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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Database-Agnostic Log Analysis and Monitoring Framework

Prior to my internship, I was informed that a previous intern had built a tool to analyse MongoDB logs and look for invalid access attempts, which served as a great reference point for my project. I was initially tasked with expanding on her prototype and filling in the gaps such as integrating it with the main monitoring tool the lab uses. Eventually, the scope grew, expanding to support other databases and a growing collection of tools. I organized the framework around an observer pattern, meaning one point in the program sending updates to the rest of the framework. Every time a log was read and parsed, it was sent to be processed by the tools, using the type of event as a means to determine which tools should get a chance to act on the log. This decouples the tools from the log reader, making future updates and additions much easier. The framework processes MongoDB logs at ~135,000 entries per second and PostgreSQL logs at ~170,500 entries per second, accurately detecting anomalies such as slow queries and connections from unknown addresses. This framework serves to fill gaps in database monitoring tools currently implemented at the lab, such as tracking failed authentication for PostgreSQL and MongoDB which had very minimal or none before this framework. National labs such as Fermilab hold sensitive data and valuable computing resources, making them attractive targets. Monitoring intrusion attempts on databases is made much easier by this comprehensive monitoring suite.

Clark, Dylan [Unlisted, US, IL; Fermilab]↗
DOE OSTI2022

Identifying Transient Candidates in the Dark Energy Survey Using Convolutional Neural Networks

The ability to discover new transient candidates via image differencing without direct human intervention is an important task in observational astronomy. For these kind of image classification problems, machine learning techniques such as Convolutional Neural Networks (CNNs) have shown remarkable success. In this work, we present the results of an automated transient candidate identification on images with CNNs for an extant data set from the Dark Energy Survey Supernova program, whose main focus was on using Type Ia supernovae for cosmology. By performing an architecture search of CNNs, we identify networks that efficiently select non-artifacts (e.g., supernovae, variable stars, AGN, etc.) from artifacts (image defects, mis-subtractions, etc.), achieving the efficiency of previous work performed with random Forests, without the need to expend any effort in feature identification. The CNNs also help us identify a subset of mislabeled images. Performing a relabeling of the images in this subset, the resulting classification with CNNs is significantly better than previous results, lowering the false positive rate by 27% at a fixed missed detection rate of 0.05.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2015

SU-E-J-248: Contributions of Tumor and Stroma Phenotyping in Computer-Aided Diagnosis

Purpose: To gain insight into the role of parenchyma stroma in the characterization of breast tumors by incorporating computerized mammographic parenchyma assessment into breast CADx in the task of distinguishing between malignant and benign lesions. Methods: This study was performed on 182 biopsy-proven breast mass lesions, including 76 benign and 106 malignant lesions. For each full-field digital mammogram (FFDM) case, our quantitative imaging analysis was performed on both the tumor and a region-of-interest (ROI) from the normal contralateral breast. The lesion characterization includes automatic lesion segmentation and feature extraction. Radiographic texture analysis (RTA) was applied on the normal ROIs to assess the mammographic parenchymal patterns of these contralateral normal breasts. Classification performance of both individual computer extracted features and the output from a Bayesian artificial neural network (BANN) were evaluated with a leave-one-lesion-out method using receiver operating characteristic (ROC) analysis with area under the curve (AUC) as the figure of merit. Results: Lesion characterization included computer-extracted phenotypes of spiculation, size, shape, and margin. For parenchymal pattern characterization, five texture features were selected, including power law beta, contrast, and edge gradient. Merging of these computer-selected features using BANN classifiers yielded AUC values of 0.79 (SE=0.03) and 0.67 (SE=0.04) in the task of distinguishing between malignant and benign lesions using only tumor phenotypes and texture features from the contralateral breasts, respectively. Incorporation of tumor phenotypes with parenchyma texture features into the BANN yielded improved classification performance with an AUC value of 0.83 (SE=0.03) in the task of differentiating malignant from benign lesions. Conclusion: Combining computerized tumor and parenchyma phenotyping was found to significantly improve breast cancer diagnostic accuracy highlighting the need to consider both tumor and stroma in decision making. Funding: University of Chicago Dean Bridge Fund, NCI U24-CA143848-05, P50-CA58223 Breast SPORE program, and Breast Cancer Research Foundation. COI: MLG is a stockholder in R2 technology/Hologic and receives royalties from Hologic, GE Medical Systems, MEDIAN Technologies, Riverain Medical, Mitsubishi, and Toshiba. MLG is a cofounder and stockholder in Quantitative Insights.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

