SEARCH · Engineering Papers

Results for “Minimization”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,441 records · Page 80

All sources NASA NTRS DOE OSTI

DOE OSTI2019

False Data Injection and Detection in LQG Systems: A Game Theoretic Approach

Cyber-physical systems are vulnerable to false data injection by adversaries who compromise cyber communication links. In this paper, an infinite horizon linear quadratic Gaussian (LQG) system is considered wherein the control inputs transmitted over cyber links are vulnerable to compromise and false data injection by adversaries. The adversarial cyber-attack is driven to minimize the performance of the LQG system, and the controller is equipped with an intrusion detection system that monitors the sequence of internal physical states to detect adversarial input modification. The problem is formulated as a two-player zero-sum game with the false alarm probability as the reward, wherein the attacker aims to achieve a target increase in controller cost while maximizing the false alarm probability, and a detector who wishes to minimize the false alarm probability while remaining consistent. It is shown that in such a game, an ε-equilibrium exists. The equilibrium attacker strategy is the one that minimizes the Kullback-Leibler distance between legitimate and falsified state dynamics, and the equilibrium detector strategy is the corresponding likelihood-ratio test. Numerical simulations are presented that showcase the equilibrium strategy pair and the intuitive strategies comparisons.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Formulation and Comparison of Two Real-Time Predictive Gear Shift Algorithms for Connected/Automated Heavy-Duty Vehicles

Our work investigates the problem of predictive gear scheduling for fuel consumption minimization in connected/automated heavy trucks. The literature highlights the fuel economy benefits of such predictive scheduling, but there is a need to optimize such scheduling online, in real time. To address this need, we begin by using dynamic programming (DP) to schedule gear shifting offline, in a manner that achieves a globally optimal Pareto tradeoff between the conflicting objectives of minimizing fuel consumption and shift frequency. The computational cost of DP is unfavorable for online implementation, but we present two algorithms addressing this issue. Both algorithms rely on the fact that in the Pareto limit where fuel consumption minimization is the sole objective, DP furnishes a simple static shift map . Our first algorithm trains a recurrent neural network to prune the shift schedule generated by this map. The second algorithm performs this pruning in a direct manner tailored to reduce the schedule's rain flow count. We simulate these algorithms for different drive cycles. Both algorithms achieve a reasonable tradeoff between fuel consumption and gear shift frequency. Yet, the rain flow count algorithm is both more effective in approaching the DP-based Pareto front and more computationally efficient.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Physics-Informed Deep Learning-Based Proof-of-Concept Study of a Novel Elastohydrodynamic Seal for Supercritical CO 2 Turbomachinery

Supercritical carbon dioxide (sCO 2 ) power cycles show promising potential of higher plant efficiencies and power densities for a wide range of power generation applications such as fossil fuel power plants, nuclear power production, solar power, and geothermal power generation. sCO 2 leakage through the turbomachinery has been one of the main concerns in such applications. To offer a potential solution, we propose an elastohydrodynamic (EHD) seal that can work at elevated pressures and temperatures with low leakage and minimal wear. The EHD seal has a very simple, sleeve-like structure, wrapping on the rotor with minimal initial clearance at micron levels. Here, in this work, a proof-of-concept study for the proposed EHD seal was presented by using the simplified Reynolds equation and Lame’s formula for the fluid flow in the clearance and for seal deformation, respectively. The set of nonlinear equations was solved by using both the conventional Prediction–Correction (PC) method and modern Physics-Informed Neural Network (PINN). It was shown that the physics-informed deep learning method provided good computational efficiency in resolving the steep pressure gradient in the clearance with good accuracy. The results showed that the leakage rates increased quadratically with working pressures and reached a steady-state at high-pressure values of 15~20 MPa, where Q = 300 g/s at 20 MPa for an initial seal clearance of 255 μm. This indicates that the EHD seal could be tailored to become a potential solution to minimize the sCO 2 discharge in power plants.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Optimum Injector Parameters for Thermoacoustic Stability in a Multi-Nozzle Can Combustion System

