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DOE OSTI2023

Physically-based control-oriented modeling for turbocharged stoichiometric spark-ignited engine with cooled EGR and flexible VVT systems

Accurate estimation and prediction of engine gas exchange system and in-cylinder conditions are critical for spark-ignited engine control and diagnostic algorithm development. In this paper, a physically-based, control-oriented model for a 2.8 l turbocharged, variable valve timing (VVT) and low pressure (LP) exhaust gas recirculation (EGR)-utilizing SI engine was developed. The model includes the impact of modulation to any combination of 10 actuators, including the throttle valve, compressor bypass valve, fueling rate, waste-gate, LP EGR valve, number of deactivated cylinders, intake valve open (IVO) timing, intake valve close (IVC) timing, exhaust valve open (EVO) timing and exhaust valve close (EVC) timing. The accuracy of the model in capturing engine dynamics was demonstrated by validating it against high-fidelity engine GT-Power simulation results for various drive cycles, particularly emphasizing elevated loads. In comparison to the open literature, novel contributions of the effort described in this paper includes in-cylinder gas composition modeling and turbine-out pressure estimation.

Zhang, Xu↗

DOE OSTI2026

TRACE Input Modernization

This work presents a Tom’s Obvious Minimal Language (TOML)-based representation of input for the US Nuclear Regulatory Commission’s TRAC/RELAP Advanced Computational Engine (TRACE) thermal hydraulics code. Implemented using the Workbench Analysis Sequence Processor (WASP), the approach maps traditional TRACE input structures to a hierarchical format composed of named parameters, typed values, and native data collections. The resulting representation preserves TRACE’s existing modeling capabilities while providing a modern, structured interface for model development and management. WASP further extends TOML through a file import directive that supports modular model composition and reusable input organization. In addition, WASP provides extended array data entry convenience with various data repeat and interpolation capabilities. Examples of the new TOML syntax are provided for major TRACE input categories, including hydraulic components, heat structures, control systems, and trip logic. The TOML representation establishes a foundation for improved validation, tooling, automation, and model maintainability while remaining compatible with existing TRACE workflows. To facilitate migration to the TOML-based input format, the TRACE executable now supports conversion of native TRACE input into an intermediate JSON representation. A Python utility subsequently transforms the JSON data into an equivalent TOML model. Lastly, the TRACE executable now supports execution using TOML-formatted input.

Lefebvre, Robert A. [Oak Ridge National Laboratory↗

DOE OSTI2022

Composition-Based Density Model for High Level Waste Glasses

In this report, the Savannah River National Laboratory (SRNL) provides a first-principles model capable of predicting the density of high-level waste (HLW) glass based on the glass composition. The model relies on the additivity of the specific volume of bound glass oxides to obtain a quantitative evaluation of the approximate glass density.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

A Predictive Model for Offgas Composition in Waste Glass Melters - Spring 2021 SULI General Audience Abstract

Approximately 56 million gallons of nuclear waste are currently stored in 177 underground storage tanks at the Hanford site in Washington state. A portion of the tank waste is targeted for immobilization by converting the nuclear waste to borosilicate glass through a process called vitrification. During vitrification, emissions are produced in addition to the intended glass product. These emissions, contained in a volume above the molten glass called the plenum, are composed of water vapor, air components, aerosols, particulates, and other gaseous species that result from evaporation, reactions, and air influx. The formation of these gasses causes the surface of the glass to foam. To reduce foaming, sucrose is added to the waste stream before the conversion to glass. Sucrose also reduces the formation of hazardous gasses in the plenum including nitrous oxides, NOx, and carboxides, COx. However, if excess sucrose is present, the reactions that produce the gasses in the plenum will be incomplete, and increased levels of NOx and COx can be observed. The Waste Treatment and Immobilization Plant at the Hanford site is equipped with the technology to treat the plenum emissions. Though many tests have been run to determine the presence of particulates in the plenum emissions, there is does not exist an established method to confidently predict the composition of the gaseous species in the plenum prior to treatment without physical testing. A model was created in the process modeling software Aspen Plus to predict the composition of NOx and COx in the plenum. The model employs a constant stirred tank reactor and user-defined reaction chemistry to determine the plenum composition. To verify the model, the offgas predicted by the model were compared to available offgas data for ten different feed compositions. It is demonstrated that the developed Aspen Plus model is capable of predicting the composition of NOx and COx in the plenum.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Data-scarce surrogate modeling of shock-induced pore collapse process

