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All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Evaluation of LANL Capabilities for Fabrication of TREAT Conversion Fuel

This report estimates costs and schedule associated with scale up and fabrication of a low-enriched uranium (LEU) core for the Transient Reactor Test Facility (TREAT) reactor. This study considers facilities available at Los Alamos National Laboratory, facility upgrades, equipment, installation and staffing costs. Not included are costs associated with raw materials and off-site shipping. These estimates are considered a rough of magnitude. At this time, no specifications for the LEU core have been made and the final schedule needed by the national program. The estimate range (+/-100%) reflects this large uncertainty and is subject to change as the project scope becomes more defined.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Technetium Inventory, Distribution, and Speciation in Hanford Tanks

The purpose of this report is three fold: 1) assemble the available information regarding technetium (Tc) inventory, distribution between phases, and speciation in Hanford’s 177 storage tanks into a single, detailed, comprehensive assessment; 2) discuss the fate (distribution/speciation) of Tc once retrieved from the storage tanks and processed into a final waste form; and 3) discuss/document in less detail the available data on the inventory of Tc in other "pools" such as the vadose zone below inactive cribs and trenches, below single-shell tanks (SSTs) that have leaked, and in the groundwater below the Hanford Site. A thorough understanding of the inventory for mobile contaminants is key to any performance or risk assessment for Hanford Site facilities because potential groundwater and river contamination levels are proportional to the amount of contaminants disposed at the Hanford Site. Because the majority of the total 99 Tc produced at Hanford (~32,600 Ci) is currently stored in Hanford’s 177 tanks (~26,500 Ci), there is a critical need for knowledge of the fate of this 99 Tc as it is removed from the tanks and processed into a final solid waste form. Current flow sheets for the Hanford Waste Treatment and Immobilization Plant process show most of the 99 Tc will be immobilized as low-activity waste glass that will remain on the Hanford Site and disposed at the Integrated Disposal Facility (IDF); only a small fraction will be shipped to a geologic repository with the immobilized high-level waste. Past performance assessment studies, which focused on groundwater protection, have shown that 99 Tc would be the primary dose contributor to the IDF performance.

storage tanks↗
DOE OSTI2014

2012-13 Blue Room Low Enriched Uranium Sample Irradiation, Associated Gas Handling System, and Subsequent Separation Chemistry

An irradiation experiment was designed for the production of 100 mCi of medical isotope Mo-99 from a Low Enriched Uranium (LEU) solution. 300 mL of 150 gU/L LEU sulfate solution (pH1) was prepared and irradiated at the LANSCE Blue Room facility. The apparatus designed for the irradiation included a gas handling system, in which safe operation could be controlled by monitoring change in gas pressure. The gas handling system also contained a hydrogen oxygen recombiner, to recombine the gases generated through radiolysis of water, and an iodine trap, primarily for I-131. Pressure transients were observed during irradiation, which could be controlled by increasing the flow rate of the circulating pump. After irradiation the LEU solution was transferred to a hot cell facility for subsequent Mo-99 recovery using a titania column separation process, with samples also subsequently shipped to a radiochemical laboratory for further analysis. Gamma spectroscopy analysis revealed that ca. 70 mCi of Mo-99 was present at end of beam, in good agreement with the predicted value when actual beam history was included into the calculation. There was 80-85 % recovery of Mo-99 through a titania column separation, excluding losses through radioactive decay. The % Mo-99 recovery was lower than observed previously for the 1 mCi Mo-99 production (Target 4) experiments undertaken at LANL using the same separation apparatus, with on this occasion evidence of lower oxidation state molybdenum remaining irreversibly bound to the titania column. Subsequent postmortem analysis of the Blue room apparatus revealed that there had been no leaks in the gas handling system, the hydrogen and oxygen recombination appeared to work efficiently, and recovery of irradiated uranium trapped in the system allowed for >99% uranium mass balance.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2013

Aerial Measuring System (AMS)/Israel Atomic Energy Commission (IAEC) Joint Comparison Study Report

