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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

6.26 Low Cost Basalt Fiber for Automotive Applications

Vehicle lightweighting is an essential component to the automotive industry to improve fuel economy of internal combustion engine (ICE) vehicles to meet ever improving emission standards and to improve the range of electric vehicles (EV). Composite materials offer high specific modulus and specific strength, which makes them appealing for these light weighting efforts. Sheet molding compounds (SMC) are particularly interesting from an automotive perspective because of the relatively low cost and high volume of producing SMC parts. Traditionally, composite materials for automotive application are glass fiber reinforced because of the attractive price - performance ratio, but basalt fibers are a cost and recycling competitive reinforcement alternative in this market. The aim of this project was to examine the feasibility of utilizing basalt fiber for automotive applications. More specifically, an effort was made to examine different fiber sizings on basalt fiber combined with vinyl-ester (VE) resin, and their performance as part of an SMC process. In addition to offering vehicle lightweighting with fiber reinforced polymer composites, basalt fiber is a fully recyclable material and thus supports the IACMI technical goal of: Demonstrate that the technology is capable at a sufficient scale for >80% recyclability or reuse of fiber reinforced polymer composites in five years into useful components with projected cost and quality at commercial scale competitive with virgin materials on a pathway to 95% recyclability or reuse starting in ten years. Three different fiber sizings were applied to a continuous roving of basalt fiber and compared to a traditional Electrical/Chemical Resistance (E-CR) glass fiber that is typically used in these types of applications. Fiber tows were examined for Loss on Ignition percentage (LOI%), Tex, and tow strength. Some sizings clearly outperformed others, and the ability to process these fibers on a pilot scale SMC line was demonstrated. A test plan for the manufacturing and mechanical testing of SMC panels was developed. This work continues outside the time frame allocated for this project. When this work is completed, it will be added to this report and posted as Appendix C. Glass fiber reinforced SMC materials have already proven feasible as a light weighting method for traditionally steel parts like the Volkswagen (VW) Atlas lift-gate (Figure 1); this project team is seeking the feasibility of basalt fiber as a drop-in replacement for glass fiber reinforced SMC. Sizing development for basalt fibers has proven that the mechanical properties are better than E-glass and closer to S-glass, which makes it an interesting material for SMC applications. Better mechanical properties translate to less material needed to achieve load case requirement for target applications. The business case has already been demonstrated for 100,000 parts per year of glass fiber reinforced SMC Atlas lift-gates compared to traditional steel manufacturing processes. Reduced overhead and assembly costs are offset by glass fiber SMC higher cost per kg beyond 100,000 parts per year, which is still a relatively low volume for the automotive industry. For basalt fiber reinforced SMC to become feasible for automotive applications, the price-performance ratio has to be precisely determined. Based on the mechanical performance it is possible to establish a range of applications and technical solutions in which the potential of basalt SMC can be utilized, while the price of the material can be used to compile the business case for such applications. Based on these business cases and the sustainability indicators, glass fiber reinforcement (or other) materials can be directly substituted. Volkswagen’s commitment to reducing carbon emissions cannot be understated. Basalt fiber shows promise of reducing the carbon footprint in SMC materials, especially if sizing optimizations can be made with thermoplastic based SMC. To fully realize the value of basalt fiber reinforced materials, a lifecycle cost analysis should be performed on basalt’s production and recycling, and then compared against E-glass. From this assessment, a true judgement can be made on the commercialization potential of this material. Figure 1. Example of Fiber Reinforced Polymer Composite Liftgate As a conclusion, we can state that Mafic basalt fiber is not a direct replacement for E-glass or E-CR glass based on price, but should be considered a technical solution when E-glass does not provide adequate performance in a composite design and S-glass, aramid and carbon fibers are too costly. Mafic basalt fiber can be placed on the high-performance fiber spectrum next to S-glass for performance but at one third the price. It should be considered for more technically challenging structural designs wherein the performance can demonstrate 20-25% performance enhancement over E-glass to elicit more strength or a weight reduction. Both Michelman and Mafic produce thermoplastic sizings which, in combination with Nylon and polypropylene resin and fibers, can further advance high speed composite implementations while maintaining an eco-friendly manufacturing process.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Disruptive neoclassical tearing mode seeding in DIII-D with implications for ITER

