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DOE OSTI2026

On High-Temperature Dynamometer Test Stand Development

RePED is a novel prototype alternator that has been designed and built to operate at 35 kW under 250 degrees C ambient temperature conditions. The operating efficiency will be measured using a 225-kW motor to drive the machine in a back-to-back configuration. The goal is to determine if the RePED alternator can deliver 35 kW at a rotational speed of 1,000 rpm while operating in 250 degrees C ambient temperature and have a minimum efficiency of 60%. Dynamometer testing of a high-temperature alternator for geothermal drilling presents several unique challenges, especially around maintaining and managing the various sources and types of energy passing through the system without impacting data quality. The objectives of this report are to (1) describe the test stand in detail, the relative orientation of each major component, and the data acquisition system and (2) discuss the behavior of the test stand components such that this report can serve as a reference document for future projects.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

No evidence of Bartonella infections in host-seeking Ixodes scapularis and Ixodes pacificus ticks in the United States

Background. Bartonella spp. infect a variety of vertebrates throughout the world, with generally high prevalence. Several Bartonella spp. are known to cause diverse clinical manifestations in humans and have been recognized as emerging pathogens. These bacteria are mainly transmitted by blood-sucking arthropods, such as fleas and lice. The role of ticks in the transmission of Bartonella spp. is unclear. Methods. A recently developed quadruplex polymerase chain reaction (PCR) amplicon next-generation sequencing approach that targets Bartonella-specific fragments on gltA, ssrA, rpoB, and groEL was applied to test host-seeking Ixodes scapularis ticks (n=1641; consisting of 886 nymphs and 755 adults) collected in 23 states of the eastern half of the United States and Ixodes pacificus ticks (n=966; all nymphs) collected in California in the western United States for the presence of Bartonella DNA. These species were selected because they are common human biters and serve as vectors of pathogens causing the greatest number of vector-borne diseases in the United States. Results. No Bartonella DNA was detected in any of the ticks tested by any target. Conclusions. Owing to the lack of Bartonella detection in a large number of host-seeking Ixodes spp. ticks tested across a broad geographical region, our results strongly suggest that I. scapularis and I. pacificus are unlikely to contribute more than minimally, if at all, to the transmission of Bartonella spp.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Advanced Test Reactor Neutron Dosimetry Report - 173B (Rev. 1)

Results of neutron dosimetry measurements in ATR for cycle 173B-1&2 are presented. Cobalt and nickel wires were installed in numerous irradiation locations for the duration of the cycle. The specific activity of these wire segments can be used in conjunction with the presented cycle history information to determine the thermal- and fast-neutron fluence rates for each irradiation position during the cycle using the referenced standard test methods.

173B↗

DOE OSTI2025

Distillable amine-based solvents for effective pretreatment of multiple biomass feedstocks

Exploring the potential of advanced distillable solvents as efficient biomass pretreatment agents is critical for biorefineries, enhancing fermentable sugar yields while enabling solvent recovery and recycling without suffering significant losses. Here, we employ distillable amine-based solvents for pretreating a wide range of lignocellulosic feedstocks, aiming to facilitate the industrial release of fermentable sugars from diverse feedstocks through enzymatic hydrolysis. Twenty-two diverse feedstocks, sourced from different geographical regions and representing various biomass categories, were surveyed for chemical (mainly carbohydrates and lignin) and lignin (S, G, and H units) profiles. Several solvents, including ethanolamine, ethanolammonium acetate, butylamine, butylammonium acetate, and triethylamine, were tested for the pretreatment of eight selected biomasses. Among these solvents, butylamine emerged as the most effective due to its favorable sugar release, excellent solvent removal rate, and low boiling point, facilitating solvent recovery and recycling. Extending butylamine pretreatment to all 22 feedstocks demonstrated desirable sugar yields and highly efficient solvent removal in the majority of the biomass sources tested. Agricultural residues and their mixtures showed particularly favorable sugar release. Despite minimal changes in cellulose crystallinity, XRD characterization of sorghum, poplar, and pine before and after butylamine pretreatment showed a decrease in intensity and a slight shift of certain peaks, indicating alterations in cellulose structure. Fourier-transform infrared spectroscopy and thermogravimetric analysis analyses suggested disruption of biomass linkages in hemicellulose and lignin, enhancing enzymatic digestibility. Scale-up experiments of the mixed agricultural feedstocks in a 1 L Parr reactor achieved over 90% glucose liberation and more than 99% butylamine removal, highlighting the scalability of the method. The resulting hydrolysates supported the growth of diverse bacterial and fungal strains, indicating downstream compatibility with commercial fermentation processes. This study presents butylamine as an effective, recoverable pretreatment solvent for a wide range of lignocellulosic feedstocks, offering a promising solution to key biorefinery challenges. The demonstrated scalability and compatibility with various biomass types and blends underscore its potential for industrial application, advancing sustainable biofuel and biochemical production.