Under the 13th Bilateral Meeting to Combat Nuclear Terrorism conducted on January 8–9, 2013, the committee approved the development of a cost-effective proposal to conduct a Comparison Study of the Aerial Measuring System (AMS) of the U.S. Department of Energy (DOE), National Nuclear Security Administration (NNSA) and Israel Atomic Energy Commission (IAEC). The study was to be held at the Remote Sensing Laboratory (RSL), Nellis Air Force Base, Las Vegas, Nevada, with measurements at the Nevada National Security Site (NNSS). The goal of the AMS and the IAEC joint survey was to compare the responses of the two agencies’ aerial radiation detection systems to varied radioactive surface contamination levels and isotopic composition experienced at the NNSS, and the differing data processing techniques utilized by the respective teams. Considering that for the comparison both teams were using custom designed and built systems, the main focus of the short campaign was to investigate the impact of the detector size and data analysis techniques used by both teams. The AMS system, SPectral Advanced Radiological Computer System, Model A (SPARCS-A), designed and built by RSL, incorporates four different size sodium iodide (NaI) crystals: 1" × 1", 2" × 4" × 4", 2" × 4" ×16", and an “up-looking” 2" × 4" × 4". The Israel AMS System, Air RAM 2000, was designed by the IAEC Nuclear Research Center – Negev (NRCN) and built commercially by ROTEM Industries (Israel) and incorporates two 2" diameter × 2" long NaI crystals. The operational comparison was conducted at RSL-Nellis in Las Vegas, Nevada, during week of June 24–27, 2013. The Israeli system, Air RAM 2000, was shipped to RSL-Nellis and mounted together with the DOE SPARCS on a DOE Bell-412 helicopter for a series of aerial comparison measurements at local test ranges, including the Desert Rock Airport and Area 3 at the NNSS. A 4-person Israeli team from the IAEC NRCN supported the activity together with 11 members of the RSL team, which consisted of pilots, mechanics, scientists, a data analyst, equipment operators, and operation specialists. All planned flight activities followed by scientific discussions on the collected data were completed. For IAEC, the joint survey provided an opportunity to characterize their system’s response to extended sources of various fission products at the NNSS. As both systems play an important role in their respective countries’ (United States and Israel) national framework of radiological emergency response and are subject to multiple mutual cooperation agreements, it was important for each country to obtain more thorough knowledge of how they would employ these important assets and define the roles that they would each play in an actual response.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis

The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.

17 WIND ENERGY↗
DOE OSTI2014

Subtask 4.27 - Evaluation of the Multielement Sorbent Trap (MEST) Method at an Illinois Coal-Fired Plant

Owners of fossil fuel-fired power plants face the challenge of measuring stack emissions of trace metals and acid gases at much lower levels than in the past as a result of increasingly stringent regulations. In the United States, the current reference methods for trace metals and halogens are wet-chemistry methods, U.S. Environmental Protection Agency (EPA) Methods 29 and 26 or 26A, respectively. As a possible alternative to the EPA methods, the Energy & Environmental Research Center (EERC) has developed a novel multielement sorbent trap (MEST) method to be used to sample for trace elements and/or halogens. Sorbent traps offer a potentially advantageous alternative to the existing sampling methods, as they are simpler to use and do not require expensive, breakable glassware or handling and shipping of hazardous reagents. Field tests comparing two sorbent trap applications (MEST-H for hydrochloric acid and MEST-M for trace metals) with the reference methods were conducted at two power plant units fueled by Illinois Basin bituminous coal. For hydrochloric acid, MEST measured concentrations comparable to EPA Method 26A at two power plant units, one with and one without a wet flue gas desulfurization scrubber. MEST-H provided lower detection limits for hydrochloric acid than the reference method. Results from a dry stack unit had better comparability between methods than results from a wet stack unit. This result was attributed to the very low emissions in the latter unit, as well as the difficulty of sampling in a saturated flue gas. Based on these results, the MEST-H sorbent traps appear to be a good candidate to serve as an alternative to Method 26A (or 26). For metals, the MEST trap gave lower detection limits compared to EPA Method 29 and produced comparable data for antimony, arsenic, beryllium, cobalt, manganese, selenium, and mercury for most test runs. However, the sorbent material produced elevated blanks for cadmium, nickel, lead, and chromium at levels that would interfere with accurate measurement at U.S. hazardous air pollutant emission limits for existing coal-fired power plant units. Longer sampling times employed during this test program did appear to improve comparative results for these metals. Although the sorbent contribution to the sample was reduced through improved trap design, additional research is still needed to explore lower-background materials before the MEST-M application can be considered as a potential alternative method for all of the trace metals. This subtask was funded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FC26-08NT43291. Nonfederal funding was provided by the Electric Power Research Institute, the Illinois Clean Coal Institute, Southern Illinois Power Company, and the Center for Air Toxic Metals Affiliates Program.

