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DOE OSTI2025

Qualification of an Additively Manufactured Irradiation Capsule for the High Flux Isotope Reactor

As part of the Advanced Materials and Manufacturing Technologies (AMMT) Program’s work package Component Manufacturing and Demonstrations from AM 316 SS, irradiation capsules have been additively manufactured (AM) from 316H stainless steel for insertion into the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL). The irradiation capsules (commonly referred to as “rabbits”) have been successfully designed, fabricated, pressure tested, qualified, and inserted into the HFIR for irradiation and post-irradiation evaluation. Each rabbit consists of an AM housing and two standard AM end caps. The design is simple and amenable to geometric and material customization. This demonstration helps pave the way for acceptance of AM safety-critical components for nuclear energy applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Using PyBioNetFit to leverage qualitative and quantitative data in biological model parameterization and uncertainty quantification

Data generated in studies of cellular regulatory systems are often qualitative. For example, measurements of signaling readouts in the presence and absence of mutations may reveal a rank ordering of responses across conditions but not the precise extents of mutation-induced differences. Qualitative data are often ignored by mathematical modelers or are considered in an ad hoc manner, as in the study of Kocieniewski and Lipniacki (2013) [Phys Biol 10: 035006], which was focused on the roles of MEK isoforms in ERK activation. In this earlier study, model parameter values were tuned manually to obtain consistency with a combination of qualitative and quantitative data. This approach is not reproducible, nor does it provide insights into parametric or prediction uncertainties. Here, starting from the same data and the same ordinary differential equation (ODE) model structure, we generate formalized statements of qualitative observations, making these observations more reusable, and we improve the model parameterization procedure by applying a systematic and automated approach enabled by the software package PyBioNetFit. We also demonstrate uncertainty quantification (UQ), which was absent in the original study. Our results show that PyBioNetFit enables qualitative data to be leveraged, together with quantitative data, in parameterization of systems biology models and facilitates UQ. These capabilities are important for reliable estimation of model parameters and model analyses in studies of cellular regulatory systems and reproducibility.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1987

Buckling Analysis of Rectangular Plates With Holes

BUCKO is computer program developed to predict buckling of rectangular compression-loaded orthotropic plate with centrally located cutout. Plate assumed balanced, symmetric laminate of uniform thickness. Cutout shape elliptical, circular, rectangular, or square. Package includes sample data demonstrating essence of program and ease of use. Written in FORTRAN V.

Nemeth, M. P.↗

NASA NTRS1987

Real time identification of large space structures

Identification of frequencies, damping ratios, and mode shapes of large space structures (LSSs) are examined in real time. Real time processing allows for quick updates of model processing after a reconfiguration of structural failure. Recursive lattice least squares (RLLS) was selected as the baseline algorithm for the identification. Simulation results on a one dimensional LSS demonstrated that it provides good estimates, was not ill-conditioned in the presence of under-excited modes, allowed activity by a supervisory control system which prevented damage to the LSS or excessive drift, and was capable of real-time processing for typical LSS models. A suboptimal version of RLLS, which is equivalent to simulated parallel processing, was derived. A NASTRAN model of the dual keel U.S. space station was used to demonstrate the input/identification algorithm package in a more realistic simulation. Because the first eight flexible modes were very close together, the identification was much more difficult than in the simple examples. Even so, the model was accurately identified in real time.

Voss, Janice E.↗

NASA NTRS2001

High Fidelity Failure Analysis for a Composite Fuselage Section

A high fidelity delamination failure analysis was developed by combining a local failure analysis with a global full-scale finite element structural analysis to address strength and delamination failure in a single package. The methodology was demonstrated through a local three-dimensional pull-off failure analysis and a geometrically nonlinear structural analysis of a five-foot composite helicopter fuselage section. Pull-off specimens were used to identify potential debonding failure of co-cured skin-stringer/frame fuselage structures. An investigation of the failed pull-off specimens was performed to determine the location of the failure initiation. Three-dimensional strain energy release rate analysis indicates that the delamination initiation and growth is controlled by Mode 1 opening mode. The bending moment at the delamination tip was identified as the crucial factor controlling the failure. The geometrically nonlinear structural analysis of a five-foot composite fuselage section was performed using a detailed finite element model. Loads were applied along the periphery of the subcomponent using displacement fields generated from solutions of a full-vehicle model.