Abstract High-frequency transverse instabilities are an important concern in can combustor configurations. In these configurations which are typically operated with multiple injectors around a central injector, each injector is subjected to different parts of the acoustic mode shape and thus respond differently for the same instability mode. Recent work by the author has modeled the response of premixed flames to excitation by natural high-frequency transverse modes in a can combustor both in the center and outer nozzles. The stability of these acoustically non-compact flames was assessed using the Rayleigh criterion (Rayleigh Integral denoted as RI) and not the overall unsteady heat release as is the case for compact flames. Several key control parameters were studied, namely — flame angle, swirling strength, nozzle location. For non-axisymmetric modes such as the commonly occurring 1-T mode, both radial and azimuthal offsets of the nozzle location affected stability. The framework was applied to an optimization study to identify the optimal combination of parameters that minimizes RI for the different nozzles in the multi-nozzle system. In this study, a N-around-1 configuration was studied, and the results indicated that the different nozzles needed to be operated at different flame angles and swirl numbers to result in an overall minimum RI. However, the specific response of the different injectors was not considered. The helical mode distribution at each injector varies as we azimuthally go around the combustor’s injector distribution and thus the most amplified mode and the resulting flame response would be different. To minimize RI, it is important to determine the injector configurations that result in a hydrodynamic profile that minimizes the individual RI for each nozzle. The resulting relationship between the injector’s flow and local hydrodynamics can then be used in a hydrodynamics study of an individual injector so that the most optimal injector is chosen depending on its location in the combustor dump plane.

Acharya, Vishal↗

DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

DOE OSTI2018

Cross-polarization systematics due to Mizuguchi-Dragone condition breaking by a continuously rotating half-wave plate at prime focus in the Huan Tran telescope

Polarization modulation using a continuously rotating half-wave plate (HWP) is a promising technique to reduce both low-frequency noise and instrumental systematics for Cosmic Microwave Background (CMB) polarization measurements targeting in ationary B-modes. Although a HWP is best placed sky-side of the telescope optics in order to minimize systematics, >0.5 meter aperture class telescopes must put the HWP elsewhere in the optics chain due to current fabrication limitations in the available HWP size. Polarbear is a ground-based CMB experiment installed on the 2.5m aperture off-axis Gregorian-Dragone type Huan Tran Telescope (HTT) designed to satisfy the Mizuguchi-Dragone condition. Polarbear-2 is a receiver that will be installed on a second HTT in 2018. Polarbear-2 is designed to have a larger field-of-view (FOV) and vastly increased sensitivity to the polarized CMB compared to Polarbear. From the third season of observations, Polarbear has installed a continuously rotating HWP at the spatially localized focus plane between the HTT primary and secondary re ectors which is an optimal location for minimizing the HWP diameter. The HWP's polarization angle re ection with respect to its birefringent axis will theoretically break the Mizuguchi-Dragone condition when placed between the two reflectors and increase cross-polarization systematics. In this study, we analyze how the Mizuguchi-Dragone condition is violated due to a HWP at this location. We then estimate the crosspolarization systematics of the HTT using physical optics simulations. We model an ideal HWP at various angles to estimate the effects of demodulation. We evaluate the increased cross-polarization as the Stokes Q-U mixing term using the Mueller Matrix formalism. It is calculated that this term creates a varying dipole beam pattern whose amplitude ranges from 1% at the center to 10% at the edge FOV pixels for Polarbear and potentially up to 20% for Polarbear-2. We also estimate the leakage of the E-mode into the B-mode angular power spectrum measurements due to this cross-polarization. We show that the cross-polarization systematic error leakage is sufficiently lower than the Polarbear-2 statistical uncertainty thanks to mitigations such as focal plane averaging and sky rotation. Currently for Polarbear-2 we are planning to place the HWP at Gregorian focus, but keeping the HWP at prime focus as a back-up solution in case that there are unforeseen telescope spatial and HWP material size constraints. Through this study we find that even though a HWP between the two reflectors will violate the Mizuguchi-Dragone condition, this HWP at prime focus will still have sufficiently low cross-polarization for Polarbear-2. The prime focus HWP is a potential configuration that can be applied to similar off-axis Gregorian-Dragone telescopes in order to minimize the required HWP diameter.

