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DOE OSTI2018

Fabrication, Assembly, and Metrology of the Neutron Imaging Pinhole

The neutron imaging pinhole is a complex aperture that is designed to have its image plane at the center of a laser fusion capsule implosion. The aperture’s high-Z materials of tungsten and gold block the neutrons so that only the neutrons passing through the machined apertures make it to the image plane and detector. The pinhole assembly consists of 11 layers of gold in between two layers of tungsten and gold. These 64 triangular pinholes and six penumbra apertures provide a matrix image that can be reconstructed to image complex deuterium-tritium neutron burn details in laser fusion capsules. The gold layers were diamond turned flat before the profiles were cut into their faces. Four of the layers were profiled with penumbral profile arrays that tapered from a radius of 250 to 150 µm. Three gold layers were just diamond turned to wedges to set the tilt of the whole aperture. Three gold layers were profiled on both sides with triangle groove arrays that consist of eight equilateral triangles with the depth of 200 to 15 µm over the 200-mm length, with a tolerance of 2 µm. Custom software programming routines were written using Labview to move the diamond-turning profiler through the required X-Y-Z movements to cut the penumbral and grooved profiles of the pinhole into the varying tilted arrays of features. The software is optimized to push the profile of the whole part into the face while eliminating any unneeded passes that do not cut any material. Each layer was thoroughly inspected on both sides using an optical coordinate measuring machine and white-light interferometer to validate each of the profiles. The pinhole assembly was inspected on a rotary stage so that both ends of the assembly can be inspected and presented in a single point cloud. The process of machining, programming, assembly, and inspection of the neutron imaging pinhole is covered.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Finding high-redshift strong lenses in DES using convolutional neural networks

We search Dark Energy Survey (DES) Year 3 imaging data for galaxy-galaxy strong gravitational lenses using convolutional neural networks. We generate 250 000 simulated lenses at redshifts > 0.8 from which we create a data set for training the neural networks with realistic seeing, sky and shot noise. Using the simulations as a guide, we build a catalogue of 1.1 million DES sources with 1.8 < g - i < 5, 0.6 < g - r < 3, r_mag > 19, g_mag > 20, and i_mag > 18.2. We train two ensembles of neural networks on training sets consisting of simulated lenses, simulated non-lenses, and real sources. We use the neural networks to score images of each of the sources in our catalogue with a value from 0 to 1, and select those with scores greater than a chosen threshold for visual inspection, resulting in a candidate set of 7301 galaxies. During visual inspection, we rate 84 as 'probably' or 'definitely' lenses. Four of these are previously known lenses or lens candidates. We inspect a further 9428 candidates with a different score threshold, and identify four new candidates. We present 84 new strong lens candidates, selected after a few hours of visual inspection by astronomers. This catalogue contains a comparable number of high-redshift lenses to that predicted by simulations. Based on simulations, we estimate our sample to contain most discoverable lenses in this imaging and at this redshift range.

Jacobs, C.↗

DOE OSTI2012

Remote Monitoring of the Structural Health of Hydrokinetic Composite Turbine Blades (Final Report)

