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NASA Electric Vertical Takeoff and Landing (eVTOL) Aircraft Technology for Public Services – A White Paper

History has shown that our personal life is highly dependent on the technology that people have developed. A strategic scan of the aerospace environment at the beginning of the 21st century strongly suggests that the world might be approaching a new age of airpower—the era of electrified/hybrid aircraft propulsion. Undeniably, starting from the Montgolfier Brothers balloon flight in 1783, to the Wright Brothers piston engine flight in 1903, and the jet engine of the 1960s, or the space age of today, one can say that leaps in propulsion technology have marked the different ages of human flight. The technological advancements, brought at the beginning of 21st century by the revolution in data exchange, computational power, sensors, wireless communication, internet, and autonomy, contributed to the vision of this new age of propulsion we are approaching. Historically, conventional vertical takeoff and landing (VTOL) aircraft have been equipped with propulsion units relying on complex internal combustion machines (turbines, piston engines, for example), and complex mechanical arrangements (gearboxes, shafts, variable pitch propeller). By contrast, electric VTOL aircraft (eVTOL)1 rely on simpler propulsion units (electric motors and in some cases fixed-pitch propellers). This promotes redundancy and improves tolerance to failures, in turn improving safety. The use of simpler electric propulsion units should also allow significant acquisition and operating cost reductions. Whether full-electric (relying solely on batteries) or hybrid-electric (relying on a combination of batteries, fuel-powered engines, and generators.), eVTOLs are also expected to generate less noise and air pollution than conventional aircraft with similar payloads. According to the 2019 Annual Review of IATA (International Air Transport Association) [ref.1], due to an expected increase in air transport traffic by 5% every year and a doubling of air transport passenger numbers to 8.2 billion by 2037 significant challenges are posed to the aviation industry. Furthermore, this report does not factor in the expected demand for short-range (intra-city) air transportation, which is in development and yet to be operational. The increased demand to fly creates a responsibility to expand in a sustainable manner and an endeavor to develop more environmentally-friendly aircraft. eVTOL aircraft, either piloted or autonomous, is gathering considerable interest worldwide. Modern and novel full-electric or hybrid-electric eVTOL configurations enable a new paradigm shift in air transportation as the aviation industry remains committed to its goals of carbon-neutral growth from 2020 onwards and cutting CO2 emissions to half 2005 levels by 2050. While electric power has been used for decades, recent developments in mobile electric/hybrid propulsion coupled with advanced materials and autonomous systems may create the possibility to transition into the next age of air mobility propelled by electric/hybrid VTOL aircraft technology. Although eVTOL aircraft might seem like an incremental improvement or even a counterintuitive regression with regard to past VTOL development, it has in fact the potential to transform air mobility across a wide range of government applications. Previous transformations in aviation generated dramatic leaps in performance, but the cost was commensurate with performance, limiting quantity produced. This next age appears to take a different approach. Performance may not increase, but at this moment technology is poised for future urban mobility that will spawn commercial passenger drone services, that is, autonomous (pilotless) air taxis and thereby add a new dimension to the urban transportation mix of the future [ref. 2]. Advances in electric propulsion, autonomous flight technology, and 5G communication networks will enable this fast new-growing market to become a reality. It is now time to envision the introduction of electric/hybrid eVTOL aircraft for Public Services2. We believe that in the next decades eVTOL aircraft will have the potential to become an essential tool to Public Service agencies around the world in applications such as firefighting, public safety, search and rescue, disaster relief and law enforcement. This is due to several major factors. • First, with the increasing popularity of small, unmanned aircraft vehicles (UAVs) or drones, many companies today are focusing on the development of passenger UAVs designed to accommodate up to five passengers or equivalent cargo payload. Many such configurations are electric or hybrid-electric designs with VTOL capabilities. Several of these projects have started a flight test program and many more are expected to