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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A scoping review of non-destructive testing (NDT) techniques in building performance diagnostic inspections

Understanding building envelope thermodynamics is an essential foundation of building sciences, mainly due to the envelope’s role as a boundary layer for exterior environments, as well as a container and regulator of internal microclimates. This paper presents a scoping literature review of select Non-destructive Testing (NDT) techniques for building envelope scanning and surveying for thermodynamic diagnostics. The investigation focuses specifically on reviewing six NDT techniques: Ground Penetrating Radar (GPR), Light Detection and Ranging (LiDAR)/Laser Scanning, Thermography, Ultrasound, Close-Range Photogrammetry and Through Wall Imaging Radar (TWIR). The aim is to identify knowledge gaps in terms of their use in accurately characterizing envelope compositions for further integration in Building Energy Modeling (BEM). Each technique was evaluated according to set categories imbibed from the American Society of Heating, Refrigerating, and Air Conditioning Engineering (ASHRAE) Standard 211P that showcase the technique’s ability to extract various relevant information. A framework is then developed to inform users on how to use hybrid NDT-based workflows applied in building envelope energy audits. The study concludes by discussing possibilities of utilizing NDT in large-scale audit automation, BEM integration, and developing built environment policies focusing on increasing existing building performance through retrofitting design.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Integration and performance of large area picosecond photodetectors in the accelerator neutrino neutron interaction experiment

ANNIE, the Accelerator Neutrino Neutron Interaction Experiment, is a 26-ton Gadolinium-loaded water Cherenkov detector located at the Booster Neutrino beam line at Fermilab to mainly measure neutron multiplicity of neutrino interactions and test the performance of Large Area Picosecond Photodetectors (LAPPD). This thesis presents the integration of LAPPD at ANNIE and the preliminary performance analysis. LAPPDs achieved 2.48ns bunch structure resolution, even considering the time of flight and the intrinsic bunch width. The analysis also achieves better than 100ps intrinsic timing resolution, sub-mm position resolution for a single photoelectron, and cm-level resolution in conditional muon track reconstruction.

Feng, Yue [Iowa State U.] (ORCID:0000000332021351)↗
DOE OSTI2022

Scale-dependent enhancement of productivity and stability in xenic Nannochloropsis cultures

Although bacterial amendments can enhance algal productivity and stability, the development of algal-bacteria consortia for commercial-scale utilization is limited. Here, for this work, we used an established high-throughput approach to generate algal-bacteria consortia, and tested consortia performance at spatial scales from microplates to 320 L raceway ponds. We used both lab and field-reared strains of Nannochloropsis oceanica to build consortia. In some experiments, we imposed environmental perturbations to test the ability of bacteria to enhance algal culture stability. In repeated assays at the scale of well plates, flasks, and bioreactors, strong effects of bacterial amendments on N. oceanica were observed. These effects were most dramatic when cultures experienced stressors such as temperature perturbations or removal of CO 2 augmentation. Isolates that were advanced for field testing included species in the genera Algoriphagus, Oceanicaulis, and Marinobacter. When consortia were generated in the field, positive effects of bacterial amendments were not observed. The amended bacteria were outcompeted, and bacterial community composition across treatments converged after the first grow out. These results highlight the complexity of using consortia in open systems, where interactions between the existing bacterial community, inoculated bacteria, and changing environmental conditions are layered upon other differences in scale and cultivation regimes. Moreover, functionally redundant bacteria are likely present in the field. Following this work, we hypothesize that tight interactions (e.g., obligate relationships between partners) will scale more predictably to outdoor systems. We suggest relying on true synthetic ecological approaches in which the relationships between bacteria and algae partners are well understood, or synthetic ecological approaches coupled with high throughput approaches to design and test consortia. We also recommend future work to examine the effect of algae-bacteria inoculation ratios on productivity and stability, track dynamics of partners through time, and manage ponds to retain beneficial symbioses.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

A visco-plastic framework for interface processes in sedimentary reservoir rocks at HPHT conditions

