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DOE OSTI2025

ACCELERATED DEPLOYMENT OF NOVEL MATERIALS BASED ON RELIABILITY INTEGRITY MANAGEMENT USING CUMULATIVE DAMAGE MODELING

There is currently no widely agreed, detailed general method for licensing a novel plant incorporating novel materials (or materials being deployed in novel environments); in many such situations, there are no directly applicable engineering code cases for decision-makers (including regulators) to rely on. This paper discusses a framework for solving this problem that is based on the Reliability and Integrity Management (RIM) approach delineated in ASME BPVC Section XI Division 2. NRC Regulatory Guide 1.246, Rev. 0, endorses, with conditions, the subject portion of the 2019 ASME Code. The proposed framework is meant to support development of a licensing case by addressing certain remaining technical challenges. The framework discussed here is compatible with the Licensing Modernization Project, but applying it in a specific case will call for advances in the state of practice, if not the state of the art. The RIM approach calls for applicants to (a) allocate reliability targets to plant structures, systems, and components (SSCs), (b) show that they are able to relate the currently observed physical condition of each SSC in the program to its failure probability well enough to determine whether the target reliability allocations are being satisfied, allowing for uncertainty related to the novelty of the materials/designs/operating environments, and (c) be able to demonstrate that the proposed program of surveillances will reliably detect unacceptable degradation of an SSC before SSC failure occurs. A modeling approach potentially applicable to item (b), based on cumulative damage modeling rather than failure rates, is briefly illustrated.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

SPEL: Software tool for Porting E3SM Land Model with OpenACC in a Function Unit Test Framework

Most high-end computers adopt hybrid architecture, porting a large-scale scientific code onto accelerators is necessary. The paper presents a generic method for porting large-scale scientific code onto accelerators using compiler directives within a modularized function unit test platform. We have implemented the method and designed a software tool (SPEL) to port the E3SM Land Model (ELM) onto the GPUs in the Summit computer. SPEL automatically generates GPU-ready test modules for all ELM functions, such as CanopyFlux, SoilTemperature, and EcosystemDynamics. SPEL breaks the ELM into a collection of standalone unit test programs for easy code verification and further performance improvement. We further optimize several ELM test modules with advanced techniques, including memory reduction, reconstructed parallel loops, and asynchronous GPU kernel launch. We hope our study will inspire new toolkit developments that expedite large-scale scientific code porting with compiler directives.

Schwartz, Peter↗

DOE OSTI2022

Pyomo.DOE: An open-source package for model-based design of experiments in Python

Predictive mathematical models are a cornerstone of science and engineering. Yet selecting, calibrating, and validating said science-based models often remains an art in practice. Model-based design of experiments (MBDoE) provides a systematic framework to maximize information gain from experiments while minimizing time and resource costs. But MBDoE remains limited to niche application areas, in part because practitioners must integrate expertise in statistics, computational optimization, and modeling. To help reduce this barrier, we introduce Pyomo.DOE, an open-source package for MBDoE. Pyomo.DOE uses a nonlinear sensitivity analysis code k_aug to quickly approximate the Fisher information matrix and leverages a new stochastic programming abstraction. We demonstrate Pyomo.DOE with the first application of MBDoE to fixed-bed breakthrough experiments, which highlights the power of Pyomo.DOE to quantify the value of experimental modifications a priori for large-scale partial differential-algebraic equation (PDAE) models. Here we also provide a mathematical primer on MBDoE targeted at general chemical engineers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Dark Matter and Track Triggering with the CMS Experiment (Final Report)

