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At least 1,405 records · Page 78
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Correlating highpower conversion efficiency of PTB7:PC 71 BM inverted organic solar cells with nanoscale structures [Unraveling the correlation between the structural aspects and power conversion efficiency in PTB7:PC 71 BM inverted organic solar cells]

Advances in materials design and device engineering led to inverted organic solar cells (i-OSCs) with superior power conversion efficiencies (PCEs) to their conventional counterparts, in addition to the well-known better ambient stability. Despite the significant progress, however, it has so far been unclear how the morphologies of the photoactive layer and its interface with the cathode modifying layer impact device performance. Here, we report an in-depth morphology study of the i-OSC active and cathode modifying layers, employing a model system with the well-established bulk-heterojunction, PTB7:PC 71 BM as the active layer and poly-[(9,9-bis(3 -( N,N -dimethylamino)propyl)-2,7-fluorene)- alt -2,7-(9,9-dioctylfluorene)] (PFN) as the cathode surface modifying layer. We have also identified the role of a processing additive, 1,8-diiodooctane (DIO), used in the spin-casting of the active layer to increase PCE. Using a variety of characterization techniques, we demonstrate that the high PCEs of i-OSCs are due to the smearing (diffusion) of electron-accepting PC 71 BM into the PFN layer, resulting in improved electron transport. The PC 71 BM diffusion occurs after spin-casting the active layer onto the PFN layer, when residual solvent molecules act as a plasticizer. Furthermore, the DIO additive, with a higher boiling point than the host solvent, has a longer residence time in the spin-cast active layer, resulting in more PC 71 BM smearing and therefore more efficient electron transport. This work provides important insight and guidance to further enhancement of i-OSC performance by materials and interface engineering.

14 SOLAR ENERGY↗
DOE OSTI2020

Contribution of cryogenic thermal cycling to the atomic dynamics in a La-based bulk metallic glass with different initial states

Structural rejuvenation in metallic glasses (MGs) induced by cryogenic thermal cycling has been intensively studied. However, the effect of thermal cycling on the atomic dynamics in MGs is still missing. In this work, we present a systematic study on the atomic dynamics in a La-based MG affected by sub-Tg annealing and thermal cycling. We find that the thermal cycling has little effect on the atomic dynamics in both as-cast and annealed MGs although it could significantly increase the free volume and change mechanical properties of the as-cast MG sample. In contrast, both the structure and mechanical properties of the well-relaxed sample are almost unchanged by thermal cycling. Further, the increased open volume, mainly in the form of atomic vacancies, does not greatly promote the atomic dynamics in the as-cast MG sample, indicating that the free volume induced by thermal cycling is not the key factor in stimulating the β-relaxation and the boson peak in the studied MG.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Gaseous time projection chambers for rare event detection: results from the T-REX project. II. Dark matter

As part of the T-REX project, a number of R and D and prototyping activities have been carried out during the last years to explore the applicability of gaseous Time Projection Chambers (TPCs) with Micromesh Gas Structures (Micromegas) in rare event searches like double beta decay, axion research and low-mass WIMP searches. While in the companion paper we focus on double beta decay, in this paper we focus on the results regarding the search for dark matter candidates, both axions and WIMPs. Small (few cm wide) ultra-low background Micromegas detectors are used to image the axion-induced x-ray signal expected in axion helioscopes like the CERN Axion Solar Telescope (CAST) experiment. Background levels as low as 0.8 × 10{sup −6} counts keV{sup −1} cm{sup −2} s{sup −1} have already been achieved in CAST while values down to ∼10{sup −7} counts keV{sup −1} cm{sup −2} s{sup −1} have been obtained in a test bench placed underground in the Laboratorio Subterráneo de Canfranc (LSC). Prospects to consolidate and further reduce these values down to ∼10{sup −8} counts keV{sup −1} cm{sup −2} s{sup −1} will be described. Such detectors, placed at the focal point of x-ray telescopes in the future International Axion Observatory (IAXO), would allow for 10{sup 5} better signal-to-noise ratio than CAST, and search for solar axions with g{sub a}γ down to few 10{sup 12} GeV{sup −1}, well into unexplored axion parameter space. In addition, a scaled-up version of these TPCs, properly shielded and placed underground, can be competitive in the search for low-mass WIMPs. The TREX-DM prototype, with ∼ 0.300 kg of Ar at 10 bar, or alternatively ∼ 0.160 kg of Ne at 10 bar, and energy threshold well below 1 keV, has been built to test this concept. We will describe the main technical solutions developed, as well as the results from the commissioning phase on surface. The anticipated sensitivity of this technique might reach ∼10{sup −44} cm{sup 2} for low mass (<10 GeV) WIMPs, well beyond current experimental limits in this mass range.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Neutron detection efficiency measurements of organic glass scintillator arrays