Understanding the mechanisms of shock-induced pore collapse is of great interest in various disciplines in sciences and engineering, including materials science, biological sciences, and geophysics. However, numerical modeling of the complex pore collapse processes can be costly. To this end, a strong need exists to develop surrogate models for generating economic predictions of pore collapse processes. Here, in this work, we study the use of a data-driven reduced-order model, namely dynamic mode decomposition, and a deep generative model, namely conditional generative adversarial networks, to resemble the numerical simulations of the pore collapse process at representative training shock pressures. Since the simulations are expensive, the training data are scarce, which makes training an accurate surrogate model challenging. To overcome the difficulties posed by the complex physics phenomena, we make several crucial treatments to the plain original form of the methods to increase the capability of approximating and predicting the dynamics. In particular, physics information is used as indicators or conditional inputs to guide the prediction. In realizing these methods, the training of each dynamic mode composition model takes only around 30 s on CPU. In contrast, training a generative adversarial network model takes 8 h on GPU. Moreover, using dynamic mode decomposition, the final-time relative error is around 0.3% in the reproductive cases. We also demonstrate the predictive power of the methods at unseen testing shock pressures, where the error ranges from 1.3 to 5% in the interpolatory cases and 8 to 9% in extrapolatory cases.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Processing and mechanical characterization of short carbon fiber-reinforced epoxy composites for material extrusion additive manufacturing

Fiber-reinforced polymer composites have been extensively utilized in recent years as feedstock materials for material extrusion additive manufacturing (AM) processes to improve strength, stiffness, and functionality of printed parts over unfilled printed polymers. However, the widespread adoption of AM of fiber-reinforced polymer composites requires a deeper understanding of the process-structure-property relationships in printed components, and such relationships are not well understood yet. Fiber length is critically important to the mechanical performance of short fiber composites, but very few studies to-date have focused on how the fiber length distribution (FLD) evolves during processing of composite feedstocks and how this evolution affects printing behavior and mechanical properties in 3D-printed composites. Here, FLD is measured for carbon fiber reinforced epoxy composites over a wide range of ink compositions and shear mixing times, and the distributions are fit with a Weibull-type distribution function. The effects of FLD on the tradeoff between ink processability, ink rheology, printing behavior and mechanical properties are investigated. Furthermore, the effects of printing parameters (nozzle size and print speed) on mechanical anisotropy and fiber orientation distribution (FOD) in printed composites are explored. Mechanical properties of printed composites are characterized via 3 pt-flexural testing, and microstructure is investigated using optical and scanning electron microscopy (SEM), and x-ray computed tomography. Finally, the fitted Weibull parameters are fed into a composite model that incorporates FLD and FOD, and model predictions are found to be in excellent agreement with experimental observations.