be in the experimental and development phase in 2020. Such revolutionary vehicles could be in commercial operations by 2030. These eVTOL systems could be ready for selected Public Services missions even sooner. • Second, although these advanced eVTOL vehicles under development still need access to fuel (hybrid) and/or electric charging capability, they can take off and land from almost anywhere. Therefore, such vehicles, both manned and unmanned can be successfully integrated for the critical missions of the Public Services with extra deployment flexibilities. • Third, advancement in electric propulsion systems in the automotive industry together with NASA’s leading efforts in electrification of aircraft propulsion systems, FAA’s ongoing active eVTOL certification programs, and EASA’s proposed framework for the certification of electric/hybrid small category VTOL aircraft in Europe [ref. 3] will help accelerate industry electric propulsion system development and integration. • Finally, eVTOL vehicles could be deployed for Public Services sooner than air taxi or other commercial applications, since Public Services missions may be more easily approved based on specific mission criteria, localized airworthiness authority for public-use aircraft3, and are normally operating under centralized airspace management and control by the theater command. Moreover, public perception and acceptance are generally less of a concern when operations save lives and benefit the wider community. The prioritized introduction of eVTOL aircraft in Public Services is ambitious, but we believe it is achievable in the coming decades if fundamental enablers (people and technologies) are engaged in defining the objectives and needs of these missions. The revolution that is currently taking place in eVTOL aircraft represents an unprecedented opportunity to develop a safer, more affordable, more available and more environmentally friendly future of vertical flight. To ensure that these novel aircraft meet the future expectations of Public Services, it is essential to take a collaborative and multi-disciplinary approach to their development, across engineering disciplines, policy-making, program management, business case development, manufacturing, and flight demonstrations. It should be noted that the term eVTOL (in the near term) used throughout this publication implies aircraft capable of transporting up to 5 persons which may or may not include a pilot if operated fully autonomously, assuming an average of 200 pounds (91 kg) per person or equivalent payload and a range up to 60 miles plus a suitable reserve. Hybrid or hydrogen powered eVTOLs would have greater range. For example, a “3-seat” eVTOL aircraft may only be able to carry two fully equipped firemen, and payload capacity is more relevant when used for the supply mission. Moreover, this paper concentrates on the “last-mile” solutions with a deployment time of no more than 6 hours. Although not specifically discussed in this document, it is understood that the future of Transformative Vertical Flight in general and Public Services, in particular, will also involve smaller UAVs that will undoubtedly play a crucial role in future aerial operations. For example, smaller unmanned aircraft may be used to dispatch medical supplies, portable filtration systems or perform the Search task of future Search and Rescue (SAR) operations. Close collaboration between the aircraft industry, the Civil Aviation Authorities (CAA), e.g., Federal Aviation Administration (FAA), European Aviation Safety Agency (EASA), Transport Canada Civil Aviation (TCCA) and the Department of Defense (DoD) certifiers, will help identify Public Services requirements, define expectations and limit development cost and timescales. Take the US Air Force Agility Prime as an example, the majority of the eVTOL application opportunities and mission elements identified are in line with the NASA TVF WG-4 objectives and use cases. Together, it forms a strong partnership to accelerate the development, certification, and practical deployment for public service missions. The US Air Force Agility Prime has been a collaboration partner on this white paper, and provided valuable input and recommendations. Most of the eVTOL public service mission elements discussed in this paper and additional use cases envisioned by the NASA TVF WG-4 team are shared by the Agility Prime program. The focus and efforts of the Agility Prime in product and system development, industry and government partnership, accelerated certifications as well as early test and deployment are totally in sync with the path forward recommended by this white paper. This kind of collaboration and partnership will help enable the practical use of the eVTOL for public service missions, benefit the eVTOL public acceptance, and accelerate the eVTOL industry revolution.