We characterize the neutron detection efficiency of pixelated organic glass scintillator (OGS) arrays manufactured in two ways: an additive method in which the OGS is cast in place in a pixelated mold, and a subtractive method in which the scintillator is first cast as a large block before being cut in bars and bonded together to form the array. The cast-in-place array utilizes a mixture of “bis(9,9-dimethyl-9H-fluoren-2-yl)diphenylsilane” (P2), “tri([1,1'-biphenyl]-4-yl)(phenyl)silane” (PB3), and “4-bis(2-methylstyryl)benzene” (MSB), and 50% by weight of polystyrene is added to the mixture for subtractive manufactured array. We compare the performance of the OGS arrays to that of an EJ-299-33M plastic scintillator array that was manufactured using a subtractive process similar to that of the second OGS array.

Neutron detectors (cold, thermal, fast neutrons)↗
DOE OSTI2022

Characterization of Properties of Laser Powder Bed Fusion 3D-Printed Inconel 718 for Centrifugal Turbomachinery Applications

Here, this paper presents the results of a comprehensive effort to characterize the properties of Inconel 718 produced by a form of laser powder bed fusion (LPBF) additive manufacturing (AM) or 3D-printing, subsequently subjected to hot isostatic pressing (HIP) and heat treatment according to standards F3055-14a and AMS 5663, respectively. Material property data, while broadly available for traditional Inconel 718 presentations (e.g. forgings or castings), is currently lacking for the 3D-printed material. It is expected that while limited in size, the experimental data sets presented provide sufficient information to glean the capability of LPBF Inconel 718. These include: 1) Chemical composition, electron backscatter diffraction (EBSD), and x-ray energy dispersive spectroscopy (XEDS) characterization of 3D-printed material structure; 2) Tensile properties — 0.2% yield stress, ultimate stress, modulus of elasticity, and elongation to failure — based on 108 samples, as functions of temperature and sample print orientation; 3) Creep rupture data including the Larson-Miller parameter, based on 21 samples; and 4) High cycle fatigue data based on 21 samples as a function of temperature. Results are compared to available standards and/or data for forged, cast, and other AM Inconel 718. A key observation of this study, based on the EBSD results, is that while the material appears to approach full recrystallization following heat treatment, there is a detectable fraction of the material that does not fully recrystallize, resulting in a material with mechanical properties (e.g. yield stress, creep rupture) measurably lower than those of forgings, but higher than those of castings.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Crystallographic Features of the α-Phase Structure in Hafnium and Hafnium–Titanium Alloys

The structure of a hafnium crystal undergoing β → α (bcc → hcp) polymorphic transformation upon gradual cooling and the structure of Hf{sub 55}Ti{sub 45} and Hf{sub 30}Ti{sub 70} alloys formed under various kinetic conditions of polymorphic transformation are studied. The structure of the α phase in cast hafnium is shown to consist of lath crystals grouped into packets. The misorientations between separate laths in a packet are less than 1°. The Hf–Ti alloys in the cast state exhibit a mixed structure consisting of α-phase crystals of several morphological types. A structure of packet martensite is observed in the Hf–Ti alloys after quenching. Each packet includes laths of several crystallographic orientations. There is no regular alternation of differently orientated laths in the packet. The same set of α-phase orientations within an initial β-phase grain is observed independently of the cooling rate of the Hf–Ti alloys upon β → α polymorphic transformation. The misorientation of substructural elements within an α-phase crystal in the Hf–Ti alloys is ~5° for the cast state and ~2.2° after quenching.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Fabrication of U-10 wt.%Zr Metallic Fuel Rodlets for Irradiation Test in BOR-60 Fast Reactor

