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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Overview of fast particle experiments in the first MAST Upgrade experimental campaigns

Abstract MAST-U is equipped with on-axis and off-axis neutral beam injectors (NBI), and these external sources of super-Alfvénic deuterium fast-ions provide opportunities for studying a wide range of phenomena relevant to the physics of alpha-particles in burning plasmas. The MeV range D-D fusion product ions are also produced but are not confined. Simulations with the ASCOT code show that up to 20% of fast ions produced by NBI can be lost due to charge exchange (CX) with edge neutrals. Dedicated experiments employing low field side (LFS) gas fuelling show a significant drop in the measured neutron fluxes resulting from beam-plasma reactions, providing additional evidence of CX-induced fast-ion losses, similar to the ASCOT findings. Clear evidence of fast-ion redistribution and loss due to sawteeth (ST), fishbones (FB), long-lived modes (LLM), Toroidal Alfvén Eigenmodes (TAE), Edge Localised Modes (ELM) and neoclassical tearing modes (NTM) has been found in measurements with a Neutron Camera (NCU), a scintillator-based Fast-Ion Loss Detector (FILD), a Solid-State Neutral Particle Analyser (SSNPA) and a Fast-Ion Deuterium- α (FIDA) spectrometer. Unprecedented FILD measurements in the range of 1–2 MHz indicate that fast-ion losses can be also induced by the beam ion cyclotron resonance interaction with compressional or global Alfvén eigenmodes (CAEs or GAEs). These results show the wide variety of scenarios and the unique conditions in which fast ions can be studied in MAST-U, under conditions that are relevant for future devices like STEP or ITER.

Physics↗
DOE OSTI2021

Progress and prospects of thermo-mechanical energy storage – A critical review

The share of electricity generated by intermittent renewable energy sources is increasing (now at 26% of global electricity generation) and the requirements of affordable, reliable and secure energy supply designate grid-scale storage as an imperative component of most energy transition pathways. The most widely deployed bulk energy storage solution is pumped-hydro energy storage (PHES), however, this technology is geographically constrained. Alternatively, flow batteries are location independent and have higher energy densities than PHES, but remain associated with high costs and low lifetimes, which highlights the importance of developing and utilizing additional larger-scale, longer-duration and long-lifetime energy storage alternatives. Here, we review a class of promising bulk energy storage technologies based on thermo-mechanical principles, which includes: compressed-air energy storage (CAES), liquid-air energy storage (LAES) and pumped-thermal electricity storage (PTES). The thermodynamic principles upon which these thermo-mechanical energy storage (TMES) technologies are based are discussed and a synopsis of recent progress in their development is presented, assessing their ability to provide reliable and cost-effective solutions. The current performance and future prospects of TMES systems are examined within a unified framework and a thermoeconomic analysis is conducted to explore their competitiveness relative to each other as well as when compared to PHES and flow battery systems. This includes carefully selected thermodynamic and economic methodologies for estimating the component costs of each configuration in order to provide a detailed and fair comparison at various system sizes. The analysis reveals that the technical and economic characteristics of TMES systems are such that, especially at higher discharge power ratings and longer discharge durations, they can offer promising performance (round-trip efficiencies higher than 60%) along with high lifetimes (> 30 years), low specific costs (often below 100 $/kWh), low ecological footprints and unique sector-coupling features compared to other storage options. TMES systems have significant potential for further progress and the thermoeconomic comparisons in this paper can be used as a benchmark for their future evolution.