Documentation for MeshKit - Reactor Geometry (&mesh) Generator

This report gives documentation for using MeshKit’s Reactor Geometry (and mesh) Generator (RGG) GUI and also briefly documents other algorithms and tools available in MeshKit. RGG is a program designed to aid in modeling and meshing of complex/large hexagonal and rectilinear reactor cores. RGG uses Argonne’s SIGMA interfaces, Qt and VTK to produce an intuitive user interface. By integrating a 3D view of the reactor with the meshing tools and combining them into one user interface, RGG streamlines the task of preparing a simulation mesh and enables real-time feedback that reduces accidental scripting mistakes that could waste hours of meshing. RGG interfaces with MeshKit tools to consolidate the meshing process, meaning that going from model to mesh is as easy as a button click. This report is designed to explain RGG v 2.0 interface and provide users with the knowledge and skills to pilot RGG successfully. Brief documentation of MeshKit source code, tools and other algorithms available are also presented for developers to extend and add new algorithms to MeshKit. RGG tools work in serial and parallel and have been used to model complex reactor core models consisting of conical pins, load pads, several thousands of axially varying material properties of instrumentation pins and other interstices meshes.

Jain, Rajeev↗
DOE OSTI2020

New Predictive Capabilities for Nuclear Weapons in Composite Fires

The prevalence of flammable carbon-based composite airframe materials and their use in high-temperature nuclear weapon re-entry systems requires analysts to address the abnormal thermal environment hazards associated with composite material fires. These fires tend to burn very differently than conventional fuel fires, usually burning less intensely, but much longer. This could lead to challenges in understanding margins in classic safety themes. The technical challenges in modeling the phenomena associated with these new types of fires are considerable, but new models have been developed. Their predictions have been compared with well-documented measurements of a vertical porous burner fire, known as a "wall fire" (a "wall-fire" validation simulation is reflected in the figures below). These measurements were conducted at FMGlobal, a mutual insurance company with a strong fire risk management program, as part of an ongoing collaboration between Sandia and FMGlobal. To date, the "wall-fire" scenario has been set up and initial model assessments with grid refinement studies have been conducted focusing on mesh resolutions suitable for full weapon system simulations. This work will continue with further verification and validation tasks assessing the predictions of the new model. Future work will address specific aspects of the wall models that are lacking in their predictive ability.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

NSTTF Voucher Program RPPR-1 (Final Report)

Sandia issued a Request for Proposals (RFP) to solicit proposals from industry, academia, research laboratories, government agencies, and individuals on the use of the National Solar Thermal Test Facility (NSTTF) to increase CSP technology market adoption across the United States. The voucher funds will be used to cover the cost of NSTTF test facilities usage and technical staff support for analysis, design and test planning and execution. Sandia will collect submitted proposals, coordinate their review through DOE SETO, and work in partnership or under contract with the applicants to complete the funded research. Through this program, participants will be supported in their use of the world class facilities and expertise available at the NSTTF at Sandia in Albuquerque, NM to accelerate the advancement of CST technologies toward meeting 2030 SETO goals for CSP. The goals of this semi-annual reporting period were to complete all administrative tasks and contracting, begin testing on three of the vouchers, and report on initial findings. The fourth voucher (University of Michigan) is predicated on the results of an ongoing heat exchanger test that is expected to conclude by the end of FY22.

14 SOLAR ENERGY↗
DOE OSTI2022

Developing an Undergraduate Research Laboratory for Experimental Physical Chemistry [Book Chapter]

Embarking on a faculty career in physical chemistry at a primarily undergraduate institution (PUI) is exciting, but also overwhelming. Becoming both an effective teacher and a productive researcher requires a good plan, hard work and support from others who understand what it takes to be successful. The phrase, “building a laboratory,” calls to mind the physical construction of a research instrument, but beginning a career at a PUI involves much more than assembling equipment. Funding for the lab must be secured, students must be recruited and mentored, and the lab must be overseen to keep things running on a daily basis. While many of these tasks would also be part of starting a career at a doctoral level institution, there are many special considerations that must be taken into account when working with undergraduate students because their laboratory experience and chemical knowledge are still within those beautiful but nascent stages. Here, this unique aspect makes building a research program challenging, but also very rewarding. Exposing young minds to the wonders of physical chemistry and building personal relationships through the mentoring process can be immensely gratifying. This chapter is a compilation of holistic advice for building an experimental physical chemistry research laboratory for undergraduates, reflecting a typical experience found in the United States.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