The fabrication technology for metallic fuel has been developed to produce the driver fuel in a PGSFR in Korea since 2007. In order to evaluate the irradiation integrity and validate the in-reactor of the starting metallic fuel with FMS cladding for the loading of the metallic fuel, U-10 wt.%Zr fuel rodlets were fabricated and evaluated for a verification of the starting driver fuel through an irradiation test in the BOR-60 fast reactor. The injection casting method was applied to U-10 wt.%Zr fuel slugs with a diameter of 5.5 mm. Consequently, fuel slugs per melting batch without casting defects were fabricated through the development of advanced casting technology and evaluation tests. The optimal GTAW welding conditions were also established through a number of experiments. In addition, a qualification test was carried out to prove the weld quality of the end plug welding of the metallic fuel rodlets. The wire wrapping of metallic fuel rodlets was successfully accomplished for the irradiation test. Thus, PGSFR fuel rodlets have been soundly fabricated for the irradiation test in a BOR-60 fast reactor.

Kim, Ki-Hwan↗
DOE OSTI2013

3D Flow and Temperature Analysis of Filling a Plutonium Mold (Revision 1) [Poster]

The plutonium foundry at Los Alamos National Laboratory casts products for various special nuclear applications. However, plutonium’s radioactivity, material properties, and security constraints complicate the ability to perform experimental analysis of mold behavior. The Manufacturing Engineering and Technologies (MET-2) group previously developed a graphite mold to vacuum cast small plutonium disks to be used by the Department of Homeland Security as point sources for radiation sensor testing. A two-stage pouring basin consisting of a funnel and an angled cavity directs the liquid into a vertical runner. A stack of ten disk castings connect to the runner by horizontal gates. Volumetric flow rates were implemented to limit overflow into the funnel and minimize foundry returns. Models using Flow-3D computational fluid dynamics software are employed here to determine liquid Pu flow paths, optimal pour regimes, temperature changes, and pressure variations.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Modular Hydropower Engineering and Pilot Scale Manufacturing

Emrgy has developed, prototyped and tested a modular hydropower system for renewable energy generation. ORNL worked with Emrgy to demonstrate the use of additive manufacturing in the production of the hydrofoils and spokes for the hydrokinetic system. Specifically, during Phase 1 of this effort, ORNL printed and finished machined patterns for both the hydrofoils and spokes that were subsequently used in a sand casting manufacturing process. Emrgy utilized the sand castings for a pilot installation in Denver, CO, where the parts represented an 80% cost savings from the previous prototype build that was manufactured using subtractive manufacturing. In addition, the castings were completed with ORNL’s newly developed AlCeMg alloy that will be tested for performance improvements including higher corrosion resistance in a water application than the 6160 alloy used previously

13 HYDRO ENERGY↗
DOE OSTI2017

Light Water Reactor Sustainability Program Interrogation of Alkali-Silica Reaction Degraded Concrete Samples using Acoustic and Thermal Techniques to Support Development of a Structural Health Monitoring Framework