New studies identify the critical parameters and physics governing disruptive neoclassical tearing mode (NTM) onset. An m/n = 2/1 mode in DIII-D that begins to grow robustly after a seeding event (edge localized mode ELM or sawtooth precursor and crash) causes the mode rotation to drop close to the plasma's Er = 0 rest frame; this condition opens the stabilizing ion-polarization current 'gate' and destabilizes an otherwise marginally stable NTM. Our new experimental and theoretical insights and novel toroidal theory-based modeling are benchmarked and scalable to ITER and other future experiments. Here, the nominal ITER rotation at q = 2 is found to be stabilizing ('gate closed') except for MHD-induced transients that could 'open the gate'. Extrapolating from the DIII-D ITER baseline scenario (IBS) discharges, MHD transients are much more likely to destabilize problematic robustly growing 2/1 NTMs in ITER; this makes predictions of seeding and control of both ELMs and sawteeth imperative for more than just minimizing divertor pulsed-heat loading.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

More Powerful Twistron Carbon Nanotube Yarn Mechanical Energy Harvesters

We report that stretching a coiled carbon nanotube (CNT) yarn can provide large, reversible electrochemical capacitance changes, which convert mechanical energy to electricity. Here, it is shown that the performance of these “twistron” harvesters can be increased by optimizing the alignment of precursor CNT forests, plastically stretching the precursor twisted yarn, applying much higher tensile loads during precoiling twist than for coiling, using electrothermal pulse annealing under tension, and incorporating reduced graphene oxide nanoplates. The peak output power for a 1 and a 30 Hz sinusoidal deformation are 0.73 and 3.19 kW kg -1 , respectively, which are 24- and 13-fold that of previous twistron harvesters at these respective frequencies. This performance at 30 Hz is over 12-fold that of other prior-art mechanical energy harvesters for frequencies between 0.1 and 600 Hz. The maximum energy conversion efficiency is 7.2-fold that for previous twistrons. Twistron anode and cathode yarn arrays are stretched 180° out-of-phase by locating them in the negative and positive compressibility directions of hinged wine-rack frames, thereby doubling the output voltage and reducing the input mechanical energy.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Demand Response Optimization and Management System for Real-TIme (DROMS-RT)

To design and demonstrate DROMS-RT, a highly distributed Demand Response Optimization and Management System for Real-Time (DROMS-RT) power flow control to support large scale integration of distributed renewable generation into the grid. AutoGrid developed a novel control and communications platform to allow highly dispatchable demand response (DR) services in time frames suitable for providing ancillary services to the transmission grid. These services will be substantially less expensive and more efficient than other forms of ancillary services options currently available to manage the intermittency associated with large-scale renewable integration. DROMSRT successfully leveraged Automated Demand Response (ADR) by fundamentally re-thinking the architecture of the DR platform from the ground up and by developing innovative new technologies in a number of areas related to DR. DROMS-RT leveraged the low-cost, open, interoperable DR signaling technology, OpenADR, and low-cost, internet-protocol based telemetry solutions to reduce the cost of hardware. This allowed DROMS-RT to provide dynamic price signals to millions of OpenADR clients. Statistically rigorous signal processing techniques were developed to reliably detect even small load reductions in the presence of noisy baseline profiles. Novel forecasting engines based on modern online machine learning algorithms enabled accurate individualized forecasts for customer loads in the presence of dynamic pricing signals, and a real-time decision engines enabled continuous optimization and optimal dispatch of DR resources across a large portfolio of heterogeneous loads that respond at varying time-scales. Moreover, the real-time optimization conducted by the decision engine can utilize grid physics to maximize load reduction at the transmission system in addition to the distribution sites, for more efficient grid operation. Finally, the Software-as-a-Service (SaaS) availability of the DROMS-RT platform has reduced the cost of deployment and enable participation of small commercial and residential customers in DR who otherwise would not be able to do so.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