Takakura, Satoru↗

DOE OSTI2020

Phased: Phase-Aware Submodularity-Based Energy Disaggregation

Energy disaggregation is the task of discerning the energy consumption of individual appliances from aggregated measurements, which holds promise for understanding and reducing energy usage. In this paper, we propose PHASED, an optimization approach for energy disaggregation that has two key features: PHASED (i) exploits the structure of power distribution systems to make use of readily available measurements that are neglected by existing methods, and (ii) poses the problem as a minimization of a difference of sub-modular functions. We leverage this form by applying a discrete optimization variant of the majorization-minimization algorithm to iteratively minimize a sequence of global upper bounds of the cost function to obtain high-quality approximate solutions. PHASED improves the disaggregation accuracy of state-of-the-art models by up to 61% and achieves better prediction on heavy load appliances.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

DOE OSTI2024

A Compound Data Poisoning Technique with Significant Adversarial Effects on Transformer-based Sentiment Classification Tasks

Transformer-based models have demonstrated much success in various natural language processing tasks. However, they are often vulnerable to adversarial attacks, such as data poisoning, which can intentionally fool the model into generating incorrect results. In this article, we present a novel, compound variant of a data poisoning attack on a transformer-based model that maximizes the poisoning effect while minimizing the scope of poisoning. Here we do so by combining the established data poisoning technique (label flipping) with a novel adversarial artifact selection and insertion technique aimed at minimizing detectability and the scope of the poisoning footprint. We find that by using a combination of these two techniques, we achieve a state-of-the-art attack success rate of approximately 90% while poisoning only 0.5% of the original training set, thus minimizing the scope and detectability of the poisoning action. These findings have the potential to advance the development of better data poisoning detection methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Polyglot Framework

Polyglot utilizes a combination of custom and open source tools and libraries to provide developers with a consistent environment for building tools, etc. for a wide variety of targets with minimal changes to the code being built. It supports a variety of architectures and operating systems/firmware in as target-agnostic way as possible. This allows for developers to minimize the amount of time/effort required to port tools—in particular, forensic tools—to a wide variety of targets. The project is comprised of two main components: a frontend toolchain that understands how to utilize other tools in order to build code for a specific target, and a minimalistic C library specific to Polyglot. These collectively provide the method to build code for a specific target, and the capability for code to interact with the underlying operating system when run on the target. Both components are written in a way to minimize the amount of target-specific knowledge required to both develop and utilize the project.

Huddleston, TimothyA.↗

DOE OSTI2024

Polyglot C Library

The C library component of Polyglot. Polyglot utilizes a combination of custom and open source tools and libraries to provide developers with a consistent environment for building tools, etc. for a wide variety of targets with minimal changes to the code being built. It supports a variety of architectures and operating systems/firmware in as target-agnostic way as possible. This allows for developers to minimize the amount of time/effort required to port tools-in particular, forensic tools-to a wide variety of targets. The project is comprised of two main components: a frontend toolchain that understands how to utilize other tools in order to build code for a specific target, and a minimalistic C library specific to Polyglot. These collectively provide the method to build code for a specific target, and the capability for code to interact with the underlying operating system when run on the target. Both components are written in a way to minimize the amount of target-specific knowledge required to both develop and utilize the project.

Huddleston, TimothyA.↗

DOE OSTI2024

Model-predictive optimal control of ferrofluidic microrobots in three-dimensional space

Ferrofluid microrobots have emerged as promising tools for minimally invasive medical procedures. Their unique properties to navigate complex fluids and reach otherwise inaccessible regions of the human body have enabled new applications in targeted drug delivery, tissue engineering, and diagnostics. Here, this paper proposes a model-predictive controller for the external magnetic manipulation of ferrofluid microrobots in three dimensions (3D). The internal optimization routine of the controller determines appropriate changes in the applied electromagnetic field to minimize the deviation between the actual and desired trajectories of the microrobot. A linear system governing locomotion is derived and used as the equality constraints of the optimization problems associated with the feedback index. In addition to ferrofluid droplets, the controller presented in this work may be applied to other magnetically-pulled microrobots. Several experiments are performed to validate the controller and showcase its ability to adapt to changes in system parameters such as the desired tracking trajectory and the size, orientation, deformation, and velocity of the microrobot. The accuracy of the controller is analyzed for each experiment, and the average error is found to be within 0.25 mm for small velocities. An additional experiment is performed to demonstrate significant improvement over a PID controller that is optimally tuned using Bayesian optimization. The results presented in this paper suggest that the proposed control algorithm could enable new microrobotic capabilities in minimally invasive medical procedures, lab-on-a-chip applications, and microfluidics.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Understanding and reducing mid-spatial frequency ripples during hemispherical sub-aperture tool glass polishing