3D printing↗

DOE OSTI2023

Preliminary IHLW Formulation Algorithm Description

This report documents the initial algorithm that could be used by the Waste Treatment and Immobilization Plant (WTP) in batching high-level waste (HLW) and glass-forming chemicals (GFCs) in the HLW melter feed preparation vessel (MFPV) (HFP-VSL-00001 and -00005). Not all Hanford tank waste can be accommodated by the models developed for this report and significant expansion of the model boundaries could be achievable to reduce the WTP mission life and total canister production count. The immobilized HLW (IHLW) must meet a series of constraints to be acceptable for disposal in the Monitored Geologic Repository, which are contained in the Specification 1 of the Contract (DOE 2000), the Waste Acceptance Product Specifications (WAPS, DOE 1996), and the Waste Acceptance System Requirements Document (WASRD, DOE 2007). The IHLW Waste Form Compliance Plan (WCP, 24590-HLW-PL-RT-07-0001, Rev 3) specifies that the formulation algorithm will be developed and used to comply with the constraints associated with glass composition and properties. This report is not an engineering calculation, does not provide design input, and is not an engineering study. Algorithm inputs include the chemical analyses of the blended HLW in the HLW blend vessel (HBV) (HLP-VSL-00028, the volume and composition of the MFPV heel, the volume and composition of the MFPV after waste addition, the volume and composition of MFPV batch after GFC addition, the compositions of individual GFCs, and the mass of glass in each canister. In addition to these inputs, uncertainties in the HLW composition and processing parameters are included in the algorithm. Using the above inputs, the algorithm calculates the following outputs: 1) the volume of HLW to be transferred from the HBV to the MFPV, 2) the mass of each GFC for addition to the MFPV, 3) the composition of the glass that will be produced along with uncertainties, and 4) the predicted properties, with associated uncertainties, of the resulting IHLW. The algorithm uses the property-composition models to calculate properties with associated uncertainties and compares them with various constraints to ensure that a processable feed is formulated and a compliant IHLW is produced. The GFC additions are determined using an optimization approach to provide high confidence that the HLW glass will meet all product quality requirements and key processing constraints. For most HLW batches there are many possible glass compositions that meet all constraints. In these cases, the glass composition is optimized for a series of target component concentrations and target property values. The algorithm also incorporates process measurement and product quality uncertainties, based on the work of Piepel et al. (2005). Estimates of the various process and measurement uncertainties that affect glass compositions and predicted glass properties have been previously reported (Piepel et al. 2005, 2006) and the impacts of these estimated uncertainties on the IHLW composition envelope that meets product quality and processing-related properties with sufficient confidence were evaluated. The details of work performed to date to develop this initial GFC addition and batching algorithm are summarized in Sections 4 and 5. An example data set is used to illustrate the calculations of the algorithm summarized in Section 6. Finally, in Section 7, there is a statement of the required work to achieve a final operational IHLW formulation control algorithm. This report is not an engineering calculation, does not provide design input, and is not an engineering study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Improved interfacial li-ion transport in composite polymer electrolytes via surface modification of LLZO

Composite polymer electrolytes that incorporate ceramic fillers in a polymer matrix offer mechanical strength and flexibility as solid electrolytes for lithium metal batteries. However, fast Li + transport between polymer and Li + -conductive filler phases is not a simple achievement due to high barriers for Li + exchange across the interphase. This study demonstrates how modification of Li 7 La 3 Zr 2 O 12 (LLZO) nanofiller surfaces with silane chemistries influences Li + transport at local and global electrolyte scales. Anhydrous reactions covalently link amine-functionalized silanes [(3-aminopropyl)triethoxysilane (APTES)] to LLZO nanoparticles, which protects LLZO in air. APTES functionalization lowers the poly (ethylene oxide) (PEO)-LLZO interphase resistance to half that of unmodified LLZO and increases effective Li + transference number, while insulating Al 2 O 3 completely blocks ion exchange and lowers transference number and conductivity in PEO-lithium bis(trifluoromethanesulfonyl)imide (LiTFSI)-LLZO composites. Modeling an inner resistive interphase between LLZO and PEO surrounded by an outer conductive interphase explains non-linear conductivity trends. Solid-state 7 Li & 6 Li nuclear magnetic resonance shows Li + only exchanges between PEO-LiTFSI and some LLZO interphase, with no appreciable Li + transport through bulk LLZO. Surface functionalization is a promising path toward lowering the polymer-ceramic interphase resistance. This work demonstrates that local changes in Li + transport affect macroscopic performance, highlighting the intricate relationships between all interfaces in inherently heterogeneous composite polymer electrolytes.