25 ENERGY STORAGE↗
DOE OSTI2024

Point spread function deconvolution using a convolutional autoencoder

A major issue in optical astronomical image analysis is the combined effect of the instrument’s point spread function (PSF) and the atmospheric seeing that blurs images and changes their shape in a way that is band and time-of-observation dependent. In this work we present a very simple neural network based approach to nonblind image deconvolution that relies on feeding a convolutional autoencoder (CAE) input images that have been preprocessed by convolution with the corresponding PSF and its regularized inverse, a method which is both conceptually simple and computationally less intensive. We also present here, a new approach for dealing with limited input dynamic range of neural networks compared to the dynamic range present in astronomical images.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Self-Consistent Simulation of the Excitation of Compressional Alfvén Eigenmodes and Runaway Electron Diffusion in Tokamak Disruptions

Alfvénic modes in the current quench (CQ) stage of the tokamak disruption have been observed in experiments. In DIII-D the excitation of these modes is associated with the presence of high-energy runaway electrons (REs), and a strong mode excitation is often associated with the failure of RE plateau formation. In this work we present results of self-consistent kinetic-MHD simulations of RE-driven compressional Alfvén eigenmodes (CAEs) in DIII-D disruption scenarios, providing an explanation of the CQ modes. Simulation results reveal that high energy trapped REs can have resonance with the Alfvén mode through their toroidal precession motion, and the resonance frequency is proportional to the energy of REs. The mode frequencies and their relationship with the RE energy are consistent with experimental observations. Further, the perturbed magnetic fields from the modes can lead to spatial diffusion of REs including the nonresonant passing ones, thus providing the theoretical basis for a potential approach for RE mitigation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

A surface ice module for wind turbine dynamic response simulation using FAST

It is a fact that developing offshore wind energy has become more and more serious worldwide in recent years. Many of the promising offshore wind farm locations are in cold regions that may have ice cover during wintertime. The challenge of possible ice loads on offshore wind turbines raises the demand of modeling capacity of dynamic wind turbine response under the joint action of ice, wind, wave, and current. The simulation software FAST is an open source computer-aided engineering (CAE) package maintained by the National Renewable Energy Laboratory. In this paper, a new module of FAST for assessing the dynamic response of offshore wind turbines subjected to ice forcing is presented. In the ice module, several models are presented which involve both prescribed forcing and coupled response. For conditions in which the ice forcing is essentially decoupled from the structural response, ice forces are established from existing models for brittle and ductile ice failure. For conditions in which the ice failure and the structural response are coupled, such as lock-in conditions, a rate-dependent ice model is described, which is developed in conjunction with a new modularization framework for FAST. In this paper, analytical ice mechanics models are presented that incorporate ice floe forcing, deformation, and failure. For lower speeds, forces slowly build until the ice strength is reached and ice fails resulting in a quasi-static condition. For intermediate speeds, the ice failure can be coupled with the structural response and resulting in coinciding periods of the ice failure and the structural response. A third regime occurs at high speeds of encounter in which brittle fracturing of the ice feature occurs in a random pattern, which results in a random vibration excitation of the structure. An example wind turbine response is simulated under ice loading of each of the presented models. This module adds to FAST the capabilities for analyzing the response of wind turbines subjected to forces resulting from ice impact on the turbine support structure. The conditions considered in this module are specifically addressed in the International Organization for Standardization (ISO) standard 19906:2010 for arctic offshore structures design consideration. Special consideration of lock-in vibrations is required due to the detrimental effects of such response with regard to fatigue and foundation/soil response. Finally, the use of FAST for transient, time domain simulation with the new ice module is well suited for such analyses.

17 WIND ENERGY↗
DOE OSTI2012

EVALUATING THE COMPETITIVENESS OF ENERGY STORAGE FOR MITIGATING THE STOCHASTIC, VARIABLE ATTRIBUTES OF RENEWABLES ON THE GRID