We report during sub-aperture tool polishing of glass optics, mid-spatial surface ripples are generated because of material removal non-uniformities during tool linear translation (resulting in feed ripples) and tool pathway step overlaps (resulting in pitch ripples). A variety of tool influence function (TIF) spots, trenches, and patches were created to understand and minimize such ripples on fused silica workpieces after polishing with cerium oxide slurry using a rotating hemispherical pad-foam tool. The feed ripple amplitude can be decreased by reducing the non-uniformities in the pad texture and/or by minimizing a derived feed ripple metric ($r_f = V^{0.5}_{max}V_f/R_t$) via adjustments in processing parameters. Pitch ripples can be minimized by reducing relative step distance to spot radius ratio ($x_s/a_t$) and by achieving a flat bottom trench shape cross section or by reducing the material removal per pass. Using the combined methods, an overall ripple error of ~1.2nm rms has been achieved.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Smoothing tool design and performance during subaperture glass polishing

During subaperture tool grinding and polishing, overlaps of the tool influence function can result in undesirable mid-spatial frequency (MSF) errors in the form of surface ripples, which are often corrected using a smoothing polishing step. Here, in this study, flat multi-layer smoothing polishing tools are designed and tested to simultaneously (1) reduce or remove MSF errors, (2) minimize surface figure degradation, and (3) maximize the material removal rate. A time-dependent convergence model in which spatial material removal varies with a workpiece-tool height mismatch, combined with a finite element mechanical analysis to determine the interface contact pressure distribution, was developed to evaluate various smoothing tool designs as a function of tool material properties, thicknesses, pad textures, and displacements. An improvement in smoothing tool performance is achieved when the gap pressure constant, $\overline{h}$ (which describes the inverse rate at which the pressure drops with a workpiece-tool height mismatch), is minimized for smaller spatial scale length surface features (namely, MSF errors) and maximized for large spatial scale length features (i.e., surface figure). Five specific smoothing tool designs were experimentally evaluated. A two-layer smoothing tool using a thin, grooved IC1000 polyurethane pad (with a high elastic modulus, E pad =360 MPa ), thicker blue foam (with an intermediate modulus, E foam =5.3 MPa ) underlayer, and an optimized displacement (d t =1 mm ) provided the best overall performance (namely, high MSF error convergence, minimal surface figure degradation, and high material removal rate).

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Deep Learning–Assisted Multiobjective Optimization of Geological CO 2 Storage Performance under Geomechanical Risks

In geological CO 2 storage, designing the optimal well control strategy for CO 2 injection to maximize CO 2 storage while minimizing the associated geomechanical risks is not trivial. This challenge arises due to pressure buildup, CO 2 plume migration, the highly nonlinear nature of geomechanical responses to rock-fluid interaction, and the high computational cost associated with coupled flow and geomechanics simulations. In this paper, we introduce a novel optimization framework to address these challenges. The optimization problem is formulated as follows: maximize total CO 2 storage while minimizing geomechanical risks by adjusting the injection schedules within bounded constraints. The geomechanical risks are primarily driven by injection-induced pressure build-up, which is characterized by ground displacement and the induced microseismicity. We used the Fourier neural operator (FNO)-based deep learning model to construct surrogate models, replacing the time-consuming coupled flow and geomechanics simulations for evaluating the aforementioned objective functions. The developed surrogate models have been incorporated into a multiobjective optimization framework through a genetic algorithm to reduce the computational burden. The proposed optimization framework reduces the computational cost from approximately 2,400 hours, when using objective function evaluations based on physics-based simulations, to around 20 minutes. A set of Pareto-optimal solutions of the proposed workflow yields nontrivial optimal decisions, reducing the microseismicity potential and the vertical displacement. This Pareto front highlights the optimal trade-offs between CO 2 storage amount, safety, and ground displacement, emphasizing the need for careful optimization and management of injection strategies to achieve a balanced outcome. The novelty of this work is twofold. First, we demonstrate the importance of incorporating the minimization of the geomechanical risks as objective functions into the CO 2 storage optimization workflow to mitigate the potential risk of induced microseismicity and ground displacement. Second, we leverage the FNO-based surrogate models to optimize a real-field CO 2 storage operation.