biomass composition↗

DOE OSTI2026

Splat Quenching as a High Throughput Rapid Solidification Testing Method for Developing Additive Manufacturing Alloys

Splat quenching as a high throughput rapid solidification screening tool is evaluated. Samples were made using known alloys (SS316, IN625, Ti-5553) to evaluate and establish the microstructures for a variety of alloy systems as well as the predicted cooling rates. The samples are inductively heated and levitated prior to being struck between two platens that produce a high contact pressure and a thin sample resulting in cooling rates on the order of 10 6 to 10 7 K/s. Process parameters were evaluated with analytical models in addition to numerical simulations to provide an effect of process variables such as substrate material, melt superheat, and platen velocity on the resulting solidification. The splat thickness was found to be controlled by platen velocity, melt superheat, as well as the feedstock volume. The sample thickness is the key controlling factor for varying the average cooling rate experienced by the splat quenched sample. The splat quenching techniques can reach regions of rapid solidification space that meet and exceed laser and electron beam techniques across the sample. In conclusion, the results of the study provide a useful foundation in understanding the splat quenching technique and its potential as a low effort tool to explore rapid solidification effects on alloys.

Alloy Design↗

DOE OSTI2015

Battery Test Manual For 12 Volt Start/Stop Hybrid Electric Vehicles (Revision 1)

This manual was prepared by and for the United Stated Advanced Battery Consortium (USABC) Electrochemical Energy Storage Team. It is based on the targets established for 12 Volt Start/Stop energy storage development and is similar (with some important changes) to an earlier manual for the former FreedomCAR program. The specific procedures were developed primarily to characterize the performance of energy storage devices relative to the USABC requirements. However, it is anticipated that these procedures will have some utility for characterizing 12 Volt Start/Stop hybrid energy storage device behavior in general.

12 Volt Start/Stop↗

DOE OSTI2016

2015 Groundwater Monitoring Report Project Shoal Area: Subsurface Correction Unit 447

The Project Shoal Area in Nevada was the site of a 12-kiloton-yield underground nuclear test in 1963. Although the surface of the site has been remediated, investigation of groundwater contamination resulting from the test is still in the corrective action process. Annual sampling and hydraulic head monitoring are conducted at the site as part of the subsurface corrective action strategy. The corrective action strategy is currently focused on revising the site conceptual model (SCM) and evaluating the adequacy of the monitoring well network. Some aspects of the SCM are known; however, two major concerns are the uncertainty in the groundwater flow direction and the cause of rising water levels in site wells west of the shear zone. Water levels have been rising in the site wells west of the shear zone since the first hydrologic characterization wells were installed in 1996. Although water levels in wells west of the shear zone continue to rise, the rate of increase is less than in previous years. The SCM will be revised, and an evaluation of the groundwater monitoring network will be conducted when water levels at the site have stabilized to the agreement of both the U.S. Department of Energy Office of Legacy Management and the Nevada Division of Environmental Protection.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Mechanical Test Results and Microstructural Characterization of the Harvested and Baseline Archival Zion RPV Materials

