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DOE OSTI2024

On the Application of Cyber-Informed Engineering (CIE)

The 2023 National Cybersecurity Strategy has recommended a transition to secure-by-design methodologies in critical infrastructure. This paper presents the adoption of the National Cyber-Informed Engineering (CIE) Strategy as initiated by the U.S. DOE’s CESER office, advocating for the integration of cybersecurity at the earliest stages of system design. The strategy targets design engineers responsible for energy infrastructure to embed CIE principles within the engineering lifecycle, thus enhancing cyber resilience. This paper discusses the expansion of secure-by-design concepts to cyber-physical systems, moving beyond traditional IT security to include engineering considerations that can mitigate cyber risks through design choices. The paper introduces Digital Risk Management, balancing traditional cybersecurity with CIE to reduce both likelihood and impact of cyber threats. A set of CIE starter questions derived from 12 core principles is detailed, aiding engineers to consider cybersecurity in their designs and highlights the importance of CIE in anticipating and reducing the impacts of cyber attacks, suggesting that such integration is essential for national security and infrastructure resilience.

42 ENGINEERING↗

DOE OSTI2024

Shape Optimization of Header Pipes in Power Plants for Enhanced Efficiency and Environmental Sustainability

In a power plant, the header pipe plays a pivotal role in optimizing the performance of diverse systems by serving as a central conduit for the collection and distribution of steam within the plant. This paper investigates the significance of header pipes within power plant setups, highlighting their critical influence on reliability, efficiency, and the performance of the power plant as a whole. The concept of shape optimization emerges as a crucial factor in power plant design and operation, with the potential to maximize performance while minimizing the use of materials. Shape optimization not only enhances efficiency but also contributes to reducing the environmental footprint of power plant installations. In this paper, we initially developed a methodology designed for optimizing header shapes with the primary goal of reducing the usage of costly new alloy materials and lowering the overall maintenance operation expenses. Secondly, we conducted a case study based on an authentic header sourced from an operational power plant.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C

Drainage structures are used to capture stormwater runoff in streets and highways in urban environments. These drainage structures, which typically consist of catch basins with grates, inlets, or combination grates/inlets, collect stormwater runoff and discharge through buried conveyance systems. They are strategically placed for public safety in curb and gutter systems to provide efficient drainage of water from roadways and thus reduce the risk of hydroplaning. The performance of drainage structures is measured in terms of hydraulic efficiency, which is defined as the percentage of flow captured by the basin as compared to the total flow drainage to the structure. Understanding of the performance of these drainage structures helps designers properly space inlets to promote an economic design that ensures the safety of the traveling public. The current design methodology used to determine drainage structure follows guidelines established in the current Michigan Department of Transportation (MDOT) Drainage Manual (2006). The guidelines in the MDOT Drainage Manual were modeled after the Federal Highway Administration’s (FHWA) Hydraulic Engineering Circular 22 “Urban Drainage Design” (HEC-22). HEC-22 includes empirically derived equations to calculate the interception capacity of drainage structures for several commonly used grate configurations, such as the parallel bar, curved vane and tilt bar grates, which are based on a research study performed by Burgi et al. in the 1970s. MDOT uses several drainage structures to capture runoff that are detailed as Standard Plans. Many of these drainage structures utilize sinusoidal type grates that are not described in HEC-22. Physical modeling of these structures has been limited, posing the need to have them analyzed to verify their capture efficiency. Current MDOT practice is to assume a similar sized reticuline grate, as described in HEC-22, for capture efficiencies. Until recently, evaluating the hydraulic performance of drainage structures was limited to physical modeling in a hydraulics laboratory. With advances in engineering software and computing power, computational fluid dynamics (CFD) modeling has become a more cost-effective alternative. The Federal Highway Administration (FHWA) provides states the option to evaluate their drainage structures using CFD through the Transportation Pooled Fund Program. This study, “Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C,” was carried out using the pooled fund. MDOT’s Cover C was chosen as the first test candidate, given its similar sinusoidal pattern to other MDOT grates, but it is typically used for high-volume, higher speed applications. A similar version, Cover CX, is used on interstate highways but does not have traverse bars for bicycle safety. Additional grates may be considered for evaluation in the future.