42 ENGINEERING↗

DOE OSTI2018

Modular Controllable Transformers (MCT)

Large Power Transformers (LPTs) are at the heart of the electricity infrastructure and are critical pieces in today’s grid. Aging assets, long turn-around times, transportation delays and dependence on foreign manufacturing for these components have created conditions for points of failure across the system. Moreover, there is no available dynamic control on these passive sections of the grid. For all the automation embedded on the low voltage side of the low voltage side of the system there is absolutely no flexibility on the high voltage side. Changes in power flow patterns are brought about by altering dispatch patterns for generators which requires a coordinated effort and is often time consuming. Traditional FACTS based approaches such as UPFC or HVDC light involve massive modifications to the existing infrastructure. Recent instances of physical attacks on LPTs and the slow recovery process associated with fixing or replacing these damaged units has created an increased awareness for this issue. LPT designs are highly customized owing to specific field requirements. Long lead times coupled with transportation delays make procuring and installing LPTs a lengthy process. In an attempt to minimize the recovery time following an LPT failure, transformer manufacturers have developed mobile transformer units. These units typically consist of either a single-phase or three-phase transformer mounted on a truck and characterized by compact form factors. By reducing the assembly time and transport time these units offer a fast and temporary solution to LPT failures. Several efforts led by DOE, Edison Electric Company (EEI) and North American Electric Reliability Corporation (NERC) have led to the RecX program. RecX transformers consist of single phase transformers transported on specialized assemblies to enable fast restoration and minimal installation time. NERC and EEI have instituted transformer sharing programs like Spare Equipment Database (SED) as well as Spare Transformer Equipment Database (STEP) which encourage utilities to maintain and share a fleet of LPTs. Mobile transformers are typically limited to less than 100 MVA to enable transportation on a trailer. Also, the efficiency of mobile transformer units and RecX transformers is lower since they are temporary solutions. The ideal replacement solution would be one that could utilize a set of standardized transformers while incorporating flexibility to influence metrics like power flow, apparent impedance and voltage profiles. In view of these issues the team at Georgia Tech proposed a concept called Modular Controllable Transformers (MCTs). This project was commissioned as a part of DOE’s Transformer Resiliency and Advance Component (TRAC) program. The approach consists of splitting one large unit rated upwards of 100 MVA with smaller modular, standardized units. Each of these smaller units are augmented with a converter to add power flow, voltage and impedance control. Splitting the power level into multiple units has two important implications. By making smaller units, the transportation times can be reduced drastically. Moreover, even though these units have very specific impedance and other parameters, the augmented converters can make it emulate the unit being replaced. Thus, faster replacement times and added controls are achieved making this an extremely resilient approach. In the event of one modular units failure, the other two controllable units can operate in the most resilient fashion keeping the net system overloads to a minimum. Moreover, for the same probability of failure only a fraction of the system capacity is lost. The converter is augmented on to the tertiary winding of the transformer making it retrofittable in the field without massive modifications to the system. The material proposed in this report highlights design considerations to minimize recovery time as well as results displaying overall improvement in resiliency. The cost analysis of this approach shows significant savings compared to UPFC and HVDC lite based approaches. Extensive analysis was conducted on numerous aspects of this project over the course of this project. Simulation studies were conducted to prove the 5MVA converter design. Challenging BIL constraints and transient issues were addressed over the course of this project. Simulations on EMTP platform presented in consequent sections were used to finely tune the control for the same. A final design for a back-to-back 5MVA neutral-point-clamped (NPC) converter was completed in this project. Furthermore, switching components like high power IGBTs from IXYS Westcode Press-Pack series and ABB Stackpack series were identified for this application. These devices exhibit a blocking voltage of 6.5 kV and a nominal collector current of 900 A. Potential housing options as well as existing commercial option were identified for this converter design. A 56 MVA modular transformer unit was designed with Delta Star Inc. with consultation and inputs from all project members. The transformer cooling systems were chosen to be Oil Natural Air Forced (ONAF) to optimize ease of transport. A full Product Requirement Document (PRD) for the converter and the transformer was generated. The team also investigated key aspects of resiliency and how to quantify the same. A metric was developed to analyze resiliency and numerous simulation cases were presented. Increased (N-1) resiliency and outage resistance was showcased through simulation on the Texas Large scale power system. Dynamic control capabilities were also showcased on numerous system level simulations. An IEEE 30 bus system was used to show the ability of the MCT approach to reduce line congestion. Power flow control; a part of the MCTs abilities, showcased a 29% reduction in transformer loading on the same system. Full control over tie line flows was demonstrated on a modified IEEE 13 bus system. Dynamic LTC capabilities were shown through simulation and were compared to traditional LTCs. Furthermore, the ability of the MCTs to alter apparent transformer impedance was simulated to promote standardization of modular transformer units while retaining the ability to emulate a varied range of impedance characteristics. Thus granular control over power flow, voltages, impedances and was presented. Regulatory analysis conducted by Oak Ridge National Laboratory (ORNL) further bolstered the efficacy of the MCT approach and verified the added resiliency achieved due to this approach. As a conclusion, it was proved that the resilience improvement obtained from using the MCT approach is justified by just one failure in a 30-year period. This means that the benefits obtained from using the MCT approach far outweigh the cost of setting this approach up. As a part of the future efforts, the team is proposing building a (12.47-24) kV/400 kVA scaled down unit to control 5MVA of power flows. Emphasis would be laid on using commercial components to speed up the build of these units. Further the actual transport of the modular transformer unit would be a part of this operation and would provide insight into transportation issues. The approach shows much promise and adds key dynamic control on passive sub transmission and transmission sectors.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Soluble and Particulate Mercury Deployment of Analytical Method for the Savannah River Site Liquid Waste System

