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DOE OSTI2025

Project Presentation: Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Autonomous thermal regulation in nuclear reactors remains crucial for maintaining stable operation and ensuring the integrity of fuel. To alleviate public skepticism of the safety of nuclear reactors, demonstrating control over this key factor is pivotal. Utilizing electric heat pads to simulate the heat released in a reactor core, thermocouples for temperature monitoring, and an Arduino micro programmable logic controller (PLC) with an embedded proportional-integral-derivative (PID) algorithm for control, a hardware-based demonstration of a reactor heating system will validate the efficacy of reactor control over this key parameter. This report covers internship project presentation as well as relevant experience with nuclear and proposal for project upgrade.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Poster: Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2018

Quantum-accurate spectral neighbor analysis potential models for Ni-Mo binary alloys and fcc metals

In recent years, efficient interatomic potentials approaching the accuracy of density functional theory (DFT) calculations have been developed using rigorous atomic descriptors satisfying strict invariances, for example, for translation, rotation, permutation of homonuclear atoms, among others. In this work, we generalize the spectral neighbor analysis potential (SNAP) model to bcc-fcc binary alloy systems. We demonstrate that machine-learned SNAP models can yield significant improvements even over the well-established high-performing embedded atom method (EAM) and modified EAM potentials for fcc Cu and Ni. We also report on the development of a SNAP model for the fcc Ni-bcc Mo binary system by machine learning a carefully constructed large computed data set of elemental and intermetallic compounds. We demonstrate that this binary Ni-Mo SNAP model can achieve excellent agreement with experiments in the prediction of a Ni-Mo phase diagram as well as near-DFT accuracy in the prediction of many key properties, such as elastic constants, formation energies, melting points, etc., across the entire binary composition range. In contrast, the existing Ni-Mo EAM has significant errors in the prediction of the phase diagram and completely fails in binary compounds. Lastly, this paper provides a systematic model development process for multicomponent alloy systems, including an efficient procedure to optimize the hyperparameters in the model fitting, and paves the way for long-time large-scale simulations of such systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

An embedded-atom method potential parameterized for sulfur-induced embrittlement of nickel

The embrittling or strengthening effect of solute atoms at grain boundaries (GBs), commonly known as the embrittling potency, is a necessary thermodynamic property for characterizing the effects of solute segregation on GB fracture. One of the more technologically relevant material systems related to embrittlement is the Ni–S system where S has a deleterious effect on fracture behavior in polycrystalline Ni. Here, we develop a Ni–S embedded-atom method (EAM) interatomic potential that accounts for the embrittling behavior of S at Ni GBs. Results using this new interatomic potential are then compared to previous density functional theory studies and a reactive force-field potential via a layer-by-layer segregation analysis. Our potential shows strong agreement with existing literature and performs well in predicting properties that are not included in the fitting database. Finally, we calculate embrittling potencies and segregation energies for six [100] symmetric-tilt GBs using the new EAM potential. We observe that embrittling potency is dependent on GB structure, suggesting that specific GBs are more susceptible to sulfur-induced embrittlement.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Embedding of Fiber Optic Sensors in Stainless Steel for Sensing in Harsh Environments

Structural health monitoring is critical for components working in harsh environments to assess their safety and integrity. This can be realized with advanced sensors, such as fiber optic sensors, embedded in these components. Recent studies have used ultrasonic consolidation (UC) and laser-based additive manufacturing (AM) techniques to embed fiber optic sensors in metals. However, sensor embedding using these techniques has been challenging, with gaps and voids around the embedded fiber. Successful embedding of fiber optic sensors requires good contact between the fiber and the matrix to eliminate potential gas/liquid leaks in critical systems such as in nuclear and aerospace services. Defect-free fiber/matrix bond is also essential for accurate measurement of parameters of interest, such as temperature and strain. This study developed a novel fiber embedding technique based on electric field-assisted sintering (EFAS). Sapphire optical fibers with diameters of 125 µm and 250 µm were embedded in stainless steel (SS) 316L using EFAS. The embedding was completed by sintering SS 316L powders at a pressure of 50MPa, hold time of 5 min, and temperatures of 1000°C, 1100°C, and 1200°C. Joule heating mechanism during EFAS enabled rapid sintering of the SS 316L powder with resulting sample densities over 99%. Microscopy analysis performed on the cross-sections revealed a defect-free bond between the embedded fiber and SS 316L. The good integrity of the embedded fiber was evidenced by optical transmittance measurement. Optical attenuation of the fiber before and after embedment was examined in the near-infrared region. Scanning electron microscopy was employed to investigate the grain morphology of SS 316L near the embedded fiber. Hardness distribution in the sintered part was also investigated to study the effect of the embedded fiber on the mechanical properties of the as-fabricated component. The results indicated that EFAS was able to embed fiber in SS with good fiber functionality and part quality.