The decommissioning of the Zion Units 1 and 2 Nuclear Generating Station in Zion, Illinois, presented a unique opportunity for developing a better understanding of materials degradation and other issues associated with extending the lifetime of existing nuclear power plants (NPPs) beyond 60 years of service. In support of extended service and current operations of the US nuclear reactor fleet, the Oak Ridge National Laboratory (ORNL), through the Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability (LWRS) Program, coordinated with Zion Solutions, LLC, a subsidiary of Energy Solutions (ES), the selective procurement of materials, structures, and components, from the decommissioned reactors including multiple segments of the Zion Unit 1 Reactor Pressure Vessel (RPV).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

UV + Damp Heat Induced Power Losses in Fielded Utility N-Type Si PV Modules

A recent trend in commercial PV modules is a transition to n-type silicon cells, including passivated emitter rear totally diffused (n-PERT), tunnel oxide passivated contact (TOPCon), and silicon heterojunction (SHJ). There is evidence via lab studies that some of these cells are more susceptible to UV induced degradation (UVID), yet there is a lack of confirmation that such degradation occurs in the field. Current IEC standards designed to screen for early module failures require only minimal UV exposure (15 kWh/m2 280-400 nm, ~2-3 months equivalent outdoor exposure). Here, we investigate fielded n-PERT silicon (Si) modules from a commercial utility that show power losses of ~2%/year. We present a comprehensive picture of the physics and chemistry of degradation supported by both module and cell electronic characterization (EL, PL, IV, EQE, and DLIT) and materials-level morphological and chemical analysis (SEM, EDS, XPS, FTIR, and HPLC). All sampled site modules show short circuit current (Isc) and open circuit voltage (Voc) losses when compared to unfielded spares, with the most severely degraded also having losses in fill factor (FF). We identify two different degradation modes contributing to overall power loss: (1) external quantum efficiency (EQE) measurements show losses in the blue range of the spectra, indicative of cell surface recombination losses, and (2) variations in high series resistance (Rs) at the cell level that are correlated with compositional differences in cell metallization. Using unfielded spares, we were able to reproduce Voc, Isc, and EQE losses via a minimum UV stress of 67.5 kWh/m2 (280-400 nm), 4.5x the exposure currently required in IEC 61215-2 (MQT 10). Degradation continued with additional UV dosage equivalent to the fielded modules (405 kWh/m2 total), with power loss leveling out at an average of 6.1%. Subsequent 1000 h of 85% RH/85degrees C damp heat testing showed that cells exposed to UV underwent additional severe series resistance degradation, even those without the susceptible paste composition seen in the field, whereas non-UV exposed cells saw little change. We attribute this to higher concentrations of acetic acid generated on the UV exposed area of the module, leading to degradation of the gridline/cell interface and high Rs. This study is unique in that it reproduces field observed utility scale UVID with an accelerated test and supports the need for standards development for longer UV exposure combined with other stress factors to catch materials interplay within a module package.

14 SOLAR ENERGY↗

DOE OSTI2018

Acoustic Techniques for UF6 Density and Mass Flow Measurements

A key enabling capability for enrichment plant safeguards is high-accuracy, non-invasive, unattended measurement of UF6 gas density and mass flow rate. Acoustic techniques are currently used to non-invasively monitor gas flow in industrial applications; however, the operating pressures at gaseous centrifuge enrichment plants (GCEPs) are roughly two orders magnitude below the capabilities of commercial instrumentation. Pacific Northwest National Laboratory is refining acoustic techniques for estimating density and mass flow rate of UF6 gas in scenarios typical of gaseous centrifuge enrichment plants, with the goal of achieving 1% measurement uncertainty. Proof-of-concept laboratory measurements of UF6 have demonstrated signature sensitivity to gas density at pressures equivalent to 10-50 Torr of UF6, typical pressures for GCEP unit header pipes. This sensitivity was clearly observable above background acoustic interference. Current efforts involve developing a test bed for conducting acoustic measurements on flowing surrogate gas, air and SF6, at representative flow rates and pressures to ascertain the viability of conducting gas flow measurements under these conditions. Density and flow measurements will be conducted to support the evaluation. If successful, the approach could enable an unattended, non-invasive approach to measure UF6 density and mass flow in unit header pipes of GCEPs.

