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DOE OSTI2022

Ultra High-Temperature Magnetic Bearing System for s-CO 2 Turbines/Expanders. Phase II Final Report

The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Countercurrent Actinide Lanthanide Separation Process (ALSEP) Demonstration Test with a Simulated PUREX Raffinate in Centrifugal Contactors on the Laboratory Scale

An Actinide Lanthanide Separation Process (ALSEP) for the separation of trivalent actinides (An(III)) from simulated raffinate solution was successfully demonstrated using a 32-stage 1 cm annular centrifugal contactor setup. The ALSEP solvent was composed of a mixture of 2-ethylhexylphosphonic acid mono-2-ethylhexyl ester (HEH[EHP]) and N,N,N',N'-tetra-(2-ethylhexyl)-diglycolamide (T2EHDGA) in n-dodecane. Flowsheet calculations and evaluation of the results were done using the Argonne’s Model for Universal Solvent Extraction (AMUSE) code using single-stage distribution data. The co-extraction of Zr(IV) and Pd(II) was prevented using CDTA (trans-1,2-diaminocyclohexane-N,N,N',N'-tetraacetic acid) as a masking agent in the feed. For the scrubbing of co-extracted Mo; citrate-buffered acetohydroxamic acid was used. The separation of An(III) from the trivalent lanthanides (Ln(III)) was achieved using citrate-buffered diethylene-triamine-N,N,N',N",N"-pentaacetic acid (DTPA), and Ln(III) were efficiently back extracted using N,N,N',N'-tetraethyl-diglycolamide (TEDGA). A clean An(III) product was obtained with a recovery of 95% americium and curium. The Ln(III) were efficiently stripped; but the Ln(III) product contained 5% of the co-stripped An(III). The carryover of Am and Cm into the Ln(III) product is attributed to too few actinide stripping stages, which was constrained by the number of centrifugal contactors available. Improved separation would be achieved by increasing the number of An strip stages. The heavier lanthanides (Pr, Nd, Sm, Eu, and Gd) and yttrium were mainly routed to the Ln product, whereas the lighter lanthanides (La and Ce) were mostly routed to the raffinate.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution of wall conditions in utility boilers. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of a coal-fired utility boiler in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2022

Full-scale Demonstration of Multi-process Sensor at a Cycling PC-fired Boiler

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2025

Unlocking America's Abundant Marine Energy Resources

NREL Marine Energy One-Pager: A resource designed for use during NREL campus visits - especially with high-profile guests - as well as at events in Washington, D.C., when engaging with the new administration, and for displays at WPTO or lab booths. The U.S. holds vast untapped marine energy resources - wave, tidal, river, and ocean currents - that can strengthen grid resilience, support coastal communities, and advance energy independence. NREL leads innovation in this space through advanced modeling tools, patented technologies, and world-class testing facilities. NREL's simulation platforms, like OpenFAST and SAM, help reduce development time and risk. Patented devices such as PKelp and FlexWEC demonstrate flexible, resilient approaches to energy capture. At Flatirons Campus, NREL offers motion simulation, structural testing, wave tanks, and megawatt-scale microgrid emulation via the ARIES platform. These capabilities help developers refine and validate devices before in-water trials. With upcoming open-water testing at PacWave and strong partnerships, NREL is accelerating the path to commercialization - positioning the U.S. as a global leader in marine energy innovation.

17 WIND ENERGY↗

DOE OSTI2021

Flaw-insensitive fracture of a micrometer-sized brittle metallic glass

Brittle materials, such as oxide glasses, are usually very sensitive to flaws, giving rise to a macroscopic fracture strength that is much lower than that predicted by theory. The same applies to metallic glasses (MGs), with the important difference that these glasses can exhibit certain plastic strain prior to catastrophic failure. Here we consider the strongest metallic alloy known, a ternary Co 55 Ta10B 35 MG. In this work, we show that this macroscopically brittle glass is flaw-insensitive at the micrometer scale. This discovery emerges when testing pre-cracked specimens with self-similar geometries, where the fracture stress does not decrease with increasing pre-crack size. The fracture toughness of this ultra-strong glassy alloy is further shown to increase with increasing sample size. Both these findings deviate from our classical understanding of fracture mechanics, and are attributed to a transition from toughness-controlled to strength-controlled fracture below a critical sample size.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Overview of Collaborative Research Between UNICAMP in Brazil and Fermilab in Cryogenics