36 - MATERIALS SCIENCE↗

DOE OSTI2017

Supersymmetric D3/D5 for massive defects on curved space

We construct the holographic dual for N=4 SYM on S 4 and AdS 4 coupled to massive N=2 supersymmetric quenched flavor fields on a codimension-1 defect, which is S 3 and AdS 3 , respectively. The holographic description is in terms of a D 3 /probe D 5 brane system. We set up and reduce the BPS equations for D 5 -brane embeddings with arbitrary supersymmetric deformations and partly solve them at the non-linear level. The remaining equations are solved explicitly in a small-mass expansion. We compute the contribution of the defect fields to the partition function on S 4 and compare to a field theory computation using supersymmetric localization, for which we set up the matrix model. Both computations agree, lending strong support to holographic probe brane constructions using D 3 /D 5 configurations in general.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2015

Design and status of the Mu2e electromagnetic calorimeter

Here, the Mu2e experiment at Fermilab aims at measuring the neutrinoless conversion of a negative muon into an electron and reach a single event sensitivity of 2.5×10 –17 after three years of data taking. The monoenergetic electron produced in the final state, is detected by a high precision tracker and a crystal calorimeter, all embedded in a large superconducting solenoid (SD) surrounded by a cosmic ray veto system. The calorimeter is complementary to the tracker, allowing an independent trigger and powerful particle identification, while seeding the track reconstruction and contributing to remove background tracks mimicking the signal. In order to match these requirements, the calorimeter should have an energy resolution of O(5)% and a time resolution better than 500 ps at 100 MeV. The baseline solution is a calorimeter composed of two disks of BaF 2 crystals read by UV extended, solar blind, Avalanche Photodiode (APDs), which are under development from a JPL, Caltech, RMD consortium. In this paper, the calorimeter design, the R&D; studies carried out so far and the status of engineering are described. A backup alternative setup consisting of a pure CsI crystal matrix read by UV extended Hamamatsu MPPC's is also presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Urban land patterns can moderate population exposures to climate extremes over the 21st century

Abstract Climate change and global urbanization have often been anticipated to increase future population exposure (frequency and intensity) to extreme weather over the coming decades. Here we examine how changes in urban land extent, population, and climate will respectively and collectively affect spatial patterns of future population exposures to climate extremes (including hot days, cold days, heavy rainfalls, and severe thunderstorm environments) across the continental U.S. at the end of the 21st century. Different from common impressions, we find that urban land patterns can sometimes reduce rather than increase population exposures to climate extremes, even heat extremes, and that spatial patterns instead of total quantities of urban land are more influential to population exposures. Our findings lead to preliminary suggestions for embedding long-term climate resilience in urban and regional land-use system designs, and strongly motivate searches for optimal spatial urban land patterns that can robustly moderate population exposures to climate extremes throughout the 21st century.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Assessment of empirical interatomic potential to predict thermal conductivity in ThO 2 and UO 2

Computing vibrational properties of crystals in the presence of complex defects often necessitates the use of (semi-)empirical potentials, which are typically not well characterized for perfect crystals. In this study we explore the efficacy of a commonly used embedded-atomempirical interatomic potential for the U x Th 1- x O 2 system, to compute phonon dispersion, lifetime, and branch specific thermal conductivity. Our approach for ThO 2 involves using lattice dynamics and the linearized Boltzmann transport equation to calculate phonon transport properties based on second and third order force constants derived from the empirical potential and from first-principles calculations. For UO 2 , to circumvent the accuracy issues associated with first-principles treatments of strong electronic correlations, we compare results derived from the empirical interatomic potential to previous experimental results. It is found that the empirical potential can reasonably capture the dispersion of acoustic branches, but exhibits significant discrepancies for the optical branches, leading to overestimation of phonon lifetime and thermal conductivity. The branch specific conductivity also differs significantly with either first-principles based results (ThO 2 ) or experimental measurements (UO 2 ). These findings suggest that the empirical potential needs to be further optimized for robust prediction of thermal conductivity both in perfect crystals and in the presence of complex defects.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Multiresolution GPC-Structured Control of a Single-Loop Cold-Flow Chemical Looping Testbed