25 ENERGY STORAGE↗

DOE OSTI2024

High Pressure Melting Curve of Fe‐Si: Implication for the Thermal Properties in Mercury's Core

The motion of liquid iron (Fe) alloy materials in the outer core drives the dynamo, which generates Mercury's magnetic field. The assessment of core models requires laboratory measurements of the melting temperature of Fe alloys at high pressure. Here, we experimentally determined the melting curve of Fe9wt%Si and Fe17wt%Si up to 17 GPa using in situ and ex situ measurements of intermetallic fast diffusion that serves as the melting criterion in a large-volume press. Our determined melting slopes are comparable with previous studies up to about 17 GPa. However, when extrapolated, our melting slopes significantly deviate from previous studies at higher pressures. For Mercury's core with a model composition of Fe9wt%Si, the melting temperature-depth profile determined in our study is lower by ∼150–250 K when compared with theoretical calculations. Using the new melting curve of Fe9wt%Si and the electrical resistivity values from a previous study of Fe8.5wt%Si, we estimate that the electronic thermal conductivity of liquid Fe9wt%Si is 30 Wm −1 K −1 at the Mercury's CMB pressure of 5 GPa and 37 Wm −1 K −1 at an assumed ICB of 21 GPa, corresponding to heat flux values of 23 mWm −2 and 32 mWm −2 , respectively. These values provide new constraints on the core models.

58 GEOSCIENCES↗

DOE OSTI2023

Waste Glass Property Database and Data Qualification Plan

The U.S. Department of Energy vitrification facilities currently employ glass property-composition models to ensure processability of waste streams and acceptability of the final glass products. The efficiency (e.g., process flexibility, reduced down time, and reduced cost) of waste vitrification is directly tied to the size of the waste processing envelope. To increase the size of the processing envelope, a larger database was developed. The database will improve the prediction accuracy of glass properties, leading to higher waste loadings, higher waste throughput, broader process flexibility, and reduced mission life. Some of the data in this expanded database has insufficient quality assurance (QA) rigor for use in nuclear facility operation and glass qualification. A plan was developed to qualify high-value data under the appropriate QA rigor for use at the Hanford Waste Treatment and Immobilization Plant’s High-Level Waste (HLW) Facility. This qualification plan first compares the data coverage over the composition region of interest to Hanford HLW by property. Those studies that significantly improve the data coverage in the Hanford HLW glass composition region were prioritized for qualification activities. Qualification methods including QA equivalence, peer review, data corroboration, and confirmatory testing have been assigned to each high-priority study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Effect of ion interactions on the Raman spectrum of NO 3 − : Toward monitoring of low-activity nuclear waste at Hanford

Raman spectroscopy is a valuable in-situ technique for many applications. The concentrations of species in complex ionic mixtures of nuclear waste can be estimated using Raman measurements. However, it has been experimentally observed that ion interactions can cause a modification of Raman peak intensities and positions. The present work explores the nonlinear behavior associated with the nitrate anion, NO 3 − , which is present in abundance in low activity nuclear waste. We examine changes in the main Raman peak of the nitrate anion in the presence of other ions. A wide range of concentrations are covered, including those expected during direct-feed low-activity waste (DFLAW) processing at the Hanford site in the State of Washington. The experiments showed that the ions interact and associate to form ion pairs, which results in a blue shift (i.e., a shift towards higher wavenumbers) in the main Raman peak of nitrate. The results indicate that cation concentration is a better predictor of the peak shift, compared to ionic strength, both for binary and multicomponent mixtures. These findings have direct implications on the development of spectra-to-composition models for the DFLAW system, since they show deviations from the linearity assumptions used in common chemometric models.

42 ENGINEERING↗

DOE OSTI2025

Corrosion resistant hot melt adhesive to bind metals

Hot melt adhesives (HMAs) play an important role in many industries, and their demand is expected to grow. HMAs don't require any solvents, and their application results in the formation of strong bonds with the substrate upon cooling within seconds. These properties differentiate them from liquid glues and make them preferable for practical application. Currently, commercial HMAs are used in bonding lightweight materials such as paper, polymers, and cartons, and have limited usage in areas necessitating the bonding of heavier objects like metals. Here, in this study, we report a design and testing of versatile platform comprising an ion-coordinating polymer and ionic fillers for performance optimization and understanding of structure–property relationships, enabling the rational design of HMAs with improved adhesion to metal surfaces. All-atom Molecular dynamics (MD) simulations and various characterization methods are used to elucidate the adhesion mechanism in model composite system containing polyethylene oxide mixed with chemically diverse salt particles. The maximum adhesion strength is found in composites with Al(OH) 3 and FeCl 3 fillers. Interestingly, the presence of Al(OH) 3 also provides a multifunctional anticorrosion property as measured electrochemically using the Tafel method. The discovered path to formulations with improved adhesion to metal surfaces constitutes an important step toward advancing HMAs for use in the structural and semi-structural metal work domain.