As energy operations face the challenge of reservoirs at ever-increasing depths, modelling the response of reservoir rocks at high pressure and high temperature (HPHT) conditions is a crucial step for successfully unlocking new resources. At these conditions, rocks can experience thermal and pressure sensitivity, as well as admit internal phase changes at the pore-solid interfaces that determine their macroscopic response to external loading. It is therefore expected that constitutive laws of Geomechanics should be enriched to accommodate such effects. In this work, a multi-physics constitutive theory for sedimentary rocks is proposed within the general framework of viscoplasticity. The viscosity of the material is assumed to be a function of the temperature, pore-pressure and energy required to alter the inter-granular interfaces. This energy is expressed through the chemical potentials of the phases involved during processes like chemical dissolution/precipitation of the interfaces or mechanical debonding. The resulting flow law and corresponding stress equilibrium are coupled to the energy and mass conservation laws, constituting a closed system of equations, which is solved using the Finite Element simulator REDBACK. A series of numerical tests for performance and calibration is then successfully performed against different types of reservoir rocks, confining pressures and temperatures (from room temperature to over 800K). Here, we show that the mechanical response of sedimentary porous rocks at strains usually achieved in laboratory testing can be explained by accounting for the interface processes taking place at the cementitious material bonding the grains, a process that can also determine the brittle-to-ductile transition of sedimentary rocks.

58 GEOSCIENCES↗
DOE OSTI2020

Microstructure Experiments-Enabled MARMOT Simulations of SiC/SiC-based Accident Tolerant Nuclear Fuel System

We have undertaken an experimental-computational project that addresses a few key technology gaps associated with the use of SiC/SiC composites for light water reactor fuel cladding. Two principal endeavors in this project are to assess the irradiation-induced microstructural changes and swelling in SiC/SiC composites, and to characterize and model the porous oxide surface layer (when exposed to steam) along SiC recession that is detrimental to the clad integrity under accident conditions. The project tasks are: (i) ion irradiation and characterization (University of Tennessee, Knoxville), (ii) mechanical tests and analysis (University of South Carolina), (iii) steam exposure tests (Oak Ridge National Laboratory), (iv) electron microscopy and spectroscopic characterization (NC State University), (v) x-ray microscopy and reconstruction (University of South Carolina and NC State University), (vi) phase field modeling and simulations (NC State University and Idaho National Laboratory). The effects of 10 MeV Au ion irradiation at 350°C on the microstructure evolution in SiC/SiC composites are investigated at doses up to 400 displacements per atom (dpa) at the University of Tennessee, Knoxville. Atomic force microscopy and optical profilometry reveal irradiation induced axial and radial shrinkage of the fibers for doses greater than 10 dpa. Based on detailed electron microscopy characterization, the primary cause of the fiber shrinkage is attributed to irradiation-induced loss of carbon packets. Additionally, the multilayer PyC interface is observed to portray high resistance to irradiation damage. The mechanical response and failure mechanisms of un-irradiated samples is also assessed through loading tests and X-ray imaging at the University of South Carolina. Steam exposure tests are performed at the Oak Ridge National Laboratory in a facility that represents a reactor pressure vessel under a loss-of-coolant-accident scenario. The samples that are analyzed methodically in this report are tested for 32/31 hours at 1200°C with a velocity of 0.25 cm/s for the pressures: 0.1 MPa, 0.45 MPa, 0.92 MPa and 1.38 MPa. Scanning/transmission electron microscopy analysis conducted at the NC State University (NCSU) shows that the oxide layer thickness increases with the steam pressure. While the oxide layer is crystalline (α- cristobalite) for the pressures 0.45 MPa, 0.92 MPa and 1.38 MPa, the layer is amorphous at 0.1 MPa. Results from Raman spectroscopy have also confirmed the formation of α-cristobalite phase of SiO₂. The abrupt increase in the integrated Raman intensity ratio between steam pressures 0.1 and 0.45 MPa suggests the onset of accelerated crystallization. Non-destructive three dimensional X-ray microscopy/tomography (XCT) and computational image processing techniques are employed by the University of South Carolina to probe the porous oxidation features on SiC samples at varying pressures. Interestingly, most pores are observed to be located away from the surface as well as the oxide-SiC interface. The average oxide layer thickness assessed from the XCT analysis is seen to be in excellent agreement with the values determined through scanning electron microscopy analysis for the highest pressures where the oxide layer is relatively more uniform. A phase-field model developed by the NC State University and Idaho National Laboratory for simulating oxidation of SiC by steam captures the paralinear kinetics of SiC oxidation with a high degree of fidelity. Results from quasi-one-dimensional and two dimensional simulations show that the pores with oxidizing species lead to a higher volatilization rate. These simulations indicate that the enhanced apparent volatilization rates at higher pressures observed in experiments can be rationalized by the increased volatilization from the pores. The project team has also successfully developed the capability to import images from experiments for realistic evolution of the oxidizing microstructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Improved Throughput and Analysis of Scratch Test Results via Automation and Machine Learning