A health monitoring approach is investigated for hydrokinetic turbine blade applications. In-service monitoring is critical due to the difficult environment for blade inspection and the cost of inspection downtime. Composite blade designs have advantages that include long life in marine environments and great control over mechanical properties. Experimental strain characteristics are determined for static loads and free-vibration loads. These experiments are designed to simulate the dynamic characteristics of hydrokinetic turbine blades. Carbon/epoxy symmetric composite laminates are manufactured using an autoclave process. Four-layer composite beams, eight-layer composite beams, and two-dimensional eight-layer composite blades are instrumented for strain. Experimental results for strain measurements from electrical resistance gages are validated with theoretical characteristics obtained from in-house finite-element analysis for all sample cases. These preliminary tests on the composite samples show good correlation between experimental and finite-element strain results. A health monitoring system is proposed in which damage to a composite structure, e.g. delamination and fiber breakage, causes changes in the strain signature behavior. The system is based on embedded strain sensors and embedded motes in which strain information is demodulated for wireless transmission. In-service monitoring is critical due to the difficult environment for blade inspection and the cost of inspection downtime. Composite blade designs provide a medium for embedding sensors into the blades for in-situ health monitoring. The major challenge with in-situ health monitoring is transmission of sensor signals from the remote rotating reference frame of the blade to the system monitoring station. In the presented work, a novel system for relaying in-situ blade health measurements in hydrokinetic systems is described and demonstrated. An ultrasonic communication system is used to transmit sensor data underwater from the rotating frame of the blade to a fixed relay station. Data are then broadcast via radio waves to a remote monitoring station. Results indicate that the assembled system can transmit simulated sensor data with an accuracy of ±5% at a maximum sampling rate of 500 samples/sec. A power investigation of the transmitter within the blade shows that continuous max-sampling operation is only possible for short durations (~days), and is limited due to the capacity of the battery power source. However, intermittent sampling, with long periods between samples, allows for the system to last for very long durations (~years). Finally, because the data transmission system can operate at a high sampling rate for short durations or at a lower sampling rate/higher duty cycle for long durations, it is well-suited for short-term prototype and environmental testing, as well as long-term commercially-deployed hydrokinetic machines.

13 HYDRO ENERGY↗

DOE OSTI2013

Assessment of the Mechanical Stress Improvement Process for Mitigating Primary Water Stress Corrosion Cracking in Nickel Alloy Butt Welds in Piping Systems Approved for Leak-Before-Break

In recent years, operating experience has shown that Alloy 82/182/600 materials used in reactor coolant system (RCS) pressure boundaries of pressurized water reactors (PWRs) are susceptible to primary water stress corrosion cracking (PWSCC). Cracking can initiate at the inside surface of these materials, in part, because of tensile residual stresses introduced by welding. These materials are present in piping systems that were approved by the U.S. Nuclear Regulatory Commission (NRC) for leak before-break (LBB) before PWSCC was found in RCS dissimilar metal butt welds. The identification of PWSCC led to concerns regarding the potential effect of this degradation on existing LBB analyses. In response to these concerns, the NRC Office of Nuclear Regulatory Research initiated a program entitled, “PWSCC in Leak-Before-Break Systems,” and a follow-on program entitled, “Degradation in Extremely Low Probability of Rupture (xLPR) Systems.” Under these programs, Pacific Northwest National Laboratory (PNNL) is assessing the various strategies being used by industry to manage potential or existing PWSCC in susceptible welds in piping systems approved for LBB. The commercial nuclear power industry has implemented strategies to manage potential or existing PWSCC at Alloy 82/182 dissimilar metal welds (DMW) in PWRs. One general strategy consists of management by a combination of mitigation plus inspection, where several mitigation techniques have been used by industry. The other general strategy is to manage potential PWSCC by inspection alone. At the request of the NRC, the American Society of Mechanical Engineers (ASME) took actions to develop improvements to the existing Code requirements to address the potential for PWSCC in Class 1 PWR piping butt welds fabricated with Alloy 82/182 weld materials. The ASME developed Code Case N-770, “Alternative Examination Requirements and Acceptance Standards for Class 1 PWR Piping and Vessel Nozzle Butt Welds Fabricated with UNS N06082 or UNS W86182 Weld Filler Material With or Without Application of Listed Mitigation Activities, Section XI, Division 1.” It was realized that the Code Case needed to be revised to address specific examinations such as welds with a design life of less than 10 years and post-weld preservice surface examinations. In general, the revised Code Case (N-770-1) has requirements for inspection of unmitigated as well as mitigated Alloy 82/182 RCS butt welds. As such, specific inspection requirements for welds mitigated by the Mechanical Stress Improvement Process (MSIP®), the subject of this technical letter report (TLR), are contained in the Code Case. The NRC incorporated ASME Code Case N-770-1 by reference into §50.55a (76 FR 36232, p. 36278) in June 2011.

