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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

SURROGATE MODEL DEVELOPMENT AND VALIDATION FOR RELIABILITY ANALYSIS OF REACTOR PRESSURE VESSELS

In nuclear light water reactors (LWRs), the reactor coolant, core and shroud are contained within a massive, thick walled steel vessel known as a reactor pressure vessel (RPV). Given the tremendous size of these structures, RPVs typically contain a large population of pre-existing flaws introduced in the manufacturing process. After many years of operation, irradiation-induced embrittlement makes these vessels increasingly susceptible to fracture initiation at the locations of the pre-existing flaws. Because of the uncertainty in the loading conditions, flaw characteristics and material properties, probabilistic methods are widely accepted and used in assessing RPV integrity. The Fracture Analysis of Vessels – Oak Ridge (FAVOR) computer program developed by researchers at Oak Ridge National Laboratory is widely used for this purpose. This program can be used in order to perform deterministic and probabilistic risk-informed analyses of the structural integrity of an RPV subjected to a range of thermal-hydraulic events. FAVOR uses a one-dimensional representation of the global response of the RPV, which is appropriate for the beltline region, which experiences the most embrittlement, and employs an influence coefficient technique to rapidly compute stress intensity factors for axis-aligned surface-breaking flaws. The Grizzly code is currently under development at Idaho National Laboratory (INL) to be used as a general multiphysics simulation tool to study a variety of degradation mechanisms in nuclear power plant components. The first application of Grizzly has been to study fracture in embrittled RPVs. Grizzly can be used to model the thermo-mechanical response of an RPV under transient conditions observed in a pressurized thermal shock (PTS) scenario. The global response of the vessel provides boundary conditions for local 3D models of the material in the vicinity of a flaw. Fracture domain integrals are computed to obtain stress intensity factors, which can in turn be used to assess whether a fracture would initiate at a pre-existing flaw. To use Grizzly for probabilistic analysis, it is necessary to have a way to rapidly evaluate stress intensity factors. To accomplish this goal, a reduced order model (ROM) has been developed to efficiently represent the behavior of a detailed 3D Grizzly model used to calculate fracture parameters. This approach uses the stress intensity factor influence coefficient method that has been used with great success in FAVOR. Instead of interpolating between tabulated solutions, as FAVOR does, the ROM approach uses a response surface methodology to compute fracture solutions based on a sampled set of results used to train the ROM. The main advantages of this approach are that the process of generating the training data can be fully automated, and the procedure can be readily used to consider more general flaw configurations. This paper demonstrates the procedure used to generate a ROM to rapidly compute stress intensity factors for axis-aligned flaws. The results from this procedure are in good agreement with those produced using the traditional influence coefficient interpolation procedure, which gives confidence in this method. This paves the way for applying this procedure for more general flaw configurations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

A Survey of Thermal Sensing Application in Additive Manufacturing

Industry 4.0 represents a significant change in manufacturing with the inclusion of such technologies as additive manufacturing and data analytics. In support of these changes, infrared thermal imaging (IR) and very-near infrared (VNIR) have proven invaluable in numerous applications related to additive manufacturing. In this review, these applications will be presented as they relate to polymer and metal-based additive manufacturing processes. Applications including in-situ characterization, post-build analysis, experimental setups, modeling, and machine learning will be covered. With a general overview complete, the review will conclude with a discussion of challenges identified throughout the literature and thoughts on future trends.

Borish, Michael↗
DOE OSTI2014

MO-A-9A-01: Innovation in Medical Physics Practice: 3D Printing Applications

3D printing, also called additive manufacturing, has great potential to advance the field of medicine. Many medical uses have been exhibited from facial reconstruction to the repair of pulmonary obstructions. The strength of 3D printing is to quickly convert a 3D computer model into a physical object. Medical use of 3D models is already ubiquitous with technologies such as computed tomography and magnetic resonance imaging. Thus tailoring 3D printing technology to medical functions has the potential to impact patient care. This session will discuss applications to the field of Medical Physics. Topics discussed will include introduction to 3D printing methods as well as examples of real-world uses of 3D printing spanning clinical and research practice in diagnostic imaging and radiation therapy. The session will also compare 3D printing to other manufacturing processes and discuss a variety of uses of 3D printing technology outside the field of Medical Physics. Learning Objectives: Understand the technologies available for 3D Printing Understand methods to generate 3D models Identify the benefits and drawbacks to rapid prototyping / 3D Printing Understand the potential issues related to clinical use of 3D Printing.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

