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

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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Assessing the Impact of Large Removable Beryllium Reflector Experiments on HFIR Performance and Safety Metrics

This study investigated the effect of various removable beryllium (RB) experiment configurations on High Flux Isotope Reactor (HFIR) metrics to address increasing interest in these facilities for materials and fuels irradiation research. The RB reflector contains eight large and four small irradiation experiment facilities that offer excellent neutron flux conditions to perform fission and fusion reactor materials and fuels irradiation research. This work aims to outline acceptable RB configurations based on safety, performance, and programmatic metrics. This study assessed experiment effects on reactivity, cycle length, fission rate density distributions, and neutron flux distributions using the Shift, HFIRCON, and SCALE ORIGEN codes. Initial evaluations focused on generic experiment materials including aluminum plugs, stainless steel plugs, molybdenum plugs, and aluminum plugs with gadolinium shields. Subsequent analyses of MiniFuel experiments were performed to evaluate a heterogenous experiment, consisting of a more complex geometry and bearing several materials, and to test the correlations developed with the generic materials on a real experiment. Furthermore, the effects of neutron poison concentrations in the standard beryllium plugs were evaluated. When assuming a reference RB configuration with eight large fresh beryllium plugs, perturbed configurations with three aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and one MiniFuel experiment resulted in a cycle length reduction of less than 1.3 days, the current threshold before requiring additional approvals. Configurations with five aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and two MiniFuel experiments meet the 1.3 day limit if irradiated beryllium plugs are considered. Fuel element fission rate density distributions remained within safety limits, with maximum local increases under 9%. Neutron flux calculations revealed large thermal flux depressions inside and around the perturbed RB facilities, while epithermal and fast neutron fluxes increased because of reduced neutron moderation by the perturbed materials. These findings provide valuable guidance for optimizing RB configurations to balance safety and performance at HFIR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Shock‐tube spectroscopic water measurements and detailed kinetics modeling of 1‐pentene and 3‐methyl‐1‐butene

Abstract To understand the effects of the chemical structure of two C 5 alkene isomers on their combustion properties, and to highlight the major chemical reactions occurring during their high‐temperature oxidation, water time histories were measured behind reflected shock waves for the oxidation of 1‐pentene (C 5 H 10 ‐1) and 3‐methyl‐1‐butene (3M1B) in 99.5% Ar. The experiments were carried out at three different equivalence ratios ( φ = 0.5, 1.0, and 2.0) at pressures and temperatures ranging from 1.29 to 1.47 atm and 1 331 to 1 877 K, respectively. The H 2 O quantification extends the database for 1‐pentene and provides new insights for 3M1B. These unique results were used to validate and to develop a new detailed kinetics model. Numerical predictions are presented, and the new model was able to capture the results with suitable accuracy, with 3M1B being notably more reactive than C 5 H 10 ‐1. Sensitivity and rate‐of‐production analyses were performed to help explain the results. Under the present conditions, the reactivity is rapidly initiated by molecular dissociation of a fraction of the pentene isomers. The initiation phase then induces H‐atom abstraction by active radicals (H, OH, O, HO 2 , and CH 3 ) to first produce alkenyl C 5 H 9 radicals (or an alkyl radical and an alkenyl radical by breaking a C─C bond) and subsequent, smaller fragments. The difference in terms of reactivity between the isomers is essentially due to the fact that 3M1B has one particularly weak tertiary allylic C─H bond, which allows for fast H‐atom abstraction compared with 1‐pentene.

Grégoire, Claire M.↗
DOE OSTI2020

Impact of installation faults in air conditioners and heat pumps in single-family homes on U.S. energy usage

To ensure that new residential air conditioners and heat pumps operate optimally, care must be taken during the initial system design and installation to avoid missteps that immediately degrade a system’s performance. Laboratory and simulation studies have quantified the impact that faults can have on capacity and efficiency. Field studies have demonstrated that installation-related faults are commonplace. However, the national impact of installation-related faults cannot be accurately estimated by only simulating a limited number of homes at several fault levels because of the variety of home characteristics and climates involved. In our analysis, we use an improved residential building stock simulation tool to predict the annual energy increase and additional utility costs resulting from two common installation faults: indoor airflow rate and refrigerant charge level. Our method considers the wide range of building characteristics and climate zones of the U.S. housing stock. We use existing field data to develop fault intensity probability distributions to inform our analysis. The study shows that these two faults result in approximately 20.7 TWh/y of additional energy use for central air conditioners and air-source heat pumps in U.S. single-family detached homes, which is a 9% increase over baseline (no-fault) usage, costing homeowners approximately $2.5 billion annually on utility bills. Air-source heat pumps are responsible for a disproportionate fraction of this energy use increase because of the larger number of operating hours compared to central air conditioners and the sensitivity of heating mode performance to the faults analyzed compared to cooling mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Enhancing membrane performance for CO 2 capture from flue gas with ultrahigh MW polyvinylamine