Pavlish, John↗
DOE OSTI2014

Final Radiological Assessment of External Exposure for CLEAR-Line Americium Recovery Operations

Los Alamos National Laboratory is currently planning to implement an americium recovery program. The americium, ordinarily isotopically pure 241Am, would be extracted from existing Pu materials, converted to an oxide and shipped to support fabrication of americium oxide-beryllium neutron sources. These operations would occur in the currently proposed Chloride Extraction and Actinide Recovery (CLEAR) line of glove boxes. This glove box line would be collocated with the currently-operational Experimental Chloride Extraction Line (EXCEL). The focus of this document is to provide an in-depth assessment of the currently planned radiation protection measures and to determine whether or not further design work is required to satisfy design-goal and ALARA requirements. Further, this document presents a history of americium recovery operations in the Department of Energy and high-level descriptions of the CLEAR line operations to provide a basis of comparison. Under the working assumptions adopted by this study, it was found that the evaluated design appears to mitigate doses to a level that satisfies the ALARA-in-design requirements of 10 CFR 835 as implemented by the Los Alamos National Laboratory procedure P121. The analyses indicate that extremity doses would also meet design requirements. Dose-rate calculations were performed using the radiation transport code MCNP5 and doses were estimated using a time-motion study developed in consort with the subject matter expert. A copy of this report and all supporting documentation are located on the Radiological Engineering server at Y:\Rad Engineering\2013 PROJECTS\TA-55 Clear Line.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2013

Status of SRNL radiological field lysimeter experiment-Year 1

The Savannah River National Laboratory (SRNL) Radiological Field Lysimeter Experiment is a one-of-a-kind field facility designed to study radionuclide geochemical processes at a larger spatial scale (from grams to tens of kilograms sediment) and temporal scale (from months to 10 years) than is readily afforded through laboratory studies. The lysimeter facility is intended to capture the natural heterogeneity of moisture and temperature regimes in the vadose zone, the unsaturated subsurface region between the surface soil and the underlying aquifer. The 48 lysimeter columns, which contain various radionuclides (and stable iodine), were opened to rainfall infiltration on July 5, 2012. The objective of this report is to provide a status of the lysimeter facility operations and to compile data collected during FY13, including leachate volume, rainfall, and soil moisture and temperature in situ probe data. Radiological leachate data are not presented in this document but will be the subject of a separate document.1 Leachate samples were collected quarterly and shipped to Clemson University for radiological analyses. Rainfall, leachate volume, moisture and temperature probe data were collected continuously. During operations of the facility this year, there were four safety or technical concerns that required additional maintenance: 1) radioactivity was detected in one of the overflow bottles (captured water collected from the secondary containment that does not come in contact with the radiological source material); 2) rainwater accumulated within the sample-bottle storage sheds; 3) overflow containers collected more liquid than anticipated; and 4) significant spider infestation occurred in the sample-bottle storage sheds. To address the first three concerns, each of the lysimeter columns was re-plumbed to improve and to minimize the number of joint unions. To address the fourth concern regarding spiders, new sample-bottle water sheds were purchased and a pest control program was established. During this retrofit, the lysimeters were temporarily capped (covered to preclude additional water from entering lysimeter columns) for about two months (except the four Tc-cementitious containing lysimeters, which remain capped). At a later date, data summarized in this report will be combined with the leachate radionuclide concentration data that are presently being analyzed. Together, these data can be numerically modeled to provide bench-marking information, to test hypotheses regarding hydrogeochemical conceptual models, and to estimate effective transport parameters under field conditions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

