a motor. The slow-moving piston is kept above the triple point temperature of the material while the pellet is forming, then cooled to below the triple point temperature before contacting the pellet to minimize any thermal conduction to the pellet. The piston incorporates a load cell to measure the force applied when the pellet breaks away from the cold zone in the barrel.The ability of the gas and punch methods to exceed the shear strength of the studied pellet materials for release has been analyzed. High pressure gas delivered by fast opening valves produce pressure shock to the pellet due to supersonic expansion of the propellant gas. Pressure (and therefore, force) oscillations are present due to transverse density propagation throughout the breech volume. Mechanical punches deliver an impact force through a high-kinetic energy impact. The effect of the mechanical shock on the pellet has been explored and will be presented in this paper. Scaling to larger ITER size SPI pellets will be described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Off-design performance of an organic Rankine-vapor compression cooling cycle using R1234ze(E)

In this study, a 264 kW th organic Rankine-vapor compression cycle (ORVC) was experimentally tested over a range of conditions to quantify the individual impact of off-design external conditions. The ORVC was designed to recover waste heat at 91 °C, reject heat to a liquid condenser stream at 30 °C, and produce chilled water at 7 °C. Here, the condenser heat rejection temperature was varied from 16.6 °C to 32.6 °C, the chilled water delivery temperature was varied between 2.1 °C and 13.1 °C, and the heat input temperature was varied from 91 °C to 120 °C. As the condenser heat rejection temperature decreased, the coefficient of performance (COP) of the ORVC improved from 0.558 at 30 °C to 0.682 at 16.6 °C, despite a reduction in compressor isentropic efficiency. Although the chilled water temperature variation had almost no impact on the organic Rankine cycle performance, the compressor efficiency decreased when the delivery temperature was below 7 °C. At the highest chilled water temperature, 13.1 °C, the COP of the ORVC was 0.643. Compressor stall was noted when the condenser heat rejection temperature was greater than 32.6 °C and the chilled water delivery temperature was below 2.1 °C. Increasing the driving heat source inlet temperature improved the COP of the ORVC and the thermal efficiency of the organic Rankine power cycle, while decreasing the efficiency of the compressor and the COP of vapor compression cycle. In addition, the integrated part load value of the system was determined through experimentation to be 0.682, which provides a realistic estimate of real-world performance.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

A Review of Water and Climate Change Analysis in Electric Utility Integrated Resource Planning

The purpose of this paper is to examine the extent to which electric utility integrated resource plans (IRPs) evaluate the impact of water constraints on electric generation resource portfolios and the extent to which IRPs consider the impacts of climate change to generation and loads. This white paper reviewed 30 IRPs to determine best practices with respect to analyzing and reporting on potential water-based and climate change risks within the integrated resource planning process. Best practices from electric utility IRPs are identified and additional recommendations and considerations are put forth. In recent years, thermal generating facilities have experienced challenges with water availability: a shortage of cooling water, conditions in which incoming cooling water is too warm for optimal operation, and/or water discharge temperatures exceeding permit limits. S&P Global Market Intelligence recently reported on a study that identified for the year 2030, 98.2 gigawatts (GW) of coal capacity at risk due to water stress. Climate change effects on hydrological cycles may adjust the timing, temperature, and volume of water availability for thermal electric cooling and for hydropower generation, which could further exacerbate the frequency and duration of operational constraints. Climate change can also impact the timing and intensity of electric loads that utilities must serve, most notably for heating and cooling.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

A Comfort Model Simplification for Tight Integration with Grid Service Optimizations

Localized generation, storage, and intelligent power electronics are increasingly being integrated into building. The excess storage, thermal, and generation capacity can be used to develop new markets for ancillary services such as peak reduction, voltage and frequency support, or load flattening. Widespread participation in these markets will make the power grid more resilient. However, widespread participation in these markets will require a simple and intuitive control over the excess capacity by the building occupants. Most importantly for adopting these technologies, participation in these markets should not require sacrificing occupant comfort. Many of the proposed control and optimization technologies for supplying the ancillary services do not explicitly incorporate occupant comfort into their models and when they do, generally utilize a rigid constraint on the indoor air temperature set a priori. This reduces flexibility in using excess thermal capacity. It also cannot take into account uncertainties in local factors that affect thermal comfort such as clothing insulation or relative humidity. In this paper we present and justify some assumptions that simplify the standard predictors of thermal comfort. We also develop a regression model of the thermal comfort that is linear with respect to the indoor air temperature. Next we develop the concept of thermal comfort variation that eliminates the dependence of the thermal comfort on uncertain thermal comfort factors. Then, we present a quadratic program utilizing the thermal comfort variation in both the objective function and as a constraint. Finally, we show the results of a time-of-use cost optimization that utilizes the simplified thermal comfort model.