ULTIMATE FY22 Creep Test Facility Report (FY23 ARPA-E Milestone Report)

In the 18-month Phase 1 of this project, a facility was assembled for creep testing of refractory metals at 1300°C. This report focuses on the four creep frames that are operational and using an inert gas system (argon) to limit oxidation of the refractory metal specimens being tested. This report details the operations for the first period of operation including the results and lessons learned for Nb- and Mo-based alloy specimens tested by the ORNL team. For an alloy development program, a particularly unique feature of the ORNL facility is more than 40 years of experience conducting mechanical properties testing on sub-sized test specimens (25 mm long dogbones). Due to proprietary constraints, only one representative set of team data are provided. The primary concern for testing Nb-based alloys is oxygen ingress. Despite several strategies to reliably limit O ingress, including getters and Ar gas purity, the experimentally informed strategy currently being developed is a new load train design intended to better seal the system. Hardware for the new design is currently being fabricated.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Blue Rock CropSpanPV - Low Cost Racking for Agricultural Solar Photovoltaics

In this work, a total of four solar panel layouts, applied to Agrivoltaics, are investigated. This study presents two hypotheses: 1. Prefabrication - Lower total cost can be achieved by constructing a pre-assembled, pre-wired solar array in a factory, with automation, then rapidly deploying it in the field. 2. Tension Structures - Using tension structures in a way to suspend an overhead solar array also reduces costs when compared to conventional support methods. Designs are presented for frames to hold the panels. Configurations are advanced to connect the frames into arrays. Supports and foundations to hold the arrays in the desired layout are calculated, selected and presented. Cost models are prepared for the four layouts, which include definition of the business enterprise, the manufacturing operation, and the required facility for production at scale. Cost models include, detail material and task/labor take-offs for both manufacturing and installation. Comparisons with conventional system adapted to Agrivoltaics reveal that the two hypotheses do not hold true. A prefabricated array requires additional material that is not needed in the base system and the cost of this additional material is not outweighed by the cost savings of reduced field installation. The cost of wire rope for a tension structure does result in an economy of material, however, the cost of end connections and tensioning devices adds significantly to the cost of the overall tension structure. Foundation loads with tension structures, especially the large wind uplift seen with a fixed tilt solar array, impose significant constraints and high costs. The following conclusions are recommended for further consideration: 1. Best Case Agrivoltaic Configuration - The best value/lowest cost configuration for agrivoltaics is the installation of solar panels mounted on a single axis tracker in either a 2-in-portrait or 2-in landscape arrangement. This is useful for grazing lands and for staple crops which require high light levels. These applications represent the vast majority of the potential agrivoltaic market. Important elements in this configuration are the specific geometric layout coordinated with the various field operations and a control system linked between the farm equipment and single axis tracker. The control system is to monitor location and orientation, then actively tilt the solar panels or brake the field equipment to provide clearance and avoid collisions. 2. Long Span Applications - The use of tension structures for an overhead fixed tilt array is beneficial where long spans are a necessity, especially where the base support in the project location has consolidated rock near the surface or some other solid structure. One application is spanning wide irrigation canals. Another may be as an installation at the top deck of parking structures. 3. Direct Ground Mount Configuration – Having skids at the base of a pre-fabricated array that extend when the array is deployed, could be a successful design. This could be a useful strategy for dense, flat, ground-mount configurations like that employed by a couple of successful commercial operations (5G Maverick and Erthos). Arrays would be orientated north and south, deployed very low on prepared grade. Arrays would be aligned closely next to each other and anchored with small ground screws or simply with ballast. This same product arrangement could be very useful for rapid deployment and set-up of solar arrays for temporary deployments, disaster response and the military operations

14 SOLAR ENERGY↗
DOE OSTI2019

Thermally Anisotropic Composites for Improving the Energy Efficiency of Building Envelopes