GeGI (Germanium Gamma Imager) Performance: Maritime Interdiction Operation

The Gamma Ray Imager (GeGI) was demonstrated during the Maritime Interdiction Operation at Point Alameda, the site of the former Naval Air Station, in Alameda, CA. During this exercise GeGI was used to localize sources within an abandoned building and a cargo ship, the Admiral Callaghan.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

New Generator Technology

New generator technology project is driven by the need to be able to remotely deploy generator technology where it is needed, when it is needed. Both the military and aid programs that provide assistance after disasters could use the ability to deploy energy generation that fits the needs of the situation. Currently, pre-specified generators are deployed, sometime more than half way around the world to provide electricity. Through our Phase-I to Phase III DARPA grant, we will provide a mechanism where a 3d print station and raw materials could be shipped to a deployment site and remotely deployed personnel. These remote personnel can collaborate with engineers at a home location where 3d print plans can be optimized for the remote purpose. The plans can then be sent electronically to the remote location for printing, much like NASA sent the plans for a socket wrench to the International Space Station for printing in . If multiple generators need to be deployed at different remote locations, within miles of each other the printer rig can be moved to print the generators where they are needed. 3d printing is growing in the field of manufacturing. 3d printing has matured to the point where many types of materials are now available for many types of manufacturing. Both magnetic and electrically conductive material materials have recently been developed which can now lead to 3d printing of engines and generators. Our project will provide a successful printer rig that can be remotely deployed, to print a generator design in the field as well as provide a process for deploying the printed generator as well. This Systems Engineering Management Plan(SEMP) will provide the planning required for a Phase I DARPA grant that may also include goals for Phase II and Phase II grants. The SEMP provides a proposed project schedule, references, system engineering processes, specialty engineering system deployment and product support sections. Each section will state how our company will provide the necessary services to make this project succeed.

3D printing, manufacturing, generator technology, ↗
DOE OSTI2015

High Temperature Mechanical Properties, Fractography and Synchrotron Studies of ATF clad materials from the UCSB-NSUF Irradiations.

A variety of tensile samples of Ferritic and Oxide Dispersion Strengthened (ODS or nanostructured ferritic) steels were placed the ATR reactor over 2 years achieving doses of roughly 4-6 dpa at temperatures of roughly 290°C. Samples were shipped to Wing 9 in the CMR facility at Los Alamos National Laboratory and imaged then tested in tension. This report summarizes the room temperature tensile tests, the elevated temperature tensile tests (300°C) and fractography and reduction of area calculations on those samples. Additionally small samples were cut from the undeformed grip section of these tensile samples and sent to the NSLS synchrotron for high energy X-ray analysis, initial results will be described here.

Energy Sciences↗
DOE OSTI2015

UCSB ATR-­NSUF Irradiation DMC Sample Inspection Report

A variety of tensile samples of Ferritic and Oxide Dispersion Strengthened (ODS or nanoferritic) steels were placed the ATR reactor over 2 Years achieving doses of roughly 4-6 dpa at temperatures of roughly 290°C. After irradiation, samples were shipped from the MFC hot cells at Idaho National Laboratory (INL) to the Wing 9 hot cells in the CMR facility at Los Alamos National Laboratory. Samples were cleaned to removed alpha contamination from the MFC hot cells, and then, as needed removed from their irradiation containers, sorted and inspected. This report will summarize the inspection of the Disc Multipurpose Coupon (DMC) inspection from packet 7-1.