Melin, Alexander↗

DOE OSTI2021

Challenges in Postprocessing of Hybrid Manufacturing of Magnet Polymer Composites to Enhance the Energy Product of NdFeB Bonded Magnets

Bonded permanent magnets need to process magnetic filler particles and binder together which is a form of hybrid or composite manufacturing that needs to simultaneously process multimaterials. Polymer bonding of the permanent magnets decreases the energy product of the bonded magnets which varies with square of loading fraction of magnetic materials. However, due to high viscosity of bonding polymer prohibits loading higher than 80 volume % of magnetic materials in most efficient loading process such as compression molding. To further increase the loading of magnetic fraction in the bonded permanent magnets, it is expected to be beneficial to introduce a fraction of nonreacting thermally sacrificial polymer along with permanent bonding polymer in the least permissible of about 20 volume % of the polymer. This process of first adding the sacrificial polymer for higher processability for composites and later removing it via post processing such as heat treatment provides a simple example of inclusion of both the additive and the subtractive stages of hybrid manufacturing. These hybrid composite magnets can be heat treated to remove the sacrificial polymer to further increase the density and energy product which might require to implement hot isostatic pressing for compaction. Although the identification of such ideal polymer requires an extensive polymer chemistry research, we have compression molded several permanent bonding polymers such as nylon, polycarbonate (PC) and polyphenyl sulfide (PPS) and potential sacrificial polymer such as polyoxymethylene (POM), polystyrene (PS), and Acrylonitrile Butadiene Styrene (ABS) and heat treated to remove the sacrificial polymers. It is discovered that oxygen free low temperature pyrolizable polymers could be the potential candidates for increasing the magnet particles loading for achieving high energy products.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Evaluation of the Thermal and Moisture Performance of Insulating Shades

Heat transfer through windows accounts for a significant percentage of a building’s energy use and adds substantially to the peak heating and cooling loads of a home. Over the past 20 years, residential window attachment retrofit technologies have been developed that significantly increase the number of options available to home builders, homeowners, and utilities when considering upgrades of overall window performance. Within the interior window attachments category, honeycomb cellular shades typically have the highest R-values because of their layered or concentric designs. During the winter when the window is fully covered, however, the added insulation reduces the amount of warm indoor air that reaches the window surface, thereby lowering the temperature of the window glass and frame and increasing the potential for condensation to collect on the interior surface of the window. The degree to which this potential is realized depends on the indoor and outdoor conditions as well as the overall thermal resistance of the window and the shades. To examine the condensation buildup potential on the interior surface of the window and the conditions under which this occurs, this report describes experimental research conducted by Pacific Northwest National Laboratory in collaboration with Hunter Douglas, using a a controlled environmental test chamber at the Hunter Douglas facility in Broomfield, Colorado. The results will be used to inform the Attachments Energy Rating Council, which provides energy performance information on all rated window attachments products.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Advancing 1D thermo-hydraulic tools for large cryogenic facilities

The Cryogenic Division at Fermilab develops large-scale cryogenic systems for particle accelerators and superconducting magnet test facilities. To support design and diagnostics, a Python-based code was created to calculate pressure drops in components such as valves and pipes. This paper presents recent enhancements to the code, including new heat transfer functions that improve the accuracy of thermal and hydraulic predictions. The first application models pressure and temperature changes in Proton Improvement Plant PIP-II relief pipes, aiding pipe sizing and protecting relief valves. The second example analyses heat load evolution in a pipe carrying sub-atmospheric helium, helping interpret temperature sensor data and understand gas return behavior to cold compressors. These improvements significantly expand the tool's capabilities, offering a practical resource for designing and troubleshooting cryogenic systems under dynamic thermal and flow conditions.