This article describes a novel application of thermal anisotropy for improving the energy efficiency of building envelopes. The current work was inspired by existing research on improved heat dissipation in electronics using thermal anisotropy. Past work has shown that thermally anisotropic composites (TACs) can be created by the alternate layering of two dissimilar, isotropic materials. Here, a TAC consisting of alternate layers of rigid foam insulation and thin, high-conductivity aluminum foil was investigated. The TAC was coupled with copper tubes with circulating water that acted as a heat sink and source. The TAC system was applied to a conventional wood-framed wall assembly, and the energy benefits were investigated experimentally and numerically. For experimental testing, large scale test wall specimens were built with and without the TAC system and tested in an environmental chamber under simulated diurnal hot and cold weather conditions. Component-level and whole building numerical simulations were performed to investigate the energy benefits of applying the TAC system to the external walls of a typical, single-family residential building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

GeoMelt{sup R} In-Container Vitrification (ICV){sup TM} for Fukushima Daiichi Water Treatment Secondary Wastes - 20212

The Japanese government is supporting development work implemented jointly by Veolia subsidiaries Kurion Japan, K.K., Veolia Nuclear Solutions (VNS), Inc., and Veolia Nuclear Solutions Federal Services, LLC for treating radioactive waste generated from Fukushima Daiichi Nuclear Power Station (NPS) water treatment using the GeoMelt{sup TM} In-Container Vitrification (ICV){sup TM} technology. The initial work consisted of glass formulation and engineering-scale testing which was completed in 2018, in the frame of an IRID (International Research Institute for Nuclear Decommissioning) program as part of a project subsidized by Japan's Ministry of Economy, Trade and Industry (METI). The Fukushima Daiichi NPS Mid- and Long-Term Road-map requires investigation of methods to stabilize solid wastes (and to immobilize radioisotopes in the wastes) generated as a result of emergency response and decommissioning activities. Cooling water treatment has resulted in a significant amount of solid and slurry secondary wastes (mostly adsorbents and ion-exchange materials) which will require processing at some point. GeoMelt{sup R} ICV{sup TM} is a joule-heated melter technology which uses a refractory-lined single-use container combining the melter and disposal container. There is no pouring required nor concerns with refractory corrosion which allows the process to accommodate a wide range of waste chemistries and high waste loadings. The testing described here consisted of three engineering-scale melts, each processing between 212 kg and 240 kg of waste simulants, glass formers, and non-radioactive cesium (Cs) and strontium (Sr) tracers. Continuous isokinetic stack sampling of off-gas emissions was performed for each test in order to calculate Cs and Sr retention in the glass wasteform. Single-pass retention of Cs in the final glass wasteform ranged from 91.46 to 99.30%, and single-pass retention of Sr ranged from 99.76 to 100%. Planned particulate recycle will increase these retention levels. Melt 1 processed a mixture of KUR-EH (a zeolite-based ion-exchange material), simulated Advanced Liquid Processing System (ALPS) Carbonate and Iron Slurries, and glass additives. Melt 2 processed a mixture of KUR-EH, KUR-TSG (a titanate-based adsorbent), and glass additives. Melt 3 processed a mixture of KUR-EH, simulated barium sulfate/iron ferrocyanide sludge (AREVA sludge), and glass additives. Waste loadings for these melts ranged from 70 weight percent (wt%) to 82 wt%. Vitrification produces a waste form much denser than the stored water treatment secondary waste wastes, resulting in significant volume reduction. Volume reductions for the three tests ranged from 74 to 79 vol%. Vitrification produces a chemically durable wasteform. Pacific Northwest National Laboratory (PNNL) tested three glass samples from each engineering-scale melt) by the Materials Characterization Center 1 (MCC-1) test, an international standard leach test of the chemical durability of nuclear waste glasses. PNNL also obtained one U.S. reference glass (EA Glass) and two Japan reference glasses P0798) and tested these under the same MCC-1 conditions (90 deg. C, 10 m-1, DIW, and 7, 14, 28-day) as the GeoMelt{sup R} ICV{sup TM} glasses. The GeoMelt{sup R} ICV{sup TM} glasses exhibited lower total normalized releases and 14- to 28-day normalized release rates than the three reference glasses. These results suggest that the GeoMelt{sup R} ICV{sup TM} glasses have durabilities on par with high-level waste glasses under standard test conditions. Post-melt process sampling and analysis indicated no Cs migration into the melter refractory materials and very little deposition of Cs or Sr onto the melter hood or off-gas piping internals. The results of the testing indicated good Cs retention in the glass, high volume reduction and waste loadings, and excellent chemical durability. These factors are important to minimize treatment costs and to protect workers and the environment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Impedance Based Fixture Neutralization (FINE) Method to Replicate Field Environments in Laboratory Settings