Johnny T. Doo↗

Preliminary conceptual design of fast neutron spectrum nuclear thermal rocket cores using monolithic uranium nitride fuel

This paper presents a few nuclear thermal rocket (NTR) reactor core preliminary conceptual designs based on the use of monolithic uranium nitride (UN) fuel plates or pins clad with tungsten (W), alloyed or unalloyed as needed. High-assay low-enriched uranium (HALEU) as well as high-enriched uranium (HEU) are considered. Nominal core thermal powers are between 300 and 1100 MW corresponding to thrusts between 66 kN and 240 kN. The estimated thrust-to-reactor-weight ratios (T/WRx) achievable with the HEU plate and pin configurations are between 3.8 and 10.9. The T/WRx achievable with the HALEU plate and pin configurations are lower, 1.9–4.0, than those achievable with HEU. It is noteworthy that even a relatively modest increase in fuel enrichment above the HALEU limit enables a significant increase in T/WRx. It must be emphasized that these results do not yet account for uncertainties and that the appropriateness of the assumed fuel thermal design limits for normal operation (i.e., peak centerline temperature of 3100 K) will need to be confirmed. Finally, just like for the other UN-based fuels currently considered for NTR applications (i.e., CERMET and CERCER), the proposed UN fuel systems need significant testing in prototypic conditions to confirm the appropriate performance for safe NTR applications. However, the monolithic fuel systems may have, overall, a higher technology readiness level (TRL), and, consequently, shorter fuel development and validation time may result.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Innovative laser-based methods for monitoring fuel retention in ITER

This paper addresses the challenge of tritium inventory management in ITER and future fusion reactors, highlighting the importance of accurate tritium measurement and its spatial distribution within the vacuum vessel. Given ITER’s operational constraints, especially the limit on tritium retention, precise measurement is essential for both safety and regulatory compliance. To tackle these questions, the paper presents the T-monitor diagnostic system developed by Forschungszentrum Jülich, which uses Laser-Induced Desorption (LID) in combination with Diagnostic Residual Gas Analysis (DRGA) to measure hydrogen isotope concentrations on the surface of divertor tiles. The system integrates a high-power laser, advanced optical components, and a Fast Scanning Mirror Unit (FSMU) for accurate laser spot positioning with rapid response. Designed to measure in situ tritium retention, the diagnostic provides high-resolution spatial mapping, vital for evaluating detritiation strategies. The laser heating process increases the divertor surface temperature to 1600 K within the laser spot, promoting hydrogen isotope desorption. Accurate measurements require the precise control of laser parameters, including pulse duration and spot size, with a target relative accuracy of 20%. The optical design includes both in-vessel and ex-vessel components, such as durable high-reflectivity mirrors made of gold and copper, selected not only for their infrared performance but also for their transmission of visible wavelengths for observation purposes. To protect optical components from contamination, a pneumatic shutter is used.

Hydrogen isotopes↗

Fast, high-fidelity, all-optical and dynamically-controlled polarization gate using room-temperature atomic vapor

We demonstrate a fast, all-optical polarization gate in a room-temperature atomic medium. Using a Polarization-Selective-Kerr-Phase-Shift (PSKPS) technique, we selectively write a π phase shift to one circularly-polarized component of a linearly-polarized input signal field. The output signal field maintains its original strength but acquires a 90° linear polarization rotation, demonstrating fast, high-fidelity, dynamically-controlled polarization gate operation. The intensity of the polarization-switching field used in this PKSPK-based polarization gate operation is only 2 mW/cm{sup 2}, which would be equivalent to 0.5 nW of light power (λ = 800 nm) confined in a typical commercial photonic hollow-core fiber. This development opens a realm of possibilities for potential future extremely low light level telecommunication and information processing systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Budget Period 2 Summary Report Part 1: Hywind Maine Project

This project was performed under the Work for Others—Funds in Agreement FIA-14-1793 between Statoil and the Alliance for Sustainable Energy, manager and operator of the National Renewable Energy Laboratory (NREL). To support the development of a 6-MW spar-mounted offshore wind turbine, Statoil funded NREL to perform tasks in the following three categories: 1. Design and analysis 2. Wake modeling 3. Concept resource assessment. This summarizes the document reports on the design and analysis work package, which built a FAST [Jonkman & Buhl, 2005] computer model of the Hywind 6-MW floating wind turbine system and uses this tool to evaluate the performance of a set of design load cases (DLCs). The FAST model was also used in Work Package 2: Wake Modeling .