International safeguards instrumentation, acoustic↗

DOE OSTI2026

UNIFI 1-MW Multi-Vendor Grid-Forming Inverter Test Updates

This presentation gives an update on UNIFI 1MW multi-vendor GFM inverter testing. The 1MW demo enters the last stage of the test, which is the integration test. And the main objectives of the integration tests include: 1) explore the interoperability of dispatching a future grid with energy mix (GFM inverters, GFL inverters and synchronous machine). The presentation highlights one example test, ROCOF, and summarizes all the key learning.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2013

Vitrification Tests with Potential Technetium Capture Streams

About 50 million gallons of high-level waste is currently stored in underground tanks at The United States Department of Energy’s (DOE’s) Hanford site in the State of Washington. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will provide DOE’s Office of River Protection (ORP) with a means of treating this waste by vitrification for subsequent disposal. The tank waste will be separated into low- and high-activity waste fractions, which will then be vitrified respectively into Immobilized Low Activity Waste (ILAW) and Immobilized High Level Waste (IHLW) products. The ILAW product will be disposed in an engineered facility on the Hanford site while the IHLW product is designed for acceptance at a national deep geological disposal facility for high-level nuclear waste. The ILAW and IHLW products must meet a variety of requirements with respect to protection of the environment before they can be accepted for disposal. The Low Activity Waste (LAW) and High-Level Waste (HLW) at Hanford will be vitrified in Joule Heated Ceramic Melters (JHCMs) to produce stable products for disposal. Technetium is an important radioactive component in the Hanford tank waste and is typically one of the principal contributors to risk in performance assessments for the ILAW disposal facility. Technetium is also one of the more volatile radionuclides and the retention of technetium in the glass under the high temperature conditions prevailing during vitrification can vary over a relatively wide range depending on the feed composition, feed chemistry, and melter operating parameters. In support of the WTP Project, the Vitreous State Laboratory (VSL) at The Catholic University of America (CUA) and EnergySolutions have developed and tested glass formulations for WTP waste envelopes to provide data to meet the WTP contract requirements and to support system design activities. That work is based upon small-scale batch melts (“crucible melts”) using waste simulants. Glass compositions suitable for processing the tank waste streams for the WTP have been identified and tested for processing and product quality requirements at various scales, ranging from crucible melts of a few grams, up to the LAW Pilot Melter at processing rates in excess of 6600 kg/day (2000 kg/m 2 /day). Recent testing performed at VSL for Washington River Protection Solutions, LLC (WRPS) has investigated the baseline “single-pass” retention of technetium over the range of WTP LAW feed compositions and glass formulations as well as the development of potential modifications to the baseline that could increase the single-pass retention. For the WTP melter systems, the liquid waste streams from the primary off-gas system components are recycled back to the pretreatment facility and, ultimately, to subsequent melter feed batches. Such a recycle loop can greatly increase the overall retention of volatile constituents in the glass product over the single-pass value. Accordingly, more recent testing at VSL has been conducted on a melter system that incorporates a recycle flow sheet. The results from that work have provided important performance data for the unit operations in the primary off-gas system with respect to technetium capture and recycle, which is crucial in assessing the amount of technetium that ultimately reports to non-glass waste forms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Additively Manufactured Compliant Hybrid Gas Thrust Bearing for Supercritical Carbon Dioxide Turbomachinery: Design and Proof of Concept Testing