Energy storage has recently attracted significant interest as an enabling technology for integrating stochastic, variable renewable power into the electric grid. To meet the renewable portfolio standards targets imposed by 29 U.S. states and the District of Columbia, electricity production from wind technology has increased significantly. At the same time, wind turbines, like many renewables, produce power in a manner that is stochastic, variable, and non-dispatchable. These attributes introduce challenges to generation scheduling and the provision of ancillary services. To study the impacts of the stochastic variability of wind on regional grid operation and the role that energy storage could play to mitigate these impacts, Pacific Northwest National Laboratory (PNNL) has developed a series of linked, complex techno-economic-environmental models to address these key questions: a. What are the future expanded balancing requirements necessary to accommodate enhanced wind turbine capacity, so as to meet the renewable portfolio standards in 2020? Specific analyses are conducted for the four North American Electric Reliability Corporation (NERC) western sub-regions. b. What are the most cost-effective technological solutions for providing either fast ramping generation or energy storage to serve these balancing requirements? PNNL applied a stochastic approach to assess the future, expanded balancing requirements for the four western sub-regions with high wind penetration in 2020. The estimated balancing requirements are quantified for four sub-regions: Arizona-New Mexico-Nevada (AZNMNV), California-Mexico (CAMC), Northwest Power Pool (NWPP), and Rocky Mountain Power Pool (RMPP). Model results indicate that the new balancing requirements will span a spectrum of frequencies, from minute-to-minute variability (intra-hour balancing) to those indicating cycles over several hours (inter-hour balancing). The sharp ramp rates in the intra-hour balancing are of significant concern to grid operators. Consequently, this study focuses on analyzing the intra-hour balancing needs. A detailed, life-cycle cost (LCC) modeling effort was used to assess the cost competitiveness of different technologies to address the future, intra-hour balancing requirements. Technological solutions considered include combustion turbines, sodium sulfur (NaS) batteries, lithium ion (Li-ion) batteries, pumped-hydro energy storage (PHES), compressed air energy storage (CAES), flywheels, redox flow batteries, and demand response (DR). Hybrid concepts are also evaluated. For each technology, distinct power and energy capacity requirements are estimated. LCC results indicate that the most cost competitive technologies include electrochemical energy storage and Na-S and Li-Ion. This finding is consistent among the four sub-regions and is generally applicable to other regions.

arbitrage↗
DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗
DOE OSTI2013

State-Space Realization of the Wave-Radiation Force within FAST: Preprint

Several methods have been proposed in the literature to find a state-space model for the wave-radiation forces. In this paper, four methods were compared, two in the frequency domain and two in the time domain. The frequency-response function and the impulse response of the resulting state-space models were compared against the ones derived by the numerical code WAMIT. The implementation of the state-space module within the FAST offshore wind turbine computer-aided engineering (CAE) tool was verified, comparing the results against the previously implemented numerical convolution method. The results agreed between the two methods, with a significant reduction in required computational time when using the state-space module.

17 WIND ENERGY↗
DOE OSTI2014

Extending the Capabilities of the Mooring Analysis Program: A Survey of Dynamic Mooring Line Theories for Integration into FAST: Preprint

Techniques to model dynamic mooring lines come in various forms. The most widely used models include either a heuristic representation of the physics (such as a Lumped-Mass, LM, system), a Finite-Element Analysis (FEA) discretization of the lines (discretized in space), or a Finite-Difference (FD) model (which is discretized in both space and time). In this paper, we explore the features of the various models, weigh the advantages of each, and propose a plan for implementing one dynamic mooring line model into the open-source Mooring Analysis Program (MAP). MAP is currently used as a module for the FAST offshore wind turbine computer-aided engineering (CAE) tool to model mooring systems quasi-statically, although dynamic mooring capabilities are desired. Based on the exploration in this manuscript, the lumped-mass representation is selected for implementation in MAP based on its simplicity, computational cost, and ability to provide similar physics captured by higher-order models.

17 WIND ENERGY↗
DOE OSTI2012

VruiNet Version 12(SOPHIA)

VruiNet Version 12 is the code used exclusively by the executable vruinet. VruiNet Version 12 provides a wrapper around the code for oglnet that makes it compatible for VRUI systems such as the CAVE at CAES.