Energy Sciences↗
DOE OSTI2014

Fast Spectrum Experiment Fuel Pin Payload Specification for Package 9330

This specification supports work to be conducted by AREVA Federal Services under Idaho National Laboratory (INL) Subcontract No. 45559, Release 50, including Statement of Work (SOW) -11417 addressing package transportation licensing. This document provides transportation payload specification for experiment fuel pins produced in the performance of INL CRADA 13-CR-15. The payload description provided in this document will be used to obtain licensing necessary to enable transportation of unirradiated experiments in ATR Fresh Fuel Shipping Containers (FFSCs). The FFSC has a current U. S. Department of Energy (DOE) certificate, USA/9330/AF-96, revision 0, which is available on the DOE RAMPAC website or upon request from the INL or DOE. Its desired payload will consist of individual experiment fuel pins (a.k.a. rods) loaded in a FFSC’s internal fuel handling enclosure (FHE), a.k.a. internal canister. Each package and its FHE arrangements should be prepared for a payload that contains less than critical mass and is certified for ground and air transportation per NRC 10 CFR 71 and International Atomic Energy Agency (IAEA) criteria. The unirradiated experiment fuel pins are all fabricated with uranium-based fuel and ferritic-martensitic stainless steel, HT-9, cladding and end plugs. The payload may include pins with and without spacer-wires. Solid pins will have minimal amounts of sodium bonding between the fuel and inside cladding. Annular pins will contain He gas installed at atmospheric pressure (~12.7 psia). Uranium fuel will be of varying enrichments with a maximum bounding enrichment of 94% U-235. Blanket material consists of depleted uranium and zirconium of varying weight percent. Section 2 provides pin parameters for NRC 10CFR71 and IAEA evaluations. Supplemental criteria titled functional and operating requirements is intended to convey other requirements, including those that protect the payload, rather than to demonstrate package compliance with regulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

IEA Bioenergy Task 40 Sustainable International Bioenergy Trade: Securing Supply and Demand (Country Report 2014—United States)

Logistical barrier are tied to feedstock harvesting, collection, storage and distribution. Current crop harvesting machinery is unable to selectively harvest preferred components of cellulosic biomass while maintaining acceptable levels of soil carbon and minimizing erosion. Actively managing biomass variability imposes additional functional requirements on biomass harvesting equipment. A physiological variation in biomass arises from differences in genetics, degree of crop maturity, geographical location, climatic events, and harvest methods. This variability presents significant cost and performance risks for bioenergy systems. Currently, processing standards and specifications for cellulosic feedstocks are not as well-developed as for mature commodities. Biomass that is stored with high moisture content or exposed to moisture during storage is susceptible to spoilage, rotting, spontaneous combustion, and odor problems. Appropriate storage methods and strategies are needed to better define storage requirements to preserve the volume and quality of harvested biomass over time and maintain its conversion yield. Raw herbaceous biomass is costly to collect, handle, and transport because of its low density and fibrous nature. Existing conventional, bale-based handling equipment and facilities cannot cost-effectively deliver and store high volumes of biomass, even with improved handling techniques. Current handling and transportation systems designed for moving woodchips can be inefficient for bioenergy processes due to the costs and challenges of transporting, storing, and drying high-moisture biomass. The infrastructure for feedstock logistics has not been defined for the potential variety of locations, climates, feedstocks, storage methods, processing alternatives, etc., which will occur at a national scale. When setting up biomass fuel supply chains, for large-scale biomass systems, logistics are a pivotal part in the system. Various studies have shown that long-distance international transport by ship is feasible in terms of energy use and transportation costs, but availability of suitable vessels and meteorological conditions (e.g., winter time in Scandinavia and Russia) need to be considered. However, local transportation by truck (both in biomass exporting and importing countries) may be a high-cost factor, which can influence the overall energy balance and total biomass costs.

09 BIOMASS FUELS↗
DOE OSTI2015

Results of Preliminary Hg Speciation Testing on Tank 21 and Solvent Hold Tank (SHT) Material

The Savannah River National Laboratory (SRNL) was tasked with preparing and shipping samples for Hg speciation by Eurofins Frontier Global Sciences, Inc. in Seattle, WA on behalf of the Savannah River Remediation (SRR) Mercury Task Team. The second shipment of samples was designated to include Tank 21 material (HTF-15-21-32) collected on March 9, 2015 and Solvent Hold Tank (SHT) material (MCU-15-28, -29, and -30) collected on March 10, 2015. Samples were collected with the minimum possible free headspace.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Results of Preliminary Hg Speciation Testing on Tank 22 and Waste Collection Hold Tank (WCHT) Material