17 WIND ENERGY↗

DCFC + Hydrogen Station Design Optimization [Slides]

Both direct current fast charging (DCFC) and Hydrogen stations are working to create successful long-term business models; however, analyses for DCFC and hydrogen fueling infrastructure are almost always performed separately. This work provides a detailed exploration of the benefit of integrating DCFC and hydrogen stations to lower the total system cost from load balancing and equipment cost sharing. To achieve this we have adapted the REopt optimization framework to simultaneously optimize the design and operation of integrated DCFC and H2 fueling station. Results indicate that 1) combining hydrogen fueling and DCFC stations can significantly reduce lifetime costs compared to separated stations. 2) Co-location with additional site load reduces DCFC costs, however, integration of DCFC with hydrogen provides an even greater cost reduction. 3) Adding PV to combined stations further reduces the lifetime station cost. 4) Capital investments in station combination today can help reduce the cost of operating DCFC tomorrow and 5) product diversification acts as a hedge against variability and enables a more dynamic response to market changes.

08 HYDROGEN↗

The Origins Space Telescope

The Universe has never been seen like this before. The window into the infrared opens only above Earth's atmosphere, and humanity has barely glimpsed outside. About half of the light emitted by stars, planets, and galaxies over the lifetime of the Universe emerges in the infrared. With an unparalleled sensitivity increase — up to a factor of 1,000 more than any previous or planned mission — the advance offered by the Origins Space Telescope (OST) is akin to that from the naked eye to humanity's first telescope, or from Galileo's first telescope to the first telescope in space. While key path-finding missions have glimpsed a rich infrared cosmos, extraordinary discovery space awaits; the time for a far-infrared revolution has begun.Are we alone or is life common in the Universe? OST will directly address this long-standing question by searching for signs of life in the atmospheres of potentially habitable terrestrial planets transiting M dwarf stars. How do planets become habitable? OST will trace the trail of cold water from the interstellar medium, through protoplanetary disks and into the outer reaches of our own Solar System. How do stars, galaxies, black holes and the elements of life form, from the cosmic dawn to today? With broad wavelength coverage and fast mapping speeds, OST will map millions of galaxies, simultaneously measuring star formation rates and black hole growth across cosmic time, peering deeper into the far reaches of the Universe than ever before.OST will be maintained at a temperature of 4 K, enabling its tremendous sensitivity gain, and will operate from 5 m to 600 m, encompassing the mid- and far-infrared. OST has two Mission Concepts: Concept 1 with a 9.1-m deployed off-axis primary, and Concept 2, described here, a non-deployed 5.9-m on-axis telescope with the equivalent collecting area of the James Webb Space Telescope (JWST). Concept 2 includes four instruments with capabilities for imaging (large surveys and pointed), spectroscopy (survey and high-resolution modes) and polarimetry, as well as an instrument for high-precision spectroscopy of transiting exoplanets. Concept 2 is optimized for maximum science return and minimal complexity, and offers fast mapping (approximately 60 arcseconds per second). We describe here the three key science themes for OST and the basic mission specifications.

Battersby, Cara↗

A Design and Fabrication Options Trade Study for Metallic Fuel without Internal Sodium Bonding