SU-F-BRA-15: Physical Aspects and Clinical Applications of Post-Treatment Yttrium-90 PET-Based Dosimetry

Purpose: The accuracy of PET-based post-treatment dosimetry of yttrium-90 microspheres has been improving over the past decade and is now at a stage, permitting volumetric dose-outcome studies. We outline the recent advances and identify the physical limitations to the accuracy of the dose calculations. Methods: Convolution of the measured PET activity density distribution with a pre-calculated voxel-dose-kernel (VDK) is the most widely used method for dose reconstruction. Therefore, accurate knowledge of the beta+ branching ratio as well as the micro-dosimetric characteristics of electron interactions within the microsphere is essential for the computation of the dose kernel. We implement a model of the microspheres used in our clinic to calculate the modified electron energy spectrum at the microsphere’s surface and to determine the impact of self-shielding on the dose reconstruction. The three-dimensional dose distributions obtained for 10 patients treated with radio-embolization with yttrium-90 microspheres are evaluated and various DVH markers are investigated for correlation with outcome. Results: The methods for reducing the overall computation uncertainty are systematically outlined in this presentation. Since the latest experimental data on yttrium-90 beta+ branching ratio has a relative uncertainty of 1.5%, all contributing factors derived from Monte Carlo simulations must be brought to a sub 1% level. The self-shielding within the microspheres is found to be responsible for up to 6% reduction of the reconstructed dose in low-gradient regions and must be taken into account. The contribution of trace amounts of other beta+ emitters introduced during the manufacturing process is also discussed. Conclusion: The accelerating pace of clinical adoption of PET-based post-treatment dosimetry is mainly due to advances in both quantitative PET imaging and physical models of dose deposition. We show that the overall physical dose uncertainty in the convolution step can be further reduced, thus making ongoing multi-institutional dose-outcome studies even more reliable.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

Influence of source batch S{sub K} dispersion on dosimetry for prostate cancer treatment with permanent implants

Purpose: In clinical practice, specific air kerma strength (S{sub K}) value is used in treatment planning system (TPS) permanent brachytherapy implant calculations with {sup 125}I and {sup 103}Pd sources; in fact, commercial TPS provide only one S{sub K} input value for all implanted sources and the certified shipment average is typically used. However, the value for S{sub K} is dispersed: this dispersion is not only due to the manufacturing process and variation between different source batches but also due to the classification of sources into different classes according to their S{sub K} values. The purpose of this work is to examine the impact of S{sub K} dispersion on typical implant parameters that are used to evaluate the dose volume histogram (DVH) for both planning target volume (PTV) and organs at risk (OARs). Methods: The authors have developed a new algorithm to compute dose distributions with different S{sub K} values for each source. Three different prostate volumes (20, 30, and 40 cm{sup 3}) were considered and two typical commercial sources of different radionuclides were used. Using a conventional TPS, clinically accepted calculations were made for {sup 125}I sources; for the palladium, typical implants were simulated. To assess the many different possible S{sub K} values for each source belonging to a class, the authors assigned an S{sub K} value to each source in a randomized process 1000 times for each source and volume. All the dose distributions generated for each set of simulations were assessed through the DVH distributions comparing with dose distributions obtained using a uniform S{sub K} value for all the implanted sources. The authors analyzed several dose coverage (V{sub 100} and D{sub 90}) and overdosage parameters for prostate and PTV and also the limiting and overdosage parameters for OARs, urethra and rectum. Results: The parameters analyzed followed a Gaussian distribution for the entire set of computed dosimetries. PTV and prostate V{sub 100} and D{sub 90} variations ranged between 0.2% and 1.78% for both sources. Variations for the overdosage parameters V{sub 150} and V{sub 200} compared to dose coverage parameters were observed and, in general, variations were larger for parameters related to {sup 125}I sources than {sup 103}Pd sources. For OAR dosimetry, variations with respect to the reference D{sub 0.1cm{sup 3}} were observed for rectum values, ranging from 2% to 3%, compared with urethra values, which ranged from 1% to 2%. Conclusions: Dose coverage for prostate and PTV was practically unaffected by S{sub K} dispersion, as was the maximum dose deposited in the urethra due to the implant technique geometry. However, the authors observed larger variations for the PTV V{sub 150}, rectum V{sub 100}, and rectum D{sub 0.1cm{sup 3}} values. The variations in rectum parameters were caused by the specific location of sources with S{sub K} value that differed from the average in the vicinity. Finally, on comparing the two sources, variations were larger for {sup 125}I than for {sup 103}Pd. This is because for {sup 103}Pd, a greater number of sources were used to obtain a valid dose distribution than for {sup 125}I, resulting in a lower variation for each S{sub K} value for each source (because the variations become averaged out statistically speaking)