Beckwith, R. [Fermilab]↗

DOE OSTI2024

Neutronics and Thermo-Fluids Simulation of Generic Pebble-Bed Fluoride-Salt-Cooled High-Temperature Reactor

The fluoride-salt-cooled high-temperature reactor (FHR) is one of the advanced reactors that has been attracting considerable interest from both the research community and the nuclear industry. To help facilitate the nuclear community's familiarity with the FHR, Kairos Power has developed a generic FHR (gFHR) benchmark. In the research performed here, this benchmark was used to assess innovative modeling methods that combine stochastic and deterministic computer codes to perform the design and analysis of the gFHR. Further, the Monte Carlo code Serpent 2 was used to generate few-group cross sections that were then used in the neutron diffusion and thermal-fluids code AGREE to perform full-core neutronics and thermal-fluids steady-state and transient core analysis. The Argonne National Laboratory code SAM was then used to model the gFHR system and to simulate the load-follow operation of the gFHR.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Particle Size Optimization of Thermochemical Salt Hydrates for High Energy Density Thermal Storage

Thermal energy storage (TES) solutions offer opportunities to reduce energy consumption, greenhouse gas emissions, and cost. Specifically, they can help reduce the peak load and address the intermittency of renewable energy sources by time shifting the load, which are critical toward zero energy buildings. Thermochemical materials (TCMs) as a class of TES undergo a solid–gas reversible chemical reaction with water vapor to store and release energy with high storage capacities (600 kWh m −3 ) and negligible self‐discharge that makes them uniquely suited as compact, stand‐alone units for daily or seasonal storage. However, TCMs suffer from instabilities at the material (salt particles) and reactor level (packed beds of salt), resulting in poor multi‐cycle efficiency and high‐levelized cost of storage. In this study, a model is developed to predict the pulverization limit or R crit of various salt hydrates during thermal cycling. This is critical as it provides design rules to make mechanically stable TCM composites as well as enables the use of more energy‐efficient manufacturing process (solid‐state mixing) to make the composites. The model is experimentally validated on multiple TCM salt hydrates with different water content, and effect of R crit on hydration and dehydration kinetics is also investigated.

25 ENERGY STORAGE↗

DOE OSTI2025

Guarded Hot Cylinder Apparatus for Characterization of Thermal Insulation Systems and Materials at Liquid Hydrogen Temperatures

As interest in liquid hydrogen (LH2) continues to grow within the energy and mobility sectors, so does the demand for testing capabilities at deep cryogenics temperatures. However, cost-, complexity-, and safety-related challenges associated with handling LH2 effectively limit the landscape of possible options. As an alternative, LH2 temperatures can be accessed via a helium-based cryogenic refrigerator, or “cryocooler”. Recently, NASA and its partners CB&I and Shell began the development of a cryocooler-based calorimeter to characterize the thermal performance of insulations and other materials down to 20 K. Deemed the Guarded Hot Cylinder (GHC), the apparatus utilizes a small vacuum chamber in conjunction with a GM cryocooler and trim heater to control the cold boundary temperature. A sealed, cylindrical copper cup bolts to the cryocooler and houses the material specimen, with an internal, cylindrical test heater assembly to maintain the warm boundary. The steady-state heat load, traveling radially through the specimen, is measured via the electrical input power to the test heater and then used to evaluate the material’s absolute thermal performance. Initial checkout and validation of the GHC using a common bulk-fill insulation material showed close agreement with published data from standardized LN2 boiloff calorimetry testing. The instrument is now considered a lab standard, with the goal of incorporating it into the ASTM C1774 standard in the future, and it is in continuous use, examining insulation materials for next-generation LH2 applications.

Swanger, Adam (ORCID:000000021487592X)↗

DOE OSTI2024

Supercharged cellulases show superior thermal stability and enhanced activity towards pretreated biomass and cellulose