Li, Jain↗

NASA NTRS2015

The Affordance Template ROS Package for Robot Task Programming

This paper introduces the Affordance Template ROS package for quickly programming, adjusting, and executing robot applications in the ROS RViz environment. This package extends the capabilities of RViz interactive markers by allowing an operator to specify multiple end-effector waypoint locations and grasp poses in object-centric coordinate frames and to adjust these waypoints in order to meet the run-time demands of the task (specifically, object scale and location). The Affordance Template package stores task specifications in a robot-agnostic XML description format such that it is trivial to apply a template to a new robot. As such, the Affordance Template package provides a robot-generic ROS tool appropriate for building semi-autonomous, manipulation-based applications. Affordance Templates were developed by the NASA-JSC DARPA Robotics Challenge (DRC) team and have since successfully been deployed on multiple platforms including the NASA Valkyrie and Robonaut 2 humanoids, the University of Texas Dreamer robot and the Willow Garage PR2. In this paper, the specification and implementation of the affordance template package is introduced and demonstrated through examples for wheel (valve) turning, pick-and-place, and drill grasping, evincing its utility and flexibility for a wide variety of robot applications.

Hart, Stephen↗

NASA NTRS2019

Advances in Low-Cost Manufacturing and Folding of Solar Sail Membranes

Solar sail membranes must have a high area-to-mass ratio and high solid volume fraction when stowed. In order to meet mission requirements, current solar sail projects, such as NASA’s Near Earth Asteroid Scout, require metallized sail membranes with thicknesses on the order of 2-3 μm. These very thin membranes do not retain creases like thicker membranes, solar panels, or paper models. For Cubesat-class spacecraft, volume, rather than mass, is often the driving requirement for deployable structural elements. These two factors make it both difficult and highly desirable to characterize the practical differences between solar sail membrane packaging methods with laboratory demonstrations. This paper presents lessons gathered from lab work with solar sail membranes at a 10-meter scale.

Stohlman, Olive R.↗

NASA NTRSDate not supplied

Advances in Low-Cost Manufacturing and Folding of Solar Sail Membrane

Solar sail membranes must have a high area-to-mass ratio and high solid volume fraction when stowed. In order to meet mission requirements, current solar sail projects, such as the NASA Near Earth Asteroid Scout and Advanced Composite Solar Sail System, require metallized sail membranes with thicknesses on the order of 2-3 μm. These very thin membranes do not retain creases like thicker membranes, solar panels, or paper models. For CubeSat-class spacecraft, volume, rather than mass, is often the driving requirement for deployable structural elements. These two factors make it both difficult and highly desirable to characterize the practical differences between various membrane designs and packaging methods with laboratory demonstrations. This paper presents lessons gathered from lab work on solar sail membranes at a 9-meter scale. Among other results, laboratory deployment of a full-scale sail quadrant revealed important differences between seaming methods.

Olive R Stohlman↗

DOE OSTI2022

Textile Carbon Fiber Packaging and NCF Production

This Technical Collaboration Project focused on packaging large tow (≥ 10 grams/meter) textile carbon fibers, for which currently there is no suitable method. Prior to this project, Oak Ridge National Laboratory (ORNL) used a crude packaging approach to deliver (approximately) 100-meter packages for evaluation by intermediates producers, composites fabricators and other collaborators. That packaging approach was simply a hoop wrap on a standard 75 mm (3 inch) cardboard tube, with paper interleaved between layers and little or no tension control during spooling. While this approach was very effective for initial fiber development and sample fiber and small composite sample evaluation, these packages were inadequate for larger-scale demonstrations and more extensive applications development. The paper-interleaved packages were inconsistent, wasteful, and too small for commercial utilization; they were designed as a quick and simple means to package material for delivery into prototyping operations and were never expected to satisfy industrial requirements for commercial production. This project aimed to develop a commercially relevant approach for packaging large tow textile carbon fibers for robust delivery into downstream commercial intermediates and composites production operations. The development of robust packaging equipment that delivers packages meeting industrial requirements is essential to commercial implementation. In this project, the team identified packaging requirements, created a design, and prototyped a new packaging concept at ORNL’s Carbon Fiber Technology Facility (CFTF) and resulting packages were tested in production of non-crimp fabric (NCF).

42 ENGINEERING↗

DOE OSTI2024

Estimation of General Area Dose Rates During Closure Weld Operations on the DOE Standard Canister Pacific Basin Nuclear Conference 2024

The Department of Energy (DOE) Spent Nuclear Fuel (SNF) Road Ready Demonstration Project is an effort to package DOE-managed SNF for road-ready dry storage. A key operation in this demonstration is performing the closure weld on the DOE Standard Canister after it has been loaded with the SNF. Planning the closure weld operations is ongoing and must consider what parts of the operations (if any) can be done manually and what parts must be done remotely. A key parameter to inform the evolving planning of these operations is the dose rate in the vicinity of the canister and the dose hazard posed to the closure weld operators and collocated workers. This study developed a Monte Carlo N-Particle (MCNP) model of the closure weld operation, which was used to estimate general area dose rates as well as dose rates to the welding location, weld operators, and collocated workers. These estimates provide some insight into the potential radiation exposure hazard for workers during the operations and are a factor to be considered in the ongoing development of designs, technology, processes, and administrative controls for packaging DOE-managed SNF for road-ready dry storage.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Drop Analysis of Department of Energy Standard Canister with Fort Saint Vrain SNF