A data analysis automation interface that incorporates machine learning (ML) has been developed to improve productivity, efficiency, and consistency in identifying and defining critical load values (or other values associated with optically identifiable characteristics) of a coating when a scratch test is performed. In this specific program, the machine learning component of the program has been trained to identify the Critical Load 2 (L C2 ) value by analyzing images of the scratch tracks created in each test. An optical examination of the scratch by a human operator is currently used to determine where this value occurs. However, the vagueness of the standard has led to varying interpretations and nonuniform usage by different operators at different laboratories where the test is implemented, resulting in multiple definitions of the desired parameter. Using a standard set of training and validation images to create the dataset, the critical load can be identified consistently amongst different laboratories using the automation interface without requiring the training of human operators. When the model was used in conjunction with an instrument manufacturer's scratch test software, the model produced accurate and repeatable results and defined L C2 values in as little as half of the time compared to a human operator. When combined with a program that automates other aspects of the scratch testing process usually conducted by a human operator, scratch testing and analysis can occur with little to no intervention from a human beyond initial setup and frees them to complete other work in the lab.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development of Large Area µRWELL Detectors for CLAS12 High Luminosity Upgrade at Jefferson Lab

The high-luminosity upgrade of the CEBAF Large Acceptance Spectrometer (CLAS12) will significantly enhance the physics reach of experiments in Hall B at JLab. However, at the current luminosity of L = 1 × 1035 cm-2 s-1, the reconstruction efficiency of charged particles in the forward region of the CEBAF Large Acceptance Spectrometer (CLAS12) is at the level of 85% and limited in part by the drift chambers inability to handle high occupancy, in the first tracking region (DC-R1) of the Forward Detector. The reconstruction efficiency is expected to drop even lower at higher luminosities with the current tracking technology. Various options under consideration to achieve the desired performance at a higher luminosity of L = 2 × 1035 cm-2 s-1 include the addition of fast tracking layers to complement DC-R1 or the replacement of DC-R1 with a different tracking detector technology altogether. In either case, a novel generation of compact, simple and robust Micro-Pattern Gaseous Detector (MPGD) known as the Resistive Micro-Well detector (µRWELL) is the ideal candidate to satisfy the requirements in terms of timing O (10 ns) and position O (100 µm) resolutions. A large µRWELL prototype, combined with a two-dimensional U-V strip readout layer based on the novel concept of capacitive-sharing approach has been developed as a proof of principle for fast tracking capabilities in the forward region of CLAS12 high-luminosity upgrade. In this talk, we will present the technical aspects of the design choices of the large µRWELL prototype under development and report on the detector assembly process and preliminary performance characteristic tests. We will also discuss the plans for the test and characterization of the prototype in beam during spring 2023 CEBAF run. Finally, we will report on ongoing R&D efforts on small prototypes with the goal to improve rate capability, spatial resolution performance and minimize material thickness.

Gnanvo, Kondo↗
DOE OSTI2022

Investigation of Plasmodium falciparum pfhrp2 and pfhrp3 gene deletions and performance of a rapid diagnostic test for identifying asymptomatic malaria infection in northern Ethiopia, 2015