Non-productive binding of cellulolytic enzymes to various plant cell wall components, such as lignin and cellulose, necessitates high enzyme loadings to achieve efficient conversion of pretreated lignocellulosic biomass to fermentable sugars. Protein supercharging was previously employed as one of the strategies to reduce non-productive binding to biomass. However, various questions remain unanswered regarding the hydrolysis kinetics of supercharged enzymes towards pretreated biomass substrates and the role played by enzyme interactions with individual cell wall polymers such as cellulose and xylan. In this study, CBM2a (from Thermobifida fusca ) fused with endocellulase Cel5A (from T. fusca ) was used as the model wild-type enzyme and CBM2a was supercharged using Rosetta, to obtain eight variants with net charges spanning -14 to +6. These enzymes were recombinantly expressed in E. coli , purified from cell lysates, and their hydrolytic activities were tested against pretreated biomass substrates (AFEX and EA treated corn stover). Although the wild-type enzyme showed greater activity compared to both negatively and positively supercharged enzymes towards pretreated biomass, thermal denaturation assays identified two negatively supercharged constructs that perform better than the wild-type enzyme (~3 to 4-fold difference in activity) upon thermal deactivation at higher temperatures. To better understand the causal factor of reduced supercharged enzyme activity towards AFEX corn stover, we performed hydrolysis assays on cellulose-I/xylan/pNPC, lignin inhibition assays, and thermal stability assays. Altogether, these assays showed that the negatively supercharged mutants were highly impacted by reduced activity towards xylan whereas the positively supercharged mutants showed dramatically reduced activity towards cellulose and xylan. It was identified that a combination of impaired cellulose binding and lower thermal stability was the cause of reduced hydrolytic activity of positively supercharged enzyme sub-group. Overall, this study demonstrated a systematic approach to investigate the behavior of supercharged enzymes and identified supercharged enzyme constructs that show superior activity at elevated temperatures. Future work will address the impact of parameters such as pH, salt concentration, and assay temperature on the hydrolytic activity and thermal stability of supercharged enzymes.

09 BIOMASS FUELS↗

DOE OSTI2022

Real time side-by-side experimental validation of energy and comfort performance of a zero net energy retrofit package for small commercial buildings

Making buildings zero-net energy (ZNE) is one of the major strategies for achieving carbon emission reduction goals. For this strategy to be successful, it entails a very significant reduction in energy use – 50% or more. In small commercial buildings, however, owners and building management teams usually have limited resources for identifying, analyzing, and procuring appropriate retrofit measures for reducing such use. An approach to overcome this limitation is the development of bundles of energy efficiency measures that can be presented to building owners/operators as a comprehensive package. The research presented in this paper focuses on an experimental evaluation of the impacts of a retrofit package developed for small office buildings in California. Performing this evaluation in a full-scale whole-building integrated systems test facility allowed a side-by-side evaluation in real time, against a reference case, of the impact of the retrofit package not only on energy use but also on visual and thermal comfort. Here, the retrofit package evaluated is comprised of a combination of HVAC, lighting (including daylighting), and plug load measures. The evaluation occurred at different times of the year in order to account for seasonal variations in environmental conditions, including solar angles and weather. The experimental facility allowed testing for two different façade orientations: south and west. Results show that the proposed ZNE retrofit package can save significant amounts of energy for small commercial buildings. During cooling-prevalent periods, total energy savings were 65% for south orientation and 68% for west orientation; during heating-prevalent periods total energy savings were 22% for south orientation and 25% for west orientation. Measurements indicate that the ZNE retrofit package resulted in small but not very significant changes in comfort levels for building occupants.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Production and testing of the powerboard for ATLAS ITk Strip barrel modules

The upgrade of the ATLAS ITk strips detector for HL-LHC will employ a custom PCB (powerboard) for on-module DC-DC conversion, HV switching, and monitoring. Production of about 14100 of such PCBs with high reliability is a big challenge. In this paper we will present the production procedure and quality control (QC) testing system for the powerboards to be installed on ITk Strip barrel modules. During production, about 150 powerboards will be produced every week. Each powerboard will need to pass QC tests before they are assembled to module. The QC tests include thermal cycling between -35 °C and 40 °C, soak test (continuous running of DC-DC converter at high load at 20 °C), and basic functionality and characterization electrical tests of the low voltage (LV), high voltage (HV), and monitoring functions of the powerboard. A custom QC test system is described, which is based on a reusable PCB (active board) with all testing circuits, a one-time powerboard carrier card, and a Z-turn SoC board which hosts and runs the testing program. The production procedure and QC test system has been tested with 400 powerboards during pre-production, and the system has been proven ready for production with the desired testing program, speed, safety, and cost. Performance and typical failures of powerboards observed during the QC test of pre-production powerboards is also presented.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Overview of Building Electrification Technologies and Market Opportunities