MSIP↗

DOE OSTI2013

Determining Remaining Useful Life of Aging Cables in Nuclear Power Plants – Interim Study FY13

The most important criterion for cable performance is its ability to withstand a design-basis accident. With nearly 1000 km of power, control, instrumentation, and other cables typically found in an NPP, it would be a significant undertaking to inspect all of the cables. Degradation of the cable jacket, electrical insulation, and other cable components is a key issue that is likely to affect the ability of the currently installed cables to operate safely and reliably for another 20 to 40 years beyond the initial operating life. The development of one or more nondestructive evaluation (NDE) techniques and supporting models that could assist in determining the remaining life expectancy of cables or their current degradation state would be of significant interest. The ability to nondestructively determine material and electrical properties of cable jackets and insulation without disturbing the cables or connections has been deemed essential. Currently, the only technique accepted by industry to measure cable elasticity (the gold standard for determining cable insulation degradation) is the indentation measurement. All other NDE techniques are used to find flaws in the cable and do not provide information to determine the current health or life expectancy. There is no single NDE technique that can satisfy all of the requirements needed for making a life-expectancy determination, but a wide range of methods have been evaluated for use in NPPs as part of a continuous evaluation program. The commonly used methods are indentation and visual inspection, but these are only suitable for easily accessible cables. Several NDE methodologies using electrical techniques are in use today for flaw detection but there are none that can predict the life of a cable. There are, however, several physical and chemical ptoperty changes in cable insulation as a result of thermal and radiation damage. In principle, these properties may be targets for advanced NDE methods to provide early warning of aging and degradation. Examples of such key indicators include changes in chemical structure, mechanical modulus, and dielectric permittivity. While some of these indicators are the basis of currently used technologies, there is a need to increase the volume of cable that may be inspected with a single measurement, and if possible, to develop techniques for in-situ inspection (i.e., while the cable is in operation). This is the focus of the present report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2014

Noble Gas Concept Of Operation

The intent of this document is to provide the reader with an understanding of a general approach to performing the noble gas component of an On Site Inspection or OSI. The authors of this document recognize that owing to the wide range of scenarios that are possible for carrying out an underground nuclear explosion, the diverse sets of information that might be available to the inspection team initially and the potential range of political and physical constraints imposed during the inspection, a satisfactory prescriptive approach to carrying out the noble gas component of an OSI is unlikely. Rather, the authors intend only to aid the reader in understanding what a reasonable course of actions or responses may be as performed by an inspection team (IT) during a general OSI. If this document helps to inform the intuition of the reader about addressing the challenges resulting from the inevitable deviations from this general scenario, it will have achieved its intent.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2013

Preliminary Thermal Modeling of Hi-Storm 100S-218 Version B Storage Modules at Hope Creek Nuclear Power Station ISFSI

This report fulfills the M3 milestone M3FT-13PN0810022, “Report on Inspection 1”, under Work Package FT-13PN081002. Thermal analysis is being undertaken at Pacific Northwest National Laboratory (PNNL) in support of inspections of selected storage modules at various locations around the United States, as part of the Used Fuel Disposition Campaign of the U.S. Department of Energy, Office of Nuclear Energy (DOE-NE) Fuel Cycle Research and Development. This report documents pre-inspection predictions of temperatures for four modules at the Hope Creek Nuclear Generating Station ISFSI that have been identified as candidates for inspection in late summer or early fall/winter of 2013. These are HI-STORM 100S-218 Version B modules storing BWR 8x8 fuel in MPC-68 canisters. The temperature predictions reported in this document were obtained with detailed COBRA-SFS models of these four storage systems, with the following boundary conditions and assumptions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Ranchero Armature Test LA-43-CT-2: PBXN-110 Explosive with no smoothing layer. Lower Slobovia, 6/13/13