Membranes for post-combustion CO 2 capture are required to have a high CO 2 permeance due to the limited driving force. For facilitated transport membranes synthesized with polyvinylamine (PVAm), a defect-free selective layer of <200 nm is usually required to render sufficient permeance with high CO 2 /N 2 selectivity. In order to meet such a demand through the knife-coating process, the coating solution needs to have a high viscosity at a relatively low concentration to minimize its penetration into the substrate. The demand was met by synthesizing PVAm with an ultrahigh molecular weight (MW) via inverse emulsion polymerization (IEP) in this study. Compared to solution polymerization, IEP isolates the reaction in inverse micelles suspended in a continuous organic phase, which allows excellent dissipation of the heat generated by the reaction and reduces gel formation drastically. The polymerization parameters, including monomer concentration, initiator concentration, and reaction temperature, were investigated to obtain the optimal MW of PVAm for membrane performance. As compared to solution polymerization, IEP enhanced the MW of PVAm from 1.2 to 12.7 MDa, which minimized the penetration of the coating solution into the substrate and hence the extra mass transfer resistance. The effect of MW and degree of hydrolysis of PVAm on the membrane transport properties were studied. Furthermore, by employing PVAm with a MW of 12.7 MDa to strengthen the polymer matrix, the loading of piperazine glycinate in the membrane was increased up to 85 wt.%. In conclusion, the resultant membrane achieved a CO 2 permeance of 839 GPU and a CO 2 /N 2 selectivity of 161 at the typical flue gas temperature of 57°C.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Thermal mechanical assessment of a SiC-SiC-composite clad fuel pin concept in a light water reactor environment

Accident Tolerant Fuels (ATFs) are designed to increase coping time following an accident scenario while preserving or improving current steady state reactor operational performance. A potential ATF concept is SiC-SiC composite claddings. Fuel performance simulations were conducted on a SiC-SiC based cladding concept utilizing a multilayered approach for improved performance. This cladding concept referred to as the Duplex concept is a duplex structure composed of a monolithic SiC layer placed on the outside of a SiC-SiC composite. A liquid metal is added to fuel-cladding gap for improved heat dissipation from the fuel. The monolithic SiC layer is used to improve the coolant corrosion characteristics and protect the SiC-SiC composite layer from exposure to the coolant. The fuel performance code BISON was used to conduct fuel performance simulations on the cladding concepts. Comparisons are made with a current prototypic fuel rod design (UO 2 fuel enclosed in Zircaloy-4 cladding). Representative steady-state cases were considered for normal power and two cycle power histories. Additionally, a PCI ramp case was simulated to analyze potential anticipated operational occurrences. Transient response during a Loss of Coolant Accident and a Reactivity Initiated Accident were also simulated. This computational study demonstrated that for normal operating conditions, the SiC concept cladding performed as well as the baseline for the standard power cases evaluated. The ramping evaluations indicate potential fracturing of the SiC-SiC composite of the composite cladding compared to the Zircaloy-4 cladding due to the temperature gradient and the subsequent differential thermal conductivity degradation and swelling across the composite thickness. In conclusion, the rod fails early at low enthalpy for RIA but survives a LOCA with minimal material loss due to high temperature steam corrosion.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Temperature-based reactive flow model for triaminotrinitrobenzene (TATB) plastic bonded explosives

A new reactive flow model is presented for triaminotrinitrobenzene (TATB)-based plastic bonded explosives, applicable to shock initiation and steady detonation problems of differing initial temperature. Temperature disequilibrium is assumed between unreacted explosive, material in the vicinity of compressed defects (called hot spots), and reaction products. The model incorporates temperature-dependent decomposition reaction rates. Particularly, Arrhenius model parameters were derived from quantum-based molecular dynamics simulations of TATB decomposition. Further, a model of detonation carbon aggregation is incorporated, describing the slow release of energy inherent to detonation in TATB-based materials. Model parameters were calibrated against gas gun shock initiation experiments and steady detonation rate stick tests. The predictive ability of the model in the shock initiation regime is tested against recent thin pulse experiments. The model is found to perform equally well in predicting the size-effect curve of ambient, cold, and hot rate sticks. The present work demonstrates the viability of incorporating results from subscale simulations into a continuum-scale reactive flow model.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