This report provides an overview of building electrification drivers and select building electrification technologies and their markets and performance. Covered topics: Building Electrification Drivers and Context; Heat Pumps for Space Conditioning; Heat Pump Market Opportunities; Life Cycle GHG Emissions Impacts of Heat Pump Space Conditioning Technologies; Heat Pump Water Heaters; Electrification of Gas Loads: Commercial and Residential; Residential Panel Capacity; Electric Vehicle Impacts and Connections to Buildings; and Building Envelope Improvements and Thermal Energy Storage (TES) Opportunities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Microphysics of Relativistic Collisionless Electron-ion-positron Shocks

Abstract We perform particle-in-cell simulations to elucidate the microphysics of relativistic weakly magnetized shocks loaded with electron-positron pairs. Various external magnetizations σ ≲ 10 −4 and pair-loading factors Z ± ≲ 10 are studied, where Z ± is the number of loaded electrons and positrons per ion. We find the following: (1) The shock becomes mediated by the ion Larmor gyration in the mean field when σ exceeds a critical value σ L that decreases with Z ± . At σ ≲ σ L the shock is mediated by particle scattering in the self-generated microturbulent fields, the strength and scale of which decrease with Z ± , leading to lower σ L . (2) The energy fraction carried by the post-shock pairs is robustly in the range between 20% and 50% of the upstream ion energy. The mean energy per post-shock electron scales as E ¯ e ∝ Z ± + 1 − 1 . (3) Pair loading suppresses nonthermal ion acceleration at magnetizations as low as σ ≈ 5 × 10 −6 . The ions then become essentially thermal with mean energy E ¯ i , while electrons form a nonthermal tail, extending from E ∼ Z ± + 1 − 1 E ¯ i to E ¯ i . When σ = 0, particle acceleration is enhanced by the formation of intense magnetic cavities that populate the precursor during the late stages of shock evolution. Here, the maximum energy of the nonthermal ions and electrons keeps growing over the duration of the simulation. Alongside the simulations, we develop theoretical estimates consistent with the numerical results. Our findings have important implications for models of early gamma-ray burst afterglows.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Load Matching Potential of Urban Renewables during Extreme Heat in New York City

Integration of renewable resources to meet growing energy demand is becoming a global priority under decarbonization mandates. This study contributes to ongoing efforts on the matter by assessing the feasibility of using offshore wind and rooftop photovoltaic systems to meet electricity demand during a period of thermal stress in New York City—August 2019. A unified modelling framework, based on the Urbanized Weather Research and Forecasting model, is used to simulate climate, renewable resources and energy demand variables. Findings show significant energy load miss-match, ranging from 3 to 5 GW, between the demand and the composite renewable generation outcome. This study provides a transferable framework for evaluating renewable integration in dense urban regions and highlights the need for additional strategies to support grid resilience during extreme heat events, while clarifying the role of local resources in fully managing NYC’s load.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

The Physical and Engineering Limits of Coupled In situ TEM Experiments

Almost all future energy systems (advanced nuclear reactors, fusion energy system, concentrating solar-thermal power (CSP), and wind technologies) are limited by degradation of key material systems exposed to multiple environmental stressors. The degradation during exposure to high temperatures, radiation, mechanical loading, and chemical attack is often dictated by mechanisms active at the microstructural level. The nature of these mechanisms and the associated variations between sequential and concurrent interplay can be explored if the transmission electron microscope (TEM) is utilized as a toolbox for exploration [1]. One such tool developed at Sandia National Laboratories to couple several of these environments is the In situ Ion Irradiation TEM (I3TEM) [2]. Several studies over the last decade utilizing this tool have shown that the scientific intuition developed over decades of sequential experiments is not always a good indicator of concurrent mechanisms or failure routes. This presentation will highlight the recent and planned additions into the I3TEM facility of a Waviks gas injection system and Raman system, respectively, as can be seen in Fig. 1, permitting environmental degradation from gas species leaked into the pole piece region during quantitative mechanical loading (indentation, monotonic loading, high temperature creep, irradiation induced creep, and high-cycle fatigue); multi-beam ion irradiation (energies ranging from 1 keV to 48 MeV and species from H to Au); laser exposure (20 W and 1064 nm), or various combinations thereof that are already possible [3]. This addition permits the facility to explore both sequential or concurrently the four axes of stressors: thermal, mechanical, radiation, and chemical. This information can be directly coupled to modeling, expediting the refinement and validation of both atomistic and mesoscale models.

degradation↗