Rueff, GordonH.↗
DOE OSTI2012

Application of Spatial Data Modeling and Geographical Information Systems (GIS) for Identification of Potential Siting Options for Various Electrical Generation Sources

Oak Ridge National Laboratory (ORNL) initiated an internal National Electric Generation Siting Study, which is an ongoing multiphase study addressing several key questions related to our national electrical energy supply. This effort has led to the development of a tool, OR-SAGE (Oak Ridge Siting Analysis for power Generation Expansion), to support siting evaluations. The objective in developing OR-SAGE was to use industry-accepted approaches and/or develop appropriate criteria for screening sites and employ an array of Geographic Information Systems (GIS) data sources at ORNL to identify candidate areas for a power generation technology application. The initial phase of the study examined nuclear power generation. These early nuclear phase results were shared with staff from the Electric Power Research Institute (EPRI), which formed the genesis and support for an expansion of the work to several other power generation forms, including advanced coal with carbon capture and storage (CCS), solar, and compressed air energy storage (CAES). Wind generation was not included in this scope of work for EPRI. The OR-SAGE tool is essentially a dynamic visualization database. The results shown in this report represent a single static set of results using a specific set of input parameters. In this case, the GIS input parameters were optimized to support an economic study conducted by EPRI. A single set of individual results should not be construed as an ultimate energy solution, since US energy policy is very complex. However, the strength of the OR-SAGE tool is that numerous alternative scenarios can be quickly generated to provide additional insight into electrical generation or other GIS-based applications. The screening process divides the contiguous United States into 100 x 100 m (1-hectare) squares (cells), applying successive power generation-appropriate site selection and evaluation criteria (SSEC) to each cell. There are just under 700 million cells representing the contiguous United States. If a cell meets the requirements of each criterion, the cell is deemed a candidate area for siting a specific power generation form relative to a reference plant for that power type. Some SSEC parameters preclude siting a power plant because of an environmental, regulatory, or land-use constraint. Other SSEC assist in identifying less favorable areas, such as proximity to hazardous operations. All of the selected SSEC tend to recommend against sites. The focus of the ORNL electrical generation source siting study is on identifying candidate areas from which potential sites might be selected, stopping short of performing any detailed site evaluations or comparisons. This approach is designed to quickly screen for and characterize candidate areas. Critical assumptions supporting this work include the supply of cooling water to thermoelectric power generation; a methodology to provide an adequate siting footprint for typical power plant applications; a methodology to estimate thermoelectric plant capacity while accounting for available cooling water; and a methodology to account for future ({approx}2035) siting limitations as population increases and demands on freshwater sources change. OR-SAGE algorithms were built to account for these critical assumptions. Stream flow is the primary thermoelectric plant cooling source evaluated in this study. All cooling was assumed to be provided by a closed-cycle cooling (CCC) system requiring makeup water to account for evaporation and blowdown. Limited evaluations of shoreline cooling and the use of municipal processed water (gray) cooling were performed. Using a representative set of SSEC as input to the OR-SAGE tool and employing the accompanying critical assumptions, independent results for the various power generation sources studied were calculated.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

Integral and Separate Effects Tests for Thermal Hydraulics Code Validation for Liquid-Salt Cooled Nuclear Reactors

