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A brief historical review of the evolution in structural materials options for fusion energy systems is presented, along with the author s perspective on emerging trends in advanced manufacturing techniques and new high-performance materials.
From beverage distributors to shipping companies and federal agencies, industry leaders turn to the National Renewable Energy Laboratory (NREL) to help green their fleet operations. Cost, efficiency, and reliability are top priorities for fleets, and NREL partners know the lab’s portfolio of tools can pinpoint fuel efficiency and emissions-reduction strategies that also support operational the bottom line. NREL is one of the nation’s foremost leaders in medium- and heavy-duty vehicle research and development (R&D) and the go-to source for credible, validated transportation data. NREL developers have drawn on this expertise to create tools grounded in the real-world experiences of commercial and government fleets. Operators can use this comprehensive set of technology- and fuel-neutral tools to explore and analyze equipment and practices, energy-saving strategies, and other operational variables to ensure meaningful performance, financial, and environmental benefits.
Steven Winter Associates, Inc. (SWA) monitored several advanced mechanical systems within a 2012 deep energy retrofitted home in the small Orlando suburb of Windermere, FL. This report provides performance results of one of the home's heat pump water heaters (HPWH) and the whole-house dehumidifier (WHD) over a six month period. In addition to assessing the energy performance of these systems, this study sought to quantify potential comfort improvements over traditional systems. This information is applicable to researchers, designers, plumbers, and HVAC contractors. Though builders and homeowners can find useful information within this report, the corresponding case studies are a likely better reference for this audience.
In evaluating next-generation materials and processes, the supply chain can have a large impact on the life cycle energy impacts. The Materials Flow through Industry (MFI) tool was developed for the Department of Energy's Advanced Manufacturing Office to be able to evaluate the energy impacts of the U.S. supply chain. The tool allows users to perform process comparisons, material substitutions, and grid modifications, and to see the effects of implementing sector efficiency potentials (Masanet, et al. 2009). This paper reviews the methodology of the tool and provides results around specific scenarios.
The mission of the Advanced Fuels Campaign (AFC) is to perform Research, Development, and Demonstration (RD&D) activities for advanced fuel forms (including cladding) to enhance the performance and safety of the nation’s current and future reactors, enhance proliferation resistance of nuclear fuel, effectively utilize nuclear energy resources, and address the longer-term waste management challenges. This includes development of a state of the art Research and Development (R&D) infrastructure to support the use of a “goal oriented science based approach.” AFC uses a “goal oriented, science based approach” aimed at a fundamental understanding of fuel and cladding fabrication methods and performance under irradiation, enabling the pursuit of multiple fuel forms for future fuel cycle options. This approach includes fundamental experiments, theory, and advanced modeling and simulation. One of the most challenging aspects of AFC is the management, integration, and coordination of major R&D activities across multiple organizations. AFC interfaces and collaborates with Fuel Cycle Technologies (FCT) campaigns, universities, industry, various DOE programs and laboratories, federal agencies (e.g., Nuclear Regulatory Commission [NRC]), and international organizations. Key challenges are the development of fuel technologies to enable major increases in fuel performance (safety, reliability, power and burnup) beyond current technologies, and development of characterization methods and predictive fuel performance models to enable more efficient development and licensing of advanced fuels. Challenged with the research and development of fuels for two different reactor technology platforms, AFC targeted transmutation fuel development and focused ceramic fuel development for Advanced LWR Fuels.
EEMS Program activities during FY 2019 focused on analytical research to understand the impacts that new mobility technologies and services will have at the vehicle, traveler, and overall transportation system-level. This research included the development of vehicle and transportation system simulation models and tools to evaluate the complex interactions among the various actors within the mobility landscape, analysis of empirical data to characterize which solutions may provide the largest benefits, and development of new control systems and algorithms that use vehicle connectivity and automation to improve the performance and efficiency of individual vehicles as well as the overall traffic system. This document presents a brief overview of the EEMS Program and documents progress and results for projects within four of the five EEMS activity areas: (1) the SMART (Systems and Modeling for Accelerated Research in Transportation) Mobility Lab Consortium, (2) High Performance Computing and Big Data Solutions for Mobility Data, (3) Advanced R&D Projects conducted by industry and academia, and (4) Core Modeling, Simulation, and Evaluation, Similarly, the remaining EEMS activity area – (5) Living Labs (managed under VTO’s Technology Integration Program). Each of the individual progress reports provide a project overview and highlights of the technical results.