This report summarizes the progress from DOE Early Career Award entitled “Dark Matter and Track Triggering with the CMS Experiment”. The first major goal of the project was to establish a sensitive Dark Matter (DM) search program for the CMS experiment in Run-2 of the LHC. Two related strategies were developed to accomplish this goal. First, we designed and executed searches for DM produced in association with heavy flavor quark pairs, top/anti-top (ttbar) and bottom/anti-bottom (bbbar). In addition, we sought to maximize the power of Run-2 DM searches through the development of a statistical combination of all major search channels within a consistent theoretical framework. The results of these aspects of the project are detailed in Section 1. The second major goal of the project was to develop a real-time “Level-1” tracking trigger system for the high-luminosity LHC (HL-LHC) CMS upgrade. Charged particle tracking in the first stage of the CMS trigger will be crucial for surviving the high-pileup environment expected at the HL-LHC. The L1 tracking trigger must process all front-end hit data sent from the inner Tracker and will have just 4us to output track primitives to the downstream L1 trigger without data loss. Our development of the CMS tracking trigger is described in Section 2. The team supported by the award is given in Section 3. The project resulted in 10 peer reviewed publications, a graduate student thesis, and contributions to the CMS Phase-2 Tracker Technical Design Report, as is detailed in Section 4. Our development work for the CMS tracking trigger has been integrated in the backend system architecture for the Tracker upgrade.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

MITgcm-AD v2: Open source tangent linear and adjoint modeling framework for the oceans and atmosphere enabled by the Automatic Differentiation tool Tapenade

The Massachusetts Institute of Technology General Circulation Model (MITgcm) is widely used by the climate science community to simulate planetary atmosphere and ocean circulations. A defining feature of the MITgcm is that it has been developed to be compatible with an algorithmic differentiation (AD) tool, TAF, enabling the generation of tangent-linear and adjoint models. These provide gradient information which enables dynamics-based sensitivity and attribution studies, state and parameter estimation, and rigorous uncertainty quantification. Importantly, gradient information is essential for computing comprehensive sensitivities and performing efficient large-scale data assimilation, ensuring that observations collected from satellites and in-situ measuring instruments can be effectively used to optimize a large uncertain control space. As a result, the MITgcm forms the dynamical core of a key data assimilation product employed by the physical oceanography research community: Estimating the Circulation and Climate of the Ocean (ECCO) state estimate. Although MITgcm and ECCO are used extensively within the research community, the AD tool TAF is proprietary and hence inaccessible to a large proportion of these users. The new version 2 (MITgcm-AD v2) framework introduced here is based on the source-to-source AD tool Tapenade, which has recently been open-sourced. Another feature of Tapenade is that it stores required variables by default (instead of recomputing them) which simplifies the implementation of efficient, AD-compatible code. The framework has been integrated with the MITgcm model’s main branch and is now freely available.

Adjoints↗

DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

14 SOLAR ENERGY↗

DOE OSTI2025

Dynamic Capacitive Wireless Power Transfer System for Electric Vehicles (CRADA Final Report)

Road transportation accounts for 23% of our nation's total energy consumption, 59% of our petroleum consumption and 22% of our total emissions. Electric vehicles (EVs) have much higher well-to-wheel efficiency compared to gasoline vehicles and can reduce our dependence on oil, minimize emissions, improve local air quality and provide a platform for technological innovation and economic growth. While major progress has been made in the development of electric vehicles, their penetration remains under 1 The main hurdles in their widespread adoption are high cost, limited range and long charging times, due to limitations in battery technology. An approach to overcome these hurdles is to substantially reduce the on-board energy storage and instead deliver power wirelessly to the vehicle while it is in motion dynamic wireless power transfer (WPT). For EV charging applications, researchers have traditionally focused on inductive WPT. An issue with inductive WPT systems is that for magnetic flux guidance and shielding, they require ferrite cores, making them expensive, bulky and difficult to embed in the roadway. Under an ARPA-E IDEAS grant, the CU Boulder team has recently developed an alternative approach to WPT based on capacitive coupling that is much smaller, lighter, less expensive, and easier to embed in the roadway than inductive WPT; and have demonstrated a 1.2-kW 6.78-MHz version of this capacitive WPT system on a stationary platform. Under this seed grant program, preliminary work will be carried out on a dynamic capacitive WPT system to prepare a strong proposal for the ARPA-E OPEN 2018 FOA.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Development and Evaluation of Velocity Predictive Optimal Energy Management Strategies in Intelligent and Connected Hybrid Electric Vehicles