Background: Rapid diagnostic tests (RDTs) are widely used for malaria diagnosis of both symptomatic and asymptomatic infections. Although RDTs are a reliable and practical diagnostic tool, the sensitivity of histidine-rich protein 2 (HRP2)-based RDTs can be reduced if pfhrp2 or pfhrp3 (pfhrp2/3) gene deletions exist in the Plasmodium falciparum parasite population. This study evaluated dried blood spot (DBS) samples collected from a national household survey to investigate the presence of pfhrp2/3 deletions and the performance of the RDT used in the cross-sectional survey in a low transmission setting. Methods: The 2015 Ethiopia Malaria Indicator Survey tested household members by RDT and collected DBS samples. DBS (n = 2648) from three regions in northern Ethiopia were tested by multiplex bead-based antigen detection assay after completion of the survey. The multiplex assay detected pan-Plasmodium lactate dehydrogenase (LDH), pAldolase, and HRP2 antigens in samples. Samples suspected for pfhrp2/3 gene deletions (pLDH and/or pAldolase positive but low or absent HRP2) were further investigated by molecular assays for gene deletions. Antigen results were also compared to each individual’s RDT results. Dose–response logistic regression models were fit to estimate RDT level of detection (LOD) antigen concentrations at which 50, 75, 90, and 95% of the RDTs returned a positive result during this survey. Results: Out of 2,648 samples assayed, 29 were positive for pLDH or pAldolase antigens but low or absent for HRP2 signal, and 15 of these samples (51.7%) were successfully genotyped for pfhrp2/3. Of these 15 P. falciparum infections, eight showed single deletions in pfhrp3, one showed a single pfhrp2 deletion, and six were pfhrp2/3 double-deletions. Six pfhrp2 deletions were observed in Tigray and one in Amhara. Twenty-five were positive for HRP2 by the survey RDT while the more sensitive bead assay detected 30 HRP2-positive samples. A lower concentration of HRP2 antigen generated a positive test result by RDT compared to pLDH (95% LOD: 16.9 ng/mL vs. 319.2 ng/mL, respectively). Conclusions: There is evidence of dual pfhrp2/3 gene deletions in the Tigray and Amhara regions of Ethiopia in 2015. As the prevalence of malaria was very low (< 2%), it is difficult to make strong conclusions on RDT performance, but these results challenge the utility of biomarkers in household surveys in very low transmission settings.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Electrical Validation Testing for ORPC MHK Generator, Modification 6: ORPC SBV for MHK Generator System (CRADA Final Report)

For the U.S. Department of Energy’s (DOE) 2016 Small Business Voucher for Marine and Hydrokinetic (MHK) System, Second Round 2016, ORPC intends to work with the National Renewable Energy Laboratory (NREL) to perform dynamometer testing of the MHK generator systems and its associated controls and inverters. ORPC will provide the generator, variable frequency drives (VFD), controls, and inverter for this testing. NREL will utilize the NREL Energy Systems Integration Facility (ESIF) and dynamometer facilities at the National Wind Technology Center (NWTC) for this work. Modification 6: Additionally, NREL will conduct a feasibility study for implementing passive DC rectification at the turbine.

17 WIND ENERGY↗
DOE OSTI2021

Metallic Fuel Performance Code Requirements for the Versatile Test Reactor Project

Metallic nuclear fuels have been proposed for use in several emerging nuclear reactor designs, and a number of codes have been developed to model these fuels and assess their performance. Qualification of these metallic nuclear fuels will ultimately require monitored irradiation of lead test assemblies, but the use of fuel performance codes can reduce the uncertainty associated with these efforts by quantifying uncertainties and estimating margins to failure ahead of time. In this work, metallic fuel performance code requirements are defined for the Versatile Test Reactor (VTR) project using input from the Experimental Breeder Reactor II functional requirements, operational requirements, and design criteria. This work focuses on the thermomechanical responses and irradiation behaviors of metallic fuel elements that are representative of the proposed VTR driver fuel design concepts. As such, many of the code requirements and physics/modeling discussions in this work are expected to be broadly applicable to metallic fuel applications outside of the VTR project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Relaxation behavior in low-frequency complex conductivity of sands caused by bacterial growth and biofilm formation by Shewanella oneidensis under a high-salinity condition

Complex electrical conductivity is increasingly used to monitor subsurface processes associated with microbial activities because microbial cells mostly have surface charges and thus electrical double layers. Although highly saline environments are frequently encountered in coastal and marine sediments, there are limited data available on the complex conductivity associated with microbial activities under a high-salinity condition. Therefore, we have developed the spectral responses of complex conductivity of sand associated with bacterial growth and biofilm formation under a highly saline condition of approximately 1% salinity and approximately 2 S/m pore water conductivity with an emphasis on relaxation behavior. A column test is performed, in which the model bacteria Shewanella oneidensis MR-1 are stimulated for cell growth and biofilm formation in a sand pack, whereas the complex conductivity is monitored from 0.01 Hz to 10 kHz. The test results indicate that the real conductivity increases in the early stage due to the microbial metabolites and the increased surface conduction with cell growth but soon begin to decrease because of the reduction of charge passages due to bioclogging. However, the imaginary conductivity significantly increases with time, and clear bell-shaped relaxation behaviors are observed with the peak frequency of 0.1–1 Hz, associated with the double-layer polarization of cells and electrically conductive pili and biofilms. The Cole-Cole relaxation model appears to capture such relaxation behaviors well, and the modeling results indicate gradual increases in normalized chargeability and decreases in relaxation time during bacterial growth and biofilm formation in the highly saline condition. Comparison with previous literature confirms that the high-salinity condition further increases the normalized chargeability, whereas it suppresses the phase shift and thus the imaginary conductivity. Our results suggest that the complex conductivity can effectively capture microbial biomass formation in sands under a highly saline condition.