CuCr 2 O 4 particle growth and evolution across sol–gel routes and calcination profiles

CuCr 2 O 4 spinel is a candidate coating material for central receivers in concentrating solar power to protect structural alloys against high temperature oxidation and related degradation. Coating performance and microstructure of dip-coated and sintered coatings is dictated by the initial particle size of the CuCr 2 O 4 and sintering temperature, but can be compromised by particle agglomeration. Here in this study, sub-micron particles were synthesised through the Pechini and modified Pechini sol–gel methods. Phase composition was confirmed via X-ray diffraction. Particle growth during calcination of the nanoparticles at different temperatures (650°C, 750°C, 850°C) and times (between 1 and 24 h) was measured via laser diffraction and scanning electron microscopy. The modified Pechini method displayed evidence of smaller particle sizes and greater agglomeration. The kinetics of particle growth observed are consistent with a diffusion limited inhibited grain growth model.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Plasma thermal-chemical instability of low-temperature dimethyl ether oxidation in a nanosecond-pulsed dielectric barrier discharge

Plasma stability in reactive mixtures is critical for various applications from plasma-assisted combustion to gas conversion. To generate stable and uniform plasmas and control the transition towards filamentation, the underlying physics and chemistry need a further look. Here, this work investigates the plasma thermal-chemical instability triggered by dimethyl-ether (DME) low-temperature oxidation in a repetitive nanosecond pulsed dielectric barrier discharge. First, a plasma-combustion kinetic mechanism of DME/air is developed and validated using temperature and ignition delay time measurements in quasi-uniform plasmas. Then the multi-stage dynamics of thermal-chemical instability is experimentally explored: the DME/air discharge was initially uniform, then contracted to filaments, and finally became uniform again before ignition. By performing chemistry modeling and analyzing the local thermal balance, it is found that such nonlinear development of the thermal-chemical instability is controlled by the competition between plasma-enhanced low-temperature heat release and the increasing thermal diffusion at higher temperature. Further thermal-chemical mode analysis identifies the chemical origin of this instability as DME low-temperature chemistry. This work connects experiment measurements with theoretical analysis of plasma thermal-chemical instability and sheds light on future chemical control of the plasma uniformity.

repetitive nanosecond pulses↗
DOE OSTI2020

Emulating climate extreme indices

We use simple pattern scaling and time-shift to emulate changes in a set of climate extreme indices under future scenarios, and evaluate the emulators' accuracy. We propose a metric for the error in emulation in the context of initial condition ensembles, to specifically characterize the role of internal variability in the emulation performance. Our metric separates systematic emulation errors from unavoidable discrepancies between emulated and target values due to internal variability. We compute the metricis at grid-point scale, and we show geographically resolved results, or aggregate them at global scale. We demonstrate the use of our error metric in the emulation of a suite of temperature and precipitation extreme indices. We test and compare simple pattern scaling and time-shift using a range of trajectories spanning targets inspired by the Paris agreement -- warming to 1.5C and 2.0C from the pre-industrial baseline -- and two of the longer-established trajectories, RCP4.5 and RCP8.5. With this suite of scenarios we can test the effects on the performance of the size of the temperature gap between emulation origin and target. We find that for most indices emulation the dominant source of discrepancy is internal variability. For at least one index, however, counting exceedances of a high temperature threshold, significant portions of the globally aggregated discrepancy and its regional pattern originate from the systematic emulation error. This error exceeds internal variability of both the target and the emulated quantities in large coherent regions at low latitudes, and the explanation can be found in the differential behavior of temperature distributions across latitudes. The metric also highlights a fundamental difference in the two methods related to the simulation of internal variability, which is dampened significantly by simple pattern scaling. This aspect is of consequence when using these methods for specific applications, where preserving variability for uncertainty quantification is deemed important. With this study we offer our metric as a diagnostic tool, facilitating the formulation of scientific hypotheses on the reasons for the error. In the meantime, we show that for many impact relevant indices by now traditional emulation techniques can be accurate within the variations unavoidably introduced by internal variability, establishing the fundamental condition for using their emulation in impact modeling.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Beta-Decay Half-Lives beyond 54 Ca: A Systematic Survey of Decay Properties Approaching the Neutron Dripline