Assessment and management of aging concrete structures in nuclear power plants require a more systematic approach than simple reliance on existing code margins of safety. Health monitoring of concrete structures is performed to understand the current condition of a structure based on heterogeneous measurements and then produce high-confidence actionable information regarding structural integrity. This information can then be used to support operational and maintenance decisions. The proposed diagnosis and prognosis framework consists of four elements: health monitoring, data analytics, uncertainty quantification, and prognosis. The objectives of this ongoing research project focuses on health monitoring and data analytics of concrete slab cast, which is cured using four pockets of reactive aggregates: pure silica, wells, placitas, and spratt. A controlled concrete slab with four aggregates is cast at Vanderbilt University in representative conditions to accelerate degradation due to alkali-silica reaction (ASR). Four nondestructive evaluation (NDE) techniques (thermography, mechanical deformation measurements, nonlinear impact resonance-acoustic spectroscopy, and vibro-acoustic modulation) are used to examine the degraded concrete slab. Heterogeneous data from these techniques are analyzed for assessing ASRrelated degradation in concrete samples. In addition, this report discusses thermography assessment of three cement bricks cured under different conditions to accelerate ASR-related degradation. The application of the digital image correlation technique to study ASR-related degradation on a large concrete sample at the University of Tennessee Knoxville is discussed and initial observations are presented in this report. The results from the data analysis of the NDE techniques on concrete slab cured at Vanderbilt University are discussed in detail in this report. The major outcome of the analysis suggests that the nonlinear impact resonance acoustic spectroscopy is able to detect potential degradation in a concrete slab but is unable to locate or isolate the degradation. Alternatively, the vibro-acoustic technique is able to detect degradation and locate the damage in the concrete slab cast. The outcomes supports development of a structural health monitoring framework.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Roll-to-Roll SOFC Manufacturing for Low Cost Energy Generation

Oak Ridge National Laboratory (ORNL) and Redox Power Systems, LLC. collaborated on this project to develop an integrated, continuous roll-to-toll (R2R) manufacturing processes to produce solid oxide fuel cells (SOFCs). SOFCs are ceramic-based electrochemical devices that efficiently produce electricity from hydrogen-containing fuels, including natural gas. Standard processes for manufacturing SOFCs include tape casting of the anode and electrolyte, followed by stacking of the layers, and lamination using a uniaxial press or isostatic press. After high temperature firing, the cathode and electrical contact are screen printed and fired once again to complete the cell. This effort aimed to further develop R2R tape fabrication processes for green cell fabrication with the DOE Battery Manufacturing Facility (BMF) at ORNL as next generation improvements to current methods, focusing on R2R calendering and slot die coating for lower cost, high volume approaches for multilayer green cell fabrication. Two paths were investigated in parallel in this project. The first path was to optimize R2R processing using traditional tape cast materials from the Redox production chain on the BMF’s heated calender for compressing and laminating multilayer materials. The second path was to use BMF’s pilot-scale slot-die coater for R2R manufacturing as an alternative to tape casting of some or all of the layers in the green cell. Processes have been developed and and process conditions have been identified. Additionally, basic process economics were estimated for comparison to Redox current manufacturing approaches for the applicable process modules. The SBV program results will enable Redox to advance lower cost R2R manufacturing processes to produce millions of green cells per year on a single production line. As a result of this work, one invention disclosure has been submitted. In addition, one paper is under preparation for submission to a peer-reviewed journal.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Vibration-Based Techniques for Concrete Structural Health Monitoring. Light Water Reactor Sustainability Program report

The objectives of this ongoing research project focus on health monitoring and data analytics of concrete slabs containing reactive aggregates and thus subjected to degradation due to alkali-silica reaction (ASR). A controlled concrete slab with four pockets of reactive aggregates (pure silica, and reactive aggregates from three different quarries) was cast at Vanderbilt University and cured in representative conditions to accelerate degradation due to ASR. A set of four concrete samples were also cast and cured at the University of Alabama for ASR testing. Of these four samples, two slabs contained reactive aggregates while the other two had the non-reactive aggregate counterparts mixed throughout the samples. Four additional slabs were cast and cured at the University of Nebraska- Lincoln. Of these four samples; one contained non-reactive aggregates and no reinforcement, one contained reactive aggregates and no reinforcement, one contained reactive aggregates and rebar reinforcement in one direction, and the last contained reactive aggregates and reinforcement in two directions. Single frequency and dual frequency tests were used on these slabs to locate ASR damage within the specimens containing reactive aggregates. The vibration tests were conducted with different sensor and actuator configurations to facilitate damage detection and localization. The results from the data analysis of the dynamic testing on concrete slabs are discussed in detail in this report. Results for damage localization are dependent on multiple parameters used in the tests. This report investigates different methods of data fusion including voting, raw averaging, damage index averaging, and Bayesian fusion.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Manufacturing of Advanced Alnico Magnets for Energy Efficient Traction Drive Motors CRADA Final Report