Savannah River National Laboratory (SRNL) developed, tested, and deployed in a radiological containment unit (CU) an analytical method for quantifying particulate total mercury and soluble total mercury in radioactive samples such as the those generated by the dilution of Savannah River Site (SRS) High-Level Waste. This method relies on direct mercury analysis and other associated capabilities for matrix independent quantification of total mercury in solids or liquids (i.e., any sample that can be introduced into the instrument oven for pyrolysis to release all mercury for measurement). The matrix independence allows for discreet measurements of the starting sample, the collected particulates and the filtrate liquid, thus enabling a mass balance quality check. For example, an analysis of a diluted sample from the SRS liquid waste system (LWS) resulted in a measured total mercury value of 55.0 mg Hg/L and a nearly matching calculated total mercury value of 55.1 mg Hg/L (± 20% 2σ) from the summation of measured soluble mercury (47.8 mg Hg/L ± 20% 2σ) and measured particulate mercury (7.26 mg Hg/L ± 20% 2σ). The advantages of the particulate-soluble mercury analysis method are: waste minimization using small radioactive liquid volumes, minimal radiological sample processing and reduced handling steps protective of workers (ALARA) and improved data quality, syringe filter technology which eliminates vacuum filtration and the potential loss of volatile species, small diameter filters (13 mm nominal to 25 mm if needed to avoid clogging) and small disposable poly filter holders (no need to clean) which minimize waste, flexibility provided for a range of starting concentrations, particulate-soluble ratios, and sample matrix conditions, soluble and particulate are measured results that, when summed, and are in good agreement with the total mercury measurement.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Chemistry Envelope for Pitting and Stress Corrosion Cracking Mitigation