Nuclear fuels using alloys of uranium, or metallic fuels, have many beneficial properties. The classical metallic fuel design uses a loose fitting cylindrical “slug” of fuel placed inside stainless-steel cladding tubes where the gap is filled with sodium. This sodium bond is liquid at operating temperature and conducts heat from the slug to the cladding, especially in early life before fuel swells into contact with the cladding. Despite the benefits of sodium bonding, there is a desire to develop metallic fuel technologies without it chiefly to reduce chemical reaction hazards in spent fuel storage from sodium fast reactors operating on once-through fuel cycles. Elimination of the sodium bond may also help unlock potential benefits for fuel fabrication, reactor neutronics, and compatibility with other types of reactors. Creating a sodium-free metallic fuel revolves around the problem of manufacturing fuel slug geometries which are in close contact with the cladding at beginning of life to facilitate heat transport while alleviating fuel-cladding chemical interactions (FCCI) at this interface and providing enough free volume to accommodate fuel swelling. Accelerating development and qualification of this fuel system will require careful selection of design and manufacturing options. To this end, a design trade-off study was performed to evaluate candidate options. Several design and manufacturing options were assessed, weighted, scored, and ranked with respect to fabrication, normal reactor operation, off-normal scenarios, and back-end considerations. This effort was performed both for “baseline” needs, which represented a once-through fuel cycle at temperatures and burnups known to be viable for sodium-bonded metallic fuel, and for “enhanced” needs to represent opportunities for closed fuel cycles and/or more aggressive temperatures/burnups. The outcomes of this study prioritized a baseline technology using U-Zr alloy with additives to mitigate FCCI, produced in annular slug geometry by continuous casting, clad in austenitic stainless-steel alloy, and followed by a final step to swage the cladding down to close the gap. This study prioritized an enhanced fuel technology using U-Mo alloy, also produced by continuous casting into an annular geometry, followed by coating/plating with an FCCI barrier on the slug, again with a final step to swage the cladding diameter down using oxide dispersion strengthened steel. It was noted that development of the enhanced fuel technology would entail more risk, thus U-Zr alloy was put forth as a backup to U-Mo if challenges are encountered with FCCI barriers, and advanced ferritic/martensitic steels are put forth as a backup to oxide dispersion strengthened steels if swaging and welding are found unworkable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Photovoltaic frequency–watt curve design for frequency regulation and fast contingency reserves

When renewable energy resources are installed in electricity grids, they typically increase generation variability and displace thermal generator control action and inertia. Grid operators combat these emerging challenges with advanced distributed energy resource (DER) functions to support frequency and provide voltage regulation and protection mechanisms. This paper focuses on providing frequency reserves using autonomous IEC TR 61850-90-7 pointwise frequency-watt (FW) functions that adjust DER active power as a function of measured grid frequency. The importance of incorporating FW functions into a fleet of photovoltaic (PV) systems is demonstrated in simulation. Effects of FW curve design, including curtailment, deadband, and droop, were analyzed against performance metrics using Latin hypercube sampling for 20%, 70%, and 120% PV penetration scenarios on the Hawaiian island of Lanai. Finally, to understand the financial implications of FW functions to utilities, a performance function was defined based on monetary costs attributable to curtailed PV production, load shedding, and generator wear. An optimization wrapper was then created to find the best FW function curve for each penetration level. Lastly, it was found that in all cases, the utility would save money by implementing appropriate FW functions.

14 SOLAR ENERGY↗

Demonstration of Essential Reliability Services by a 300-MW Solar Photovoltaic Power Plant

The California Independent System Operator (CAISO), First Solar, and the National Renewable Energy Laboratory (NREL) conducted a demonstration project on a large utility-scale photovoltaic (PV) power plant in California to test its ability to provide essential ancillary services to the electric grid. With increasing shares of solar- and wind-generated energy on the electric grid, traditional generation resources equipped with automatic governor control (AGC) and automatic voltage regulation controls -- specifically, fossil thermal -- are being displaced. The deployment of utility-scale, grid-friendly PV power plants that incorporate advanced capabilities to support grid stability and reliability is essential for the large-scale integration of PV generation into the electric power grid, among other technical requirements. A typical PV power plant consists of multiple power electronic inverters and can contribute to grid stability and reliability through sophisticated 'grid-friendly' controls. In this way, PV power plants can be used to mitigate the impact of variability on the grid, a role typically reserved for conventional generators. In August 2016, testing was completed on First Solar's 300-MW PV power plant, and a large amount of test data was produced and analyzed that demonstrates the ability of PV power plants to use grid-friendly controls to provide essential reliability services. These data showed how the development of advanced power controls can enable PV to become a provider of a wide range of grid services, including spinning reserves, load following, voltage support, ramping, frequency response, variability smoothing, and frequency regulation to power quality. Specifically, the tests conducted included various forms of active power control such as AGC and frequency regulation; droop response; and reactive power, voltage, and power factor controls. This project demonstrated that advanced power electronics and solar generation can be controlled to contribute to system-wide reliability. It was shown that the First Solar plant can provide essential reliability services related to different forms of active and reactive power controls, including plant participation in AGC, primary frequency control, ramp rate control, and voltage regulation. For AGC participation in particular, by comparing the PV plant testing results to the typical performance of individual conventional technologies, we showed that regulation accuracy by the PV plant is 24-30 points better than fast gas turbine technologies. The plant's ability to provide volt-ampere reactive control during periods of extremely low power generation was demonstrated as well. The project team developed a pioneering demonstration concept and test plan to show how various types of active and reactive power controls can leverage PV generation's value from being a simple variable energy resource to a resource that provides a wide range of ancillary services. With this project's approach to a holistic demonstration on an actual, large, utility-scale, operational PV power plant and dissemination of the obtained results, the team sought to close some gaps in perspectives that exist among various stakeholders in California and nationwide by providing real test data.