42 ENGINEERING↗

DOE OSTI2026

Carbon dioxide pipeline network transportation cost model: evaluating economic and geographic factors for efficient carbon capture, storage, and utilization

This study presents a comprehensive pipeline network modeling framework to estimate the CO 2 delivery cost for CO 2 utilization and geologic CO 2 storage across the United States. We developed a Python-based CO 2 pipeline transportation cost model leveraging Argonne National Laboratory’s pipeline engineering expertise and detailed natural gas transmission pipeline cost data across U.S. regions. Using existing road corridors as practical routing guides, the model designs pipeline networks that aggregate CO 2 from one or multiple sources and deliver it to selected destinations. It then minimizes the total transportation cost by optimizing pipeline diameters and incorporating booster pumps. A key contribution is the incorporation of up-to-date, region-specific cost factors with itemized components for materials, labor, miscellaneous construction expenses, and right-of-way acquisition. Results emphasize that regional variation and economies of scale associated with CO 2 pipeline costs are significant and should be explicitly accounted for in screening and planning studies. By combining realistic routing constraints with regionalized cost inputs, the model provides transparent design methodology and location-specific insights into source–destination delivery costs, including the effects of routing complexity along existing road networks. We demonstrate the model with two illustrative case studies – one for CO 2 storage and one for CO 2 utilization – in which the model designs pipeline networks spanning hundreds of miles across the states, collecting CO 2 from multiple sources and delivering it to designated endpoints while minimizing levelized cost of delivery via diameter and compression optimization. The model offers a practical, scalable approach for alternative design option screening and early-stage CO 2 transportation planning.

CCS↗

DOE OSTI2027

Conceptual design of highly-constrained splitters for the FFA@CEBAF energy upgrade study

The Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab is investigating a significant energy upgrade utilizing Fixed-Field Alternating-gradient (FFA) recirculating arcs. This upgrade requires the design of complex horizontal beam splitters to manage up to six concurrent beam passes. This paper presents the conceptual design of these splitters, which are subject to severe physical constraints imposed by the existing accelerator tunnel and multifaceted beam dynamics requirements for matching into the permanent-magnet FFA arcs. The design methodology, centered on multi-pass simulations in the Bmad toolkit, is detailed from the initial geometric layout through the advanced optics matching. Key results include a robust geometric arrangement that fits within the spatial boundaries and the development of multiple, flexible optics matching solutions. Furthermore, the design integrates a viable scheme for extracting high-energy beams for the experimental halls, a critical operational requirement. This work establishes a comprehensive and viable conceptual design, forming a baseline for future engineering and performance optimization studies.

Bodenstein, R.M. [Thomas Jefferson National Accele↗

DOE OSTI2026

Generalized Theory and Realization of Reconfigurable Bandpass Filtering Equalizers

Here, in this article, a generalized theory of bandpass filtering equalizers is proposed. A filtering equalizer is a device that combines the frequency-selective properties of a filter with the controllable slope of an equalizer into a single component. The equations used to design the function for a desired slope are provided, and the design methodology to determine the necessary filtering polynomials is also shown. The controllable slope of the dual-function component is realized using variable capacitors, which are used to tune both a transmission zero and a matching network to achieve the desired slope. A third-order bandpass filtering equalizer is designed, fabricated, and measured to verify the generalized theory. The component is designed to operate at 1 GHz with a slope that can be reconfigured from 1 to 3 dB along the passband. This proposed filtering equalizer demonstrates the feasibility of a tunable, low-cost, size, weight, and power (C-SWaP) solution to enable increased flatness in the overall system response and thereby decrease the error vector magnitude (EVM) of future radio frequency (RF) systems and a design process that allows for future development of filtering equalizers.

Filter↗

DOE OSTI2022

Design and Challenges of Edge Computing ASICs on Front-End Electronics

In situ or hardware-embedded data processing of raw signals, close to their source, in radiation detectors is expected to provide dramatic improvements in data quality and volumes. However, the implementation of artificial neural networks (ANNs) in the front-end electronics, and the design of custom integrated circuits (ASICs), comes with challenges. In addition, detectors have to operate with limited power budget and implement complex functionalities in a very dense space. They often are exposed to extreme conditions as they work in high-radiation environments and/or cryogenic temperatures. This paper presents examples of applications and design methodologies for in-situ ANNs, along with the challenges of retaining the fidelity of the trained networks. For illustration, we use the problem of estimating the energy deposited by the radiation from digitized waveforms. The proposed implementation starts with an ML algorithm trained in Qkeras and eventually leads to an equivalent ASIC implementation. The associated design challenges in realizing energy and area efficient implementations in CMOS processes are reviewed. Novel approaches that employ hybrid technologies (combination of CMOS with memristors), in-memory computing models, and bio-inspired spiking neural networks are also highlighted

