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DOE OSTI2025

Simplified Model and Approach to Transform Infrared Surface Temperature to Film Effectiveness in a Conjugate Heat Transfer Experiment

In the pursuit of more efficient gas turbines, film cooling is a critical technology. This article describes a simplified engineering model based on a one-dimensional thermal resistance network. The model is used to relate film-cooling effectiveness and heat transfer augmentation to local overall cooling effectiveness in a conjugate flat plate experiment. Here, this article presents experimental proof-of-concept data to demonstrate the potential for this model. In contrast to previous approaches, neither the wall heat flux nor the adiabatic wall temperature is required to estimate the local film-cooling performance parameters. The model predicts surface temperatures that are within the experimental uncertainties over the range for which the model is trained and to within five percent when the model is extrapolated to higher coolant channel Reynolds numbers. This article is relevant to conjugate test rigs that can measure the hot-surface temperature distribution with and without film cooling. This information may also be relevant to designers as a method to approximate surface temperatures or used as an approximate heat transfer model for optimization studies.

advanced turbines↗

DOE OSTI2021

Tuning Multigrid Methods with Robust Optimization and Local Fourier Analysis

Local Fourier analysis is a useful tool for predicting and analyzing the performance of many efficient algorithms for the solution of discretized PDEs, such as multigrid and domain decomposition methods. The crucial aspect of local Fourier analysis is that it can be used to minimize an estimate of the spectral radius of a stationary iteration, or the condition number of a preconditioned system, in terms of a symbol representation of the algorithm. In practice, this is a “minimax” problem, minimizing with respect to solver parameters the appropriate measure of work, which involves maximizing over the Fourier frequency. Often, several algorithmic parameters may be determined by local Fourier analysis in order to obtain efficient algorithms. Analytical solutions to minimax problems are rarely possible beyond simple problems; the status quo in local Fourier analysis involves grid sampling, which is prohibitively expensive in high dimensions. In this paper, we propose and explore optimization algorithms to solve these problems efficiently. Finally, several examples, with known and unknown analytical solutions, are presented to show the effectiveness of these approaches.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Modeling a High-Temperature Electrochemically Driven Water-Gas-Shift Process Using a Mixed-Conducting Membrane without External Electrical Power

This paper develops a model to predict and interpret the performance of an elevated-temperature, electrochemical, membrane-assisted, water-gas-shift process. The process uses separated feed streams of H 2 O and CO to produce separated streams of H 2 and CO 2 , without an external electrical power source. The dense ceramic membrane is mixed ionic-electronic-conducting (MIEC) gadolinium-doped ceria (GDC) and the porous composite electrodes are Ni-YSZ. At elevated temperature, GDC conducts both oxygen ions and small polarons. The present process uses chemical potential to drive the process. Electrochemical oxidation of CO proceeds within the composite anode and H 2 O reduction proceeds within the composite cathode. At high temperature (e.g., T > 700 °C), GDC has significant electronic leakage in the form of a reduced-cerium small polaron, which supports the charge-transfer reactions. In a typical electrolyzer or fuel cell, this leakage is significantly problematic. However, the present process depends on the leakage current to complete the electrochemical circuit. Model development and validation is based on measured material properties and reactor performance. Potential applications include using CO-rich blast-furnace off gases in steel processing, producing separated streams of H 2 and CO 2 .

Zhu, Huayang↗

DOE OSTI2020

Linking crop traits to transcriptome differences in a progeny population of tetraploid potato