DOE manages over 300 types of SNF, most of which are located at the INL site. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF at the INL site for ?road-ready dry storage?. ?Road-ready dry storage? is a SNF management concept where SNF is packaged into dry and sealed canisters, which are then placed in on-site storage in anticipation of later transportation. The forward-looking goal of the Demonstration is establishing the foundation for a large-scale road-ready dry storage program at the INL site. The Demonstration will first package Fort Saint Vrain SNF currently stored at INL into several DOE Standard Canisters. These Standard Canisters will then be loaded into another commercial transportation or storage containment system (e.g., storage cask or transportation package). The Standard Canister is a class of standardized canisters designed for containing the large variety of DOE-managed SNF during interim storage, transportation and/or disposal at a geological repository. One critical aspect of road-ready dry storage is the ability to license the DOE Standard Canisters and its associated transportation package to 10 CFR 71. Depending on the SNF and transportation strategy, the Standard Canisters may have to maintain structural integrity under normal conditions of transport and hypothetical accident scenarios (i.e., drop events). The 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 been completed to support the recent Demonstration. This analysis will consider the Ø0.5 m × 5.1 m Standard Canister under drop scenario(s) considered in previous INL tests and analyses, including the 9 m drop at 80 degree off vertical. However, this analysis will consider the more recent Fort Saint Vrain loading configurations proposed for the Demonstration. This analysis will performed using strain-based acceptance criteria established by the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 3. It will be compared to previous analyses and form the foundation of further formal calculations that will be used to support licensing efforts of the road-ready dry storage system at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1984

Canadian Attitude Sensing Experimental Package (CASEP)

The Canadian Attitude Sensing Experiment Package (CASEP) was designed to demonstrate and verify the operation of an attitude sensing subsystem prior to committing its use on an operational mission. Data telemetry/recording requirements, power and physical requirements, and mission requirements of the experiment package are defined.

Reynaud, A. H.↗

NASA NTRS2013

Packaging Technologies for High Temperature Electronics and Sensors

This paper reviews ceramic substrates and thick-film metallization based packaging technologies in development for 500degC silicon carbide (SiC) electronics and sensors. Prototype high temperature ceramic chip-level packages and printed circuit boards (PCBs) based on ceramic substrates of aluminum oxide (Al2O3) and aluminum nitride (AlN) have been designed and fabricated. These ceramic substrate-based chiplevel packages with gold (Au) thick-film metallization have been electrically characterized at temperatures up to 550degC. A 96% alumina based edge connector for a PCB level subsystem interconnection has also been demonstrated recently. The 96% alumina packaging system composed of chip-level packages and PCBs has been tested with high temperature SiC devices at 500degC for over 10,000 hours. In addition to tests in a laboratory environment, a SiC JFET with a packaging system composed of a 96% alumina chip-level package and an alumina printed circuit board mounted on a data acquisition circuit board was launched as a part of the MISSE-7 suite to the International Space Station via a Shuttle mission. This packaged SiC transistor was successfully tested in orbit for eighteen months. A spark-plug type sensor package designed for high temperature SiC capacitive pressure sensors was developed. This sensor package combines the high temperature interconnection system with a commercial high temperature high pressure stainless steel seal gland (electrical feed-through). Test results of a packaged high temperature capacitive pressure sensor at 500degC are also discussed. In addition to the pressure sensor package, efforts for packaging high temperature SiC diode-based gas chemical sensors are in process.