58 GEOSCIENCES↗
DOE OSTI2022

ORNL Neutron Cross Section Measurements of 90 Zr

Nuclear criticality modeling and simulations rely on the quality of the existing evaluated nuclear data libraries such as Evaluated Nuclear Data File (ENDF)/B, the Joint Evaluated Fission and Fusion (JEFF) nuclear data library, or the Japanese Evaluated Nuclear Data Library (JENDL). In some cases, the cross-section evaluations of those libraries were found to be deficient in describing criticality benchmarks accurately. More than two decades ago, the US Nuclear Criticality Safety Program (NCSP) established a Nuclear Data (ND) task which encompassed experiments and evaluations. In response to this, the Oak Ridge National Laboratory (ORNL) formed a Nuclear Criticality and Data group which performed ND experiments, data analysis, and evaluations to produce ENDF files for the ND libraries as identified in the NCSP Five-Year Plan. Before being submitted to the ENDF library, files were processed and tested for performance by running benchmark calculations. This procedure was centralized in the ORNL group and is now often referred to as the ND pipeline. NCSP collaborates with the Joint Research Center (JRC) of the European Commission in Geel, Belgium, to perform high-resolution neutron-induced cross section measurements at the Geel Linear Accelerator (GELINA). The objective is to address emerging ND problems in criticality calculations. Difficulties with ND include insufficient neutron energy range, missing covariances, and previously unrecognized inaccuracies with experiments. New neutron total and capture cross sections of 90 Zr in the neutron energy range from 100 eV to several hundred keV were recently performed. These measured data will be used, together with existing high-resolution transmission data from a metallic 90 Zr sample, to improve representation of the cross sections.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Multichannel Fiber-Optic Silicon Fabry–Pérot Interferometric Bolometer System for Plasma Radiation Measurements

A single-channel fiber-optic bolometer system based on a high-finesse silicon Fabry–Pérot interferometer (FPI) was previously reported, intended to measure plasma radiation from the magnetically confined fusion chamber. Recently, we developed a multichannel fiber-optic bolometer system with five bolometers multiplexed using a coarse wavelength division multiplexer (CWDM) and interrogated with a white-light system involving a superluminescent light-emission diode source and a high-speed spectrometer. One of the bolometers was used as the reference bolometer to compensate for the ambient temperature variations, and the other four bolometers were used for radiation measurement. The bolometers have a simple structure with a silicon pillar at the end of the single-mode fiber and a gold disk on the other side of the silicon pillar. They are also easy to fabricate without stringent requirements on the optical alignment. Analysis of the system optimization was performed to improve the noise performance and to mitigate the vibration effect that may present in the practical application. The system had a significantly enhanced measurement range compared to the previous high-finesse FPI bolometer system for measuring radiation. Test results performed in air using a 405 nm laser as the radiation source showed that the temperature resolution and the noise-equivalent power density of the sensing bolometers connected to each channel of the CWDM were, respectively, ~0.4 mK and ~0.1 W/m2, with a time constant of ~220 ms, which is comparable to the previous more complicated fiber-optic bolometer systems based on high-finesse FPIs that were interrogated using wavelength-scanning lasers.

Uddin, Nezam↗
DOE OSTI2026

STANDARD REFERENCE MATERIAL CHARPY TESTING FROM HIGH FLUENCE SURVEILLANCE CAPSULE

The Palisades Nuclear Generating Station included in its original surveillance program a surveillance capsule, designated A-60. The capsule was removed from its surveillance position in early 1995 and has been resident in the spent fuel pool since that time. It was harvested to perform characterization of surveillance specimens in this capsule in 2023. This capsule was irradiated to a fluence of 1.96x1020 n/cm2 (E> 1MeV) that is equivalent for more than 150 effective full power years for the current US reactor pressure vessel (RPV) fleet. This capsule contained several materials, including Charpy specimens of standard reference material (SRM) from Heavy-Section Steel Technology (HSST) A533-B Plate 01. To perform Charpy testing of this highly irradiated material, the new Charpy specimen transfer system was designed and implemented on Charpy impact testing machine in the hot cell to accommodate remote testing of these specimens. This new transfer system includes integrated environmental chamber to cool or heat Charpy specimens to the desired temperature. Testing of this highly irradiated material revealed very large shift of Charpy transition temperature, 188oC.