The objective of the 3-year project was to collect integral effects test (IET) data to validate the RELAP5-3D code and other thermal hydraulics codes for use in predicting the transient thermal hydraulics response of liquid salt cooled reactor systems, including integral transient response for forced and natural circulation operation. The reference system for the project is a modular, 900-MWth Pebble Bed Advanced High Temperature Reactor (PB-AHTR), a specific type of Fluoride salt-cooled High temperature Reactor (FHR). Two experimental facilities were developed for thermal-hydraulic integral effects tests (IETs) and separate effects tests (SETs). The facilities use simulant fluids for the liquid fluoride salts, with very little distortion to the heat transfer and fluid dynamics behavior. The CIET Test Bay facility was designed, built, and operated. IET data for steady state and transient natural circulation was collected. SET data for convective heat transfer in pebble beds and straight channel geometries was collected. The facility continues to be operational and will be used for future experiments, and for component development. The CIET 2 facility is larger in scope, and its construction and operation has a longer timeline than the duration of this grant. The design for the CIET 2 facility has drawn heavily on the experience and data collected on the CIET Test Bay, and it was completed in parallel with operation of the CIET Test Bay. CIET 2 will demonstrate start-up and shut-down transients and control logic, in addition to LOFC and LOHS transients, and buoyant shut down rod operation during transients. Design of the CIET 2 Facility is complete, and engineering drawings have been submitted to an external vendor for outsourced quality controlled construction. CIET 2 construction and operation continue under another NEUP grant. IET data from both CIET facilities is to be used for validation of system codes used for FHR modeling, such as RELAP5-3D. A set of numerical models were developed in parallel to the experimental work. RELAP5-3D models were developed for the salt-cooled PB-AHTR, and for the simulat fluid CIET natural circulation experimental loop. These models are to be validated by the data collected from CIET. COMSOL finite element models were used to predict the temperature and fluid flow distribution in the annular pebble bed core; they were instrumental for design of SETs, and they can be used for code-to-code comparisons with RELAP5-3D. A number of other small SETs, and numerical models were constructed, as needed, in support of this work. The experiments were designed, constructed and performed to meet CAES quality assurance requirements for test planning, implementation, and documentation; equipment calibration and documentation, procurement document control; training and personnel qualification; analysis/modeling software verification and validation; data acquisition/collection and analysis; and peer review.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Modular Undersea Compressed Air Energy Storage (UCAES) System

This project has been devoted to the design, optimization, and cost analysis of a unique power plant with integral energy storage. The proposed facility combines a novel underwater compressed air energy storage (UCAES) system with a customized gas turbine generator, providing exceptional power management and overall efficiency. Unlike conventional CAES, opportunities for underwater storage are plentiful and proximal to the power grid. The UCAES system provides coastal and island communities a practical means for managing the volatility of large-scale wind and solar power resources. The result is higher renewable energy absorption and improved electrical reliability with reduced fossil fuel consumption. The UCAES power plant is composed of three major subsystems: The underwater air containment system (ACS), the air transport pipe (ATP), and the land-based power conversion system (PCS). The underwater ACS is made up of modular concrete shell units, structurally optimized for minimal material usage while employing conventional production methods and equipment. Each shell is designed to receive and control loose fill or gravel, serving as the ballast. The static nature of the final structures make them an asset to marine habitats and includes features intended to permit safe and cost-effective deployment. The ATP Connects the ACS modules to each other and to the on-land power conversion system and utilizes high density polyethylene (HDPE) pipe for low cost and long life. The PCS Houses the turbine-generator ‘expander modules’, with peak capacity of 12.3 MWe each, engineered from existing gas turbine equipment and includes electrically driven commercial 3-stage intercooled centrifugal compressors, each nominally drawing 6.6 MWe when matching the turbine flow requirements. The subsystems listed above are designed with the intent to serve as building-blocks to achieve a peak power output rating in the 40 to 120 MWe range, with 0.25 to 4 hours of energy storage capacity. The modular facility with integral energy storage provides some remarkable transient maneuvers and load-following features unachievable by competing technologies. The system can operate as a dispatchable power plant with a fuel-to-electric efficiency over 41%; substantially better that the average existing Hawaiian peak power generation assets. Optimal efficiency can be maintained while load-following due to modular PCS design and is operable with a range of liquid or gaseous fuels while meeting the most stringent California (CARB) emission standards. The system can operate as a peaking energy plant in discharge mode. Power ramp-up equivalent to 215% of continuous load rating within 1 second accomplished by simply turning off the electric compressor(s). Contrarily, the system can offer energy absorption during periods of grid surplus generation. The electric compressors may be sequenced on to absorb power within seconds. More moderate transitions are easily achieved with standard compressor control functions. The system offers unique features as compared to energy storage systems. ‘Round-trip efficiency’, as calculated by industry standard methods, is in the 90% range. The PCS equipment has a mean-time between overhauls of 80,000 hours, with maintenance costs of less than $0.005/kW-hr of electricity delivered. The underwater ACS structures and piping employ materials and designs specified to achieve a 75 year life. With the underwater containment modules qualified as a marine habitat, there would be no decommissioning costs. In conjunction with the engineering work invested in the design of the UCAES power plant, Brayton Energy has employed a team of manufacturing specialists, marine construction engineers, and power industry experts to create a comprehensive economic model that captures the many site-related variables and configuration options. The cost results and methodology have been validated by suppliers, engineers, and deployment specialists through a detailed case study on Hawaii. While creation of the parametric cost model was based on inputs specific to Hawaii, the proposed construction and deployment steps were chosen to be general enough to allow extrapolation across locations world-wide. Analysis of the proposed system shows it to be a viable option and addresses the principal challenges described by the Department of Energy by offering competitive costs, validated safety and reliability, consideration of the regulatory environment, and utilization of industry accepted practices and equipment. The UCAES system is recommended for immediate consideration in Hawaii. Estimation of time to complete planning, design, and construction of the facility is anticipated to take 3 to 5 years. Other coastal and island communities world-wide should realize similar benefits; as the results presented in this report are considered generally transferable to other locations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2014