The primary theme of this Technology Commercialization Fund (TCF) project was refining the pre-alloyed powder processing approach (with alnico 8, modified for higher coercivity) of that came out of the previous Development of Radically Enhanced alnico Magnets (DREaM) project to permit full size net-shape alnico magnets to be produced in a reproducible manner that could allow testing in an advanced Permanent Magnet (PM) drive motor. Previously, a lack of sufficient coercivity in alnico magnets limits their energy product and their application in automotive traction drive motors, despite their high temperature stability. Use of enhanced sintered alnico magnets, instead of rare earth (RE) magnets or larger cast alnico magnets, could lower costs and decrease cooling needs of these motors. Conventional production of the best (aligned) alnico magnets (alnico 9) involves costly directional solidification (DS) and achieves good alignment, but modest energy product (10 MGOe), because of low coercivity. Other limitations of cast alnico 9 magnets are poor mechanical properties and difficulty in scaling special casting molds to mass production. In spite of these problems with alnico 9, a commercial electric motor company, UQM, developed a fully capable traction drive motor that met many 2022 DOE-VTO performance targets, except full speed operation, due to brittle mechanical behavior. While UQM demonstrated an advanced drive motor that used alnico 9, they also encouraged the development of improved alnico, especially for greater coercivity (seeking 2X) and improved mechanical properties. While commercial sintered alnico magnets are less brittle and have improved coercivity, they have an inferior energy product due to their non-aligned, fine-grained microstructure. Thus, full development and up-scaling of well-aligned alnico magnets with a further increase in coercivity and good mechanical properties by a low cost powder processing route became the theme of this TCF project. The processing route for this project involved high-pressure gas atomization, at Ames and Carpenter, of modified alnico 8 compositions, compression molding of the resulting pre-alloyed powders into bulk samples, de-binding and sintering the samples to full density, and a final magneto-thermal treatment of the resulting bulk magnets, at Ames and Arnold Magnetic Technologies, to produce aligned magnets, which were intended for motor testing at UQM and Ford.