The Long-Baseline Neutrino Facility (LBNF) situated at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, serves as the host for the Deep Underground Neutrino Experiment (DUNE), employing cryostats with nearly 70,000 metric tons of high purity liquid argon (LAr). The integrity of LAr quality is pivotal in determining the electron lifetime within DUNE, directly impacting its signal-to-noise ratio. Specifically, Far Detector 1 (FD-1) in cryostat 1 requires an electron lifetime over 3 ms within its 3.5 m drift, corresponding to less than 100 parts-per-trillion (ppt) Oxygen equivalent contamination. Far Detector 2 (FD-2) in cryostat 2 demands over 6 ms electron lifetime within its 6.0 m drift, corresponding to less than 50 ppt Oxygen equivalent contamination. Nitrogen (N2) absorption of LAr scintillation light, known as quenching, necessitates N2 contamination in LAr to remain below 1 ppm to minimize photon loss and enhance energy reconstruction. Studies indicate that at 1 ppm N2, approximately 20% of scintillation light is lost, highlighting the importance of minimizing N2 contamination. Brazil State University of Campinas's (UNICAMP) contribution to LBNF focuses on developing argon purification and regeneration for DUNE FD-1 and FD-2. To that effect, they constructed a test facility to perform studies on LAr purification at a smaller scale, the Purification Liquid Argon Cryostat (PuLArC) with approximately 90 liters of LAr. One of the filtration materials was considered and tested Li-FAU molecular sieve. Value engineering on argon purification media was conducted, leading to the identification of Li-FAU zeolite's ability to effectively capture N2 impurities during LAr circulation. Testing at UNICAMP's PuLArC facility demonstrated that 1 kg of Li-FAU is capable of reducing N2 contamination from 20-50 ppm to 0.1-1.0 ppm within 1-2 hours of circulation. In October 2023, testing at the Iceberg cryostat in Fermilab's Noble Liquid Test Facility (NLTF), with approximately 2,625 liters of LAr, confirmed the efficacy of 3 kg of Li-FAU in reducing N2 contamination from ~ 5 ppm of injected N2 down to less than 1 ppm over 96-hour cycles, showcasing its potential for larger-scale LAr cryostats. Further tests are planned to validate Li-FAU's use as a possible alternative to Molecular Sieve 4A in LBNF-DUNE and related liquid argon experiments. This contribution will describe how the research was performed and present the test setups and results in detail. This advancement not only has the potential to enhance DUNE's precision but also to elevate liquid argon experiments globally, showcasing the power of international scientific collaboration.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

A Scalable Process for Upcycling Carbon Dioxide (CO 2 ) and Coal Combustion Residues into Construction Products

Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of concrete masonry units (CMUs) at bench scale, where the units exceeded the required 13.8 MPa compressive strength requirements. The overall goal of this project was to accelerate the development of a CO 2 mineralization process that synergistically utilizes CO 2 in flue gas and coal combustion residues (CCRs) to synthesize carbonated concrete, a functional replacement for traditional concrete. The culmination of this work resulted in 12 successful production runs at the Integrated Test Center (ITC), Gillette, WY using coal flue gas as a CO 2 source. This was followed by 6 production runs which were completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using coal-fired and natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC and ITC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. The ITC and NCCC demonstrations achieved an average of 0.19 and 0.1 g CO 2 /g reactant, respectively. Both demonstrations exceeded the project’s target goals of uptake > 0.05 g CO 2 /g reactant. Average compressive strength of the ITC blocks was 18.24 MPa at 28-days. This exceeded the target strength of 13.8 MPa specified by ASTM C90. ITC and NCCC produced an average CO 2 utilization efficiency of 74.9 and 57.9%, respectively. Both demonstration averages were within the target range of 50 to 90% utilization efficiency. For some production runs the NCCC demo did exceeded the a CO 2 utilization efficiency of 75%. An LCA of the Reversa process compared to an industry standard product revealed a net CO 2 reduction of 39% to 42%. This exceeded the target requirement of >25% net CO 2 reduction. Collection of this data was used to determine that the project was successful as the demonstration goals were achieved: (1) achieving in excess of 75% CO 2 utilization efficiency, (2) utilizing greater than 250 kg of CO 2 per production batch/run, and (3) ensuring compliance of carbonated blocks with industry standard specifications (ASTM C90).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Analysis of Transient Groundwater Flow Near the Cheshire Test at Pahute Mesa, Nevada National Security Site