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

WE-AB-207A-10: Transmission Characteristics of a Two Dimensional Antiscatter Grid Prototype for CBCT

Purpose: Scattered radiation remains to be a major contributor to image quality degradation in CBCT. To address the scatter problem, a focused, 2D antiscatter grid (2DASG) prototype was designed, and fabricated using additive manufacturing processes. Its scatter and primary transmission properties were characterized using a linac mounted CBCT system. Methods: The prototype 2DASG was composed of rectangular grid holes separated by tungsten septa, and has a grid pitch of 2.91 mm, grid ratio of 8, and a septal thickness of 0.1 mm. Each grid hole was aligned or focused towards the x-ray source in half-fan (i.e. offset detector) geometry of the Varian TrueBeam CBCT system. Scatter and primary transmission experiments were performed by using acrylic blocks and the beam-stop method. Transmission properties of a radiographic ASG (1DASG) (grid ratio of 10) was also performed by using the identical setup. Results: At 30 cm phantom thickness, scatter to primary ratio (SPR) was 4.51 without any ASG device. SPR was reduced to 1.28 with 1DASG, and it was further reduced to 0.28 with 2DASG. Scatter transmission fraction (Ts) of 1DASG was 21%, and Ts was reduced to 5.8% with 2DASG. The average primary transmission fraction (Tp) of 1DASG was 70.6%, whereas Tp increased to 85.1% with 2DASG. Variation of Tp across 40 cm length (the long axis of flat panel detector) was 2.6%. Conclusion: When compared to conventional ASGs, the focused 2DASG can vastly improve scatter suppression and primary transmission performance. Due to precise alignment of 2DASG’s grid holes with respect to beam divergence, high degree of primary transmission through the 2DASG was maintained across the full length of the prototype. We strongly believe that robust scatter rejection and primary transmission characteristics of our 2DASG can translate into both improved quantitative accuracy and soft tissue resolution in linac mounted CBCT systems.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2026

Design optimization of MAPS-based detectors using a data-driven fast simulation approach

A parametric simulation tool for pixel sensors is presented. A realistic pixel response is simulated purely based on measurement input, without requiring detailed knowledge of the underlying manufacturing process. As such, it provides an efficient alternative to the use of Technology Computer-Aided Design simulations, which typically depend on proprietary process information. Due to its parametric approach, the package is fast and thus particularly useful for larger detector systems and high hit rate environments. This work presents measurements, simulation and its validation for the MALTA2 sensor. It is a small collection electrode monolithic active pixel sensor produced in the Tower 180 nm complementary metal-oxide-semiconductor imaging process. Modifications to the sensor’s periphery, mainly in the hit merger, are studied in order to optimize the performance for tracking and calorimetry. This optimization is of special interest as part of the MALTA3 sensor redesign in the 65 nm Tower Partners Semiconductor Co. process.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Innovations Toward the Valorization of Plastics Waste