Electronic packaging↗

NASA NTRS2013

Packaging Technologies for High Temperature Electronics and Sensors

This paper reviews ceramic substrates and thick-film metallization based packaging technologies in development for 500 C silicon carbide (SiC) electronics and sensors. Prototype high temperature ceramic chip-level packages and printed circuit boards (PCBs) based on ceramic substrates of aluminum oxide (Al2O3) and aluminum nitride (AlN) have been designed and fabricated. These ceramic substrate-based chip-level packages with gold (Au) thick-film metallization have been electrically characterized at temperatures up to 550 C. A 96% alumina based edge connector for a PCB level subsystem interconnection has also been demonstrated recently. The 96% alumina packaging system composed of chip-level packages and PCBs has been tested with high temperature SiC devices at 500 C for over 10,000 hours. In addition to tests in a laboratory environment, a SiC JFET with a packaging system composed of a 96% alumina chip-level package and an alumina printed circuit board mounted on a data acquisition circuit board was launched as a part of the MISSE-7 suite to the International Space Station via a Shuttle mission. This packaged SiC transistor was successfully tested in orbit for eighteen months. A spark-plug type sensor package designed for high temperature SiC capacitive pressure sensors was developed. This sensor package combines the high temperature interconnection system with a commercial high temperature high pressure stainless steel seal gland (electrical feed-through). Test results of a packaged high temperature capacitive pressure sensor at 500 C are also discussed. In addition to the pressure sensor package, efforts for packaging high temperature SiC diode-based gas chemical sensors are in process.

Chen, Liang-Yu↗

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↗

DOE OSTI2023

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly – 24139

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Antenna With Embedded Die in Glass Interposer for 6G Wireless Applications

This article presents the antenna-integrated glass interposer for D-band 6G wireless applications using dieembedding technology. Here, we implement the die-embedded package on glass substrates and characterize the electrical performance in the D-band. The electrical characterization employs embedded test dies with the 50-Ω ground–signal–ground (GSG) ports and coplanar waveguides. We achieve low-loss die-to-package transitions by using staggered dielectric vias, which are compared with the transitions of wire-bonding and flip-chip assembly. This article provides detailed information on the design, modeling, fabrication, and characterization of the die-to-package interconnects. This article also demonstrates the integration of microstrip patch antenna array and embedded dies in the D-band. The results show superior electrical performance provided by the die-embedded glass interposer. The die-to-package interconnect exhibits good matching (less than —10-dB S11) and low loss (0.2-dB loss) in the D-band. The integrated 1 × 8 patch antenna array shows 11.6-dB broadside gain and good matching with the embedded die. In addition, by using a temporary carrier, the antenna-integrated glass interposer also has great potential for further heterogeneous integration and thermal management.

42 ENGINEERING↗

DOE OSTI2020

Transporting Non-Compliant TRU Wastes in the OPTIMUS{sup TM} Packages - 20493

The OPTIMUS{sup TM} product line of packages was developed with the purpose of providing a versatile and modular packaging option for shipping problematic wastes and fissile material contents. The product line includes a high-activity design in the OPTIMUS-H and a low activity design in the OPTIMUS-L. The two variants utilize a singular containment vessel design, that is enclosed in different protective components that offer different levels of shielding along with thermal and impact protection. The thick shielding provided by the OPTIMUS-H packaging allows for higher activity contents than the OPTIMUS-L to be transported. But the lightweight design of the OPTIMUS-L packaging allows for more packages to be transported in a single shipment. The containment vessel design shared between the two packages provides leak-tight containment of all radioactive contents along with the capabilities to easily leak test and the option to inert and backfill the contents, as necessary, prior to each shipment of the package. Together the OPTIMUS package designs offer significant flexibility and are capable of handling a wide variety of waste materials and other radioactive contents. One of the primary contents covered in the initial design effort for these packages is TRU waste contents beyond the standard waste materials that are compliant with the WIPP Waste Acceptance Criteria. More specifically, the initial content of interest is TRU Waste drums containing sealed containers with potentially flammable gases. While there are multiple other packaging options available for transporting standard WIPP compliant TRU wastes, the goal of the OPTIMUS packages is to offer a superior option for transporting both standard TRU wastes as well as the more problematic non-compliant wastes, among other contents. The non-compliant TRU waste contents explicitly included for the OPTIMUS packages are standard aerosol cans and DOT 3E lecture bottles. However, the methods applied for the package containment can be easily adjusted to cover other sealed container types with potentially flammable gases. The primary challenges with including these items are both the obvious issue of potential for flammable gases (e.g. aerosol propellants) in the package, but also the uncertainty in the exact state of the contents. Because these desired contents are waste materials, the characterization of the materials present in the waste may include some uncertainties. For example, though it may be known that there are one or more aerosol cans in a TRU waste drum, it may not be known if this can is full, spent, or anywhere in between. Also there may be equal uncertainty in the contents of the aerosol can, specifically in the potentially flammable propellant remaining in the can. To include these types of non-compliant items as acceptable contents for the package, the methods utilized in the safety analyses of the OPTIMUS packages must consider all of the uncertainties in the characterization of the waste. The methods utilized cover a range of concerns with transporting contents of this nature including pressure buildup, gas generation, and gaseous combustion for demonstrating the containment of the package. The ability to transport these problematic contents in the OPTIMUS packages gives TRU waste generating sites the option to relocate these drums to an offsite location where the non-compliant items can be properly managed through removal or destruction. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