FrESCO

The National Cancer Institute (NCI) monitors population level cancer trends as part of its Surveillance, Epidemiology, and End Results (SEER) program. This program consists of state or regional level cancer registries which collect, analyze, and annotate cancer pathology reports. From these annotated pathology reports, each individual registry aggregates cancer phenotype information and summary statistics about cancer prevalence to facilitate population level monitoring of cancer incidence. Extracting cancer phenotype from these reports is a labor intensive task, requiring specialized knowledge about the reports and cancer. Automating this information extraction process from cancer pathology reports has the potential to improve not only the quality of the data by extracting information in a consistent manner across registries, but to improve the quality of patient outcomes by reducing the time to assimilate new data and enabling time-sensitive applications such as precision medicine. Here we present FrESCO: Framework for Exploring Scalable Computational Oncology, a modular deep-learning natural language processing (NLP) library for extracting pathology information from clinical text documents.

Spannaus, Adam [Oak Ridge National Lab. (ORNL), Oa↗
DOE OSTI2025

DNN-based Signal Processing for Liquid Argon Time Projection Chambers

We investigate a deep learning-based signal processing for liquid argon time projection chambers (LArTPCs), a leading detector technology in neutrino physics. Identifying regions of interest (ROIs) in LArTPCs is challenging due to signal cancellation from bipolar responses and various detector effects observed in real data. We approach ROI identification as an image segmentation task, and employ a U-ResNet architecture. The network is trained on samples that incorporate detector geometry information and include a range of detector variations. Our approach significantly outperforms traditional methods while maintaining robustness across diverse detector conditions. This method has been adopted for signal processing in the Short-Baseline Neutrino program and provides a valuable foundation for future experiments such as the Deep Underground Neutrino Experiment.

Bhat, Avinay [Chicago U.]↗
DOE OSTI2017

XPRESS: eXascale PRogramming Environment and System Software, Final Report

The University of Oregon (UO) was a partner in the XPRESS project together with Sandia National Laboratories (SNL), Indiana University (IU), Lawrence Berkeley National Laboratory (LBL), Louisiana State University (LSU), Oak Ridge National Laboratory (ORNL), University of Houston (UH), and University of North Carolina (RENCI). UO's objective in the project was to develop "APEX (Asynchronous Performance Environment for eXascale)": performance measurement, analysis, feedback and control infrastructure to asynchronous tasking runtimes, specifically HPX (LSU) and HPX-5 (IU). During the project period, our efforts focused on the need to measure complex tasking models where the traditional instrumentation methods would not work due to an absent/meaningless call-path context and runtime control of task pre-emption and resumption, usually on a different operating system thread. In addition to the challenges of performance measurement, we developed a framework to provide information from all levels of the stack (hardware, operating system, runtime, application) to a feedback & control mechanism for controlling concurrency, task granularity, networking parameters, and other aspects of execution in order to improve execution performance, throughput and/or efficiency. UO demonstrated these developments on leading edge HPC machines at large scale, including a 2017 Gordon Bell submission in which APEX was used to optimize key bottlenecks in an astrophysics application. The following final report summarizes our accomplishments during the XPRESS project.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Downselection and Basic Properties of Additively Manufactured ODS Alloys

In the AMMT program the work package for development of new materials aimed to explore the advanced manufacturing techniques that are feasible for the manufacturing of advanced materials components. A merit-based feasibility study was attempted to identify an accelerated development path for dispersion strengthened (ODS) alloys by creatively combining additive manufacturing (AM) technologies with the recent advances in ODS materials and traditional manufacturing technologies. For the fiscal year, the primary tasks were focused to develop additive manufacturing (AM) and post-build processing route for oxide dispersion strengthened (ODS) ferritic (Fe-Cr alloy or 14YWT) and austenitic (Fe-Cr-Ni alloys or 316L and 316H) alloys and to perform basic microstructural and mechanical characterizations to provide feedbacks to the alloy and processing design. Further, the multi-laboratory effort created collaboratively a decision criteria matrix to evaluate and downselect the new materials processed by advanced manufacturing methods. This report is to describe the ODS alloy processing routes combining AM processes and post-build thermomechanical treatments, mechanical and microstructural characteristics of the newly developed materials, and the application results of the decision criteria matrix for the AM ODS alloys including a downselected material and feasible processing route. Key mechanical test results including tensile strength, tensile ductility, and fracture toughness data and are reported and explained. Higher strength was measured from the ferritic ODS alloys, while higher ductility and fracture toughness were measured from the austenitic ODS alloys. Many of the decision criteria were scored the same for the AM ferritic and austenitic ODS alloys, however, the generally known fact that the austenitic alloys have higher corrosion resistance and significantly better ductility. Although these scores are not significantly different to make them highly discernable, the austenitic ODS alloys were downselected to be the primary materials group in the future research on ODS materials in AMMT program.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The Early Career Research Program Annual Progress Report: Using ARM Data and Multiscale Models to Advance the Understanding of Liquid-Phase Cloud Response to Aerosol Perturbation over Ocean and Land