Chemical looping is a near-zero emission process for generating power from coal. It is based on a multi-phase gas-solid flow and has extremely challenging nonlinear, multi-scale dynamics with jumps, producing large dynamic model uncertainty, which renders traditional robust control techniques, such as linear parameter varying H ∞ design, largely inapplicable. This process complexity is addressed in the present work through the temporal and the spatiotemporal multiresolution modeling along with the corresponding model-based control laws. Namely, the nonlinear autoregressive with exogenous input model structure, nonlinear in the wavelet basis, but linear in parameters, is used to identify the dominant temporal chemical looping process dynamics. The control inputs and the wavelet model parameters are calculated by optimizing a quadratic cost function using a gradient descent method. The respective identification and tracking error convergence of the proposed self-tuning identification and control schemes, the latter using the unconstrained generalized predictive control structure, is separately ascertained through the Lyapunov stability theorem. The rate constraint on the control signal in the temporal control law is then imposed and the control topology is augmented by an additional control loop with self-tuning deadbeat controller which uses the spatiotemporal wavelet riser dynamics representation. The novelty of this work is three-fold: (1) developing the self-tuning controller design methodology that consists in embedding the real-time tunable temporal highly nonlinear, but linearly parametrizable, multiresolution system representations into the classical rate-constrained generalized predictive quadratic optimal control structure, (2) augmenting the temporal multiresolution loop by a more complex spatiotemporal multiresolution self-tuning deadbeat control loop, and (3) demonstrating the effectiveness of the proposed methodology in producing fast recursive real-time algorithms for controlling highly uncertain nonlinear multiscale processes. The latter is shown through the data from the implemented temporal and augmented spatiotemporal solutions of a difficult chemical looping cold flow tracking control problem.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Improved representation of black carbon mixing structures suggests stronger direct radiative heating

Black carbon significantly influences the Earth system because of its strong solar radiation absorption. However, its direct radiative effect remains poorly understood in current climate models, partly because current climate models oversimplify the diverse structures formed when black carbon mixes with other atmospheric components. Here we show that incorporating more realistic, multi-mixing-structure representations of black carbon increases the direct radiative effect. We find that aged black carbon particles, with thicker coatings and higher embedded fractions, enhance the direct radiative effect more efficiently. Using machine learning alongside the Community Earth System Model, we show that the direct radiative effect at the top of the atmosphere in regions with heavy black carbon pollution is 31.6% greater when multi-mixing structures are considered. These findings highlight the importance of modeling complex mixing structures of particle-resolved black carbon to accurately capture their warming impacts on global atmosphere, particularly in highly polluted regions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Constrained Block Nonlinear Neural Dynamical Models

Neural network modules conditioned by known priors can be effectively trained and combined to represent systems with nonlinear dynamics. This work explores a novel formulation for data-efficient learning of deep control-oriented nonlinear dynamical models by embedding local model structure and constraints. The proposed method consists of neural network blocks that represent input, state, and output dynamics with constraints placed on the network weights and system variables. For handling partially observable dynamical systems, we utilize a state observer neural network to estimate the states of the system's latent dynamics. We evaluate the performance of the proposed architecture and training methods on system identification tasks for three nonlinear systems: a continuous stirred tank reactor, a two tank interacting system, and an aerodynamics body. Models optimized with a few thousand system state observations accurately represent system dynamics in open loop simulation over thousands of time steps from a single set of initial conditions. Experimental results demonstrate an order of magnitude reduction in open-loop simulation mean squared error for our constrained, block-structured neural models when compared to traditional unstructured and unconstrained neural network models.

Skomski, Elliott↗

DOE OSTI2021

An integrated numerical model for coupled poro-hydro-mechanics and fracture propagation using embedded meshes

Integrated models for fluid-driven fracture propagation and general multiphase flow in porous media are valuable to the study and engineering of several systems, including hydraulic fracturing, underground disposal of waste, and geohazard mitigation across such applications. This work extends the coupled model multiphase flow and poromechanical model of Ren et al. (2018) to admit fracture propagation (FP). The coupled XFEM-EDFM scheme utilizes a separate fracture mesh that is embedded on a static background mesh. The onset and dynamics of fracture propagation are governed by the equivalent stress intensity factor (SIF) criterion. A domain-integral method (J integral) is applied to compute this information. Additionally, an adaptive time-marching scheme is proposed to rapidly restrict and grow temporal resolution to match the underlying time-scales. The proposed model is verified with analytical solutions, and shows the capability to accurately and adaptively co-simulate fluid transport and deformation as well as the propagation of multiple fractures.