In this study, a thorough and definitive evaluation of Predictive Optimal Energy Management Strategy (POEMS) applications in connected vehicles using 10 to 20 s predicted velocity is conducted for a Hybrid Electric Vehicle (HEV). The presented methodology includes synchronous datasets gathered in Fort Collins, Colorado using a test vehicle equipped with sensors to measure ego vehicle position and motion and that of surrounding objects as well as receive Infrastructure to Vehicle (I2V) information. These datasets are utilized to compare the effect of different signal categories on prediction fidelity for different prediction horizons within a POEMS framework. Multiple artificial intelligence (AI) and machine learning (ML) algorithms use the collected data to output future vehicle velocity prediction models. The effects of different combinations of signals and different models on prediction fidelity in various prediction windows are explored. All of these combinations are ultimately addressed where the rubber meets the road: fuel economy (FE) enabled from POEMS. FE optimization is performed using Model Predictive Control (MPC) with a Dynamic Programming (DP) optimizer. FE improvements from MPC control at various prediction time horizons are compared to that of full-cycle DP. All FE results are determined using high-fidelity simulations of an Autonomie 2010 Toyota Prius model. The full-cycle DP POEMS provides the theoretical upper limit on fuel economy (FE) improvement achievable with POEMS but is not currently practical for real-world implementation. Perfect prediction MPC (PP-MPC) represents the upper limit of FE improvement practically achievable with POEMS. Real-Prediction MPC (RP-MPC) can provide nearly equivalent FE improvement when used with high-fidelity predictions. Constant-Velocity MPC (CV-MPC) uses a constant speed prediction and serves as a “null” POEMS. Results showed that RP-MPC, enabled by high-fidelity ego future speed prediction, led to significant FE improvement over baseline nearly matching that of PP-MPC.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Mutual Detectability: A Targeted SETI Strategy That Avoids the SETI Paradox

As our ability to undertake searches for extraterrestrial intelligence (SETI) grows, so does interest in the controversial endeavor of messaging extraterrestrial intelligence (METI). METI proponents point to the SETI Paradox—if all civilizations refrain from METI then SETI is futile. I introduce mutual detectability as a game-theoretic strategy to increase the success potential of targeted SETI. Mutual detectability comprises four laws that establish how SETI participants can engage each other based on mutual evidence of mutual existence. I argue that the party whom both SETI participants can judge to have better quality evidence, or common denominator information (CDI), has an onus to transmit to avoid the SETI Paradox. Transiting exoplanets within the Earth Transit Zone form a target subset that satisfies mutual detectability requirements. I identify the intrinsic time-integrated transit signal strength, which for Earth is 10{sup 3} L{sub ⊙} ppm hours yr{sup −1}, as suitable CDI. Civilizations on habitable-zone planets of radius R{sub p}/R{sub ⊕}≲(L{sub ∗}/L{sub ⊙}){sup −1/7} have superior CDI on us, and so under the mutual detectability framework have game-theory incentive (onus) to transmit. While the onus to transmit falls on us for habitable planets around L{sub *} > L{sub ⊙} stars, considerations of relative stellar frequency, main-sequence lifetime and planet occurrence rates mean that such systems are likely to be in a small minority. Surveys of the Earth Transit Zone for Earth-analog transiting planets around subsolar luminosity hosts would facilitate targeted SETI programs for civilizations who have game-theory incentive to transmit signals to us. A choice to remain silent, by not engaging in METI toward such systems, does not in this case fuel concerns of a SETI Paradox.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF

42 ENGINEERING↗

DOE OSTI2022

A phenology- and trend-based approach for accurate mapping of sea-level driven coastal forest retreat

