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DOE OSTI2017

FY2016 Advanced Batteries R&D Annual Progress Report - Part 3 of 5

The Advanced Batteries research and development (R&D) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for projects focusing on batteries for plug-in electric vehicles. Program targets focus on overcoming technical barriers to enable market success including: (1) significantly reducing battery cost, (2) increasing battery performance (power, energy, durability), (3) reducing battery weight & volume, and (4) increasing battery tolerance to abusive conditions such as short circuit, overcharge, and crush. This report describes the progress made on the research and development projects funded by the Battery subprogram in 2016. This section covers the summaries of the Applied Batteries Research for Transportation Projects part 2.

25 ENERGY STORAGE↗

DOE OSTI2017

Workplace Charging Challenge Progress Update 2016: A New Sustainable Commute

In the 2016 Workplace Charging Challenge annual survey, partners shared for the how their efforts were making an impact in their communities and helped identify best practices for workplace charging. The Workplace Charging Challenge Progress Update highlights the findings from this survey and recognizes leading employers for their workplace charging efforts.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

FY2016 Advanced Batteries R&D Annual Progress Report - Part 4 of 5

25 ENERGY STORAGE↗

DOE OSTI2017

FY2016 Advanced Batteries R&D Annual Progress Report

The Advanced Batteries research and development (R&D) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for projects focusing on batteries for plug-in electric vehicles. Program targets focus on overcoming technical barriers to enable market success including: (1) significantly reducing battery cost, (2) increasing battery performance (power, energy, durability), (3) reducing battery weight & volume, and (4) increasing battery tolerance to abusive conditions such as short circuit, overcharge, and crush. This report describes the progress made on the research and development projects funded by the Battery subprogram in 2016. This section covers the Vehicle Technologies Office overview; the Battery subprogram R&D overview; Advanced Battery Development project summaries; and Battery Testing, Analysis, and Design project summaries. It also includes the cover and table of contents.

25 ENERGY STORAGE↗

DOE OSTI2016

FY2015 Lightweight Materials R&D Annual Progress Report

The Lightweight Materials research and development (R&D) area within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies under development. Research focuses on addressing critical barriers to commercializing lightweight materials for passenger and commercial vehicles. This report describes the progress made on the research and development projects funded by the Lightweight Materials area.

36 MATERIALS SCIENCE↗

DOE OSTI2017

FY2016 Advanced Batteries R&D Annual Progress Report - Part 2 of 5

25 ENERGY STORAGE↗

DOE OSTI2017

FY 2017-Progress Report on the Design and Construction of the Sodium Loop SMT-3

This report provides an update on the design of a forced-convection sodium loop to be used for the evaluation of sodium compatibility of advanced Alloy 709 with emphasis on long term exposures of tensile, creep, fatigue, creep fatigue, and fracture toughness ASTM-size specimens in support of ASME Code qualification and NRC licensing. The report is a deliverable (Level 4) in FY17 (M4AT-17AN1602094), under the Work Package AT-17AN160209, “Sodium Compatibility” performed by Argonne National Laboratory (ANL), as part of the Advanced Materials Program for the Advanced Reactor Technology. This work package enables the development of advanced structural materials by providing corrosion, microstructure, and mechanical property data from the standpoint of sodium compatibility of advanced structural alloys. The first sodium loop (SMT-1) with a single tank was constructed in 2011 at ANL and has been in operation for exposure of subsize sheet specimens of advanced alloys at a single temperature. The second sodium loop with dual tanks (SMT-2) was constructed in 2013 and has been in operation for the exposure of subsize sheet specimens of advanced alloys at two different temperatures. The current loop (SMT-3) has been designed to incorporate sufficient chamber capacity to expose a large number of ASTM-size specimens to evaluate the sodium effects on tensile, creep, fatigue, creep-fatigue, and fracture toughness properties, in support of ASME Code Qualification and USNRC Licensing. The design of individual components for the third sodium loop SMT-3 is almost complete. The design also has been sent to an outside vendor for piping analysis to be in compliance with ASME Code. A purchase order has been placed with an outside vendor for the fabrication of major components such as the specimen exposure tanks. However, we have contracted with another vendor to establish the piping design in compliance with ASME design codes. The piping design was completed in FY2017 and the information is being transmitted to the tank fabricator. The SMT-3 loop will be located in Building 206 adjacent to the currently operating SMT-2 loop. In addition, we have demolished the aged power supply system in Building 206 and installed a new transformer, wiring, and power panels for the new loop. Procurement of some of the long lead items such as valves, EM pumps, EM flowmeters, etc. is in progress and will continue in FY 2018. The construction of components such as cold trap, economizers, piping arrangement etc. will be performed in the central shops at ANL. About 150 liters of sodium for the loop will be procured in early FY2018. The loop system is designed to circulate sodium through the sample tanks and the associated loop without an operator for an extended period of time. With the three sodium loops (with single-tank, dual-tank and four–tanks), materials can be tested at different sodium temperatures, and large tensile, creep, fatigue, creep-fatigue, and fracture toughness specimens can be exposed to sodium for extended periods of time and generate data on mechanical properties in support of ASME Code Qualification and USNRC Licensing of advanced Alloy 709 for use as a structural material in SFRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