This report focuses on analysis and determination of the causes of transient water levels measured between 1964 and 2017 near the Cheshire underground nuclear test, which was detonated on February 14, 1976 in Area 20 (USDOE, 2015) of the Pahute Mesa (PM) testing areas of the Nevada National Security Site (NNSS) located in southern Nevada (Figure 1). Transient water levels near Cheshire indicate influences of a water-production well and yet-unexplained water level rise attributed to testing effects (Jackson and Fenelon, 2018; Jackson et al. 2021). Transient groundwater flow is relevant to the implementation of the hydrologic source term (HST), which prescribes the quantity and release rates of radionuclide source terms to be applied at individual test locations in assessment of regional-scale radionuclide transport (Carle and Tompson, 2021; Carle et al., 2021), as previously investigated for NNSS testing areas at PM (Pawloski et al., 2001), Frenchman Flat (Carle et al, 2007), Yucca Flat (Mcnab, 2009; Tompson, 2009), and Rainier Mesa (Carle, 2011; Tompson et al., 2011).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Analysis of Transient Groundwater Flow Near the Cheshire Test at Pahute Mesa, Nevada National Security Site

This report focuses on analysis and determination of the causes of transient water levels measured between 1964 and 2017 near the Cheshire underground nuclear test, which was detonated on February 14, 1976 in Area 20 (USDOE, 2015b) of the Pahute Mesa (PM) testing areas of the Nevada National Security Site (NNSS) located in southern Nevada (Figure 1). Transient water levels near Cheshire indicate influences of a water-production well and yet-unexplained water level rise attributed to testing effects (Jackson and Fenelon, 2018; Jackson et al. 2021). Transient groundwater flow is relevant to the implementation of the hydrologic source term (HST), which prescribes the quantity and release rates of radionuclide source terms to be applied at individual test locations in assessment of regional-scale radionuclide transport (Carle and Tompson, 2021; Carle et al., 2021), as previously investigated for NNSS testing areas at PM (Pawloski et al., 2001), Frenchman Flat (Carle et al, 2007), Yucca Flat (Carle et al., 2009; Mcnab, 2009; Tompson et al., 2009), and Rainier Mesa (Carle, 2011; Tompson et al., 2011).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Low-Cost High-Power Anodes for Electric Vehicle Batteries

Saratoga Energy has developed a system for making graphite from carbon dioxide. LBNL has experience in benchmarking graphites for Li-ion battery applications. In half cells, we tested graphites for their reversible capacity and their rate capability. They used this data to support a phase II proposal that was funded by DOE to scale up their best material and test in larger cells.

25 ENERGY STORAGE↗

DOE OSTI2023

Manufacturability Advancement of Low-Temperature Titanium Electroplating Methods

Three tasks were proposed for this work. All three were completed. The tasks were as follows: Task 1: A larger plating system will be purchased for process scale-up. TiF 3 will be tested as the metal precursor in an effort to reduce water sensitivity of the process. Task 2: Ti on steel samples will be created at PNNL and shipped to Atlas Technologies. Atlas Technologies will diffusion bond the samples to aluminum and test the bond strength. The results will be reported to PNNL. Task 3: Investigation into DOE mission relevant Ti and Zr alloys and demonstration on larger scale work pieces.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Accelerating Collective Communication in Data Parallel Training across Deep Learning Frameworks

This work develops new techniques within Horovod, a generic communication library supporting data parallel training across deep learning frameworks. In particular, we improve the Horovod control plane by implementing a new coordination scheme that takes advantage of the characteristics of the typical data parallel training paradigm, namely the repeated execution of collectives on the gradients of a fixed set of tensors. Using a caching strategy, we execute Horovod’s existing coordinator-worker logic only once during a typical training run, replacing it with a more efficient decentralized orchestration strategy using the cached data and a global intersection of a bitvector for the remaining training duration. Next, we introduce a feature for end users to explicitly group collective operations, enabling finer grained control over the communication buffer sizes. To evaluate our proposed strategies, we conduct experiments on a world-class supercomputer — Summit. We compare our proposals to Horovod’s original design and observe 2x performance improvement at a scale of 6000 GPUs; we also compare them against tf.distribute and torch.DDP and achieve 12% better and comparable performance, respectively, using up to 1536 GPUs; we compare our solution against BytePS in typical HPC settings and achieve about 20% better performance on a scale of 768 GPUs. Finally, we test our strategies on a scientific application (STEMDL) using up to 27,600 GPUs (the entire Summit) and show that we achieve a near-linear scaling of 0.93 with a sustained performance of 1.54 exaflops (with standard error +- 0.02) in FP16 precision.