Plastics are an extremely important class of materials that are prevalent in all facets of society; however, their widespread use over time, combined with limited end-of-life strategies, has led to increasing levels of waste accumulation. Although currently considered a burden, plastics waste is potentially an untapped feedstock for numerous chemical and manufacturing processes. In this study, we discuss the state of the art of approaches for valorization of plastics waste from a materials research perspective, including previous efforts to utilize plastics waste and recent innovations that have opportunities to add significant value. Although additional progress is necessary, we present several diverse capabilities and strategies for valorization that, when brought together, address end-of-life challenges for plastics at every stage of design and product consumption. In short, a materials research–based framework offers a unique perspective to address the urgent issues posed by plastics, unlocking the potential of polymers and plastics waste.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Catalyst-layer ionomer imaging of fuel cells

Investigation of membrane/electrode assembly (MEA) microstructure has become an essential step to optimize the MEA components and manufacturing processes or to study the MEA degradation. For these investigations, transmission electron microscopy (TEM) is a tool of choice as it provides direct imaging of the different components. TEM is then widely used for analyzing the catalyst nanoparticles and their carbon support. However, the ionomer inside the electrode is more difficult to be imaged. The difficulties come from the fact that the ionomer forms an ultrathin layer surrounding the carbon particles and in addition, these two components, having similar density, present no difference in contrast. In this paper, we show how the recent progresses in TEM techniques as spherical aberration (Cs) corrected HRTEM, electron tomography and X-EDS elemental mapping provide new possibilities for imaging this ionomer network and consequently to study its degradation.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

ARJUNA: An Electrochemical Interface Mapping Probe for Solid-State Batteries

Solid-state batteries (SSBs) are promising candidates for next-generation energy storage, although their performance can be compromised by interfacial heterogeneity within the electrolyte. Furthermore, ensuring the quality of large form-factors electrolyte film is crucial for establishing a robust manufacturing platform for solid-state batteries. Herein, we report on the use of ARJUNA, an electrochemical interface mapping system, to characterize heterogeneities at solid electrolyte interfaces and to serve as a quality control system for SSB manufacturing. In addition to spatial mapping, the proposed system can also probe the interface behavior as a function of pressure and temperature. We present the operating principle, design, instrumentation, and evaluation of the system alongside a typical hybrid solid electrolyte produced using two common manufacturing processes. This report showcases the capability of ARJUNA to probe the heterogeneity and quality of processed solid electrolyte films.

25 ENERGY STORAGE↗
DOE OSTI2019

Time-of-Flight Neutron Diffraction (TOF-ND) Analyses of the Composition and Minting of Ancient Judaean “Biblical” Coins

TOF-ND elastic scattering of thermal neutrons offers some important advantages over X-ray diffraction (XRD), X-ray fluorescence (XRF), and metallography for the study of archaeological and numismatic problems. Traditional analytical methods are usually destructive and often probe only the surface. Neutrons deeply penetrate samples, simultaneously giving nondestructive bulk information about the crystal structure, composition, and texture (alignment of crystallites) from which thermomechanical manufacturing processes (e.g., cast, struck, or rolled) may be inferred. An analysis of the metal composition and minting processes used for making ancient Judaean bronze and leaded bronze coins from first century BCE and CE is used as a case study. One of the first ND analyses of the temperature used for striking bronze coins is also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2021

adamantine-sim/adamantine

Thermal field simulation of the additive manufacturing process enhanced using data assimilation.

Turcksin, Bruno [Oak Ridge National Lab. (ORNL), O↗
DOE OSTI2023

Fierro Version 2.x

FIERRO is a parallel C++ code designed to simulate fluid mechanics, heat transfer, and solid mechanics in two- and three-dimensional space. FIERRO is written to run on homogeneous (CPU) and heterogeneous (CPU+GPU) high performance computing machines. Fierro can aid a) modeling and design efforts that have historically relied on commercial implicit and explicit finite element codes, b) numerical methods research, c) manufacturing research, and d) computer science research. The code contains diverse numerical methods to solve the governing physics equations for both quasi-static and dynamic problems. Mathematical optimization solvers are coupled to the numerical methods to research topology and shape optimization that has application to additive manufacturing, and to create novel numerical approaches. Phase-field methods with micromechanical solvers are provided to simulate microstructure formation and evolution in manufacturing processes. The micromechanical solvers can also help research efforts create continuum-scale constitutive models for solids, as a function of the microstructure, in situ in a calculation or in a stand-alone manner. No physical data exists within the code.