FY2017 Technology Integration Annual Progress Report

The 2017 Technology Integration Annual Progress Report covers 27 multi-year projects funded by the Vehicle Technologies Office. The report includes information on 20 competitively awarded projects, ranging from training on alternative fuels and vehicles for first responders, to safety training and design for maintenance facilities housing gaseous fuel vehicles, to electric vehicle community partner programs. It also includes seven projects conducted by several of VTO’s national laboratory partners, Argonne National Laboratory, Oak Ridge National Laboratory and the National Renewable Energy Laboratory. These projects range from a Technical Assistance project for business, industry, government and individuals, to the EcoCar 3 Student Competition, and the Fuel Economy Information Project.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Recent Progress in Electron Scattering at SLAC

Since the last meeting in this conference series in Paris in 1981, there has been major progress in electron scattering at SLAC on several fronts. A new experiment on ep elastic scattering at large momentum transfer, Experiment El36, has recently completed data taking. A new measurement of deep inelastic electron scattering from nuclear targets, Experiment El39, has been completed and preliminary results are available. A new program of experiments has begun, called Nuclear Physics at SLAC (NPAS), that will use a new injector on the SLAC linac to provide high intensity beams in the energy range from 0.5 to 6 GeV.

43 PARTICLE ACCELERATORS↗

DOE OSTI2016

Accident progression analysis P-300

To understand the basics of severe accident progression, from the onset of core damage to the release of a radioactive source term to the environment – Onset of core damage (for PWRs) often defined as the uncovering of the top of active fuel (TAF) • Temperature criteria also used – Two phases: core degradation and containment challenge • In-vessel and ex-vessel – Release to the environment often characterized in terms of Large Early Release Frequency (LERF)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Progress Summary: Simulating stochastic and additively manufactured foams at large strains and high strain rates

Motivation: Understanding the mechanical response of polymer foams is essential in developing system material models and in designing replacements for legacy pads and cushions. Simulations can help elucidate structure-property relationships and compare local stress distributions to understand aging behavior and improve designs. In many applications,these materials experience significant loadings and computations need the capability to reproduce those conditions. Significance: In designing the compressive and shear response of additively manufactured foams, we expect the curvature of the substrate to influence their mechanical behavior. Progress:We have the capability of mapping planar structures to arbitrary curved surfaces and are currently developing the software and procedures to translate the mapped pattern into a geometrical model that can be imported to either finite element or material point software to evaluate the mechanical response. Figure 1 depicts a four-layer face-centered tetragonal pattern (FCT) mapped to a hemispherical surface. Because the mapping cannot exactly preserve both distances and angles, we expect some local variation in mechanical properties and porosity. These models will help determine the sensitivity of these variations to structure and curvature, optimize the mapping procedure, and inform the design of foams for non-planar surfaces.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Progress Summary: 12-Month Compression Set and Load Retention of Thermally Accelerated Aged Siloxane Specimens (Additively Manufactured by the Direct-Ink-Write (DIW) 3D Printing Technique) Was Measured