This report is for the first fiscal year of this ECRP project. This ECRP project aims to study the response of liquid-phase clouds to aerosol perturbation and reduce the related uncertainty in the DOE Earth system model. During this fiscal year, this project mainly made progress on the tasks about observational analyses for Objective 1; and successfully set up two Large-Eddy Simulation (LES) models for Objective 2. A postdoctoral researcher and a graduate student summer intern are on board and fully dedicated to this project. In addition to internal collaboration within LLNL, this project has routinely maintained external collaboration with scientists from universities, NASA Langley Research Center, and other DOE national laboratories. For the next reporting period, we plan to complete the tasks scheduled for the second year. Furthermore, we will promote the findings to communities of interest and proactively seek new collaborations to increase the impact of this project.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Assessment of SFR Wire Wrap Simulation Uncertainties

Predictive modeling and simulation of nuclear reactor performance and fuel are challenging due to the large number of coupled physical phenomena that must be addressed. Models that will be used for design or operational decisions must be analyzed for uncertainty to ascertain impacts to safety or performance. Rigorous, structured uncertainty analyses are performed by characterizing the model’s input uncertainties and then propagating the uncertainties through the model to estimate output uncertainty. This project is part of the ongoing effort to assess modeling uncertainty in Nek5000 simulations of flow configurations relevant to the advanced reactor applications of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. Three geometries are under investigation in these preliminary assessments: a 3-D pipe, a 3-D 7-pin bundle, and a single pin from the Thermal-Hydraulic Out-of-Reactor Safety (THORS) facility. Initial efforts have focused on gaining an understanding of Nek5000 modeling options and integrating Nek5000 with Dakota. These tasks are being accomplished by demonstrating the use of Dakota to assess parametric uncertainties in a simple pipe flow problem. This problem is used to optimize performance of the uncertainty quantification strategy and to estimate computational requirements for assessments of complex geometries. A sensitivity analysis to three turbulent models was conducted for a turbulent flow in a single wire wrapped pin (THOR) geometry. Section 2 briefly describes the software tools used in this study and provides appropriate references. Section 3 presents the coupling interface between Dakota and a computational fluid dynamic (CFD) code (Nek5000 or STARCCM+), with details on the workflow, the scripts used for setting up the run, and the scripts used for post-processing the output files. In Section 4, the meshing methods used to generate the THORS and 7-pin bundle meshes are explained. Sections 5, 6 and 7 present numerical results for the 3-D pipe, the single pin THORS mesh, and the 7-pin bundle mesh, respectively.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Decaf: Decoupled Dataflows for In Situ High-Performance Workflows

Decaf is a dataflow system for the parallel communication of coupled tasks in an HPC workflow. The dataflow can perform arbitrary data transformations ranging from simply forwarding data to complex data redistribution. Decaf does this by allowing the user to allocate resources and execute custom code in the dataflow. All communication through the dataflow is efficient parallel message passing over MPI. The runtime for calling tasks is entirely message-driven; Decaf executes a task when all messages for the task have been received. Such a messagedriven runtime allows cyclic task dependencies in the workflow graph, for example, to enact computational steering based on the result of downstream tasks. Decaf includes a simple Python API for describing the workflow graph. This allows Decaf to stand alone as a complete workflow system, but Decaf can also be used as the dataflow layer by one or more other workflow systems to form a heterogeneous task-based computing environment. In one experiment, we couple a molecular dynamics code with a visualization tool using the FlowVR and Damaris workflow systems and Decaf for the dataflow. In another experiment, we test the coupling of a cosmology code with Voronoi tessellation and density estimation codes using MPI for the simulation, the DIY programming model for the two analysis codes, and Decaf for the dataflow. Such workflows consisting of heterogeneous software infrastructures exist because components are developed separately with different programming models and runtimes, and this is the first time that such heterogeneous coupling of diverse components was demonstrated in situ on HPC systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Energy Intensity Baselining and Tracking Guidance