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

ARC-100 Reactor Security-by-Design Summary 2025

This report applies the security-by-design methodology developed in a previous National Nuclear Security Administration–sponsored work to the ARC-100, a sodium-cooled fast reactor (SFR) being developed by ARC Clean Technology, Inc (ARC). The report contains no proprietary information specific to the ARC 100 reactor. The insights developed in this report are high-level, and generally applicable to other sodium fast reactor designs. The information presented here is the result of a qualitative safety-based analysis and would not inform any potential adversary beyond what would be found in a docketed safety analysis report. The scope of this present report covers ARC-100’s reactor core, used fuel storage, used fuel assembly wash station, cesium trap, sodium cold trap, noble gas decay tanks, used fuel dry storage facility, damaged fuel storage facility, and radioactive waste building. These systems are also compared to a generic SFR design assumed in the previous study. The security assessment results show changes in structures, systems, and components (SSCs) safety importance relative to the generic SFR SSCs. Several SSCs have higher importance rankings than others, and it is recommended that protection efforts are prioritized for these SSCs. Results from this work will furnish a technical justification for the feasibility of these solutions for the ARC reactor's design and, where applicable, identify any regulatory benefits conferred by the proactive design aspect within a risk management framework. This initiative will contribute to a more secure design of the ARC reactor and support its licensing process.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗

DOE OSTI2024

Ground Source Heat Pump Screening Tool and Related Resources

This archive contains both a link to Oak Ridge National Laboratory's Ground Source Heat Pump (GSHP) Screening Tool and related resources documenting its development, technical features, and applications. The web-based screening tool is a techno-economic analysis resource designed to evaluate the feasibility, costs, and benefits of implementing GSHP systems in buildings across various U.S. climate zones. It is intended for use by building owners, HVAC system designers, and installers to support decision-making in residential and commercial applications, incorporating advanced modeling capabilities such as ground heat exchanger design. The included resources detail the tool's creation and use, covering topics such as innovative ground heat exchanger design methodologies, the development of an open library of g-functions for borehole configurations, and studies on GSHP performance and economic viability in retrofitting single-family homes.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Self-Resonant Coil Design for High-frequency High-Power Inductive Wireless Power Transfer

In this paper, the design methodology of a high-frequency, high-power, long-distance inductive wireless power transfer (WPT) is presented. The airgap (d) of a traditional high-power (>1 kW) WPT is limited to a few hundred millimeters, which is almost 1/4th of the coil diameter, D; d ≤ D/4. In this paper, the power transfer distance is significantly increased (d ≥ 1.5D) by adopting a high-frequency magnetic design and GaN-based power electronics. The material and design of the coil and shield are investigated using FEA and tested experimentally. A high frequency 6.78 MHz wireless charging system was built to transfer 1 kW power over 3 m airgap.

Mohammad, Mostak↗

DOE OSTI2025

Transforming Aeration Energy in Water Resource Recovery Facilities (WRRFs) through Suboxic Nitrogen Removal (Final Report)

The objective of this project was to advance two key technological components—aeration control strategies and process design methodologies—to support the development and broader adoption of suboxic biological nitrogen removal (SBNR). The project focused on achieving the following three goals: • Enhance Model Predictive Control (MPC) Technology: Advance the DO/Nmaster MPC platform from its initial 2018 pilot deployment at the Chico Water Resource Recovery Facility in California to full-scale integration. This included partnering with a blower technology commercialization partner and incorporating machine learning (ML) capabilities to enable nationwide deployment. • Bridge Knowledge Gaps in SBNR Process Design: Address fundamental gaps in SBNR process understanding through controlled pilot-scale testing at a dedicated pilot facility. These efforts supported the development of robust kinetic models to inform reliable SBNR control, operational strategies, and design frameworks. • Demonstrate Full-Scale Implementation of Low DO/SBNR with ML: Transition low dissolved oxygen (DO)/SBNR coupled with ML from pilot-scale trials to full-scale demonstration in flow-through biological nutrient removal (BNR) systems, with the goal of enabling scalable, nationwide adoption in activated sludge treatment processes. The project included demonstration of SBNR at the pilot scale as performed by Hampton Roads Sanitation District (HRSD) and at the full-scale as performed by the Los Angeles County Sanitation Districts' (LACSD) Pomona Water Reclamation Plant (POWRP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Materials Selection Principles for Designing Electro‐Thermal Neurons

Artificial neurons exhibiting volatile threshold switching and action potential‐like oscillations are crucial for brain‐inspired computing. While Complimentary Metal‐Oxide‐Semiconductor (CMOS)‐based strategies require hundreds of transistors to simulate each neuron, neuronal oscillations arise spontaneously in individual electro‐thermal devices due to nonlinearities like the Mott transition in VO 2 . Despite improved understanding of the physics, quantitative connections between neuronal performance and material properties remain under‐explored, preventing predictive neuron design and rational materials selection. In this work, a physics‐aware forward design methodology is developed for interrogating a wide palette of materials with properties varying by orders of magnitude, and their performance (high frequency, high dynamical reconfigurability and low power) under external circuit and device geometry constraints is assessed. The space of viable materials is identified to be much larger than previously recognized, with candidates from a range of materials classes, including Ge, GaP and MoS 2 . CMOS‐compatible performance (such as 100 GHz oscillating frequencies) can be achieved with CMOS‐compatible node sizes (≈10 nm). Finally, combinations of material properties yielding desired neuronal performance under uncertain design constraints are considered. This work solidifies forward design principles for electro‐thermal neuron devices, a necessary pre‐condition for inverse design from desired neuronal performance to required materials properties.

