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DOE OSTI2020

Quality Procedures for TCR Metal Core Structure Advanced Manufacturing Processes

The Transformational Challenge Reactor (TCR) Manufacturing WBS# 3.02.04.02 organization is responsible for the advanced manufacturing process, research, development, and implementation that supports the TCR program under the TCR Additive Manufacturing (AM) Thrust. Advanced manufacturing at Oak Ridge National Laboratory (ORNL) includes the development and capabilities to use modern advanced manufacturing techniques, such as AM (e.g., 3D printing) and other novel methods, to rapidly design, develop, produce, finish, and characterize parts, samples, and components to support the nuclear and other high-quality standards industries. Deliverable # M2TC-20OR04020110 involved the development of TCR quality procedures for the TCR metal core structure by using the advanced manufacturing processes being developed at ORNL’s Manufacturing Demonstration Facility (MDF) and other ORNL locations. This report discusses the details of these procedures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Science and Technology Review (May 2021)

Lawrence Livermore has been on the forefront of cancer research for over 60 years. Early interest in cancer statistics stemmed from the nature of work, particularly how radiation affects humans. The Department of Energy funded research to investigate the effects of radiation on workers with long term exposure. This research quickly morphed into a wider breadth of cancer research topics, including the use of advanced computational models to investigate mutations in genes. Livermore is regarded as a leader in cancer research, from the Human Genome Center to its participation in the National Cancer Institute’s “Moonshot” project. The highly interdisciplinary Laboratory unites research in one more example: bringing together cancer biology, 3D printing, high-performance computing, big data, and materials science to address this pressing medical challenge.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Extremely Lightweight Optical Structures for Rapid Deployment

The structures that surround and support optical components play a key role in the performance of the overall optical system. For aerospace applications, creating an opto-mechanical structure that is athermal, lightweight, robust, and can be quickly developed from concept through to hardware is challenging. This project demonstrates a design and fabrication method for optical structures using origami-style folded, photo-etched sheetmetal pieces that are micro-welded to each other or to 3d printed metal components. Thin flexures, critical for athermal mounting of optics, can be thinner with sheetmetal than from standard machining, which leads to more compact designs and the ability to mount smaller optics. Building a structure by starting with the thinnest features, then folding that thin material to make the ''thicker'' sections is the opposite of standard machining (cutting thin features from thicker blocks). A design method is shown with mass savings of >90%, and stiffness to weight ratio improvements of 5x to 10x compared to standard methods for space systems hardware. Designs and processes for small, flexured, actively aligned systems are demonstrated as are methods for producing lightweight, structural, Miura-core sandwich panels in both flat and curved configurations. Concepts for deployable panels and component hinges are explored, as is a lens subcell with tunable piston movement with temperature change and an ultralight sunshade.

42 ENGINEERING↗

DOE OSTI2022

Patterning of magneto-optical nanomaterials

Patterning of colloidal particles in precisely organized architectures has attracted intense research interest for decades. This is due to their potential applications in flexible electronics, magnetic and optical devices, sensors, biotechnology, communications, etc. However, creation of mesoscale assemblies at commercial scales have received less attention. The mesoscale systems reside between the micro- and macroscopic scales, with length dimensions from ≈ 100 µm to 5 mm. By leveraging decades of experimental and theoretical research in nanomaterial fields, we were able to precisely create and control the placement of nanoscale materials, allowing us to create mesoscale materials. We developed a versatile and automatic mesoscale patterning technology (via SEM-FIB and 3D printing) that provides precise and consistent control and special arrangement of functional nanomaterials. The versatility of the strategy is demonstrated by patterning nanoparticles with different dimensions, shapes and compositions, tethered with various functionalities and subjected to different external stimuli.