Background: Potato is the third most consumed crop in the world. Breeding for traits such as yield, product quality and pathogen resistance are main priorities. Identifying molecular signatures of these and other important traits is important in future breeding efforts. In this study, a progeny population from a cross between a breeding line, SW93–1015, and a cultivar, Désirée, was studied by trait analysis and RNA-seq in order to develop understanding of segregating traits at the molecular level and identify transcripts with expressional correlation to these traits. Transcript markers with predictive value for field performance applicable under controlled environments would be of great value for plant breeding.Results: A total of 34 progeny lines from SW93–1015 and Désirée were phenotyped for 17 different traits in a field in Nordic climate conditions and controlled climate settings. A master transcriptome was constructed with all 34 progeny lines and the parents through a de novo assembly of RNA-seq reads. Gene expression data obtained in a controlled environment from the 34 lines was correlated to traits by different similarity indices, including Pearson and Spearman, as well as DUO, which calculates the co-occurrence between high and low values for gene expression and trait. Our study linked transcripts to traits such as yield, growth rate, high laying tubers, late and tuber blight, tuber greening and early flowering. We found several transcripts associated to late blight resistance and transcripts encoding receptors were associated to Dickeya solani susceptibility. Transcript levels of a UBX-domain protein was negatively associated to yield and a GLABRA2 expression modulator was negatively associated to growth rate.Conclusion: In our study, we identify 100’s of transcripts, putatively linked based on expression with 17 traits of potato, representing both well-known and novel associations. This approach can be used to link the transcriptome to traits. We explore the possibility of associating the level of transcript expression from controlled, optimal environments to traits in a progeny population with different methods introducing the application of DUO for the first time on transcriptome data. We verify the expression pattern for five of the putative transcript markers in another progeny population.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

LANSCE 21st Century Deterrence

The LANSCE accelerator is an important tool in the assessment and certification of the nation’s nuclear stockpile. LANSCE provides critical materials and nuclear data needed to develop a predictive capability for the performance of nuclear weapons. As the stockpile ages, materials are replaced, and manufacturing processes change, it is critical that we understand how these changes impact device performance. Dynamic proton radiography and neutron diffraction are ideally suited to contribute to this need. These capabilities are essential to enabling the NNSA labs to become more responsive and agile in advancing the deterrent of the future.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

FY19 FES Theory Performance Target (Final Report)

Understanding the relevant turbulent transport mechanisms at the edge of a high-performance tokamak is essential for predicting and optimizing the H-mode pedestal structure in future burning plasma devices. Global electromagnetic gyrokinetic simulations will be performed based on representative experimental pedestal scenarios in order to clarify which instabilities are most important for each of the particle and heat transport channels. Edge transport modeling will be performed in order to estimate and bound the particle and heat sources—e.g., the ionization density source and the atomic energy loss channels due to ionization, charge exchange, and radiation. Comparisons will be made with data from the DIII-D, JET, C-Mod and NSTX or MAST experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Uncertainties in Density and Simulation Parameters for Radiographic Reconstructions Using Machine Learning

We will develop new and improved methods that will enable a fuller and more extensive use of experimental data, such as from radiographic imaging, towards better characterizing and reducing uncertainties in predictive modeling of weapons performance. We will achieve this by leveraging recent developments in the areas of computational imaging, statistical and machine learning, and reduced order modeling. Key new aspects of our approach include (a) a coupling of deep learning based density reconstruction with fast hydrodynamics simulators that will permit the development of certain guarantees on extrapolatability and bounds on certain other hydrodynamics-related para- metric uncertainties and (b) a dual approach towards better characterizing uncertainties in density reconstruction using deep learning based surrogates to accelerate Bayesian reconstructions on the one hand and using variational inference and Bayesian machine learning on the other hand.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

Hydrodynamic and Radiographic Toolbox (HART)

With a multi-lab and university team, we propose to develop new methods for a Hydrodynamic and Radiographic Toolbox (HART) that will enable a fuller and more extensive use of experimental radiographic data towards better characterizing and reducing uncertainties in predictive modeling of weapons performance. We will achieve this by leveraging recent developments in areas of computational imaging, statistical and machine learning, and reduced order modeling of hydrodynamics. In terms of software practices, by partnering with XCP (RISTRA Project) we will conform to recent XCP standards that are inline with modern software practices and standards and ensure compatibility and ease of inter-operability with existing codes. Three new activities under this proposal include (a) the development and use of deep learning-based surrogates to accelerate reconstruction and variational inference of density fields from radiographs of hydrotests, (b) a model-data fusion strategy that couples deep learning-based density reconstructions with fast hydrodynamics simulators to better constrain the reconstruction, and (c) a method for treating asymmetries using techniques adopted from limited view tomography. All three new activities will be based on improved treatment of scatter, noise, beam spot movement, detector blur, and flat fielding in the forward model, and a use of sophisticated priors to aid in the re construction. The improvements to the forward model and improved algorithmic design of the reconstruction when complete will be contained in the iterative reconstruction code SHIVA—a code project that we have recently initiated. The many ways in which machine learning can be used in the reconstruction work will be contained in a code HERMES that has been initiated with DTRA support. For example, the significant levels of acceleration that will likely be achieved by the use of machine learning techniques will permit us (and are required) to quantify uncertainties in density retrievals. Next, the two-way coupling between density reconstruction and model-based simulation of the hydrodynamics will be contained in code EREBUS, and will permit a fuller realization of the potential of the data to constrain the hydrodynamic model and better address issues related to asymmetries in the problem. Finally, we anticipate that the better consistency with physics achieved in our reconstructions will allow them to be used by X-Division more so than today.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