42 ENGINEERING↗

DOE OSTI2019

Embedded Sensor Development in Metallic Structures for the Transformational Challenge Reactor

The ability to make minimally intrusive measurements of process conditions has tremendous potential for improving system performance and control in applications such as nuclear power generation. Towards this end, emerging and evolving advanced manufacturing methods, such as additive manufacturing, present new opportunities for more seamlessly integrating sensing with structure. This technical report summarizes the progress of work performed to assess the feasibility of embedding commercial off-the-shelf (COTS) sensors in a metallic reactor core using advanced manufacturing methods. The progress of four research and development tasks are documented: 1) A survey of COTS sensors for nuclear applications that are candidates for embedded fabrication, 2) Development of a conceptual framework for investigating the feasibility of sensor embedment, 3) Definition of structural geometries and other characteristics that will represent compelling proof-of-concept, and 4) Preliminary prototyping of embedded sensors. For the purposes of this initial study, nuclear grade K-type thermocouples were selected for investigation of embedment methodologies. This sensor was selected as an initial candidate because it represents one of the simplest sensor configurations that can provide useful process information. A selective laser melting (SLM) additive manufacturing process was used to fabricate structures with complexity representative of the core design of the transformational challenge reactor (TCR) and methods were developed to embed a thermocouple with a complex two-dimensional routing path. There are many challenges associated with embedding sensors during the additive manufacturing process including securing the sensor in the structure, relocating the part in the additive machine if using a “pick and place” sensor placement method, mitigating the potential for powder contamination, optimizing energy deposition parameters to build as closely as possible around the sensor path and improve structural integrity of the part, and tuning energy deposition to mitigate thermally induced warpage of the sensor and part as well as potential for damaging the sensing device. Preliminary results indicate that it is feasible to integrate the sensor while minimally compromising the structural integrity of the part and preserving sensor performance. This first phase of this work focused on developing a workflow for embedding sensors and controlling energy deposition during the additive manufacturing process to better understand the build characteristics around the sensor. Future work will perform more in-depth characterization of prototype parts using X-ray computed tomography and scanning electron microscopy to better understand fabricated structures, performance testing of embedded sensors in high temperature environments, adding new embedded measurement modalities, embedding devices with dissimilar materials in contact with additive powders, and the development of methods for embedding sensors with three-dimensional routing paths.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Dual Material System for Polymer Large Scale Additive Manufacturing

Big Area Additive Manufacturing (BAAM) technology allows for manufacturing of large-scale objects with a potential to reduce energy embedded in products, reduce or eliminate energy necessary for transportation of goods along with reducing the lead time and cost in some cases. Over the last few years, Oak Ridge National Laboratory (ORNL) has been focusing on large-scale printing of single material systems, typically un-reinforced or short fiber reinforced polymers, in order to address needs in stiffness-limited applications. This paper describes the development of a multi-material large-scale AM system through a collaboration with Cincinnati Inc. and Performance Feed Screw Inc. Modifications to the Big Area Additive Manufacturing (BAAM) system includes a new extruder design to accommodate a dual feed system, an expanded two-dryer system with a capacity of 273 kg/dryer, and a system that is capable of mixing pelletized materials up to 60Kg/hr. This article highlights the advantages and limitations of the multi-material system as well as potential applications.

Smith, Tyler↗

DOE OSTI2016

Optimal Power Flow for Distribution Systems under Uncertain Forecasts

The paper focuses on distribution systems featuring renewable energy sources and energy storage devices, and develops an optimal power flow (OPF) approach to optimize the system operation in spite of forecasting errors. The proposed method builds on a chance-constrained multi-period AC OPF formulation, where probabilistic constraints are utilized to enforce voltage regulation with a prescribed probability. To enable a computationally affordable solution approach, a convex reformulation of the OPF task is obtained by resorting to i) pertinent linear approximations of the power flow equations, and ii) convex approximations of the chance constraints. Particularly, the approximate chance constraints provide conservative bounds that hold for arbitrary distributions of the forecasting errors. An adaptive optimization strategy is then obtained by embedding the proposed OPF task into a model predictive control framework.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Consequences of realistic embedding for the L 2,3 edge XAS of α-Fe 2 O 3

Cluster models of condensed systems are often used to simulate the core-level spectra obtained with X-ray Photoelectron Spectroscopy, XPS, or with X-ray Absorption Spectroscopy, XAS, especially for near edge features.

Environmental Molecular Sciences Laboratory↗

DOE OSTI2019

Memory embedded non-intrusive reduced order modeling of non-ergodic flows

Generating a digital twin of any complex system requires modeling and computational approaches that are efficient, accurate, and modular. Traditional reduced order modeling techniques are targeted at only the first two, but the novel nonintrusive approach we present in this study is an attempt at taking all three into account effectively compared to their traditional counterparts. Based on dimensionality reduction using proper orthogonal decomposition (POD), we introduce a long short-term memory neural network architecture together with a principal interval decomposition (PID) framework as an enabler to account for localized modal deformation. As an effective partitioning tool for breaking the Kolmogorov barrier, our PID framework, therefore, can be considered a key element in the accurate reduced order modeling of convective flows. Our applications for convection-dominated systems governed by Burgers, Navier-Stokes, and Boussinesq equations demonstrate that the proposed approach yields significantly more accurate predictions than the POD-Galerkin method and could be a key enabler toward near real-time predictions of unsteady flows.

42 ENGINEERING↗