Morgan, Nathaniel↗
DOE OSTI2023

Fierro

FIERRO is a parallel C++ code designed to simulate fluid mechanics, heat transfer, and solid mechanics in two- and three dimensional space. FIERRO is written to run on homogeneous (CPU) and heterogeneous (CPU+GPU) high performance computing machines. Fierro can aid a) modeling and design efforts that have historically relied on commercial implicit and explicit finite element codes, b) numerical methods research, c) manufacturing research, and d) computer science research. The code contains diverse numerical methods to solve the governing physics equations for both quasi-static and dynamic problems. Mathematical optimization solvers are coupled to the numerical methods to research topology and shape optimization that has application to additive manufacturing, and to create novel numerical approaches. Phase-field methods with micromechanical solvers are provided to simulate microstructure formation and evolution in manufacturing processes. The micromechanical solvers can also help research efforts create continuum-scale constitutive models for solids, as a function of the microstructure, in situ in a calculation or in a stand-alone manner. No physical data exists within the code.

Morgan, Nathaniel↗
DOE OSTI2025

Laser Powder Bed Fusion Microstructure Surrogate Model

SAND2025-11467O The Laser Powder Bed Fusion (LPBF) Microstructure Surrogate Model is a machine-learning-based tool. It predicts statistics of microstructures that are produced by the LPBF additive manufacturing process. It includes a series of codes for training, testing, and analyzing the model as well as utility scripts for handling data. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Moser, Daniel [Sandia National Lab. (SNL-CA), Live↗
DOE OSTI2024

Low-velocity impact resistance and failure characteristics of all thermoplastic woven polymer-fiber-reinforced plastic composites

This study addresses the impact performances of recyclable composites made of all thermoplastic polymer-fiber-reinforced plastics (PFRPs), where the reinforcing fibers and matrix are made of thermoplastic polymers. Three woven PFRPs systems were evaluated, including polypropylene fibers, polypropylene matrix, and high-density polyethylene matrix. In low-velocity impact scenario with an impactor speed of less than 6 m/s, our results demonstrate the energy absorption capabilities of the flat laminate PFRPs compared to woven carbon fiber-reinforced plastics (CFRPs) and aluminum alloy 5052. For the systems studied, the PFRPs can reach the specific energy absorption 89% to 115% of the CFRPs. Even compared with the aluminum alloy 5052, the PFRPs can reach up to 97%. We investigate the failure morphologies of the PFRPs using X-ray µCT scans. They reveal the PFRPs’ unique ductile failure morphologies compared to common CFRPs. In addition, we heal the perforated region in the PFRPs by applying the manufacturing process identical to the initial curing process. The healed panels are perforated again, and they recovered 30% to 38% of their original specific energy absorption, a recovery not achievable with CFRPs. This study provides valuable experimental results, and concrete insights into the potential applications of recyclable PFRPs in various engineering fields. It emphasizes their excellent energy-absorbing capability and repairability.

CFRPs↗
DOE OSTI2021

Advancing lightweight mirror design: a paradigm shift in mirror preforms by utilizing design for additive manufacturing

Additive manufacturing is a disruptive technology that can be leveraged by the redesign of components in most engineering fields. Fundamental engineering resources for lightweight mirrors were developed more than 30 years ago with a main design limitation, state of the art manufacturing. In this study, we present two design methodologies for the design of lightweight mirrors. The first method utilizes analytical expressions to design a traditional isogrid mirror, which provided the foundation for most lightweight mirrors to date. The second method employs a combination of topology optimization, lattice infill, and analytical estimation to develop an advanced lightweight mirror designed for additive manufacturing. The advanced mirror design outperforms the traditional design for each functional requirement, including a 94% reduction in predicted surface quilting and a higher specific stiffness. The manufacturing of the advanced mirror is only possible with an additive manufacturing process.

36 MATERIALS SCIENCE↗