Test article vibration test responses will vary from one test laboratory to another due to differences in shaker and fixture dynamic characteristics. This is also seen between the field and laboratory due to the differing dynamic characteristics between field assembly loading and boundary conditions compared to the laboratory configuration. This work introduces a technique called Impedance Fixture Neutralization which customizes input forces to cause consistent responses for the Device Under Test across different vibration testing conditions. The customized force neutralizes the dynamic variations between configurations for the Device Under Test. The device responses can be replicated in several situations: when using a different fixture with the same attachment points, when the test article mounting location on the fixture changes, when the force location changes, or any combination of these situations. Impedance Fixture Neutralization uses the uncoupled dynamic characteristics of the test article and excitation fixtures to customize the input thereby causing the same test article responses between two mounting configurations (either field to laboratory or two different laboratory configurations). The application of the technique is shown using an analytical model of a two-beam system and analytically using experimental FRFs from plate and frame component hardware characterization tests. In both cases a device under test is attached to two test fixtures wherein the dynamic differences in the configurations are neutralized.

Laboratory↗
DOE OSTI2022

Study of the electrothermal and MHD instabilities in exploding cylindrical foil liner

Abstract An experimental and numerical study of the plasma instabilities in an electrical exploding cylindrical Al liner is reported. The Al liner 3 mm in diameter and 10 μ m in thickness is exploded at the Qin-1 facility (450 ns, 400 kA). Various diagnostics, such as multi-frame laser shadowgraphy, an x-ray framing camera, and an x-ray backlighting system are developed. The different imaging systems are sensitive to plasma of different areal densities based on the comparison between the experiments and simulation, which reveal the dynamics of the exploding liner in more detail. The laser shadow images show the low-density plasma (∼1–2 × 10 −4 g cm −2 ) at the edge of the liner, and both the amplitude and wavelength of the plasma instabilities increase over time, which are considered to be magnetohydrodynamic (MHD) instabilities rather than electrothermal instabilities. During the ablation of the liner, quasi-periodic azimuthally correlated striations are directly observed in extreme ultraviolet (EUV) self-emission images. Meanwhile, the vertical filaments, which are electrothermal instabilities for plasma under the condition of ∂ η /∂ T < 0, are also observed in EUV self-emission images. The x-ray backlighting images of the exploding liner are obtained by placing an X -pinch load on the current-return path to serve as an x-ray point source (∼1 ns, ∼10 μ m). The x-ray backlighting results show the behavior of the high-density plasma (∼1.89 × 10 −3 g cm −2 ), which includes the transition from electrothermal to MHD instabilities. Finally, we realized a 2D MHD simulation of the exploding liner under experimental conditions, which shows good agreement with the results of the experimental perturbation.

Physics↗
DOE OSTI2025

Structural and functional analyses of SARS-CoV-2 Nsp3 and its specific interactions with the 5’ UTR of the viral genome