Motivation: Accelerated aging of polymeric materials is needed to predict their long-term mechanical functionality. Two key metrics used to evaluate their performance are compression set and load retention. A baseline(time=0)mechanical assessment was done prior to initiating the accelerated aging process to acquire initial thickness and load values for future calculation of compression set and load retention.Specimens are beingaged under compressive strain (13%for the current studies) at four different temperatures (25, 40, 55, and 70°C) for at least 1 year; compression set and load retention will be measured at various timepoints. Time-temperature superposition (TTS) will be applied to the isothermal data to obtain long-term predictions. Significance: Compression set is increasing with time and temperature, as expected. The increasing compression set is accompanied by decreasing load retention.The relativelylow compression set indicates the material is performing well.In a previous aging study, the legacy S5370 RTV foam exhibited 40% relative compression set after 12 months at 70°C, which is more than twice that of the DIW material. Progress:Data has been acquired out to the 12-month timepoint. Relative compression set and load retention versus time are shown in Fig. 1.A technical issue with the method of measuring load retention was discovered and previously reported load retention values have been adjusted; the current load retention values are estimates. TTS predictions are shown in Fig. 2.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Progress Report-Keystone 3

In the second quarter of FY2017, the focus of Keystone 3 was jointly on the establishment of methods for evaluation of high energy cells both electrochemically and through the use of advanced characterization techniques and resources, establishment of methods for the preparation of 1 Ah or larger cells, and use of different models to identify cell design parameters for achieving both 300 and 500 Wh/kg. These routes directly support the fourth quarter milestone in FY17 of achieving 300 Wh/kg and the ability to cycle the cell a minimum of 50 times. To facilitate discussions between the Keystone 3 team members biweekly meetings have been held to discuss path and to ensure progress is moving forward.

25 ENERGY STORAGE↗

DOE OSTI2018

Casting of Reinforced Concrete Beam: Project Progress

Aging concrete structures in nuclear power plants undergo mechanical, physical, chemical, and radioactive degradation. One of the chemical degradation mechanisms that is investigated in the research project under the Plant Modernization Pathway of the Light Water Reactor Sustainability Program is the alkali-silica reaction (ASR). The ASR is a chemical process that over time, causes expansion of calcium silicate hydrate gel. To date, the research project has studied the ASR gel formation and expansion in non-reinforced concrete specimens using vibro-acoustic modulation (VAM) technique. However, nuclear plant concrete structures are reinforced, and it might influence the application of VAM technique on reinforced concrete specimens compared to non-reinforced specimens. A research activity is initiated between Idaho National Laboratory, Vanderbilt University, and University of Nebraska - Lincoln to study the impact of reinforcement in concrete structures on the application of the VAM technique. To support this activity, University of Nebraska - Lincoln is casting and curing four reinforced concrete samples that at the end of the curing period will be transferred to Vanderbilt University to perform experimental VAM study. Vanderbilt University and Idaho National Laboratory will perform the data analysis and enhance the developed structural health monitoring framework. In this report, a progress on casting and curing of reinforced concrete samples at University of Nebraska – Lincoln is provided.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Identification and Shipment Progress of the INL and LANL Samples to Be Received at ORNL