In an experiment performed at the Facility for Rare Isotope Beams (FRIB) using the FRIB Decay Station initiator, 15 new half-lives of isotopes near 54 Ca were measured. A new method of extracting lifetimes from experimental data, taking into account the unknown 𝛽-delayed neutron emission branches of very neutron-rich nuclei, was developed to enable systematic uncertainty analysis. The experiment observed a dramatic change in the half-life systematics for the isotopes with neutron number 𝑁 = 34. Beyond 𝑁 = 34, the decline of nuclear lifetime is much slower, leading to longer than anticipated lifetimes for near-dripline nuclei. State-of-the-art shell-model calculations can explain the experimental results, revealing the imprint of shell effects and the need for modification of single-particle neutron states. In conclusion, the results from a newly developed quasiparticle random phase approximation model with potential for making global predictions were also tested against the experimental results and good agreement was found.

Physics - Nuclear physics and radiation physics↗
DOE OSTI2023

Benchmarking for AI for Science

AI has been instrumental for recent developments in a number of domains of the sciences. With several hundred machine learning (ML) algorithms and models, and numerous AI-specific hardware platforms, a common quest for all scientists working on AI for Science is around the selection of machine learning algorithm(s) to solve their domain-specific scientific problems. A number of different initiatives around AI Benchmarking have been set up and have been useful in understanding the benefits of different ML algorithms for different tasks.However, with the majority of these AI Benchmarking initiatives focusing on the conventional notions of benchmarking, where the focus is purely runtime performance (such as training time or inference time), their suitability for benchmarking different ML algorithms for solving scientific problems has been viewed as a performance problem even though both are hardly the same. To make reasonable, explainable, and justifiable advancements in science using AI, it is critical to focus on the merits of these algorithms in handling different domain science problems. In other words, more emphasis must be given on Benchmarking for AI for Science than AI Benchmarking. The vision of the former is not only to assess the performance of ML algorithms, but also to assess, and understand the benefits and merits of different ML algorithms in handling scientific problems. Benchmarking for AI for Science, instead of pure performance focused AI Benchmarking, has several benefits: (i) it has the potential to offer advances in the sciences, much more rapidly than through pure performance-based AI methods, (ii) it will encourage the community to focus on developing better domain-specific AI techniques, particularly given the provision for being able to benchmark different techniques, and (iii) it will encourage hardware manufacturers to focus on developing science-specific hardware subsystems.

Thiyagalingam, Jeyan↗
DOE OSTI2023

GenSLMs: Genome-scale language models reveal SARS-CoV-2 evolutionary dynamics

We seek to transform how new and emergent variants of pandemic-causing viruses, specifically SARS-CoV-2, are identified and classified. By adapting large language models (LLMs) for genomic data, we build genome-scale language models (GenSLMs) which can learn the evolutionary landscape of SARS-CoV-2 genomes. By pre-training on over 110 million prokaryotic gene sequences and fine-tuning a SARS-CoV-2-specific model on 1.5 million genomes, we show that GenSLMs can accurately and rapidly identify variants of concern. Thus, to our knowledge, GenSLMs represents one of the first whole-genome scale foundation models which can generalize to other prediction tasks. We demonstrate scaling of GenSLMs on GPU-based supercomputers and AI-hardware accelerators utilizing 1.63 Zettaflops in training runs with a sustained performance of 121 PFLOPS in mixed precision and peak of 850 PFLOPS. We present initial scientific insights from examining GenSLMs in tracking evolutionary dynamics of SARS-CoV-2, paving the path to realizing this on large biological data.

Zvyagin, Maxim↗
DOE OSTI2020

Origin and effect of film sub-stoichiometry on ultraviolet, ns-laser damage resistance of hafnia single layers