Sokolov, Mikhail [ORNL] (ORCID:0000000256373346)↗
DOE OSTI2025

High-Temperature Active Magnetic Bearing Development for Supercritical CO 2 Machinery Applications

Hermetic machinery utilizing gas bearings for MW-scale supercritical CO 2 (sCO 2 ) machinery applications can have significantly lower power loss and enable improved cycle efficiency compared to conventional machinery with oil-lubricated bearings. Active magnetic bearings (AMBs) are another option anticipated to have similar power loss and load capacity to gas bearings as well as offering larger mechanical tolerances, the ability to tune properties, and high reliability due to lack of mechanical wear. AMBs also have proven commercial experience at MW-scale, though environments for high-temperature sCO 2 power cycle machinery conditions are novel. Besides the potential impact of AMBs for sCO 2 turbomachinery, the technology also offers promising benefits for steam and gas turbines for power generation, compressors and expanders for industrial heat and power, and in other oil and gas and space applications. The goals of this project were to conceptual design an AMB and perform material testing. Conceptual designs for radial and thrust AMBs were produced based on a hermetically-sealed sCO 2 machinery waste-heat recovery (WHR) application for sizing and loads, and choosing a target design temperature of 540°C useful for high-temperature sCO 2 turbines for concentrating solar power (CSP) applications. Conceptual designs were initially developed for multiple radial and thrust AMBs with spreadsheet-based calculations before selecting one of each to develop further using higher-fidelity design methods for magnetic and structural performance. It was found that the radial AMB at 540°C was feasible, but the thrust AMB needed to be limited to 315°C for high-speed operation. The decision for a reduced-temperature thrust AMB was the result of several significant conclusions: 1) Hiperco 50A, originally chosen for good magnetic performance at high temperature, had insufficient strength for high-speed operation, so it was replaced with 17-4 PH. 2) The reduced magnetic performance from 17-4 PH yielded a larger bearing size, reducing the strength margin. 3) This ultimately led to a creative design implementing a more-compact E-core topology, compared to the original (conventional) C-core, and an integral shaft-disk with Hirth joint connection. These conceptual designs are unique for the size and temperature in CO 2 , relevant for MW-scale CSP applications. Long term, high temperature test data was generated for several materials, filling a void in the current body of literature. Corrosion and magnetic performance measurements were produced for PM materials (Alnico 5-7C, Alnico 9C, and SmCo) with and without nickel-coating for environments of high-temperature CO 2 up to 550°C at atmospheric pressure and 450°C at 103 bar for up to 6,000 hours. Corrosion measurements were also produced for Hiperco 50, a SM material relevant for AMB laminations, with and without C5 coating. Comparisons were also made for 450°C and 550°C, atmospheric pressure air exposures up to 5,000 hours. Results generally show that coatings can be effective at improving oxidation resistance of the bare materials, and Alnicos generally outperformed SmCo after high-temperature exposure. In addition to technical feasibility demonstrated by the design, economic feasibility was demonstrated by updating the TEA from the reference machine, re-evaluating it with CAPEX and OPEX to reflect estimated changes from process-lubricated bearings to AMBs. AMBs were shown to be comparable in performance to process-lubricated bearings, still showing a notable improvement over conventional machinery architecture with oil-lubricated bearings.

42 ENGINEERING↗
DOE OSTI2025

Commercial building HVAC demand flexibility with model predictive control: Field demonstration and literature insights