Ferritic-martensitic steel Grade 92, with T91 as a reference, together with austenitic stainless steel (or Incoloy Alloy) 800H and its grain-boundary-engineered version 800H-TMP (ThermoMechanical Processing), is investigated in this project. A total of fifteen Grade 92 samples from two or three heats, four T91 samples from two heats, and six 800H and six 800H-TMP samples from one heat were selected, which were primarily irradiated in the Advanced Test Reactor of Idaho National Laboratory (INL), with the rest in the High Flux Isotope Reactor of Oak Ridge National Laboratory (ORNL), BOR-60 of Russia, and Phénix reactor of France. The samples were irradiated in the temperature range of 241 to 720°C and a dose range of 1.28 to ~70 displacements per atom. All the INL samples, most of the ORNL samples, and part of the LANL (Los Alamos National Laboratory) samples from the ATR, BOR-60 and Phénix reactors have been received at the Irradiated Materials Examination and Testing (IMET) hot cell facility and Low Activation Materials Design and Analysis (LAMDA) laboratory of ORNL. Post-irradiation examination of the received samples is in progress at ORNL. The effects of irradiation temperature, dose, reactor (e.g., dose rate, neutron-spectrum-induced difference in transmutation), TMP, and heats variation on the microstructures and mechanical properties of the samples will be evaluated.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Recent Progress with APC Nb 3 Sn Conductors [Slides]

1.Development of APC-PIT multi wires started in 2017. Since then progress has been fast; 2.Tests up to 31 T at 4.2 K show that B irr is 26-27 T, B c2 is 27-28 T, ~1-2 T higher than RRP; 3. R&D in the past two years has led to significant improvement of wire recipe and quality. The non-Cu J c is on similar level with present RRP wires, in spite that the Nb 3 Sn % is still low and grain size is not fully refined due to unoptimized wire recipe and heat treatment; 4.The Nb 3 Sn layer J c at 16 T is ~2.5 times of RRP despite grain size not fully refined; 5.The improvement is still ongoing. The following levels are expected: 1) By improving conductor recipe and quality and heat treatment, the fine-grain Nb 3 Sn fraction can be increased to ~40%, as in standard tube type and PIT wires; 2) By optimizing O content and heat treatment, the grain size can be reduced to 50-65 nm or less, which leads to a Nb 3 Sn layer J c of 5000-6000 A/mm 2 for 4.2 K, 16 T. If so, this means the 4.2 K, 16 T non-Cu Jc can reach 2000-2400 A/mm 2 . This will surpass the FCC spec and also provide >30% margin. Above 16 T, the APC conductors should give extra Jc gain due to higher B irr and shift in F p -B curve peak to higher fields.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

Polymer Aging/Characterization Core Capability Enhancement is Underway (Progress Summary)

Motivation: Accelerated aging of polymeric materials is needed to predict their long-term mechanical functionality. Two key metrics used to evaluate their performance are compression set and load retention. Currently, specimens are aged under compressive strain at four different temperatures (25, 40, 55, and 70°C) for 1-2 years, and compression set and load retention are measured at various timepoints. At each timepoint, specimens are measured at three different relaxation times (immediately, 1 hr, and 24 hrs) after removal from the aging fixtures. The measurements include both thickness measurement and load testing. Time-temperature superposition (TTS) is applied to the isothermal data to obtain long-term predictions. There is a desire to reduce both the length of the studies and the amount of effort required to perform the studies. Significance: Additional aging ovens will provide the opportunity to add a higher fifth temperature, which could reduce the length of accelerated aging studies, as well as provide a spare oven in case one fails. If determined to be feasible, instrumented aging fixtures could reduce the amount of effort required to perform the studies, potentially eliminating the need to remove the specimens from the fixtures. Progress: Two new aging ovens have been received. The controllers were verified to be operational. The nitrogen purge still needs to be verified. Instrumented aging fixtures potentially including gap adjustment (to set the aging strain and measure specimen thickness) and a load transducer are under consideration.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Batteries 2018 Annual Progress Report

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2018 (FY 2018). In FY 2018, the DOE VTO battery R&D funding was approximately $101 million. Its R&D focus was on the development of high-energy batteries for PEVs and very high-power devices for hybrid vehicles. The electrochemical energy storage roadmap describes ongoing and planned efforts to develop electrochemical storage technologies for PEVs. To advance battery technology to improve the market penetration of PEVs and hybrid vehicles, the program focuses on overcoming specific technical barriers typically related to the battery’s cost, performance, life (both calendar life and cycle life), its tolerance to abusive conditions, and its recyclability/sustainability. Various battery chemistries are being investigated with that aim.

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