Product Consistency Test Results for the LXC-Series Glasses

This report provides chemical analysis of a series of Product Consistency Test (PCT) leachates from simulated nuclear waste glasses. The resulting data will be used in the development of improved property/composition models. For some of the glass leachates, minor scatter among the triplicate values of some analytes was observed. For other leachates, there were more significant differences among the triplicate values. A review of the PCT data noted that there was little difference between the normalized values on the basis of targeted or measured glass composition. Several of the canister centerline cooled study glasses have NC i values that are greater than the Hanford Tank Waste Treatment and Immobilization Plant immobilized low-activity waste constraint of 4 g/L for B and Na. The results of these glasses will help ensure the ability of advanced glass performance models to appropriately predict acceptable compositions. For many of the study glasses, heat treatment had only a marginal impact on the NC i values. The samples of the Environmental Assessment (EA) reference glass included with each PCT set had generally consistent NC i values. The release rates for boron and sodium, and for sodium and silicon were highly correlated for the study glasses, while for the other analytes, less correlation was observed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Product consistency test results for the LAW Phase 4 gases

In this report, the Savannah River National Laboratory provides chemical analysis of Product Consistency Test (PCT) leachates from a series of simulated nuclear waste glasses fabricated at the Pacific Northwest National Laboratory (PNNL). The series included quenched and canister-centerline cooled (CCC) versions of the glasses. The resulting data will be used in the development of enhanced property/composition models for waste vitrification at Hanford. For some of the glass leachates, minor scatter among the triplicate values of some analytes were observed. For other leachates, there were more significant differences among the triplicate values. A review of the PCT data noted that there was little difference between the normalized values based on targeted or measured glass composition. Several of the study glasses have normalized concentration of element “i” (NCi) values that are greater than the Hanford Tank Waste Treatment and Immobilization Plant immobilized low-activity waste constraint of 4 g/L for boron (B), sodium (Na), and silicon (Si). The results of these glasses will help ensure the ability of advanced glass performance models to appropriately predict acceptable compositions. For the study glasses with NCi values exceeding 4 g/L, the CCC heat treatment samples had generally lower NCi values than quenched samples. The samples of the Environmental Assessment (EA) reference glass included with each PCT set had generally consistent NCi values. The release rates for boron (B), potassium (K), lithium (Li), sodium (Na), and silicon (Si) were highly correlated for the study glasses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Compact Solid-State High-Voltage Switch

Researchers at Sandia have developed a semiconductor-based high-voltage switch, with experimental results showing potential for enhanced radiation hardness, for use in multiple power conversion applications. Gallium nitride (GaN) metal-oxide semiconductor field effect transistors (MOSFETs) were modeled using commercial and Sandia CHARON simulation software to understand their performance and for future prediction of device operation in radiation environments.