Each company joining the U.S. Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) commits to establishing an energy consumption and energy intensity (EI) baseline and to tracking its energy performance over a 10-year period against that baseline. The baseline must reflect a company’s energy consumption over a 12-month period, covering all its U.S.-based operations. Energy consumption is calculated by fuel type in terms of primary energy (also known as source energy). EI is broadly defined as the amount of energy consumed per unit of output produced. For this guidance document and for the program, the term energy performance represents an evaluation of a facility’s capacity to use energy efficiently. Metrics used to assess a facility’s energy performance can include EI, energy consumption, improvements in EI, etc. Establishing an energy baseline and tracking system is a critical first step in effectively managing energy use. Developing a baseline can help a company understand energy use within the corporation and give it a point of comparison to evaluate future efforts to improve energy performance. It can also support efforts to validate a company’s energy management activities, improve comparative analyses when using benchmarks, and help in predicting future energy needs. In addition, a company that normalizes its performance data can determine highly defensible measures of energy savings generated through implemented energy efficiency projects. Establishing a baseline and tracking energy performance is also a requirement for ISO 50001 certification. Although basic energy data can be collected through utility bills, most manufacturers will have to perform additional analyses to develop accurate and robust energy baselines and tracking systems. Energy is consumed in many ways within the manufacturing sector and can come from multiple sources. Energy is sometimes generated and sold to other parties or captured and reused on-site. External events can exert a significant impact on a facility or company’s energy use independent of any purposeful efforts to improve energy efficiency. Operational changes, such as production shifts—which may be inevitable for some companies over the 10-year period covered by the program—can also make a big difference in energy use. Since Better Plants asks companies to account for all their U.S.-based operations, mergers, acquisitions, and divestitures can also have significant implications for a company’s energy metrics. This document aims to demystify the sometimes complex baselining process. It devotes special attention to the task of normalizing and adjusting energy consumption to account for external factors, such as weather and production changes. A key recommendation is that companies use regression analysis to normalize their energy consumption data whenever possible. Regression analysis is a statistical technique that estimates the dependence of a variable (i.e., energy use in the context of Better Plants) on one or more independent variables such as ambient temperature, while controlling for the influence of other variables at the same time. A properly developed regression analysis can provide a reliable estimate of energy savings resulting from energy improvement strategies and projects by accounting for the effects of variables such as annual production levels and weather. DOE has developed a companion Energy Performance Indicator software tool (EnPI) to simplify the baselining process. This tool can run regression models, calculate changes in EI at the facility level, and automatically compile facility-level data into a corporate-wide metric. Note that although the relevant equations used to calculate EI are provided in this document, the EnPI tool will automatically perform most calculations for the user. Additionally, Better Plants Partners (Partners) can call on their Technical Account Manager (TAM) to help them establish a baseline and assist with the necessary calculations to track progress.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

A novel transfer learning framework for sorghum biomass prediction using UAV-based remote sensing data and genetic markers

Yield for biofuel crops is measured in terms of biomass, so measurements throughout the growing season are crucial in breeding programs, yet traditionally time- and labor-consuming since they involve destructive sampling. Modern remote sensing platforms, such as unmanned aerial vehicles (UAVs), can carry multiple sensors and collect numerous phenotypic traits with efficient, non-invasive field surveys. However, modeling the complex relationships between the observed phenotypic traits and biomass remains a challenging task, as the ground reference data are very limited for each genotype in the breeding experiment. In this study, a Long Short-Term Memory (LSTM) based Recurrent Neural Network (RNN) model is proposed for sorghum biomass prediction. The architecture is designed to exploit the time series remote sensing and weather data, as well as static genotypic information. As a large number of features have been derived from the remote sensing data, feature importance analysis is conducted to identify and remove redundant features. A strategy to extract representative information from high-dimensional genetic markers is proposed. To enhance generalization and minimize the need for ground reference data, transfer learning strategies are proposed for selecting the most informative training samples from the target domain. Consequently, a pre-trained model can be refined with limited training samples. Field experiments were conducted over a sorghum breeding trial planted in multiple years with more than 600 testcross hybrids. The results show that the proposed LSTM-based RNN model can achieve high accuracies for single year prediction. Further, with the proposed transfer learning strategies, a pre-trained model can be refined with limited training samples from the target domain and predict biomass with an accuracy comparable to that from a trained-from-scratch model for both multiple experiments within a given year and across multiple years.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The effect of support functions in a computerized procedure system on interface management tasks - 235