Improving Energy Efficiency by Developing Components for Distributed Cooling and Heating Based on Thermal Comfort Modeling (General Motors LLC Final Project Report)

On November 3, 2009, General Motors (GM) accepted U.S. Department of Energy (DOE) Cooperative Agreement award number DE-EE0000014 from the National Energy Technology Laboratory (NETL). GM was selected to execute a three-year cost shared research and development project on Solid State Energy Conversion for Vehicular Heating, Ventilation & Air Conditioning (HVAC) and for Waste Heat Recovery. The primary objective of this project was to develop a distributed automotive HVAC system that provides thermal comfort equivalent to current state-of-the-art centralized systems while using significantly less energy. To satisfy this objective, the team identified the following goals: • Reduce by at least 30% of the “billions of gallons” the fuel used in cooling mode to maintain occupant comfort through the localized use of thermoelectric (TE) technology while maintaining occupant comfort and safety. • Develop TE HVAC components with a coefficient of performance (COP) greater than 1.3 for cooling and greater than 2.3 for heating, then integrate and test these components as part of a reliable distributed HVAC system in a conventional vehicle (an eAssist Buick Lacrosse) and an extended range electric vehicle (a Chevrolet Volt). • Update the UCB Thermal Comfort model to predict the response of vehicle occupants to localized heating and cooling based on human subject testing, and develop associated computer-aided engineering (CAE) tools to support the integration of distributed HVAC components into future vehicle designs. A secondary objective of the project was to improve the efficiency of thermoelectric generators for converting engine waste heat into electricity.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites (FY 2015 Third Quarterly Report)

During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pellets to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens. Preparation of a computer-aided engineering (CAE) model to predict the performance is in progress. 12) Autodesk fixed an error in the implementation of the proper orthogonal decomposition (POD) calculation of fiber length that had caused the ASMI solution to crash and provided an updated build of ASMI containing the fix. 13)Autodesk reviewed and provided feedback for the complex part molding and measurement locations. 14) Autodesk provided support to set up the workflow for ASMI-ABAQUS® analysis, and provided a fix and workaround for a bug in the ASMI-ABAQUS® output command. 15) Autodesk helped build ASMI analysis models for the complex parts with and without ribs. 16) Autodesk worked on improving the orientation prediction accuracy in the shearing layer for 3D meshes based on comparison to measured data of the plaque moldings. 17) PNNL installed a new ASMI version received from Autodesk and performed comparative analyses to assess mid-plane versus 3D fiber length predictions using the full fiber length model and the reduced-order model (ROM) using POD. 18) PNNL presented the project scope, accomplishments, significant results and future plans to DOE and the USCAR Materials Tech Team on June 3rd, 2015. 19) PNNL discussed the cutting of samples from molded parts and finalized a plan with Magna and the team suggesting the sample size, locations and number of samples per location. 20) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, and preliminary analyses of the part with ribs were conducted using the actual molding parameters received from Magna. 21) PNNL worked on a procedure to extract fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS model. This procedure is essential to import ASMI fiber orientation and length to a 3D ABAQUS model of the part allowing future part structural analysis for weight reduction study.