42 ENGINEERING↗

DOE OSTI2022

Tardigrade (NA-22 Quarterly Report)

Tardigrade is an effort to create tunable thermal expansion materials for use in a ruggedized lens housing. This requires new computational algorithms to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

VTO battery project FY2022 Q2 (Quarterly Report)

The project has two primary objectives: (1) down select three-dimensional (3D) printing and post-processing approaches for SSE/cathode integration, and (2) understand battery failure mechanisms via ex situ and in situ characterization.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Llama 20, 40, 50 and 60 Siloxanes for Direct Ink Write – Compositional Information

The following information provides a quick lookup table for compositions that relate to the constituents within a series of variable hardness [Durometer, Shore A] siloxanes useful for 3D printing using Direct Ink Write [DIW]. These siloxanes are formulated to have a thixotropic character with long pot life and are thermally cured for 16 hours at 150 °C prior to use.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Methane Consuming Biocatalysts in Gas-Solid Reactor System

Carbon dioxide and methane are the two most abundant greenhouse gases with methane having a higher global warming potential (GWP) than carbon dioxide. Use of methanotrophs as a biocatalyst is a green alternative to chemical conversion of methane. Methanotrophs were immobilized in a 4-arm poly (-ethylene glycol)-tetra-acrylate, PEGTA, hydrogel that is supported by a 3D printed lattice containing micropores. The consumption rate of methane was 2.5 and 42 g CH 4 /L-hr in samples that were at 1 and 3 atm, respectively. A small increase in pressure of the system improves the consumption rate by almost 20x with minimal changes to the reactor system. This system relies on the mass transport of gas through a solid-like material rather than dissolving the gas in a liquid. Immobilization of cells in hydrogel allows for higher cell density and overall increased conversion rates compared to traditional stirred tank reactors. There are many other applications of the use of immobilized biological materials in polymers that require gas-phase reactions.

36 MATERIALS SCIENCE↗

DOE OSTI2022

U.S. Building Stock Characterization Study: A National Typology for Decarbonizing U.S. Buildings

To support the U.S. Department of Energy's (DOE's) Advanced Building Construction (ABC) Collaborative, the National Renewable Energy Laboratory (NREL) has been tasked with characterizing the U.S. building stock and developing a national typology of buildings. The potential use cases of such a typology are flexible and evolving, but in this initial phase, the primary intention is to help identify technology requirements and engineering solutions for moving the U.S. building stock toward a zero-carbon future by mid-century. This typology will also support the development of appropriate ABC research goals for existing buildings, such as cost targets for new technology development, and in a later phase, the typology can be used to support the implementation of ABC solutions by informing market aggregation and business model development. The ABC Initiative invests in new technologies that enable high building performance, can be deployed quickly with minimal onsite construction time, and are affordable and appealing to building owners, investors, and occupants. Funding awardees use many innovations, including new building materials, 3D printing, offsite manufacturing, robotics, and digital art-to-part. Although the goals of ABC cover a broad range of objectives around energy, comfort, and health, the primary ABC-related application of this national building characterization study is the development of retrofit packages that can be applied to reduce thermal loads in buildings. Retrofit packages will be determined collaboratively by the DOE and the ABC Collaborative. We anticipate a range of upgrade measures covering envelope-, HVAC-, and water-heating-related loads.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Pressurized Tube Creep Testing of Graded Transition Joints (GTJ) for G91 and 347H Base Metals

This report briefly describes part of the research activities dedicated to a DOE FE project, graded transition joints (GTJ) development for G91 and 347H steels. The task was focused on pressurized tube creep testing on the 3D-printed GTJ materials. A specimen with reduced gage section is developed that includes G91, GTJ, and 347H subsections. A tapered GTJ subsection is introduced to address the technical challenge of mechanical testing with mismatched rupture times of the base metals. The report provides the descriptions of basic considerations, specimen preparation, testing system, and experimental results along with main findings.

36 MATERIALS SCIENCE↗

DOE OSTI2022

VTO FY2022 Q3 (Quarterly Report)

36 MATERIALS SCIENCE↗

DOE OSTI2022

Analysis of Defects in Metal Additive Manufacturing with Augmented Data Generation