A new additional wavelength-tuning capability has been implemented on the National Ignition Facility (NIF) laser allowing for unprecedented control of crossed-beam energy transfer (CBET) between all groups of beams for better performance of indirect-drive inertial confinement fusion (ICF) ignition experiments. In particular, this advance allows for negation and reversal of flow-induced CBET and the rebalancing of the intensity of different groups of beams within an indirect-drive (ICF) hohlraum. The experiments conducted at the NIF using a 1.1 MJ laser pulse with peak power of 390 TW demonstrate this high level of control through measurements of the precise changes to stimulated Brillouin scattering, typically driven by flow-induced CBET at the end of the pulse. Additionally, this new capability is shown to be able to predictably control gold-wall plasma expansion in the target driven by early-time flow-induced CBET. Estimates of early-time CBET from the wall expansion are shown to be consistent with simulation expectations. This new additional capability to control symmetry and backscatter expands the design space of current experiments and provides extra margin for increased laser energy in near-future experiments.
Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.
Nuclear materials are highly complex multiscale, multiphysics systems,and an effective prediction of nuclear reactor performance and safety requires simulation capabilities that tightly couple different physical phenomena. The Idaho National Laboratory’s Multiphysics Object Oriented Simulation Environment (MOOSE) provides the computational foundation for performing such simulations. With the move towards advanced reactors, such as the Molten Salt Reactor (MSR), that employ high temperature fluids compared to conventional reactors, corrosion has become a problem of great interest. A new application called Yellowjacket is currently under development to directly couple thermodynamic equilibrium and kinetics with phase field models in order to model corrosion in MSRs. As part of Yellowjacket, a Gibbs energy minimiser is being developed to perform thermochemical equilibrium calculations for a range of different materials, which is currently in its infancy. This report describes the further progress towards the development of Yellowjacket Gibbs energy minimiser. Ontario Tech University is developing a new Gibbs energy minimiser for Yellowjacket which is the primary contribution of this work. The aim to develop a thermochemistry solver for the MOOSE framework following the same development philosophy and using the same tools and libraries. A special focus is on performance, documentation and SQA. Furthermore through a scope extension partway through the fiscal year a thorough assessment of the MSTDB-TC v1.3 was performed at Ontario Tech University in the context of continuous improvement and quality assurance. The objective of the work was to have an arm’s length review of the database to give confidence that the database is performing as it was intended while assessing its current state to give recommendations to future developments. This assessment involved two parts: A) a quantitative assessment, and B) a qualitative assessment. Part A involved developing an automated test-suite that would compute values from the database using Thermochimica with comparisons to experimental measurements for validation purposes, which gives confidence to the database’s stakeholders that its functioning properly. Part B involved reviewing all binary systems in the database and making a qualitative assessment with two performance indicators: comprehensiveness and overall confidence. It is important to note that the models in the database are empirical, which is to say that the quality of any model is highly dependent on the experimental data used to inform its development.
Numerous studies have shown that advanced control of a wave energy converter's (WEC's) power take off (PTO) can provide significant increases (on the order of 200-300%) in WEC energy absorption. Transitioning these control approaches from simplified paper studies to application in full-scale devices remains an open and extremely challenging problem will be central to creating economically competitive WECs and delivering clean renewable energy to the US electrical grid. The Advanced WEC Dynamics and Controls project is targeted on assisting WEC developers to apply novel control systems for their devices and thus achieving major increases in performance and economic viability. The success of any control strategy is based directly upon the availability of a reduced-order model with the ability to accurately capture the dynamics of the system with sufficient accuracy. A model-scale WEC was designed and fabricated for use in studies to advance the state-of-the-art in WEC controls. This test, which is the first in a series of planned tests, focused on system identification (system ID) and model validation.
Among engineering materials, ceramics are indispensable in energy applications such as batteries, capacitors, solar cells, smart glass, fuel cells and electrolyzers, nuclear power plants, thermoelectrics, thermoionics, carbon capture and storage, control of harmful emission from combustion engines, piezoelectrics, turbines and heat exchangers, among others. Advances in additive manufacturing (AM) offer new opportunities to fabricate these devices in geometries unachievable previously and may provide higher efficiencies and performance, all at lower costs. This article reviews the state of the art in ceramic materials for various energy applications. The focus of the review is on material selections, processing, and opportunities for AM technologies in energy related ceramic materials manufacturing. The aim of the article is to provide a roadmap for stakeholders such as industry, academia and funding agencies on research and development in additive manufacturing of ceramic materials toward more efficient, cost-effective, and reliable energy systems.