The Savannah River national Laboratory (SRNL) was tasked with preparing and shipping samples for Hg speciation by Eurofins Frontier Global Sciences, Inc. in Seattle, WA on behalf of the Savannah River Remediation (SRR) Mercury Task Team. The third shipment of samples was designated to include Tank 22 material (HTF-22-15-34) collected on March 23, 2015, and Wast Collection Hold Tank (WCHT) material (ETP LIMS #30170) collected on March 16, 2015. Samples were collected with the minimum possible free headspace.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

FY2014 LX-21 Blasting Cap Testing

For a new material to qualify as an Extremely Insensitive Substance (EIS), the material must pass the UN Test 7, EIS Cap Test. This test attempts to measure the shock sensitivity of the material to a standard detonator at its nominal shipping density. The standard detonator specified for this test is based upon the historical number eight, #8, blasting cap. The standard detonator must contain a base charge (output charge) greater than or equal to 450mg and have a detonation velocity of at least 7.0 km/s. The Du Pont E-1A blasting cap, which is no longer made by Du Pont, was originally used to qualify TATB-based insensitive materials in the DOE. This detonator met the requirements of the EIS Cap Test. Several other commercial vendors currently sell products that are listed as equivalent to a number eight blasting cap, but have, in several cases, exceeded the original output energy of the historical number eight. By the loose specification that the number eight contain at least 450mg of output explosive, any product containing at least this quantity can be labeled as a number eight. Indeed, for most applications, higher output energy merely means a better, more reliable product. For standards testing, variation the output energy greatly affects the test results. Pantex has maintained a quantity of the original, number eight blasting caps the DOE used to qualify TATB materials (The DOE uses an IHE qualification, which is similar to the HD 1.6 classification, and requires a similar EIS Cap Test.) In FY-13, we acquired blasting caps from the original Pantex supply and from two commercial vendors for characterization and comparison. Our goals were to first characterize each of the three standard detonators with the intention of using a detonator that was as equivalent to the Du Pont number eight blasting cap as possible. Second, to work with a commercial vendor to produce a number eight equivalent that would either be based on a safer initiation technology such as an exploding bridge wire (EBW) or exploding foil initiator (EFI) – most commercial units hot-wire based, which present considerable safety concerns.

42 ENGINEERING↗
DOE OSTI2015

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Second FY 2015 Quarterly Report

During the second quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Autodesk reviewed 3D fiber orientation distribution (FOD) comparisons and provided support on improving accuracy. 2) Autodesk reviewed fiber length distribution (FLD) data comparisons and provided suggestions, assisted PNNL in FOD and FLD parameter settings optimization, and advised PNNL on appropriate through thickness thermal conductivity for improved frozen layer effect on FOD predictions. Autodesk also participated in project review meetings including preparations and discussions towards passing the go/no-go decision point. 3) Autodesk implemented an improved FOD inlet profile specification method through the part thickness for 3D meshes and provided an updated ASMI research version to PNNL. 4) The University of Illinois (Prof. C.L. Tucker) provided Autodesk with ideas to improve fiber orientation modeling 5) Purdue University re-measured fiber orientation for the fast-fill 50wt% LCF/PA66 edge-gated plaque, and delivered the fiber orientation data for this plaque at the selected locations (named A, B, and C, Figure 1) to PNNL. Purdue also re-measured fiber orientation for locations A on the fast-fill 30wt% LCF/PP and 50wt% LCF/PA66 center-gated plaques, which exhibited anomalous fiber orientation behavior. 6) Purdue University conducted fiber length measurements and delivered the length data to PNNL for the purge materials (slow-fill 30wt% LCF/PP and 30wt% LCF/PA66 purge materials) and PlastiComp plaques selected on the go/no-go list for fiber length model validation (i.e., slow-fill edge-gated 30wt% LCF/PP and 30wt% LCF/PA66 plaques, Locations A, B, and C). 7) PNNL developed a method to recover intact carbon fibers from LCF/PA66 materials. Isolated fibers were shipped to Purdue for length distribution analysis. 8) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber orientation (FO) model validation and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 9) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber length distribution (FLD) model validation and compared the predicted length distributions with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 10) PNNL tested the new ASMI version received from Autodesk in March 2015, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 11) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corporation (Magna) participated in discussions with team members on the go/no-go plan. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.

42 ENGINEERING↗