The rapid replacement of upland forest by encroaching marshland is a striking manifestation of global sea-level rise (SLR). Timely and high-resolution information on the location and extent of transition forest (the ecotone between upland forest and marsh where tree mortality due to seawater intrusion begins) is fundamental to understanding the processes and patterns of SLR-driven landscape reorganization. Despite its significance, accurate characterization of salt-impacted transition forest remains challenging due to the complexity of coastal environments, scarcity of ground-truth data, and the lack of effective mapping algorithms. Here we use the full archive of Landsat images between 1984 and 2021 to investigate the spectral, temporal, and phenological characteristics of transition forest, and develop a robust framework for monitoring coastal vegetation shifts in the mid-Atlantic U.S., a global SLR hotspot. Here, we found that transition forest exhibits strong negative NDVI trends and a deviation of land surface phenology from marsh and upland forest that distinguishes itself from surrounding vegetation. By integrating temporal trends and land surface phenology, our results demonstrate superior discrimination between marsh and coastal forests to existing map products (e.g. NOAA Coastal Change Analysis Program, National Land Cover Database) that allows a reliable identification of the coastal treeline. We applied the approach to map regional land cover in 1985, 2000 and 2020 (overall classification accuracy >92%) and found that the area of coastal forest decreased by 22.0% from 1985 to 2020, the majority of which transitioned to marshland (92.3%, 5.3 × 10 3 ha). Based upon fine-scale patterns of coastal transgression, we created a practical workflow for spatially explicit quantification of forest retreat rates. Concurrent with rising sea level, coastal forests migrated upslope from 0.63 (± 0.27) m above sea level in 1985 to 0.78 (± 0.32) m above sea level in 2020, and horizontal forest retreat rates accelerated from 3.1 (range of 0–36) m yr -1 during 1985–2000 to 4.7 (0–55) m yr -1 during 2001–2020. As SLR continues to accelerate, our study may serve as a scalable solution for consistent tracking of coastal landscape evolution that is urgently needed for sustainable forest and wetland management.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Cross-scale sensing of field-level crop residue cover: Integrating field photos, airborne hyperspectral imaging, and satellite data

Conservation tillage practices can bring benefits to agricultural sustainability. Accurate spatial and temporal resolved information of field-scale crop residue cover, which reflects tillage intensity, is highly valuable for evaluating the outcomes of government conservation programs and voluntary ecosystem service markets, as well as facilitating agroecosystem modeling to quantify cropland biogeochemical processes. Remote sensing has the potential to cost-effectively detect crop residue cover, however, existing regional-scale studies were limited by insufficient ground truth data, scale mismatch between coarse satellite pixels and ground data, and the lack of key spectral data for detecting crop residues. Therefore, this study developed an innovative cross-sensing framework to integrate proximal sensing, airborne hyperspectral imaging, and satellite Earth Observation through deep learning to quantify field-level crop residue cover fractions at the regional scale. Specifically, we have collected intensive ground orthographic photos and conducted airborne hyperspectral surveys at corn and soybean fields of Champaign and nearby counties in Illinois, the heartland of the U.S. Corn Belt. Through semi-automatic labeling aided by ResNet-50 and superpixel image segmentation, we obtained 6719 records of ground residue fractions. With these ground data, we developed the 1-dimensional convolution neural network (CNN) model using airborne hyperspectral reflectance, which has 0.5m spatial resolution and 3–5 nm spectral resolution from 400 to 2400 nm, to predict residue fractions. By applying the CNN model to airborne pixels, we augmented “ground truth” data of crop residues and further combined them with Harmonized Landsat and Sentinel-2 (HLS) satellite data to quantify regional residue fractions at 30 m resolution. Results show that airborne hyperspectral imagery with CNN can accurately detect residue fractions (R 2 = 0.82, relative RMSE = 11.73%) to effectively generate quasi “ground truth” data to support satellite upscaling to all fields. With independent ground data for testing, we found that the ground-airborne-satellite integrative framework achieved better predictions in estimating crop residue cover (R 2 = 0.67, relative RMSE = 17.53%) than the conventional ground-satellite upscaling (R 2 = 0.22, relative RMSE = 32.09%). Here we also found that the shortwave infrared wavelengths, particularly 2100–2300 nm, are vital for predicting crop residue cover. Sentinel-2 and Landsat-8 data have a comparable capability to track residue fractions due to similar shortwave infrared wavelengths. This study highlights the high accuracy of hyperspectral imaging to detect agroecosystem tillage management practices and the advantages of cross-scale sensing to cost-effectively integrate multi-source data to quantify field-level agroecosystem variables across scales.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