Laser powder bed fusion (LPBF) is a method of additive manufacturing (AM) that selectively melts and fuses together microscopic metallic powder. LPBF offers the benefit of producing custom structures out of high strength metals that can be difficult to fabricate with conventional methods. The challenge of LPBF is that 3D printed structures often have internal pores due to process flaws. Pulsed thermal tomography (PTT) is a method for reconstructing the depth profile of materials, allowing the visualization internal voids in solids. In prior work, we developed a convolutional neural network (CNN) which, having been trained on simulated 2D PTT images of subsurface elliptical defects, was able to classify the semi-major radii, semi-minor radii, and angular orientation of the best-fit ellipses in previously unseen PTT images. The unseen PTT images contained subsurface irregular defect shapes imported from scanning electron microscopy (SEM) images of metallic LPBF-printed specimens. Training the CNN on irregular defect shapes instead of on elliptical shapes would make the resulting classifications more descriptive of actual defect shapes. However, this requires a much higher volume of SEM images of material defects, which are difficult to obtain because of random occurrence of defects in LPBF. To address this challenge, we developed a generative adversarial network (GAN) to augment the existing dataset of SEM defect images. The GAN model is demonstrated to create novel yet realistic defect shapes that can be used as input for simulated PTT images to train CNN.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Biopolymer Concrete

Cement production for concrete has been responsible for ~7–8% of global greenhouse gas (GHG) emissions, and nearly equally contribution for steel production processes (EPA, 2020). In order to achieve carbon neutrality by 2050, a novel solution has to be investigated. This project aims to develop fundamental mechanistic understanding and experimental characterization to create a 3D printable biopolymer concrete using plant-based polyurethane as an innovative and sustainable alternative for Portland cement concrete, with significantly low carbon footprint. Future construction will utilize the advances in digital additive manufacturing (3D printing) to produce optimal geometries with a minimum waste of materials. Understanding the polymerization process, factors impacting the composite rheology, and the structural behavior of this biopolymer concrete will enable us to engineer the next generation of concrete structures with low carbon footprint. This project aims to improve the nation’s ability to control Greenhouse Gas emission neutrality for the set goal of 2050 via introducing a structurally viable bio-based polymer concrete.

42 ENGINEERING↗

DOE OSTI2022

Designing a Particle Flow Control Apparatus

Flow control within a particle-based Concentrated Solar Power (CSP) system is essential in determining the heat transfer coefficient, and therefore, the power generation capability of these systems. There are three areas where particle flow control is significant: the receivers, storage tanks, and particle-sCO2 heat exchangers. The focus of this work is on designing a new mechanism to control the flow in the particle-sCO2 heat exchangers due to the simplicity and potential cost savings when compared to the other areas of interest. The goal is for this new design to have quicker response times in terms of particle flowrate than a slide gate or flow control valve, which are designs currently used. The design resembles that of a chuck mechanism within a drill where a rotation of the sleeve elicits movement of the jaws both vertically and horizontally to close the outlet area of the nozzle. Additionally, this design will utilize the current actuator that is already used within these heat exchangers to reduce the complexity of implementation. The jaws are designed to be closed at an angle of 76˚ which is just slightly steeper than the hopper leading to the mechanism. Furthermore, this design can be tuned to limit particle bridging and other particle flow phenomena that result in blockages. The prototypes were 3D printed out of polylactic acid (PLA) and scaled up to 100%, 200%, and 400% to be able to observe the velocity profiles of the mechanism more clearly. Experiments are performed with this prototype to compare the inlet and outlet mass flow rates at different configurations of the jaws. The particles used in these experiments are 0.3mm HSP 40/70 that are commonly used in particle-based CSP systems.

14 SOLAR ENERGY↗

DOE OSTI2022

A Subcritical Assembly for Training and Education Use at the Oak Ridge National Laboratory [Slides]

Sufficient AGN-201M fuel plate material exists at Y-12 to support the development of a new, inherently safe, subcritical assembly for use in NCS training courses at ORNL. Four experiments with the ORNL subcritical assembly are possible and feasible. Future work includes the final design of the core and reflector and split table component design specifications. The ORNL Material Demonstration Facility (MDF) may be used to 3D print ORSA stand/table components and graphite reflector. Researchers will consider fuel coatings for contamination control, rather than an Al can. A visit to Y-12 will be made to determine the location of AGN fuel plates and remaining fuel transportation considerations. Final facility location will be considered

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Development of Novel Materials for Direct Air Capture of CO 2 : MIL-101(Cr)-Amine Sorbents Evaluation Under Realistic Direct Air Capture Conditions (Final Report)