14 SOLAR ENERGY↗

Code Validation of SAM Using Forced and Natural Circulation Data from NACIE-UP Benchmark

Heavy liquid metals (HLMs) are promising candidates as coolants of Generation IV fast reactors due to their thermophysical properties. In the last decade, experimental work has been proposed as part of research and development efforts to develop such systems. In this context, researchers from the Brasimone Research Center have conducted many experiments using the Natural Circulation Experiment Upgrade (NACIE-UP) facility to study the thermofluid dynamic behavior of HLMs in rod bundle configurations with or without wire wrappers. This facility consists of a rectangular loop operated with lead-bismuth eutectic. Sensors across the loop monitor relevant parameters, i.e. temperatures, heat transfer, and flow conditions. Here, in the present work, we carefully select published data from NACIE-UP to validate the System Analysis Module (SAM), a modern system analysis code developed at Argonne National Laboratory. We developed one SAM model using specifications of the facility geometry and materials existing in relevant papers and reports. On top of that, these references provided the boundary conditions for simulating natural circulation and forced convection experiments in either steady or transient conditions. The SAM model simulates five test cases with diverse operating conditions. Ultimately, the code is proven to predict temperatures and mass flow rates that closely match the experiments. The discrepancies between numerical predictions and diverse transients are limited to a few degrees Celsius, showcasing that SAM is well suited for analyzing nuclear systems relying on HLM coolants.

advanced reactors↗

Status of the PIP-II Cryoplant

The Proton Improvement Plan-II (PIP-II) is an essential upgrade to the Fermilab accelerator complex featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (Linac). The Linac contains 23 SRF cryomodules with the SRF cavities operating at 2 K, a high temperature thermal shield at 40 K and low temperature intercepts at 4.5 K. The PIP-II cryoplant will provide the necessary cooling for the cryomodules and the cryogenic distribution system interconnecting cryoplant and cryomodules. This paper describes the evolution of the PIP-II cryoplant conceptual design and specifications, including the expected heat loads, required cooling features and the integrated design. The cryoplant capacity margin analysis and fast cool-down mode will also be discussed.

43 PARTICLE ACCELERATORS↗

National Assessment of Energy Storage for Grid Balancing and Arbitrage: Phase 1, WECC

To examine the role that energy storage could play in mitigating the impacts of the stochastic variability of wind generation on regional grid operation, the Pacific Northwest National Laboratory (PNNL) examined a hypothetical 2020 grid scenario in which additional wind generation capacity is built to meet renewable portfolio standard targets in the Western Interconnection. PNNL developed a stochastic model for estimating the balancing requirements using historical wind statistics and forecasting error, a detailed engineering model to analyze the dispatch of energy storage and fast-ramping generation devices for estimating size requirements of energy storage and generation systems for meeting new balancing requirements, and financial models for estimating the life-cycle cost of storage and generation systems in addressing the future balancing requirements for sub-regions in the Western Interconnection. Evaluated technologies include combustion turbines, sodium sulfur (Na-S) batteries, lithium ion batteries, pumped-hydro energy storage, compressed air energy storage, flywheels, redox flow batteries, and demand response. Distinct power and energy capacity requirements were estimated for each technology option, and battery size was optimized to minimize costs. Modeling results indicate that in a future power grid with high-penetration of renewables, the most cost competitive technologies for meeting balancing requirements include Na-S batteries and flywheels.