TAMM: Tensor algebra for many-body methods

Tensor algebra operations such as contractions in computational chemistry consume a significant fraction of the computing time on large-scale computing platforms. The widespread use of tensor contractions between large multi-dimensional tensors in describing electronic structure theory has motivated the development of multiple tensor algebra frameworks targeting heterogeneous computing platforms. In this paper, we present Tensor Algebra for Many-body Methods (TAMM), a framework for productive and performance-portable development of scalable computational chemistry methods. TAMM decouples the specification of the computation from the execution of these operations on available high-performance computing systems. With this design choice, the scientific application developers (domain scientists) can focus on the algorithmic requirements using the tensor algebra interface provided by TAMM, whereas high-performance computing developers can direct their attention to various optimizations on the underlying constructs, such as efficient data distribution, optimized scheduling algorithms, and efficient use of intra-node resources (e.g., graphics processing units). The modular structure of TAMM allows it to support different hardware architectures and incorporate new algorithmic advances. We describe the TAMM framework and our approach to the sustainable development of scalable ground- and excited-state electronic structure methods. We present case studies highlighting the ease of use, including the performance and productivity gains compared to other frameworks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

User Manual - HydraGNN: Distributed PyTorch Implementation of Multi-Headed Graph Convolutional Neural Networks

This document serves as user manual for HydraGNN, a scalable graph neural network (GNN) architecture that allows for a simultaneous prediction of multiple target properties using multi-task learning (MTL). The HydraGNN architecture is constructed by successive superposition of three different sets of layers. The first set is made of message-passing layers to exchange information across nodes in the graph and use this to update the nodal features. The second set is made of global pooling layers that aggregate information from all the nodes in the graph and map it into a scalar, and is needed only for global target properties that are related to the entire graph. The third set of layers is dedicated to the implementation of MTL, which is enabled by forking of the architecture into separate heads, each one of them dedicated to the predictive task of one specific target property. Through an object-oriented programming paradigm, HydraGNN is templated over different message-passing policies, which allows for a user-friendly hyperparameter study to assess the sensitivity of the predictive performance of the HydraGNN architecture on a specific dataset with respect to the choice of the message-passing policy. The object-oriented paradigm used by HydraGNN also allows for a user-friendly inclusion of newly developed message passing policies within the existing framework. HydraGNN supports distributed computing capabilities for scalable data reading and scalable training on leadership-class supercomputers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

NEXT Generation Energy Technologies for Connected and Automated On-Road Vehicles (NEXTCAR Phase I & II)

The Ohio State University’s ARPA-E NEXTCAR project was a multi-phase, multi-year research, development, and demonstration program focused on improving the energy efficiency of connected and automated vehicles (CAVs). The team developed and validated advanced vehicle motion and powertrain control algorithms that coordinate propulsion and automation systems to optimize energy use. Key technologies included Dynamic Skip Fire engine control, predictive eco-driving functions such as Eco-Approach and Departure (Eco-AND) and Eco-Adaptive Cruise Control (Eco-ACC), and powertrain-agnostic optimization frameworks for hybrid, plug-in hybrid, and battery electric vehicles. The project successfully demonstrated up to 30% energy-efficiency improvement during real-world testing at the Transportation Research Center and the American Center for Mobility. The outcomes provide a foundation for scalable, cost-effective deployment of energy-optimized CAV technologies across the automotive industry.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Truchas Overview

Truchas and Truchas-PBF are two sister codes for part-scale multi-physics modeling of manufacturing processes. Both programs are open source and made publicly available. They’re designed for efficient use of HPC resources and can be programmatically driven from Python packages. This enables automatic execution and analysis of ensembles of simulations, in some cases allowing 1000s of simulations to be evaluated in a day on HPC. Beyond just giving engineers a window into the concealed internal state of a system, the goal of Truchas is to provide a framework for developing novel manufacturing processes by understanding how the entire space of engineering inputs affects thermal state. It often is used to explore combinations of capabilities uncommon in commercial software, or to scale up analyses beyond the capabilities of commercial software.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

42 ENGINEERING↗