The overarching goal of this project is to evaluate the CO 2 adsorption properties of a small family of metal-organic framework (MOFs) materials functionalized with amines at sub-ambient conditions. Our goal is to develop capabilities to measure CO 2 adsorption at conditions more relevant to the weather of the planet. For this purpose, Georgia Tech is constructing a “sub-ambient adsorption facility” in partnership with ZCP Sorbent Development, LLC, aimed specifically at rapidly and deeply characterizing the performance of DAC candidate materials in this important operational range (adsorption at -20 to 20 °C and RH of 0-100%). Here, we use the sub-ambient lab instrumentation designed or adapted to study the behavior of the pristine metal organic framework (MOF) MIL-101(Cr) and the MOF in the presence of amines ranging from small molecules (e.g. TREN, tris(2-aminoethylamine)) to oligomers (e.g. PEI, poly(ethyleneimine)). Any DAC sorbent must be amenable to deployment in practical contactors for gas-solid contacting (traditional pellet-based fixed beds are impossible at scale). To this end, we developed and tested these DAC materials in the forms of composite polymer/MOF fibers and custom 3D-printed monolith structures containing MOF DAC sorbents. The proposed studies advance these materials from technology readiness level (TRL) 2 to TRL 3.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Investigating Hydrogen Isotope Exchange Reactions on Lithium Aluminate Pellets in TPBAR (FY22 Report)

We developed a novel operando Raman spectroscopy method for investigation of hydrogen (H) isotope exchange reactions in the lithium aluminate (γ-LiAlO 2 ) that allows modeling of tritium behaviors in high temperature and in an irradiated environment. The lithium aluminate pellet is a main component in the Tritium-Producing Burnable Absorber Rod (TPBAR). We used deuterium ( 2 H or D) as a surrogate to simulate tritium ( 3 H or T). We used a surface analysis tools in situ/operando Raman spectroscopy to observe the transformation OH and OD compositional changes. We also used ToF-SIMS to analyze the lithium aluminate pellet control sample to build the base line for future in situ/operando analysis. To conduct operando Raman spectroscopy, we developed a custom reaction cell with a detachable micro heater using microelectromechanical systems (MEMS) and 3D printing techniques. Multiple versions were developed and tested. Using the new reaction cell, we demonstrated operando Raman spectroscopy of water (H 2 O) and deuterated water (D 2 O) with nitrogen (N 2 ) exposure onto the lithium aluminate (LiAlO2) pellet specimen, respectively, using a wet gas injection setup. We also successfully developed a detachable microheater that can heat up to ~250°C for ~90 mins. The Raman spectra did not show clear H 2 O and D 2 O characteristic peaks, which indicates that introducing H 2 O and D 2 O onto the surface of the pellet is challenging due to its dense structure nature. Our efforts suggest that various improvements are needed, such as increasing reaction cell operating gas pressure and thinning pellet sample thickness, to obtain meaningful measurements.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2023

Microtructure and Low-Cycle Fatigue Behavior of Additively Manufactured 316L Stainless Steel at 300°C

Metal additive manufacturing (AM) or 3D printing has the potential to transform the nuclear industry by producing high quality components faster and cheaper, thus enhancing the operating performance of current plants and advanced reactors. Two AM 316L tubes - intended to act as surrogates for complex components where nuclear equipment vendors are more likely to consider AM technologies - were printed using a Renishaw AM400 Laser Powder Bed Fusion (L-PBF) system. The porosity of the as-built material was found to be small, 0.06%. In prior research, the fatigue and corrosion fatigue crack growth rate (CGR) response of the AM specimens in the as-built condition was found to be similar to that expected for conventional alloys, and extremely resistant to stress corrosion cracking (SCC). The present research demonstrates that the low-cycle fatigue behavior of the AM material in air is similar to that of wrought stainless steel at LWR temperature. The data suggest that low porosity levels do not have a significant effect on the fatigue performance of AM materials. Taken together, all data generated to date demonstrate that the use of AM alloys in a nuclear environment is plausible. Additional research on environmental fatigue, crack initiation, and SCC needs to be conducted to provide the performance information needed to qualify AM materials for LWR applications.

36 MATERIALS SCIENCE↗