The present waste chemistry controls for the Hanford double-shell tanks (DSTs) were established in the 1980s in response to tank failures caused by stress corrosion cracking (SCC) at the DOE Savannah River Site (SRS). Portions of the SRS chemistry limits were coupled with corrosion testing results from Pacific Northwest Laboratory (PNL) and adopted for corrosion control of the DST waste at the Hanford Site. Since that time, the temperatures of many DST wastes have decreased to less than 50 °C as the radioactive material has decayed, the testing program in Argentina demonstrated that chloride ion in Hanford Site waste could cause pitting, and other work showed that dilute solutions could cause pitting at the liquid air interface (LAI). Moreover, future transfers from the single shell tanks and the waste treatment plant and process changes may shift the DST waste chemistries to a broader range of compositions with higher aggressive anion concentrations than the wastes that are presently stored. The decreasing temperatures led to the formulation of new chemistry controls for the minimization of SCC risks for operations below 50 °C in 2010, and these controls were partially adopted. The Tank Integrity Expert Panel (TIEP) Corrosion Subgroup (CSG) recommended that additional testing be performed to assess the potential for pitting and LAI corrosion. Since 2015, DNV-GL, SRNL, and the Hanford Site laboratory have investigated pitting and LAI corrosion at current and anticipated DST chemistries and Savannah River National Laboratory (SRNL) undertook a statistically based investigation of the role of nitrate and halide ion induced pitting corrosion. The objective was to develop a comprehensive waste chemistry envelope for the simultaneous minimization of the pitting and SCC risks caused by halide and nitrate ions. This report summarizes the technical basis for the new waste chemistry envelope to minimize the potential for both pitting and cracking corrosion induced by nitrate and halide ions, and the strategies used for the validation of the new controls.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Sodium Exposure Tests of A709 Steel (FY2020 Progress Report)

Sodium exposure tests were conducted on the first commercial heat, H58776 of A709 steel. Six different processing and heat treatment conditions were investigated, including three processing conditions, namely, Argon-Oxygen-Decarburization (AOD), Electro-slag Remelting (ESR), and Electro-slag Remelting with subsequent homogenization (HOMO), and two heat treatment conditions, i.e. solution annealing at 1100°C (SA1100°C) or 1150°C (SA1150°C). Specimens of AOD-SA1100°C, AOD-SA1150°C, ESR-SA1100°C, ESR-SA1150°C, HOMO-SA1100°C, and HOMO-SA1150°C were tested in sodium at 650°C and for times up to 10,152 h. Specimens in the AOD-SA1100°C and AOD-SA1150°C conditions were also tested in sodium at 550 and 600°C. Parallel thermal aging experiments were carried out for comparison with sodium exposure tests to separate the thermal and sodium effects. It was found that A709 H58776 generally showed a weight loss after sodium exposures at 650°C except a few data points of the ESR-SA1100°C specimens. The corrosion rate showed large variations in the initial stage and decreased with increasing exposure time. Long-term exposure tests are needed to determine its steady-state corrosion rate. The AOD-SA1100°C and HOMO-SA1100°C specimens showed similar tensile responses after thermal or sodium exposures at 650°C. The yield stress increased, the ultimate tensile strength decreased, and the uniform and total elongations were reduced after thermal or sodium exposures. A longer exposure time had a minimal effect on the tensile strength but further reduced the tensile ductility. The sodium-exposed specimens had higher tensile strength than the thermally-aged specimens. In contrast, the ESR-SA1100°C specimens showed an increase in the yield stress and the ultimate tensile strength after thermal or sodium exposures at 650°C and ~10,000 h. The AOD-SA1150°C and ESR-SA1150°C specimens showed similar tensile behavior after thermal or sodium exposures at 650°C.Thermal or sodium exposures at 650°C increased the yield stress, decreased the ultimate tensile strength, and reduced uniform and total elongations. There were minimal differences in tensile properties between the sodium-exposed and thermally-aged specimens after an ~3000 h exposure. After an exposure for ~10,000 h the sodium-exposed specimens showed higher yield stress and ultimate tensile strength and lower uniform and total elongations than the thermally-aged specimens. For the HOMO-SA1150°C specimens, thermal or sodium exposures at 650°C significantly increased the yield stress but had a minimal effect on the ultimate tensile strength. Both uniform and total elongations were significantly reduced at an exposure time of ~3,000 h, and they were further reduced after an exposure of ~10,000 h. The sodium-exposed specimens had lower tensile ductility than the thermally-aged specimens. Before exposure, the stress-strain curves of the specimens in all six processing-heat treatment conditions showed serrations indicating the dynamic aging effect at 650°C. Thermal aging or sodium exposures at 650°C after ~10,000 h completely removed the serrations of the flow curves in A709 H58776, indicating strong precipitation during thermal or sodium exposures. Longer-term sodium exposure tests are needed to determine the steady-state corrosion rates in sodium for A709 H58776 and fully understand the influence of sodium exposures on its mechanical performance.

36 MATERIALS SCIENCE↗