Adhesive and cohesive forces↗

DOE OSTI2025

Sound velocities and thermal equation of state of fcc -iron-nickel alloys at high pressure and high temperature: Implications for the cores of Moon and several planets

Fcc-Fe-Ni alloy is believed to be the most dominant solid constitute of moderate-sized terrestrial planetary cores. Investigating the physical properties, especially the density and sound velocity of Fe-Ni alloys and comparing them with seismic observations is an indispensable approach to constructing compositional models for planetary interiors. In this study, we conducted sound velocity measurements on Fe-Ni alloys with 10 wt.% and 20 wt.% Ni up to ∼13.5 GPa and 1073 K, using the ultrasonic interferometry technique in a multi-anvil apparatus in conjunction with synchrotron radiation. By fitting the experimental data to finite strain equations, the bulk and shear moduli and their pressure and temperature derivatives are derived, yielding K S0 =145.8(14) GPa, G 0 = 73.2(7) GPa, K S0 ’ = 5.89(24), G 0 ’ = 2.89(8), (∂K S /∂T) P = -0.0181(12) GPa/K and (∂G/∂T) P = -0.0393(10) GPa/K for fcc-Fe 80 Ni 20 . An examination of the density-velocity relationship shows that compressional wave velocity is insensitive to temperature within the current pressure and temperature range, while shear wave velocity exhibits a large reduction with increasing temperature. Here, extrapolation of the sound velocities following the finite strain theories suggests that much slower Vs should be expected at pressure and temperature conditions corresponding to those of the lunar core. Possible core density and velocity profiles for other moderate planets and satellites, such as Mars, Mercury, and Ganymede are also calculated.

Equation of state↗

DOE OSTI2025

Application of pH-dependent environmental protection agency test method 1313 to low-activity nuclear waste glass

Here, in this study, we present results of a room temperature, pH-dependent leach test established by United States Environmental Protection Agency (EPA) Leaching Environmental Assessment Framework (LEAF) (EPA Method 1313 and further abbreviated EPA 1313) to study the alteration behavior of low-activity nuclear waste (LAW) glasses. Implementation of EPA 1313, which is closer to LAW disposal temperatures, could allow for more flexibility in the formulation of Hanford LAW glasses, specifically in terms of increased waste loading. A set of 48 LAW glasses were selected to test with EPA 1313. Briefly, the test method consists of adding glass to a number of solutions at different initial pH values and at a fixed mass-to-solution-volume ratio. The glass is then allowed to corrode for two days and the final solution pH and concentration of different glass elements in solution is measured. The test was modified from the published procedure to constrain particle size to provide more reproducible results, reduce the studied pH range to a more applicable range, and to reduce solution volume to reduce costs associated with material preparation. Compositional modeling was used to predict the measured elemental releases at various pH. The model predictions improved in tests where there was a relatively small difference between initial and final solution pH indicating that pH controls would result in better predictive models.

Accelerated aging↗

DOE OSTI2021

Nanoscale hydration in layered manganese oxides

Birnessite is a layered MnO2 mineral with a nanoscale interlayer region that accommodates layers of intercalated water. Variable distributions of Mn sites with oxidation states of II, III and IV are responsible for the high catalytic reactivity of birnessite in nature and as a valuable candidate for energy storage solutions. We here report water loading capabilities and the vibrational spectral signatures of two forms of birnessite of strongly contrasting particle size. Using X-ray diffraction we find that potassium-birnessite accommodates no more than one monolayer (1W) of water in its interlayer region. Molecular simulations show that this is an energetically favorable hydration state where interlayer potassium-water and direct water-birnessite interactions are greater than at other hydration levels. Simulations also suggest a stable 2W state but that is not achieved experimentally by contact with water vapor. Finally, this work provides a means to predict the distribution of adsorbed and interlayer water molecules using a recently developed composite model.