This presentation describes the ExaWind project and the team's progress in creating a suite of performance-portable codes designed for predictive simulations of wind farms on next-generation exascale-class supercomputers. Such simulations will require the resolution of scales spanning many orders of magnitude, from blade boundary layers to wind farm flow structures. In the U.S., the first exascale systems will be GPU accelerated, and different GPU manufacturers have been chosen for the different systems. At the heart of the ExaWind software is a hybrid-solver approach based on the codes Nalu-Wind and AMR-Wind, which are computational fluid dynamics solvers for the incompressible Navier-Stokes equations. Nalu-Wind is an unstructured-grid code used to resolve wind turbine geometry and blade boundary layers, whereas AMR-Wind is a structured-grid background solver for atmospheric turbulent flow and turbine wake propagation. The models are coupled with overset meshes and global linear systems are approximated through a loose-coupling algorithm. Results will include validation-quality high-fidelity simulations and strong/weak scaling results from the Summit supercomputer.
Since the invention of the integrated circuit in 1958, advances in microelectronics have followed Moore’s law and other scaling laws. These have led to over a billion-fold increase in the number of transistors on a chip. The Department of Energy’s Office of Science (DOE-SC) programs have always been at the cutting edge of microelectronics, making major contributions to the scientific understanding, materials, and advanced instrumentation that enabled innovations to promote scaling. This has driven transformative advances in microelectronics for the challenging demands of DOE’s high performance computing and science facilities. Now, strong evidence exists that scaling is approaching its physical and economic limits, and yet, the growth of data-centric computing and sensor networks is redefining computing workloads and microelectronics needs. In addition, greatly improved microelectronics are needed for the nation’s electricity grid if it is to be energy-efficient, resilient to natural phenomena and intentional attack, and agile in adapting to fluctuations in demand and power generation. Sustained and rapid progress in microelectronics science and technology from millivolt to megavolt scales is thus essential if we are to continue pushing the boundaries of science within DOE, and more significantly, to continue to lead the global information and power technology revolution. In October 2018, DOE-SC convened a workshop to address Basic Research Needs for Microelectronics by a “co-design” approach. Participants focused on scientific issues associated with advanced microelectronics technologies for applications relevant to the DOE mission, including computing, power grid management, and science facility workloads. (Topics of direct relevance to quantum information science and quantum computing were outside the scope of this workshop.) The workshop was organized around microelectronics needs for three areas: 1) future DOE-SC facilities, 2) high performance computing beyond exascale (a billion billion calculations per second), and 3) power control, conversion, and detection for a modernized electrical grid and related high power applications. Panels were formed around each of these areas, with a fourth panel formed to address Crosscutting Research. Workshop participants were asked to focus on a co-design innovation ecosystem in which materials, chemistries, devices, systems, architectures, algorithms, and software are researched and developed in a closely integrated fashion, with feedback and interdisciplinary collaboration at each interface in this microelectronics technology hierarchy. The panels identified the five Priority Research Directions on the following page.
When evaluated at the process level, next-generation technologies may be more energy and emissions intensive than current technology. However, many advanced technologies have the potential to reduce material and energy consumption in upstream or downstream processing stages. In order to fully understand the benefits and consequences of technology deployment, next-generation technologies should be evaluated in context, as part of a supply chain. This work presents the Material Flows through Industry (MFI) scenario modeling tool. The MFI tool is a cradle-to-gate linear network model of the U.S. industrial sector that can model a wide range of manufacturing scenarios, including changes in production technology, increases in industrial energy efficiency, and substitution between functionally equivalent materials. The MFI tool was developed to perform supply chain scale analyses in order to quantify the impacts and benefits of next-generation technologies and materials at that scale. For the analysis presented in this paper, the MFI tool is utilized to explore a case study comparing a steel supply chain to the supply chains of several functionally equivalent materials. Several of the alternatives to the baseline steel supply chain include next-generation production technologies and materials. Results of the case study show that aluminum production scenarios can out-perform the steel supply chain by using either an advanced smelting technology or an increased aluminum recycling rate. The next-generation material supply chains do not perform as well as either aluminum or steel, but may offer additional use phase reductions in energy and emissions that are outside the scope of the MFI tool. Future work will combine results from the MFI tool with a use phase analysis.
Marine energy developers are beginning to rely more heavily on advanced composite materials for their load-bearing structures. Understanding how these materials respond and degrade in harsh marine environments is a complex problem. Much research has been performed at smaller laboratory scales to understand the fundamental physical and chemical degradation mechanisms, but little structural testing research has been performed at larger scales to understand how these physical and chemical interactions scale and how they should be accounted for in the design process. The Advanced Materials project is a multilaboratory research collaboration that addresses these issues with the intention of reducing risks and barriers to marine energy developers wanting to adopt advanced composite materials. The National Laboratory of the Rockies has been playing a leading role in developing larger-scale testing infrastructure and test methods to validate complex numerical degradation models and standardize testing procedures to do so. This paper reviews past structural testing activities, how they have grown into current research activities, and how they will continue to evolve to directly address industry needs. This paper covers key research areas - large-scale water absorption and subsequent structural validation testing, qualification of bolted and adhesive connections, and combined submerged fatigue testing at increasing scales. It provides insights into the complex requirements for testing infrastructure and test method development to effectively qualify materials and certify marine energy structures for harsh marine environments. This research program paves the way for better guidance and standardization within the industry when adopting advanced composite materials.