36 MATERIALS SCIENCE↗
DOE OSTI2015

SubDyn User's Guide and Theory Manual

SubDyn is a time-domain structural-dynamics module for multimember fixed-bottom substructures created by the National Renewable Energy Laboratory (NREL) through U.S. Department of Energy Wind and Water Power Program support. The module has been coupled into the FAST aero-hydro-servo-elastic computer-aided engineering (CAE) tool. Substructure types supported by SubDyn include monopiles, tripods, jackets, and other lattice-type substructures common for offshore wind installations in shallow and transitional water depths. SubDyn can also be used to model lattice support structures for land-based wind turbines. This document is organized as follows. Section 1 details how to obtain the SubDyn and FAST software archives and run both the stand-alone SubDyn or SubDyn coupled to FAST. Section 2 describes the SubDyn input files. Section 3 discusses the output files generated by SubDyn; these include echo files, a summary file, and the results file. Section 4 provides modeling guidance when using SubDyn. The SubDyn theory is covered in Section 5. Section 6 outlines future work, and Section 7 contains a list of references. Example input files are shown in Appendixes A and B. A summary of available output channels are found in Appendix C. Instructions for compiling the stand-alone SubDyn program are detailed in Appendix D. Appendix E tracks the major changes we have made to SubDyn for each public release.

17 WIND ENERGY↗
DOE OSTI2016

As-Run Thermal Analysis for the Utah State University Experiment in the Advanced Test Reactor

The Utah State University (USU) Advanced Test Reactor (ATR) National Scientific User Facility experiment is a materials test consisting of specimens of hafnium aluminide intermetallic and composite. Specimens were contained in sealed, drop-in capsule pairs that were irradiated in the ATR B2 position for up to four reactor cycles (149A, 149B, 150 B and 151A). The experiment configuration was modeled using ABAQUS CAE Version 6.14-2 for construction of the finite element model and ABAQUS Standard to calculate specimen temperatures under as-run irradiation conditions. This ECAR report was formalized as requested by the NSUF project manager (Attachment A). A thermal analysis was performed to determine the irradiation temperatures of each test specimen for up to four irradiation cycles (149A, 149B, 150 B and 151A) that comprised the irradiation campaign. Computed minimum, average and maximum specimen temperatures are given for each of the 132 specimens for an average set of heat rates provided by the physics analysis. In addition, bounding temperatures are given for each specimen using the maximum heat rates from the physics analysis. Specimens in Capsules C 1, D 1 and B 2 experienced the lowest temperatures, followed by those in Capsules B 1, C 2 and D-2, and the highest temperatures were in specimens located in Capsules A-1 and A-2. Temperatures of the specimens for all cycles were between 325.2K and 424.7K. The highest average specimen temperature of 422.9K occurred in the intermetallic rod specimens in Capsule A-1 during Cycle 149B. The highest bounding temperature in the specimens was 424.7K. This information will be used in conjunction with PIE measurements to elucidate the thermophysical mechanisms occurring during, and as a result of, irradiation in the ATR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

SULI Final Report

This project looks at alternative water sources, specifically in the field of desalination and selective ion removal through capacitive deionization (CDI). It project aims to both scale up the desalination capabilities of CDI cells as well as determine the selectivity of CDI for particular ions. My task is to design and build cells that have reproducible performance and characterize the materials for building these cells. The scientific methods I’ve learned through my work in CDI and the data mining and analysis tools I’ve become familiar with through CAES will be important catalysts in my future success in a graduate program. The purpose of this presentation is to give a standard of practice for my current method of building of capacitive deionization cells. Parts 1 and 2 will be discussed in which the electrodes are prepared, and the cell is built.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