Cheng, Wei↗

DOE OSTI2021

Density of Fe-Ni-C Liquids at High Pressures and Implications for Liquid Cores of Earth and the Moon

The presence of light elements in the metallic cores of the Earth, the Moon, and other rocky planetary bodies has been widely proposed. Carbon is among the top candidates in light of its high cosmic abundance, siderophile nature, and ubiquity in iron meteorites. It is, however, still controversial whether carbon-rich core compositional models can account for the seismic velocity observations within the Earth and lunar cores. In this paper we report the density and elasticity of Fe 90 Ni 10 -3 wt.% C and Fe 90 Ni 10 -5 wt.% C liquid alloys using synchrotron-based X-ray absorption experiments and first-principles molecular dynamics simulations. Our results show that alloying of 3 wt.% and 5 wt.% C lowers the density of Fe 90 Ni 10 liquid by ~2.9-3.1% at 2 GPa, and ~3.4-3.6% at 9 GPa. More intriguingly, our experiments and simulations both demonstrate that the bulk moduli of the Fe-Ni-C liquids are similar to or slightly higher than those of Fe-Ni liquids. Thus, the calculated compressional velocity ($v_p$) of Fe-Ni-C liquids are higher than that of pure Fe-Ni alloy, promoting carbon as a possible candidate to explain the elevated v p in the Earth's outer core. However, the values and slopes of both density and v p of the studied two Fe-Ni-C liquids do not match the outer core seismic models, suggesting that carbon may not be the sole principal light element in Earth's outer core. The high $v_p$ of Fe-Ni-C liquids does not match the presumptive $v_p$ of the lunar outer core well, indicating that carbon is less likely to be its dominant light element.

58 GEOSCIENCES↗

DOE OSTI2023

Search for photons above 10 19 eV with the surface detector of the Pierre Auger Observatory

We use the surface detector of the Pierre Auger Observatory to search for air showers initiated by photons with an energy above 10 19 eV. Photons in the zenith angle range from 30° to 60° can be identified in the overwhelming background of showers initiated by charged cosmic rays through the broader time structure of the signals induced in the water-Cherenkov detectors of the array and the steeper lateral distribution of shower particles reaching ground. Applying the search method to data collected between January 2004 and June 2020, upper limits at 95% CL are set to an E -2 diffuse flux of ultra-high energy photons above 10 19 eV, 2 × 10 19 eV and 4 × 10 19 eV amounting to 2.11 × 10 -3 , 3.12 × 10 -4 and 1.72 × 10 -4 km -2 sr -1 yr -1 , respectively. While the sensitivity of the present search around 2 × 10 19 eV approaches expectations of cosmogenic photon fluxes in the case of a pure-proton composition, it is one order of magnitude above those from more realistic mixed-composition models. The inferred limits have also implications for the search of super-heavy dark matter that are discussed and illustrated.

ultra high energy photons and neutrinos↗

DOE OSTI2022

Discovery of TOI-1260d and the characterization of the multiplanet system

ABSTRACT We report the discovery of a third planet transiting the star TOI-1260, previously known to host two transiting sub-Neptune planets with orbital periods of 3.127 and 7.493 d, respectively. The nature of the third transiting planet with a 16.6-d orbit is supported by ground-based follow-up observations, including time-series photometry, high-angular resolution images, spectroscopy, and archival imagery. Precise photometric monitoring with CHEOPS allows to improve the constraints on the parameters of the system, improving our knowledge on their composition. The improved radii of TOI-1260b and TOI-1260c are $2.36 \pm 0.06 \rm R_{\oplus }$, $2.82 \pm 0.08 \rm R_{\oplus }$, respectively while the newly discovered third planet has a radius of $3.09 \pm 0.09 \rm R_{\oplus }$. The radius uncertainties are in the range of 3 per cent, allowing a precise interpretation of the interior structure of the three planets. Our planet interior composition model suggests that all three planets in the TOI-1260 system contains some fraction of gas. The innermost planet TOI-1260b has most likely lost all of its primordial hydrogen-dominated envelope. Planets c and d were also likely to have experienced significant loss of atmospheric through escape, but to a lesser extent compared to planet b.

Lam, K. W. F. (ORCID:0000000299106088)↗