42 ENGINEERING↗

DOE OSTI2022

Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions

Many materials of interest to Sandia transition from fluid to solid or have regions of both phases coexisting simultaneously. Currently there are, unfortunately, no material models that can accurately predict this material response. This is relevant to applications that "birth stress" related to geoscience, nuclear safety, manufacturing, energy production and bioscience. Accurately capturing solidification and residual stress enables fully predictive simulations of the evolving front shape or final product. Accurately resolving flow of proppants or blood could reduce environmental impact or lead to better treatments for heart attacks, thrombosis, or aneurism. We will address a science question in this proposal: When does residual stress develop during the critical transition from liquid to solid and how does it affect material deformation? Our hypothesis is that these early phases of stress development are critical to predictive simulation of material performance, net shape, and aging. In this project, we use advanced constitutive models with yield stress to represent both fluid and solid behavior simultaneously. The report provides an abbreviated description of the results from our LDRD "Stress Birth and Death: Disruptive Computational Mechanics and Novel Diagnostics for Fluid-to-Solid Transitions," since we have written four papers that document the work in detail and which we reference. We give highlights of the work and describe the gravitationally driven flow visualization experiment on a model yield stress fluid, Carbopol, at various concentrations and flow rates. We were able to collapse the data on a single master curve by showing it was self-similar. We also describe the Carbopol rheology and the constitutive equations of interest including the Bingham-Carreau-Yasuda model, the Saramito model, and the HB-Saramito model including parameter estimation for the shear and oscillatory rheology. We present several computational models including the 3D moving mesh simulations of both the Saramito models and Bingham-Carreau-Yasuda (BCY) model. We also show results from the BCY model using a 3D level set method and two different ways of handling reduced order Hele-Shaw modeling for generalized Newtonian fluids. We present some first ever two-dimensional results for the modified Jeffries Kamani-Donley-Rogers constitutive equation developed during this project. We include some recent results with a successful Saramito-level set coupling that allows us to tackle problems with complex geometries like mold filling in a thin gap with an obstacle, without the need for remeshing or remapping. We report on some experiments for curing systems where fluorescent particles are used to track material flow. These experiments were carried out in an oven on Sylgard 184 as a model polymerizing system. We conclude the report with a summary of accomplishments and some thoughts on follow-on work.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Producing ENDF/B-quality Evaluations of 239 Pu(n,f) and 235 U(n,f) Average Prompt Neutron Multiplicities using the CGMF Model

This report documents evaluations of the neutron-induced 239 Pu and 235 U average prompt neutron multiplicities, $\overline{v}_p$, using the CGMF model developed at LANL. These evaluations are not updates of existing ENDF/B-VIII.0 nuclear data, but were both re-done from "scratch". That is, all experimental data were extracted from EXFOR, re-normalized to the newest nuclear data representing monitor observables, and detailed uncertainties were estimated from information in EXFOR as well as from templates of expected measurement uncertainties. We also included experimental data that were not yet available for ENDF/B-VIII.0, for instance, the data of Marini et al. for 239 Pu(n,f) $\overline{v}_p$ or the data of Khoklov et al. for 235 U(n,f) $\overline{v}_p$. Finally, we include the CGMF model; it computes $\overline{v}_p$ based on model parameters that at the same time calculate fission fragments as a function of mass, Y (A), the average total kinetic energy as a function of incident-neutron energy, $\langle TKE \rangle$(E inc ), etc. Such a detailed fission model that ties together many fission quantities has not been used to date for any $\overline{v}_p$ evaluation in ENDF/B. Here, we show that we can get evaluated 235 U(n,f) and 239 Pu $\overline{v}_p$ that not only correspond well to experimental $\overline{v}_p$, but that the associated evaluated model parameters also yield parameterizations of Y (A), $\langle TKE \rangle$(E inc ), etc., that correspond well to their respective experimental data. The new evaluated 239 Pu(n,f) $\overline{v}_p$ was also combined into a 239 Pu test file with the newest nuclear data for the 239 Pu prompt-fission neutron spectrum and fission cross sections. This new 239 Pu file performed reasonably well in predicting PU-MET-FAST assemblies, reaction rates in Jezebel and Flattop and three LLNL pulsed spheres. Due to that, the new 239 Pu(n,f) $\overline{v}_p$ evaluation presented here is being considered for ENDF/B-VIII.1. Hence, we can show here that CGMF is able to produce ENDF/B quality $\overline{v}_p$ nuclear data.

239Pu, 235U, Average Prompt-fission Neutron Multip↗

DOE OSTI2022

Development of a Gibbs Energy Minimiser for the MOOSE-based Corrosion Modelling App Yellowjacket and Validation of MSTDB