By adapting digital and computer technology, the design of main control rooms (MCR) in nuclear power plants has been changed. When operators operate a nuclear power plant, the tasks using soft controls in advanced MCRs include primary tasks and secondary tasks. Primary tasks are to control nuclear power plant devices and secondary tasks are to find appropriate screens or devices by screen navigations and selections before performing the primary task. The secondary task including interface management tasks is newly introduced in advanced MCRs. In this paper, the tasks are analyzed based on the simulation data of APR1400 which is one of the digitalized nuclear power plants. For analyzing tasks, the unit tasks are divided into three types: navigation, manipulation, and acknowledgement. The primary task represents the manipulation of devices and the secondary task indicates the navigating screens, opening control panels, closing control panels, and confirming the acknowledging alarms. To analyze the effect of support functions of a computerized procedure system (CPS), one of the functions which is expected to have a significant effect on the secondary tasks was considered, that is 'related screen link button.' Two factors, 'ratio of screen alteration' and 'ratio of using screen link button', were used to see the effect of 'related screen link button'. From the task analysis result, it was observed that the secondary tasks which is one of the unique features in advanced MCRs have a quite much portion than that of the primary tasks. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Materials for Advanced Ultrasupercritical Steam Turbines Task 3: Materials for Non-Welded Rotors, Buckets, and BoltingMaterials for Advanced Ultrasupercritical Steam Turbines

The primary objective of the task was to characterize the materials suitable for mechanically coupled rotor, buckets and bolting operating with an inlet temperature of 760°C (1400°F). A previous study DOE-FC26-05NT42442, identified alloys such as Haynes®282®, Nimonic 105, Inconel 740, Waspaloy, Nimonic 263, and Inconel 617 as potential alloys that met the requirements for the necessary operating conditions. Of all the identified materials, Waspaloy has been widely utilized in the aviation industry in the form of disk and other smaller forgings, and sufficient material properties and vendor experience exist, for the design and manufacture of large components. The European program characterizing materials for A-USC conditions are evaluating Nimonic 263 and Inconel 617 for large components. Inconel 740 has been studied extensively as a part of the boiler consortium and is code approved. Therefore, the consortium focused efforts in the development of material properties for Haynes®282® and Nimonic 105 to avoid replicative efforts and provide material choices/trade off during the detailed design of large components. Commercially available Nimonic 105 and Haynes®282® were evaluated for microstructural stability by long term thermal exposure studies. Material properties requisite for design such as tensile, creep / rupture, low cycle fatigue, high cycle fatigue, fatigue crack growth rate, hold-time fatigue, fracture toughness, and stress relaxation are documented in this report. A key requisite for the success of the program was a need demonstrate the successful scale up of the down-selected alloys, to large components. All property evaluations in the past were performed on commercially available bar/billet forms. Components in power plant equipment such as rotors and castings are several orders in magnitude larger and there is a real need to resolve the scalability issue. Nimonic 105 contains high volume fraction y’ [>50%], and hence the alloy is best suited for smaller forging and valve internals, bolts, smaller blades. Larger Nimonic 105 forgings, would precipitate y’ during the surface cooling during forging, leading to surface cracks. The associate costs in forging Nimonic 105 to larger sizes [hotter dies, press requirements], were beyond the scope of this task and not investigated further. Haynes®282® has 20 - 25% volume fraction y’ was a choice for large components, albeit untested. A larger ingot diameter is pre-requisite for a larger diameter forging and achieves the “typically” accepted working ratio of 2.5-3:1. However, Haynes®282® is manufactured via a double melt process [VIM-ESR] limited by size [<18-16” diameter], which limited the maximum size of the final forging. The report documents the development of a 24” diameter triple melt ingot, surpassing the current available technology. A second triple melt ingot was manufactured and successfully forged into a 44” diameter disk. The successful developments in triple melting process and the large diameter forging of Haynes®282® resolved the scalability issues and involved the first of its kind attempt in the world for this alloy. The complete characterization of Haynes®282® forging was performed and documented in this report. The dataset from the commercially available Haynes®282® [grain size ASTM 3-4] and the finer grain size disk forging [ASTM 8-9] offer an additional design tradeoff to balance creep and fatigue during the future design process.

Saha, Deepak↗