This test, documented as LA-43-CT-2, was performed to verify calculations which indicate that the smoothing layer employed for Ranchero Armatures is not required when the slapper point spacing is 18 mm (“On the efficacy of an acrylic layer in the Ranchero armature,” Bob Watt, published in “Ranchero Status Report” LA-14463). [Naming this test –CT-2 acknowledges the previous test performed during 1/11 as the initial test in the series, and we will refer to that test as LA-43-CT-1 in the future.] In addition, higher velocity is achieved when the volume occupied by the smoother is replaced by HE. Two framing cameras were used on the shot, and a 20 point PDV array was fielded to ascertain armature performance in specific conditions. The conclusions are that the armature is smooth enough, and the terminal velocity is increased from ~3.1 mm/μs to ~3.3 mm/μs. The armature tested had casting voids in the HE that were observed in pre-test inspections, and were expected to cause ruptures. (See Appendix 3 of the Ranchero Status Report.) Such “blowouts” were observed in all three locations identified in pre-shot inspection. In addition, ruptures occurred in locations having no pre-shot indication of a problem. These unpredicted blowouts have a difference in appearance from those typically seen. Further visual examination of the inspection radiographs do not reveal the cause, and that is a serious concern for future efforts with such castings. A path forward will include attempting to digitize the inspection x-rays for the charge tested, to see if the cause of the “new” ruptures can be found via computer enhancement. In addition, there are two additional armatures from the same casting lot, and these might also be tested to see if there is some problem with the HE or the armature material in this batch. For now, this plan is on hold, pending the outcome of tests and cost estimates related to using PBX-9501 in place of the PBXN-110. Casting issues would be eliminated in such configurations.

42 ENGINEERING↗

DOE OSTI2017

Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE), has completed the project “Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development” under U.S. Department of Energy (DOE) Award Number DE-FE0024076. This project was part of DOE’s Novel Crosscutting Research and Development to Support Advanced Energy Systems program. AUSC Tube Membrane Panel Development was a two and one half year project to develop and verify the manufacturability and serviceability of welded tube membrane panels made from high performance materials suitable for the AUSC steam cycles, defined as high pressure steam turbine inlet conditions of 700-760°C (1292-1400°F) and 24.5-35MPa (3500-5000psi). The difficulty of this challenge lies in the fact that the membrane-welded construction imposes demands on the materials that are unlike any that exist in other parts of the boiler. Tube membrane panels have been designed, fabricated, and installed in boilers for over 50 years with relatively favorable experience when fabricated from carbon and Cr-Mo low alloy steels. The AUSC steam cycle requires membrane tube panels fabricated from materials that have not been used in a weldment with metal temperatures in the range of 582-610°C (1080-1130°F). Fabrication materials chosen for the tubing were Grade 92 and HR6W. Grade 92 is a creep strength enhanced ferritic Cr-Mo alloy and HR6W is a high nickel alloy. Once the materials were chosen, GE performed the engineering design of the panels, prepared shop manufacturing drawings, and developed manufacturing and inspection plans. After the materials were purchased, GE manufactured and inspected the tube membrane panels, determined if post fabrication heat treatment of the tube membrane panels was needed, performed pre- and post-weld heat treatment on the Grade 92 panels, conducted final nondestructive inspection of any heat treated tube membrane panels, conducted destructive inspection of the completed tube membrane panels,and performed simulated shop repairs on the panel fabricated using Grade 92. GE executed the program as the prime contractor under the direction of Principal Investigator Mr. James Pschirer. Other participants in this project included GE Boiler Engineering, GE Chattanooga Manufacturing, GE Materials Technology Center, GE Rocky Mountain Service Center, and a Technical Consultant from Electric Power Research Institute (EPRI).

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

FINAL DESIGN REVIEW REPORT Subcritical Experiments Gen 2, 3-ft Confinement Vessel Weldment

A Final Design Review (FDR) of the Subcritical Experiments (SCE) Gen 2, 3-ft. Confinement Vessel Weldment was held at Los Alamos National Laboratory (LANL) on September 14, 2017. The review was a focused review on changes only to the confinement vessel weldment (versus a system design review). The changes resulted from lessons-learned in fabricating and inspecting the current set of confinement vessels used for the SCE Program. The baseline 3-ft. confinement vessel weldment design has successfully been used (to date) for three (3) high explosive (HE) over-tests, two (2) fragment tests, and five (5) integral HE experiments. The design team applied lessons learned from fabrication and inspection of these vessel weldments to enhance fit-up, weldability, inspection, and fitness for service evaluations. The review team consisted of five (5) independent subject matter experts with engineering design, analysis, testing, fabrication, and inspection experience. The