The Firebrick Resistance-heated Energy-storage System (FIRES) is under development at MIT for two applications: (1) integration with the Nuclear Air-Brayton Combined Cycle (NACC), a high-performance power conversion system (PCS) that may be used with high- temperature advanced reactors; and (2) industrial heat supply. This paper describes some key features of FIRES and equivalent systems configured for industrial heat supply and presents an assessment of the revenue achievable by a system operating under the conditions expected for early demonstration FIRES installations. The greatest technical challenge of the 21. century is likely to be the effort to minimize the damage caused by global climate change. This effort will require massive reductions in greenhouse gas (GHG) emissions throughout our economy and a transition to an electric power system driven entirely by very-low-carbon generators. Many investigators agree that this will require a substantial increase in electricity generation and in the use of nuclear power, and there is growing awareness that this will also require new technologies and systems for managing and storing energy and matching intermittent supply of renewable resources with electricity demand. Thermal energy storage systems (TESS) will, in some applications, be much more cost effective than the more popular and widely discussed battery electric storage systems and may provide unique capabilities. The Firebrick Resistance-heated Energy-storage System (FIRES) is under development at MIT for two applications: (1) integration with the Nuclear Air-Brayton Combined Cycle (NACC), a high-performance power conversion system (PCS) that may be used with high-temperature advanced reactors like the Fluoride-salt-cooled High-temperature Reactor (FHR), molten salt reactor (MSR) and sodium-cooled fast reactors (SFR); and (2) industrial heat supply. FIRES installations include a stack of refractory firebrick with imbedded electric heaters and airflow channels, a compressor or air blower, and a duct system to connect the firebrick with the heat demand (turbine or industrial customer). Analysis of the FIRES design space has shown that the concept is suitable for a wide range of peak operating temperatures (from about 200 deg.C up to at least 1800 deg. C) and pressures (from ambient to at least 20 atmospheres) and offers very high energy density (up to 1 MWh per cubic meter of firebrick for high temperature systems) at very low cost (as low as $5/kWh). These results favor early demonstration of FIRES. If the cost target of $5/kWh for FIRES systems were achieved, even the lowest expected operating income calculated here could cover the capital cost of a 10 MWh system in a single year. If the FIRES system were assumed to operate for at least 10 years, this level of operating income could readily recover a capital investment up to $50/kWh, which is simultaneously much cheaper than the costs expected for near-future battery systems (in excess of $200/kWh) and much more expensive than the small, low temperature firebrick systems already available for domestic heating. This provides a large margin for unexpected development costs and other uncertainties. FIRES would set a minimum price of electricity near that of natural gas-improving nuclear, wind, and solar economics while reducing greenhouse gas emissions from the industrial sector. (authors)
This fact sheet highlights work done at the ESIF in collaboration with EPRI. NREL is collaborating with the Electric Power Research Institute (EPRI) to validate the performance of a Spirae-developed advanced microgrid controller capable of managing 1-10 megawatts of aggregated generation capacity. The aim is to develop a commercially viable and flexible microgrid controller, easily adapted to different end-user applications and to a range of electric grid characteristics.
Marine energy developers are beginning to rely more heavily on advanced composite materials for their load bearing structures. Understanding how these materials respond and degrade in harsh marine environments is a complex problem. Much research has been performed at smaller laboratory scales to understand the fundamental physical and chemical degradation mechanisms, but little structural testing research has been performed at larger scales to understand how these physical and chemical interactions scale and how they should be accounted for in the design process. The Advanced Materials project is a multilaboratory research collaboration that has been addressing these issues with the intention of reducing risks and barriers to marine energy developers wanting to adopt advanced composite materials. The National Laboratory of the Rockies has been playing a leading role in developing larger scale testing infrastructure and test methods to validate complex numerical degradation models and standardize testing procedures to do so. This paper provides a review of past structural testing activities and how they have grown into current research activities and will continue to evolve into the future to directly address industry needs. This paper covers key research areas large-scale water absorption and subsequent structural validation testing, qualification of bolted and adhesive connections, and conducting combined submerged fatigue testing at increasing scales. This paper provides insights into the complex requirements for testing infrastructure and test method development to effectively qualify materials and certify marine energy structures for harsh marine environments. This research program paves the way for better guidance and standardization within the industry when adopting advanced composite materials.