Romero, Joshua↗

DOE OSTI2023

CODEX: Role of velocity substructure in the scaling relations of galaxy clusters

The use of galaxy clusters as cosmological probes relies on a detailed understanding of their properties. They define cluster selection and ranking linked to a cosmologically significant cluster mass function. Previous studies have employed small samples of clusters, concentrating on achieving the first calibrations of cluster properties with mass, while the diversity of cluster properties has been revealed via detailed studies. The large spectroscopic follow-up on the CODEX cluster sample with SDSS and NOT enables a detailed study of hundreds of clusters, lifting the limitations of previous samples. We aim to update the spectroscopic cluster identification of CODEX by running the spectroscopic group finder on the follow-up spectroscopy results and connecting the dynamical state of clusters to their scaling relations. We implemented a reproducible spectroscopic membership determination and cleaning procedures, based on the redMaPPer membership, running the spectroscopic group finder on the follow-up spectroscopy results and cleaning the membership for spectroscopic outliers. We applied the Anderson-Darling test for velocity substructure and analysed its influence on the scaling relations. We also tested the effect of the X-ray-to-optical centre offset on the scaling relations. We report on the scaling relations between richness, X-ray luminosity, and velocity dispersion for a complete sample of clusters with at least 15 members. Clusters with velocity substructure exhibit enhanced velocity dispersion for a given richness and are characterized by 2.5 times larger scatter. Clusters that have a strong offset in X-ray-to-optical centres have comparable scaling relations as clusters with substructure. We demonstrate that there is a consistency in the parameters of the scaling relations for the low- and high-richness galaxy clusters. Splitting the clusters by redshift, we note a decrease in scatter with redshift in all scaling relations. We localize the redshift range where a high scatter is observed to z < 0.15, which is in agreement with the literature results on the scatter. We note that the increase in scatter for both high- and low-luminosity clusters is z < 0.15, suggesting that both cooling and the resulting active galactic nucleus feedback are at the root of this scatter.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2020

Perturbation theory for modeling galaxy bias: validation with simulations of the Dark Energy Survey

We describe perturbation theory (PT) models of galaxy bias for applications to photometric galaxy surveys. We model the galaxy-galaxy and galaxy-matter correlation functions in configuration space and validate against measurements from mock catalogs designed for the Dark Energy Survey (DES). We find that an effective PT model with five galaxy bias parameters provides a good description of the 3D correlation functions above scales of 4 Mpc/$h$ and $z < 1$. Our tests show that at the projected precision of the DES-Year 3 analysis, two of the non-linear bias parameters can be fixed to their co-evolution values, and a third (the $k^2$ term for higher derivative bias) set to zero. The agreement is typically at the 2 percent level over scales of interest, which is the statistical uncertainty of our simulation measurements. To achieve this level of agreement, our {\it fiducial} model requires using the full non-linear matter power spectrum (rather than the 1-loop PT one). We also measure the relationship between the non-linear and linear bias parameters and compare them to their expected co-evolution values. We use these tests to motivate the galaxy bias model and scale cuts for the cosmological analysis of the Dark Energy Survey; our conclusions are generally applicable to all photometric surveys.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Ultra-clear Aerogels for Insulated Glass in Refrigeration Doors (CRADA Final Report)

Display refrigerators commonly employ glass doors to provide product visibility; however, these doors exhibit significantly poorer thermal insulation than solid doors, resulting in increased heat transfer and higher energy consumption. To address this limitation, this project investigated the use of silica aerogel as a transparent insulating medium for refrigerator glass doors, with the objective of enhancing thermal performance without compromising visual clarity. In Phase I of the project, we assessed the feasibility of silica aerogel insulation through laboratory and full-scale studies, including material characterization, durability testing, and heat transfer measurements, along with the development and performance evaluation of prototype glass doors under realistic operating conditions. In Phase II, the project focused on scaling the technology toward practical deployment. This included scaling up the manufacturing process to achieve a surface area roughly 20 times larger for commercial applications, developing full-scale prototypes that integrated silica aerogel into standard display refrigerator doors, and conducting field evaluations to assess thermal performance, energy savings, and operational durability under real-world conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