ABSTRACT Non-structural protein 3 (Nsp3) is the largest open reading frame encoded in the SARS-CoV-2 genome, essential for the formation of double-membrane vesicles (DMV) wherein viral RNA replication occurs. We conducted an extensive structure-function analysis of Nsp3 and determined the crystal structures of the ubiquitin-like 1 (Ubl1), nucleic acid binding (NAB), β-coronavirus-specific marker (βSM) domains, and a sub-region of the Y domain of this protein. We show that the Ubl1, ADP-ribose phosphatase (ADRP), human SARS Unique (HSUD), NAB, and Y domains of Nsp3 bind the 5’ UTR of the viral genome and that the Ubl1 and Y domains possess affinity for recognition of this region, suggesting high specificity. The Ubl1-Nucleocapsid (N) protein complex binds the 5’ UTR with greater affinity than the individual proteins alone. Our results suggest that multiple domains of Nsp3, particularly Ubl1 and Y, shepherd the 5’ UTR of the viral genome during translocation through the DMV membrane, priming the Ubl1 domain to load the genome onto N protein. IMPORTANCE The largest protein encoded by the SARS-CoV-2 genome is Nsp3. In infected cells, this multi-domain protein forms a pore structure in the virus-induced double-membrane vesicles (DMV). We have incomplete data on Nsp3 molecular structure, and here, we describe crystal structures for multiple domains of Nsp3. It is thought that newly replicated viral RNA transits through the DMV pore; however, we possess incomplete data on which regions of Nsp3 actually interact with RNA. Here, we present data showing that five domains of Nsp3 interact with the 5’ UTR of the SARS-CoV-2 RNA, including the Y domain for which no function has ever been discovered. These data suggest that the pore structure plays an active role in recognizing the terminal end of the genome, transiting and loading the viral RNA onto the cytoplasmic nucleocapsid protein. These data help expand our knowledge of Nsp3 structure and function and the SARS-CoV-2 replication cycle.

Microbiology↗
DOE OSTI2025

Thermal and structural analysis of a new WEST reciprocating probe head with Titanium-Zirconium-Molybdenum armour material

The Tore Supra tokamak was transformed into an X-point divertor fusion device in the frame of the WEST (W-for tungsten-Environment in Steady-state Tokamak) project, launched in support of the ITER tungsten divertor strategy. WEST began operation in 2017. A new reciprocating probe head, equipped with a Titanium-Zirconium-Molybdenum (TZM) heat shield, was recently built and operated on WEST during the C9 Campaign in early 2024. TZM was chosen as armour material for its very good mechanical properties between 700 °C and 1400 °C. This material was already extensively used for probe heads and other plasma facing components on the Alcator C-Mod tokamak. Here, this paper presents the design of the new WEST probe head. It is equipped with tungsten filaments that can be heated to emit electrons and provide a direct measurement of the plasma potential in the scrape-off layer, and it is also equipped with a pair of Langmuir probes. The probe plunges vertically into the plasma, reaches its maximum dive depth, then returns to its protected resting position in about 0.25 s. Thermal loads are calculated using as input the thermal properties of TZM and radial profiles of the heat flux measured in the past by other reciprocating probes, and scaled upwards to the expected heat loads in the WEST scrape-off layer. An analytical estimation of Electromagnetic (EM) loads will also be presented, as well as a thermal and structural analysis of the probe for 15 cycles at maximum plunge depth. The probe is observed by an infrared camera. Comparisons between the heat flux deduced by the Langmuir probe and the infrared radiance of the probe housing during plasma exposure are finally presented.

Diagnostic↗
DOE OSTI2021

Design and Analysis of an Advanced Three-Point Bend Test Approach for Miniature Irradiated Disk Specimens

Candidate tungsten armor materials in a magnetic confinement fusion device must be able to withstand thermal variation that leads to internal stresses caused by the impinging heat load. In addition, the thermomechanical properties of these materials are degraded by irradiation-induced defect accumulation. Fission reactor–based irradiation data are used to predict the fusion neutron damage and property change. This study examines the motivation and design of a custom-designed three-point bend test for neutron-irradiated disk specimens that are 3 mm in diameter to be able to define the flexural strength of advanced tungsten materials, alloys, and composites—and to the extent that embrittlement occurs after neutron irradiation. The theory provided shows a calculation for the flexural deflection and shear deflection due to the small-geometry constraints. A finite element deformation analysis is performed to evaluate the mechanical stress field of disk bend specimens. The stress values above 80% of the maximum stress are concentrated in 2.4 mm of the 3.0-mm length of the centerline across the tungsten disk diameter. A bend test fixture has been designed and fabricated to enable testing of these specimens with precisely engineered tolerance and minimal machine compliance. This fixture will be able to be placed inside a universal testing frame at elevated temperatures for the mechanical property evaluation of future neutron-irradiated disk specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Design and Development of a Robotic Exoskeleton Device for use in Glove Boxes - 20374