Model Predictive Control (MPC) for building Heating Ventilation and Air Conditioning (HVAC) systems is beginning to gain traction in the market, with a few controls companies incorporating it into their product offerings. However, it remains difficult to assess whether the energy cost savings are enough to justify the cost of MPC implementation for a particular building, given the limited number of reported demonstrations. For small commercial and residential buildings with relatively uniform systems, standardized approaches can help lower implementation costs. In contrast, for large buildings or district systems, the potential magnitude of cost savings could justify more customized solutions. Estimating the cost-effectiveness of MPC becomes more challenging for medium and large commercial buildings, where a one-size-fits-all solution may not be suitable, and the potential energy cost savings may be insufficient to justify a customized solution. To make MPC technology more appealing, incorporating additional value streams beyond energy efficiency alone can significantly increase its attractiveness. One such revenue stream is demand flexibility, in response to dynamic electricity prices, where MPC can leverage the thermal mass of the building to shift the load and support the grid. Building on an extensive literature review of MPC field studies focused on cost savings and demand flexibility, this paper presents the results of implementing MPC control in a large office building HVAC system in Berkeley, CA. Four different dynamic electricity price profiles were integrated into the MPC objective function to shift building demand while maintaining comfort, and field testing was performed with each price profile across four seasons. The results show potential for 40–65 % demand decrease percentage and up to 61 % annual cost savings compared to the existing rule-based control strategy, under the tested dynamic price scenarios. This paper also presents a sensitivity analysis on the cost savings with respect to the price profile variability, discusses the implementation effort for the price-responsive MPC, and compares the cost savings found in this study to those found in literature on the basis of dynamic price variability, or so-called Electricity Price Relative Standard Deviation.

Zanetti, Ettore↗
DOE OSTI2025

Mechanical response of HFIR-irradiated M5FRAMATOME cladding under simple and complex loading conditions

This study investigates the mechanical behavior of High Flux Isotope Reactor (HFIR) irradiated M5FRAMATOME cladding under simple and complex loading conditions through axial tensile and reversible cyclic bending. Axial tension specimens were pre-machined prior to HFIR irradiation while cyclic bend specimens were inserted as intact tubes. Tests articles were neutron-irradiated to 4 and 16 dpa, and specimens were tested at ORNL's hotcell facilities. The axial tension tests were conducted under constant displacement control, and the reversible cyclic bend tests were performed using ORNL's Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) apparatus. Results showed that mechanical response of Cr-coated and uncoated M5FRAMATOME cladding were similar and independent of irradiation dose for axial tension tests, while Cr-coated specimens’ reversible cyclic bend behavior differed from uncoated counterparts. For all tests, irradiation temperature showed a significant impact on the mechanical behavior. Below 280°C, all axial tensile specimens whether coated or not behaved similarly. Above 280°C, YS and UTS showed decrease with increasing irradiation temperature. A similar behavior was also observed in cyclic bend tests as well. The mechanical damage during cyclic bend tests was linked to damage accumulation in unirradiated Cr-coated zircaloy-4 specimens, and the effect of irradiation temperature was related to changing characteristics of defect mobility during high temperature irradiation.

Cinbiz, Nedim [ORNL] (ORCID:0000000346268515)↗
DOE OSTI2021

High Speed Hybrid Reluctance Motor Utilizing Anisotropic Materials

With high cost and volatility driving continued efforts to decrease reliance on the critical heavy rare earth materials used in traction drive applications, General Motors developed three variants of heavy rare earth-free (HRE-free) electric motors. The variants focused on taking advantage of advanced magnet technologies and new rotor topologies to improve mechanical strength and achieve power targets. The three variants were a HRE-free permanent magnet reluctance motor, a synchronous reluctance motor utilizing small HRE-free permanent magnets, and an induction motor with inserted copper bars and cast aluminum end-rings. Motors were designed with the intent of primary or secondary traction applications, depending on the topology. Variant 1 achieved performance comparable to HRE-containing permanent magnet motors through optimized topology and validation of HRE-free magnets, focusing on achieving energy products and demagnetization resistance comparable to those of HRE-containing magnets. Demagnetization testing demonstrated the motor robustness to currents and temperatures exceeding expected vehicle conditions, a key challenge to the use of HRE-free magnets. The Variant 1 motor also showed the best capability of meeting the US Drive technology 2020 targets, due to the high power-density of the permanent magnet motor and the potential cost reductions enabled by the removal of heavy rare earth materials. Variant 2 exhibited high efficiency in high speed regions due to the low high-speed losses, an important consideration for secondary traction applications, and significantly thrifted on magnet mass to reduce cost. Variant 3 contained copper bars within the induction rotor to reduce losses compared to cast aluminum, while using cast aluminum end-rings to reduce the cost and mass of the rotor. Optimization of the Cu-Al interface were focused on, as the interface is prone to forming brittle intermetallic compounds during the casting process. Prototypes of each motor variant were built and tested for performance, mechanical strength, and demagnetization resistance (Variants 1 and 2 only), with torque and power resulting close to the predicted values.

33 ADVANCED PROPULSION SYSTEMS↗