42 ENGINEERING↗
DOE OSTI2019

Seamless Nb tubes for SRF cavities

A. Executive Summary Understanding Developed Relationships between level of work, plastic strain orientation, level of annealing, grain size, strength, ductility, and texture were developed for heavily worked bulk RRR grade cast pure niobium (Nb). Technical Effectiveness of Approach Part A: The approach used for plastic deformation of bulk Nb was room temperature equal channel angular extrusion (ECAE). This approach is very effective for microstructural breakdown of worked and post-strain recrystallized Nb. A major problem with breaking down the microstructure of cast Nb is development of a consistent (repeatable) and uniform microstructure. This is most effectively accomplished by a series of orthogonal working steps (multipass ECAE (mECAE)) separated by full recrystallization. Forming tube from such material leads to a uniform microstructure in the tube. Part B: The approach developed to produce a microstructure in thin-walled tube that is very favorable for hydroforming into a superconducting radio frequency (SRF) cavity is tube-ECAE (tECAE). Tube-ECAE results in an axisymmetric circumferentially uniform microstructure with a texture more favorable for expansion hydroforming than tube formed by conventional methods such as extrusion, drawing, and ironing. Economic Feasibility of Methods Investigated and Demonstrated Although this was not demonstrated because of funding limitations, it is strongly believed that mECAE combined with intermediate recrystallization heat treatments and tECAE are economically viable approaches for producing a consistent, uniform, fine- or coarse-grained microstructure in RRR grade Nb tube starting from a large-grained and highly textured cast ingot. These methods are relatively easy to apply; the challenge is development of equipment and tooling that works well and is operator friendly. Commercially viable ECAE tooling for bulk Nb microstructure breakdown was developed; significant progress was made on the design of scaled-up equipment for tECAE. Patents on tECAE have been granted in Europe, Japan, and the United States. Public Benefit The approaches developed for fabricating RRR grade Nb tubing suitable for hydroforming into multi-cell SRF cavities have substantial public benefit because they will enable the manufacture of lower cost multicell SRF cavities for advanced linear particle accelerators. In addition, the approach developed for fabricating uniform and consistent axisymmetric microstructures in metal tubing can be applied to tubes made of metal alloys other than Nb. Applications exist in Ta tubing for superconductor wire applications, Mg alloy tubing for bio-implants, and aerospace tubing for structural hollow section components. The idea of tECAE can be applied to heal the heat affected zone (HAZ) in seam-welded tubing, thus erasing or healing the low-strength properties in the weld zone.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Intentional Uranium Tagging for Material Provenance and Pathway Forensics (LA19-Intentional-Forensics-NDD3Bb) (Annual Report for FY21)

This report describes the outcomes of the third and final year of a project to research the feasibility of tagging uranium materials, especially nuclear fuels. The experimental focus remained on metallic uranium forms under prospective surface and bulk tagging scenarios. Overall, the results showed that the tags could be successfully imparted and characterized in both as-built and degraded conditions. This was in line with expectations coming into this project, indicating promise for both surface and bulk tagging of metallic forms of uranium. Multiple surface tagging techniques and detection strategies were explored in FY21, with an emphasis on improving tag quality, readability, and detection in the field. Non-radioactive materials were used as a testbed. Selective deposition via laser beam was determined to be successful in imparting a readable titanium deposit on a stainless steel base plate, and can be read with high resolution characterization techniques (e.g., scanning electron microscopy) and field capable tools (e.g., eddy current testing). Other deposition techniques, such as selective deposition via electron beam and photoluminescent tags, were explored in FY21, and while success for these techniques would be dependent on additional work, these techniques showed potential for surface tagging applications. To survey bulk taggant elements for bulk uranium metal, 16 tagging elements were spread among 18 depleted uranium castings (4 baseline, 3 mix, 1 dilution, and 10 recycle). Most of these were made and characterized in FY21. Taggant acceptability was based upon manufacturability, detectability, and persistence from the standpoint of two detection options: bulk chemical analysis (for “chemical taggants”) and microstructural analysis (for “second phase taggants”). Taggant detection in both up-front manufacturing and in the face of “degradations” such as dilution, mixing, and recycling was generally good. Two independent laboratories carried out chemical analysis on most of the castings, and often at several locations within a casting, and the results are discussed. Scanning electron microscopy+EDS microanalysis revealed the second phases mostly contained the expected tagging elements. The shapes and 2 spatial distributions of these micron-sized carbides, oxides, and intermetallic particles offers opportunities for further science-based investigation and tagging optimization. Overall, V and Co currently appear as the best choices for chemical taggants while Al, Ti, Mn, Co, Pd, and Tb all look good as second phase taggants. The other elements considered here – Sc, Ni, Ge, Nb, Ce, Ta, W, Ir, and Au – while not being ruled out, require more study to become viable options. It is of special note that in the recycling study only one of the 12 elements fell out of detection even after 10 meltings, demonstrating their persistence. An Appendix tabulates all chemical analysis results to enable more quantitative and statistical studies of detection opportunities and limitations, as a part of a related project.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗
DOE OSTI2023

Light Water Sustainability Program: Optimizing Information Automation Using a New Method Based on System-Theoretic Process Analysis