Glovebox operators in nuclear facilities often operate under radioactive environment and typically perform monotonous, dull and repetitive work. This can result in muscle fatigue leading to increased levels of accidents. Current research work aims in assisting the glovebox operators by designing a novel upper limb exoskeleton device to reduce injuries and increase worker efficiency. Almost none of the commercially available hand and upper body exoskeletons are directly suitable for use in gloveboxes. This explains the novelty of the present work in developing a wearable powered robotic exoskeleton device. The device consists of electronics, motors and spring systems mounted on adjustable plates and is supported by a stationary frame behind the worker. The device is intended to be portable and adjustable according to the operator height. The elbow has a flexion movement assisted with motor control by way of a Bowden cable system. The system is floated on a spring and pulley combination that allows for extra safety and smoothness of operation. The end points are fixed near the pivot points to help minimize unwanted movement/torque. The extension movement of the upper and lower arm are assisted by gravity and a counter spring. The shoulder and upper arm movement are held in a neutral position with a spring system for counter balance allowing small movements within the glovebox. This initial concept considers only the vertical movement of the arm. The abduction and adduction movement will not be assisted or impeded by the over shoulder plate or at the forearm plate allowing for full range of motion. Several glovebox aspects such as the level of task assistance, ergonomic design, minimum hindrance in dexterity/operator movements and tear resistance for hazardous safety reasons will be considered in the design of the exoskeleton. Computer models will be simulated to test the load levels and stress conditions on the exoskeleton to enhance the designs. The exoskeleton focusses on major muscular involvement reduction through weight offset and active assistance with minimal parts and hence the device is derived with several joint links and contains both passive and active joints. The paper details the various stages in the design development and prototype testing of the exoskeleton device. Upon successful prototype device development, human testing will be conducted in a replica of the SRS-235F hot cell facility constructed at FIU-ARC. The final stage of the project will be potential testing/deployment of the exoskeleton device in one of the glovebox facilities in Savannah River Nuclear Waste site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

International Actions to Reduce Miscellaneous Electrical Loads Energy Consumption

Miscellaneous electric loads (MELs) research dates back over 30 years, with the earliest publications about MELs originating in the late 1980s. As the number and types of MELs have grown during the intervening decades, so has the body of minimum energy performance standards (MEPS) and regulations put in place to control what is now a significant energy end use in the residential and commercial sectors. In particular, these MEPS are designed to control off-mode, standby, and connected standby power consumption to prevent energy waste. Research on MELs focuses a great deal on analyzing the characteristics of MELs, approaches for measuring their consumption, and at a higher level what constitutes a MEL. Despite these advances, there have been few comparisons of different approaches to curtail MELs energy consumption across regulatory bodies of MELs—both between and within countries—to identify similarities, gaps, and opportunities for crafting common language and standards. This study provides an analysis of international MELs-related voluntary and mandatory MEPSs across 12 economies to address this gap. The analysis demonstrates that although economies may share the commitment to regulate the energy consumption of MELs, there still is no common language for framing MELs, nor is there a shared understanding for harmonizing MEPS for MELs.

Butzbaugh, Josh↗
DOE OSTI2026

Transformative Efficiency and Automation in Modular Homes (TEAMH)

This report documents the Transformative Efficiency and Automation in Modular Homes (TEAMH) project, which evaluates the integration of advanced building envelope technologies and automation-assisted modular construction to improve residential energy performance and construction efficiency. The study investigates high-performance insulation systems, including vacuum insulation panels (VIPs), combined with light gauge steel (LGS) modular construction and factory automation. Laboratory testing, whole-building energy modeling across multiple climate zones, and factory demonstrations were conducted to assess thermal performance, energy savings, and production efficiency. Results indicate that upgraded envelope assemblies can achieve up to ~50% heating and ~34% cooling energy savings relative to IECC 2018 code-compliant homes, while automation-assisted construction can reduce wall assembly time by 24%–46% compared to conventional wood framing. The findings demonstrate the potential for scalable, high-performance modular homes that deliver significant energy savings with competitive projected costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology

The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