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2018

Eyes On the Ground: Final Report

This report summarizes the work performed under the Sandia LDRD project "Eyes on the Ground: Visual Verification for On-Site Inspection." The goal of the project was to develop methods and tools to assist an IAEA inspector in assessing visual and other information encountered during an inspection. Effective IAEA inspections are key to verifying states' compliance with nuclear non-proliferation treaties. In the course of this work we developed a taxonomy of candidate inspector assistance tasks, selected key tasks to focus on, identified hardware and software solution approaches, and made progress in implementing them. In particular, we demonstrated the use of multiple types of 3-d scanning technology applied to simulated inspection environments, and implemented a preliminary prototype of a novel inspector assistance tool. This report summarizes the project's major accomplishments, and gathers the abstracts and references for the publication and reports that were prepared as part of this work. We then describe work in progress that is not yet ready for publication. Approved for public release; further dissemination unlimited.

47 OTHER INSTRUMENTATION↗

DOE OSTI2018

Performance of Advanced Signal Processing and Pattern Recognition Algorithms Using Raw Data from Ultrasonic Guided Waves and Fiber Optics Transducers

The Light Water Reactor Sustainability Program was initiated to evaluate technologies that could be used to perform online monitoring of piping and other secondary system structural components in commercial nuclear power plants. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real-time measurements, rather than at a pre-determined inspection interval. This transition to condition-based, risk-informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for most nuclear power generation costs. This report describes the current state of research related to ultrasonic guided wave testing and its application to detecting defects in commercial nuclear power plants. The report analyzes the applicability of the guided wave technology to secondary piping systems, as well as studying the potential for expanding the range of guided wave technology to include bent piping and other piping components. The ultrasonic guided waves can inspect long stretches of straight piping; however, more complex geometries such as elbows, welds, and tees are causing spurious reflections and coherent noise, which significantly decreases the sensitivity of the technique. To deal with these limitations, high-definition fiber optic sensors are applied to complex piping geometries, and advanced machine learning algorithms are used to detect deviations from healthy states. This report also analyzes the performance of advanced signal processing and machine learning-based pattern recognition algorithms in detecting defects in secondary structures. It is demonstrated on guided wave data collected at nuclear power plants that the independent component analysis can separate different coherent noise components and segregate them from useful signals. It also demonstrates that advanced machine learning techniques, such as neural networks, support vector machines, and deep learning networks, can detect minor defects present in inspected structures. Recommendation about the applicability of advanced machine learning techniques to online piping monitoring are also given.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Submittal of Solid Waste Management Units and Areas of Concern Annual Long-Term Monitoring and Maintenance Report for Calendar Year 2017

This SWMU and AOC Annual Long-Term Monitoring and Maintenance (LTMM) Report for Calendar Year 2017 (Annual LTMM Report) details the measures performed for 21 Solid Waste Management Units (SWMUs) and Areas of Concern (AOCs) at Sandia National Laboratories/New Mexico (SNL/NM) in accordance with the requirements of the “Long-Term Monitoring and Maintenance [LTMM] Plan for SWMUs and AOCs Granted Corrective Action Complete with Controls” in Attachment M of the Resource Conservation and Recovery Act Facility Operating Permit (Permit), which took effect February 26, 2015. This Annual LTMM Report does not present the measures for SWMU 76, Mixed Waste Landfill (MWL), as the applicable MWL reporting adheres to the approved MWL LTMM Plan, Section 4.8.1 and requires a separate annual report which will be submitted to the New Mexico Environment Department by June 30, 2018. Measures at these SWMUs and AOCs include surveillance of site conditions and maintenance of institutional controls. Conditions requiring maintenance or repair activities were identified at three of the inspected SWMUs and AOCs (SWMUs 45, 46, and 87) during the Permit-required annual site inspections. One SWMU identification sign located at SWMU 46 and two identification signs located at SWMU 87 were replaced due to weathered lettering. Evidence of erosion was observed at SWMU 45 during the annual site inspection; erosion controls will be implemented as needed to prevent the inadvertent exposure of hazardous wastes or hazardous waste constituents. SWMU 45 is located on the sloped border of Tijeras Arroyo south of Technical Area-IV. The erosion controls planned for the Tijeras Arroyo Escarpment will address not only SWMU 45, but also SWMUs 46 and 229 as a best management practice. SNL/NM personnel plan to complete this work in calendar year 2018. The status and progress of this project will be reported in the 2018 Annual SWMUs and AOCs Annual LTMM Report for Calendar Year 2018 to be submitted to the New Mexico Environment Department on March 31, 2019, as required by the Permit. Based upon the inspections performed and site conditions observed, the administrative and physical institutional controls in place at the SWMUs and AOCs are effectively providing continued protection of human health and the environment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Eyes On the Ground (Final Report)