compact model↗

DOE OSTI2024

Models implemented in the methodological approach to design the initial STEP first wall contour

The official Spherical Tokamak for Energy Production mission aims to demonstrate the ability to generate net electricity from fusion with the STEP Prototype Power plant. One of the key technological and engineering challenges in fusion power plants is managing the loads on the first wall within acceptable limits. Therefore, the conceptual design development of the STEP Prototype Power plant needs to be based on load estimates derived using legitimate plasma physics assumptions through dynamic and flexible tools. The current design foresees the STEP main chamber first wall to withstand steady-state heat loads of up to ~1 MW/m 2 , excluding critical regions expected to receive higher heat loads such as the baffle regions approaching the divertors. These critical areas will require ad hoc assessments and will be designed with the presence of limiters. This article focuses on the models and methodology adopted for designing the 2-D poloidal contour of the STEP first wall, based on the anticipated charged particle and radiation heat loads during normal operation. Firstly, the models adopted for calculating the charged particle and radiation heat loads are introduced. The first model is validated through benchmarking against the particle tracing code SMARDDA, while the second model is verified by comparing it with data from the MAST-U experiment. Secondly, the model used to design the 2-D first wall contour according to the heat loads is explained. We acknowledge that this preliminary design stage assumes certain simplifications, notably an axisymmetric geometry, for computational efficiency and clarity in presentation. It is understood that subsequent design phases will address the complexities of real-world engineering, including non-axisymmetric effects, transient plasma scenarios, and the impact of disruptions on the first wall design. Finally, an automatic procedure based on these models is presented for defining the 2-D poloidal contour of the STEP first wall to minimize heat loads, taking into account the need to radiate most of the alpha-particle and auxiliary heating power. Here, by providing an overview of the models, methodology, and an automatic procedure, this paper contributes to the design process of the STEP first wall, addressing the engineering challenges associated with fusion power plant development.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Report on FY 2023 Research and Development on Specially Designed Creep-fatigue Experiments on Alloy 617 in Support of Improving Creep-fatigue Evaluation Approaches

Experimental and numerical studies in support of developing the integrated Elastic–Perfectly Plastic (EPP) plus Simplified Model Test (SMT) design methodology, referred to as the EPP+SMT method, continued in FY 2023. This report focuses on the methods for extrapolating the EPP+SMT creep-fatigue life curves at long hold times and low strain ranges at elevated temperatures. In this work, the available uniaxial creep-fatigue failure data on Alloy 617 at temperatures of 950°C and 850°C were analyzed to provide a guidance on the development of the extrapolation method and the creep-fatigue failure criteria. A viscoplastic constitutive model for Alloy 617 was adopted to extrapolate the mechanical responses to low strain ranges and long hold times. A set of design curves of Alloy 617 at temperatures of 950°C, 850°C, and 800°C with tensile hold times of 1 hr, 100 hr, and 1,000 hr are developed. Furthermore, creep-fatigue testing on two notch specimen geometries, shallow-notch and sharp V-notch, on Alloy 617 was performed 950°C to understand the multiaxial stress relaxation behavior. The experimental and numerical results on the notch specimens were compared with those on the standard uniaxial smooth bar specimens. The effect of multi-axial stress state combined with elastic follow-up on the stress relaxation behavior was investigated in this report.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Support of the Development of EPP Plus SMT Design Method (FY2020 Test Results)

Experiments in support of the development of the integrated Elastic–Perfectly Plastic (EPP) analysis and Simplified Model Test (SMT) design methodology continued in FY 2020. The previously developed single-bar SMT (SBSMT) technique was successfully extended to tubular shaped Alloy 617 specimens for evaluation of the effect of primary pressure load on SMT creep-fatigue (CF) properties at 950°C. A series of pressurized SMT tests were performed with various elastic follow-up factors and strain ranges. The results show that the primary pressure load reduces the SMT CF cycles. The reduction of SMT CF life due to primary load was found to be dependent on strain ranges, elastic follow up and test temperatures. These results are crucial for verification of the EPP strain range analysis in the EPP+SMT evaluation procedure. Additionally, hold time effect on the SMT CF life cycles is a determining factor for generating the EPP+SMT CF design curves. Lack of test data in the high cycle and low strain range region results in major uncertainty in developing the design curves. In FY2020, experiments were designed, and testing started on Alloy 617 at 950°C to fill the gap in experimental data. The on-going CF and additional SMT CF with elastic follow-up at low strain ranges will generate the information needed to verify the methods for extrapolation to long hold time and finalize the EPP+SMT design method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