Understanding the origin of laser damage-prone precursors in high index materials such as hafnia holds the key to the development of laser damage-resistant multilayer dielectric coated optics for high power and energy laser systems. In this study, we investigate the source of sub-stoichiometry, a potent laser damage precursor, in hafnia films produced by an ion beam sputtering (IBS) deposition method and the effect of such defects on the film performance upon ns ultraviolet (UV) laser (8 ns, 355 nm) exposure. Chemical analysis of data obtained via Rutherford backscattering spectroscopy (RBS) suggests that hafnia films deposited at two different planetary locations from the same deposition run exhibit anisotropic and location-dependent stoichiometries. While the oxygen-to-hafnium ratio is at the stoichiometric value of 2 for the hafnia film at the edge location, the ratio is significantly deviated and is 1.7 for that deposited at the planetary center. The sub-stoichiometric hafnia films display a much lower 1-on-1 damage onset at 1.6 ± 0.2 J/cm 2 compared to 2.3 ± 0.2 J/cm 2 in a stoichiometric film. The low damage performance films also have an over three times higher damage density at fluences above initiation. Coupled with Monte Carlo simulations, we reveal that sub-stoichiometry is primarily attributed to preferential removal of oxygen during film deposition by the bombardment of energetic reflected argon neutrals. The resulting oxygen deficiencies create the sub-bandgap states which facilitate the strong laser energy coupling and reduce the resistance to laser-induced damage in the hafnia single layer films.

36 MATERIALS SCIENCE↗
DOE OSTI2021

RAVEN Theory Manual

RAVEN is a software framework able to perform parametric and stochastic analysis based on the response of complex system codes. The initial development was aimed at providing dynamic risk analysis capabilities to the thermohydraulic code RELAP-7, currently under development at Idaho National Laboratory (INL). Although the initial goal has been fully accomplished, RAVEN is now a multi-purpose stochastic and uncertainty quantification platform, capable of communicating with any system code. In fact, the provided Application Programming Interfaces (APIs) allow RAVEN to interact with any code as long as all the parameters that need to be perturbed are accessible by input files or via python interfaces. RAVEN is capable of investigating system response and explore input space using various sampling schemes such as Monte Carlo, grid, or Latin hypercube. However, RAVEN strength lies in its system feature discovery capabilities such as: constructing limit surfaces, separating regions of the input space leading to system failure, and using dynamic supervised learning techniques. The development of RAVEN started in 2012 when, within the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, the need to provide a modern risk evaluation framework arose. RAVEN’s principal assignment is to provide the necessary software and algorithms in order to employ the concepts developed by the Risk Informed Safety Margin Characterization (RISMC) program. RISMC is one of the pathways defined within the Light Water Reactor Sustainability (LWRS) program. In the RISMC approach, the goal is not just to identify the frequency of an event potentially leading to a system failure, but the proximity (or lack thereof) to key safety-related events. Hence, the approach is interested in identifying and increasing the safety margins related to those events. A safety margin is a numerical value quantifying the probability that a safety metric (e.g. peak pressure in a pipe) is exceeded under certain conditions. Most of the capabilities, implemented having RELAP-7 as a principal focus, are easily deployable to other system codes. For this reason, several side activates have been employed (e.g. RELAP5-3D, any MOOSE-based App, etc.) or are currently ongoing for coupling RAVEN with several different software. The aim of this document is to provide a set of commented examples that can help the user to become familiar with the RAVEN code usage.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

RAVEN User Manual

RAVEN is a generic software framework to perform parametric and probabilistic analysis based on the response of complex system codes. The initial development was aimed to provide dynamic risk analysis capabilities to the Thermo-Hydraulic code RELAP-7, currently under development at the Idaho National Laboratory (INL). Although the initial goal has been fully accomplished, RAVEN is now a multi-purpose probabilistic and uncertainty quantification platform, capable to agnostically communicate with any system code. This agnosticism includes providing Application Programming Interfaces (APIs). These APIs are used to allow RAVEN to interact with any code as long as all the parameters that need to be perturbed are accessible by inputs files or via python interfaces. RAVEN is capable of investigating the system response, and investigating the input space using Monte Carlo, Grid, or Latin Hyper Cube sampling schemes, but its strength is focused to- ward system feature discovery, such as limit surfaces, separating regions of the input space leading to system failure, using dynamic supervised learning techniques. The development of RAVEN has started in 2012, when, within the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, the need to provide a modern risk evaluation framework became stronger. RAVEN principal assignment is to provide the necessary software and algorithms in order to employ the concept developed by the Risk Informed Safety Margin Characterization (RISMC) program. RISMC is one of the pathways defined within the Light Water Reactor Sustainability (LWRS) program. In the RISMC approach, the goal is not just the individuation of the frequency of an event potentially leading to a system failure, but the closeness (or not) to key safety-related events. Hence, the approach is interested in identifying and increasing the safety margins related to those events. A safety margin is a numerical value quantifying the probability that a safety metric (e.g. for an important process such as peak pressure in a pipe) is exceeded under certain conditions. The initial development of RAVEN has been focused on providing dynamic risk assessment capability to RELAP-7, currently under development at the INL and, likely, future replacement of the RELAP5-3D code. Most the capabilities that have been implemented having RELAP-7 as principal focus are easily deployable for other system codes. For this reason, several side activates are currently ongoing for coupling RAVEN with soft- ware such as RELAP5-3D, etc. The aim of this document is the explanation of the input requirements, focalizing on the input structure.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Energy-dependent optimization of the prompt fission neutron spectrum with CGMF