This report describes the interim progress for research supporting the design and optimization of information automation systems for nuclear power plants. Much of the domestic nuclear fleet is currently focused on modernizing technologies and processes, including transitioning toward digitalization in the control room and elsewhere throughout the plant, along with a greater use of automation, artificial intelligence, robotics, and other emerging technologies. While there are significant opportunities to apply these technologies toward greater plant safety, efficiency, and overall cost-effectiveness, optimizing their design and avoiding potential safety and performance risks depends on ensuring that human-performance-related organizational and technical design issues are identified and addressed. This report describes modeling tools and techniques, based on sociotechnical system theory, to support these design goals and their application in the current research effort. The report is intended for senior nuclear energy stakeholders, including regulators, corporate management, and senior plant management. We have developed and employed a method to design an optimized information automation ecosystem (IAE) based on the systems-theoretic constructs underlying sociotechnical systems theory in general and the Systems-Theoretic Accident Modeling and Processes (STAMP) approach in particular. We argue that an IAE can be modeled as an interactive information control system whose behavior can be understood in terms of dynamic control and feedback relationships amongst the system’s technical and organizational components. Up to this point, we have employed a Causal Analysis based on STAMP (CAST) technique to examine a performance- and safety-related incident at an industry partner’s plant that involved the unintentional activation of an emergency diesel generator. This analysis provided insight into the behavior of the plant’s current information control structure within the context of a specific, significant event. Our ongoing analysis is focused on identifying near-term process improvements and longer-term design requirements for an optimized IAE system. The latter analyses will employ a second STAMP-derived technique, System-Theoretic Process Analysis (STPA). STPA is a useful modeling tool for generating and analyzing actual or potential information control structures. Finally, we have begun modeling plantwide organizational relationships and processes. Organizational system modeling will supplement our CAST and STPA findings and provide a basis for mapping out a plantwide information control architecture. CAST analysis findings indicate an important underlying contributor to the incident under investigation, and a significant risk to information automation system performance, was perceived schedule pressure, which exposed weaknesses in interdepartmental coordination between and within responsible plant organizations and challenged the resilience of established plant processes, until a human caused the initiating event. These findings are discussed in terms of their risk to overall system performance and their implications for information automation system resilience and brittleness. We present two preliminary information automation models. The proactive issue resolution model is a test case of an information automation concept with significant near-term potential for application and subsequent reduction in significant plant events. The IAE model is a more general representation of a broader, plantwide information automation system. From our results, we have generated a set of preliminary system-level requirements and safety constraints. These requirements will be further developed over the remainder of our project in collaboration with nuclear industry subject matter experts and specialists in the technical systems under consideration. Additionally, we will continue to pursue the system analyses initiated in the first part of our effort, with a particular emphasis on STPA as the main tool to identify weak or weakening control structures that affect the resilience of organizations and programs. Our intent is to broaden the scope of the analysis from an individual use case to a related set of use cases (e.g., maintenance tasks, compliance tasks) with similar human-system performance challenges. This will enable more generalized findings to refine the Proactive Issue Resolution and IAE models, as well as their system-level requirements and safety constraints. We will use organizational system modeling analyses to supplement STPA findings and model development. We conclude the report with a set of summary recommendations and an initial draft list of system-level requirements and safety constraints for optimized information automation systems.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Advances in Binder Jet Additive Manufacturing

Binder Jetting is a powerful additive manufacturing technology due to its low cost and wide range of types of materials it can shape. The industry partner ExOne has a range of binder jet products for applications such as casting tools, composite layup tools, single-alloy metal components, and more. As such, research and development is of high interest in the area of specialized binders for each type of material, processing technology that improves reliability and quality, and materials to enhance the performance of the final parts. Thus, this work focuses on developing novel binders for sand tools and metal prints, new capabilities in multi-material printing, and build monitoring and correction. The result of this work includes a novel binder system that makes binder jet sand stronger than concrete while still being water soluble, a casting binder that is environmentally friendly and produces better surface finishes on castings, and a binder for metals that reduces the residual carbon.

36 MATERIALS SCIENCE↗