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2025

EMPOWERED Distributed Energy Resources Permit Accelerator Pilot

This report summarizes the EMPOWERED Distributed Energy Resources (DER) Permit Accelerator Pilot project. Its primary objective was to streamline the design, installation, permitting, and inspections of targeted Distributed Energy Resource (DER) solutions. Streamlining these processes is critical to strengthening and accelerating the adoption of DER solutions nationwide. Moreover, streamlined processes help expedite the clean energy transition and expand energy resilience by improving understanding and capability among key stakeholders like property owners, code officials, and the general workforce. The project team accomplished this by developing and deploying a set of design and permitting guides for simple DER solutions, which they rolled out via a permitting pilot program. The project team developed nine permitting and inspection guides for simple DER solutions, as follows: 1. Single-Family and Duplex: Electric Vehicle Service Equipment (EVSE), and Storage, Solar + Storage (each in two code cycles) 2. Multi-family and Office: EVSE, Storage, Solar + Storage (each in two code cycles) 3. A permitting process guide to support the implementation of the permitting guides. The guides cover key code requirements via plan review and field inspection checklists for code officials and building owners to follow to streamline the permitting and inspections process for DER solutions. Following the development of the initial set of guides, the project team formed two cohorts, each made up of four jurisdictions, to participate in the Permit Accelerator Pilot. Each cohort received training and technical assistance to support them in incorporating the guides into use. The project successfully engaged jurisdictions in two disparate US regions: Chelsea, Somerville, Natick, and Norwood in metro Boston; and Pima County, Town of Gilbert, Flagstaff, and Sedona in Arizona. Feedback gathered from the project was valuable in refining the guides to better address jurisdictional needs. After the pilot period, the project team developed final versions of the guides based on extensive feedback from the cohorts and from external technical peer review. Feedback included needs and barriers related to implementation, as well as detailed technical improvements from external peer review. The final guides were presented in a series of webinars with a national reach, with 192 attendees from 35 states in the live session of the final webinar, and the final guides are posted online and available for use nationwide. Key findings: • The most receptive jurisdictions were those adjacent to other jurisdictions that had already adopted similar initiatives. The least receptive jurisdictions were those in the midst of adopting new code cycles. • The most common barrier to jurisdictional adoption of new guidelines were internal administrative and process delays, more so than technical barriers. • The main technical barrier to adoption proved to be the concern of fire hazard risks posed by energy storage systems. There is some apprehension in the code enforcement community about the safety of the batteries. Education coordinated with fire and safety services will help alleviate concerns and increase confidence in the acceptance of innovative technologies. • Opportunities to further leverage and advance the guides and related resources include outreach, education, and jurisdictional support; updates to the resources to align with code cycle changes and local requirements; and advancements supporting emerging technologies.

14 SOLAR ENERGY↗

DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

This research focuses on the application of advanced ultrasonic testing techniques developed by The Phased Array Company (TPAC) for inspecting defects in additive manufacturing (AM) parts. Traditionally, X-ray computed tomography is the standard for inspecting AM components. Although, the long inspection and analysis time, along with relatively high cost make implementation difficult. Thus, an alternative nondestructive evaluation (NDE) approach is necessary to support quality assurance efforts within the field of AM. TPAC is recognized as a leader in ultrasonic testing innovation, deploying sophisticated algorithms such as Total Focusing Method (TFM) and Phased Wave Imaging (PWI) for ultrasonic data processing and interpretation. This work will explore how the TFM and PWI algorithms can assist defect detection within polymer AM parts. The AM field is seeking novel NDE methods to provide support within quality control and assurance efforts. Advanced ultrasonics inspection have the potential to fulfill this need.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

36 MATERIALS SCIENCE↗