Throughout the course of FY21, significant effort was put into investigating models within the LANL developed Hauser-Feshbach fission fragment decay code, CGMF, to understand and potentially solve the long-standing challenge of a too-soft prompt fission neutron spectrum, PFNS. Several inputs and models to CGMF were investigated, including the discrete nuclear levels, the optical model potential, level densities, and the fission fragment initial conditions. Some of the global models within CGMF led to a slight hardening of the neutron spectrum—particularly the likely incomplete discrete levels in through which γ-rays decay—but none of the changes where large enough for the tail of the PFNS to reproduce experimental data. A significant hardening of the spectrum tail was observed when the fission fragment initial conditions were optimized based on their sensitivities to the PFNS data for thermal incident neutrons. In this way, the parameters for the CGMF mass and total kinetic energy distributions, along with the spin cutoff factor were adjusted to better reproduce the experimental PFNS measurements. This optimization hardened the tail of the PFNS slightly but led to unphysical mass distributions for the fission fragments before neutron emission. It was clear from the above that we do not expect to be able to produce an evaluation-quality PFNS with CGMF in the near future. Challenges at thermal will persist–and possibly worsen–with increasing incident energy, where more models are needed to completely describe the fission. Basic-science research funding exceeding the amount available and scope of our NCSP funds would be needed to tackle this decade-long challenge impacting many fission-fragment event generator. And, in fact, Amy Lovell won LDRD ECR funding to do so over the next few years. Therefore, we focused in FY22 on extending evaluation capabilities beyond thermal incident neutrons, to take into account the incident energy dependence of the PFNS and fission fragment initial condition distributions in CGMF. We chose to set up the evaluation methodology to perform PFNS evaluations with CGMF across incident-neutron energies, in order to have it readily available for future NCSP evaluations when the PFNS from CGMF has improved. In this report, we outline the evaluation methodology, along with the results of the optimization, including full model calculations with CGMF using the evaluated parameters.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗
DOE OSTI2024

FY24 Progress Report: SRNL Analysis of ICCWR LCM and WAMS data for Corrosion and Cracking

Algorithms for Machine Learning (ML) and data analysis for the 3013 Surveillance Program have been developed in an ongoing collaborative effort by the Savannah River National Laboratory (SRNL) and the University of South Carolina (USC). The objective of the algorithms is to automate the identification of corrosion and crack formation in the Inner Container Closure Weld Region (ICCWR) of the canister system used to store Pu-bearing material. Data for corrosion and cracking is collected from large binary files generated by a Laser Confocal Microscope (LCM), the Wide Area 3D Measurement System (WAMS), or,in a recent proposal, by a Scanning Electron Microscope (SEM). The ML software uses the physical attributes in the data files (e.g., one or more of: height, color, and 16-bit grayscale values as functions of position in a plane projection) to detect signs of surface corrosion and cracking after being trained on similar data, with the features to be detected. Although the initial scope included screening for broader indicators of corrosion, e.g., pitting, identification of potential cracks was prioritized for the past several years at the request of program leadership. Labeled training data is essential to developing the ML algorithm, and enhancements to data labeling capability have been developed to address this essential precursor to application of ML routines. Efficient labeling is particularly important in view of the large volume of data required to train ML algorithms and the relative rarity of cracks in the ICCWR data set. The updated program will read binary data from either LCM, WAMS or SEM files, interrogate data attributes, facilitate user labeling of data for training ML algorithms, execute ML algorithms, output parameters from trained ML algorithms, report ML model accuracy with respect to labeled data, and generate graphical representations for various analyses. In FY24, hourglass neural networks (HNNs) that were initiated in FY22 were further developed and tested using available LCM data, and their performance was tested against that of the alternative U-Net Neural Network algorithm structure. HNNs along with previously developed Convolutional Neural Networks (CNNs) and Deep Neural Networks (DNNs) comprise a suite of ML tools for identification of cracks in the ICCWR

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