energy storage↗

Continuous Evaluation of Fast Processes in Climate Models Using ARM Measurements

This five-year award supports the project “Continuous Evaluation of Fast Processes in Climate Models Using ARM Measurements (FASTER)”. The goal of this project is to produce accurate, consistent and comprehensive data sets for initializing both single column models (SCMs) and cloud resolving models (CRMs) using data assimilation. A multi-scale three-dimensional variational data assimilation scheme (MS-3DVAR) has been implemented. This MS-3DVAR system is built on top of WRF/GSI. The Community Gridpoint Statistical Interpolation (GSI) system is an operational data assimilation system at the National Centers for Environmental Prediction (NCEP) and has been implemented in the Weather Research and Forecast (WRF) model. This MS-3DVAR is further enhanced by the incorporation of a land surface 3DVAR scheme and a comprehensive aerosol 3DVAR scheme. The data assimilation implementation focuses in the ARM SGP region. ARM measurements are assimilated along with other available satellite and radar data. Reanalyses are then generated for a few selected period of time. This comprehensive data assimilation system has also been employed for other ARM-related applications.

54 ENVIRONMENTAL SCIENCES↗

International Applications for Floating Solar PV (FPV) [Slides]

Floating solar is a comparatively new concept. Floating solar is about to form a third pillar in the market for solar energy next to ground mounted and rooftop solar. The Asia-Pacific region already dominates the fast-emerging market in floating solar PV (FPV), and it looks set to build on that position as more nations get on board and costs fall. Asia-Pacific is set to increase its market share from 74% in 2020 to 87% in 2026 in terms of global installed FPV capacity. However, since floating solar systems are still a new application, there is a lack of information on its performance, cost, technical complexity, and operations and maintenance (O&M). This seminar series seeks to partially remedy that through presenting case studies that highlight the benefits, challenges, and applications of FPV in South and Southeast Asia.

14 SOLAR ENERGY↗

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗

Advanced Reactor Designs Security Analysis, Risk, and Recommendations: Risks, Consequences, and Possible by-Design Mitigation Approaches Associated with Select Advanced Reactors

Next-generation advanced reactors (ARs) incorporate enhanced safety systems, have smaller source terms, and feature compact modular designs, which should lessen their collective risk profiles. However, to fully evaluate risk, security needs to be a part of the equation. Without taking security into consideration, safety systems and components in the new ARs may be vulnerable to sabotage. These base attributes, coupled with enhanced security features specific to AR design through sound engineering and security-by-design (SeBD), should provide developers and operators with lower inherent security risk profiles. Building security early into the AR design may remove or passively secure potential critical targets from an adversary’s reach , thereby increasing overall safety and security. An integrated approach and diverse design team that includes engineering, operations, and security experts are fundamental to building security into the design without sacrificing fundamental operational efficiencies and principles. The objective of this project was to evaluate the security and safety interfaces for five classes of reactors, identify potential security vulnerabilities of structures, systems, and components (SSC), and underscore the need to consider security alongside safety in the design o f these concepts. The five reactor classes evaluated in this project and presented in this report are molten-salt reactors (MSR), high temperature gas reactors (HTGR), sodium-fast reactors (SFR), advanced light-water reactors (ALWR), and microreactors. These designs were selected because they reflect the concepts that are closest to market deployment and have received significant resource investments from the public and private sector. This project assesses the inherent security risks posed by common classes of ARs, provides a methodology and framework to assess security along with safety, and offers an analysis of potential mitigation strategies that could be incorporated. For each AR technology, the SSCs that relate to radionuclide source safety functions are discussed to understand the SSC contribution to safety and relative importance in the protective strategy for the design. The assumptions that went into evaluating each reactor concept originated from generic publicly available nonproprietary information and should not directly be used to qualify an absolute risk profile nor to rank specific AR designs. Instead, the purpose of the analysis is to understand and compare the generic inherent security risks of different AR technologies.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