Nuclear materials are highly complex multiscale, multiphysics systems,and an effective prediction of nuclear reactor performance and safety requires simulation capabilities that tightly couple different physical phenomena. The Idaho National Laboratory’s Multiphysics Object Oriented Simulation Environment (MOOSE) provides the computational foundation for performing such simulations. With the move towards advanced reactors, such as the Molten Salt Reactor (MSR), that employ high temperature fluids compared to conventional reactors, corrosion has become a problem of great interest. A new application called Yellowjacket is currently under development to directly couple thermodynamic equilibrium and kinetics with phase field models in order to model corrosion in MSRs. As part of Yellowjacket, a Gibbs energy minimiser is being developed to perform thermochemical equilibrium calculations for a range of different materials, which is currently in its infancy. This report describes the further progress towards the development of Yellowjacket Gibbs energy minimiser. Ontario Tech University is developing a new Gibbs energy minimiser for Yellowjacket which is the primary contribution of this work. The aim to develop a thermochemistry solver for the MOOSE framework following the same development philosophy and using the same tools and libraries. A special focus is on performance, documentation and SQA. Furthermore through a scope extension partway through the fiscal year a thorough assessment of the MSTDB-TC v1.3 was performed at Ontario Tech University in the context of continuous improvement and quality assurance. The objective of the work was to have an arm’s length review of the database to give confidence that the database is performing as it was intended while assessing its current state to give recommendations to future developments. This assessment involved two parts: A) a quantitative assessment, and B) a qualitative assessment. Part A involved developing an automated test-suite that would compute values from the database using Thermochimica with comparisons to experimental measurements for validation purposes, which gives confidence to the database’s stakeholders that its functioning properly. Part B involved reviewing all binary systems in the database and making a qualitative assessment with two performance indicators: comprehensiveness and overall confidence. It is important to note that the models in the database are empirical, which is to say that the quality of any model is highly dependent on the experimental data used to inform its development.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Thermal Property Measurements for an LEU-Fueled Molten Salt Reactor (Final CRADA Report)

Argonne performed thermodynamic modeling to predict eutectic compositions in the LiF-NaF-UF4 and LiF-NaF ThF4 systems. Three compositions each of LiF-NaF-UF4 and LiF-NaF-ThF4 molten salts were produced and the thermal properties between 400 and 600 °C were measured. One composition from each salt system was selected for measurements of heat capacity and thermal diffusivity across temperature ranges suggested by FEI experts as beneficial to industry.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

A Block-Structured Adaptive Mesh Framework to Solve Radiation Transfer Equation in Irregular Embedded Geometries

Radiation transport arises in various scientific, industrial, and medical fields, and understanding its effect in applications is needed to make accurate predictions, safety assessments and performance optimizations. Solving the Radiation Transport Equation (RTE) is challenging due to its integro-differential nature, which involves both differential and integral terms. The differential term describes the change in radiation intensity due to absorption and emission, while the integral term accounts for scattering. The accurate modeling of radiation is further complicated in many applications due to the complex, irregular geometries. Various methods exist for solving the RTE, including the zonal, Monte Carlo, spherical harmonics, discrete ordinates, and finite volume methods. Traditional mesh-based approaches, which rely on structured or unstructured meshes, struggle with irregular geometries due to: a) the difficulty of conforming structured grids to irregular domains, b) challenges in enforcing boundary conditions correctly, and c) the additional computational cost of unstructured mesh methods. This work presents a second-order accurate method for solving the RTE in irregular geometries. The radiation intensity is discretized using the finite-volume method in both spatial and angular directions on regular Cartesian grid blocks. Leveraging the block-structured adaptive mesh refinement (AMR) framework provided by AMReX, our method refines the grid locally to reduce spatial discretization error, ensuring a converged numerical solution while minimizing computational costs elsewhere. A two-stage deferred correction approach is employed: First, a first-order discretization on grid blocks is solved using an algebraic multigrid method in HYPRE. Second, a correction term is applied explicitly to achieve second-order accuracy. The correction term is calculated by approximating the radiation flux on cell faces using a Total Variation Diminishing (TVD) scheme. This approach ensures quick convergence of the multigrid method while preserving higher-order accuracy of the numerical solution. Irregular geometries are resolved as embedded boundaries (EB), resulting in both cut cells and regular cells. In cut cells, we modify the fluxes using face fractions and incorporate additional contributions from EB boundary conditions. To ensure higher-order convergence near the EB interface, the correction term is modified by interpolating the radiation intensity to fictitious ghost points. The implementation takes advantage of modern supercomputers by leveraging AMReX’sMPI/X parallelization strategy where X can be MPI or a GPU accelerator including CUDA, HIP and DPC++. We validate our solver using classical test cases, both with and without EB, demonstrating accuracy and efficiency. Additionally, we analyze the impact of adaptive mesh refinement on solution accuracy and computational cost, highlighting the advantages of our approach for high-resolution radiation transport simulations.

computational fluid dynamics (CFD)↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

36 MATERIALS SCIENCE↗