The following paper presents a new type of gas lubricated thrust bearing that utilizes additive manufacturing or also known as direct metal laser melting (DMLM) to fabricate the bearing. The motivation for the new bearing concept is derived from the need for highly efficient supercritical carbon dioxide (sCO2) turbomachinery in the mega-watt power range. The paper provides a review of existing gas thrust-bearing technology, outlines the need for the new DMLM concept, and discusses proof-of-concept testing results. The new concept combines hydrostatic pressurization with individual tilting pads that are flexibly mounted using hermetic squeeze film dampers (HSFD) in the bearing-pad support. This paper describes the thrust-bearing concept and discusses the final design approach. Proof-of-concept testing in air for a 6.8 in. (173 mm) outer diameter thrust gas bearing was performed; with thrust loading, up to 1500 lbs (6.67 kN) and a thrust runner speed of 10krpm (91 m/s tip speed). The experiments were performed with a bent shaft resulting in thrust runner axial vibration magnitudes of 2.9 mils (74 μm) p-p and dynamic thrust loads of 270 lbs (1.2 kN) p-p. In addition, force deflection characteristics and stiffness coefficients of the bearing system are presented for an inlet hydrostatic pressure of 380 psi (2.62 MPa). Results at 10 krpm show that the pad support architecture was able to sustain high levels of dynamic misalignment equaling 6 times the nominal film clearance while demonstrating a unit load-carrying capacity of 55 psi (0.34 Mpa). Gas-film force deflection tests portrayed nonlinear behavior like a hardening spring, while the bearing pad support stiffness was measured to be linear and independent of gas film thickness.

Engineering↗

DOE OSTI2025

Self-Lubricating Bushing Testing for John Day Dam Ka plan Turbine Replacement

The goal of this testing program is to find suitable self-lubricated alternatives to replace the in use oil lubricated grooved-bronze bushing in Kaplan runner hubs that are currently being utilized at John Day Dam operated by the U.S. Army Corps of Engineers (USACE). Scaled bushing testing utilizing a Pacific Northwest National Laboratory designed, fabricated, and operated Bushing Test Stand under the direction and funding from USACE determined that self-lubricated bushings tested appear capable of outperforming the current oil-lubricated bronze bushings. Performance tests are focused on durability which includes cyclic load bearing properties and articulations under various loading scenarios. This testing was performed at nominally 1/5 th scale. A scaling sensitivity analysis determined that scaled testing results apply to prototypic size. This report shows the direct comparison between the current baseline bronze bushing to self-lubricated bushings from various manufacturers. Bushing data like coefficient of friction and bushing material loss (associated with bushing wear) was determined. Self-lubricated bushings tested include products manufactured specifically for hydropower applications by the following companies: Trelleborg, Kamatics, Anonymous, and Tenneco/Deva.

42 ENGINEERING↗

DOE OSTI2013

A Historical Evaluation of the U16a Tunnel, Nevada National Security Site, Nye County, Nevada Volume 1

This report presents a historical evaluation of the U16a Tunnel on the Nevada National Security Site in southern Nevada. The work was conducted by the Desert Research Institute at the request of the U.S. Department of Energy, National Nuclear Security Administration Nevada Site Office and the U.S. Department of Defense, Defense Threat Reduction Agency. The U16a Tunnel was used for underground nuclear weapons effects tests in Shoshone Mountain in Area 16 of the Nevada National Security Site. Six nuclear tests were conducted in the U16a Tunnel from 1962 to 1971. These tests are Marshmallow, Gum Drop, Double Play, Ming Vase, Diamond Dust, and Diamond Mine. The U.S. Department of Defense Threat Reduction Agency, with participation from Lawrence Livermore National Laboratory and Las Alamos National Laboratory, sponsored the tests. Fifteen high explosives tests were also conducted at the tunnel. Two were calibration tests during nuclear testing and the remaining were U.S. Department of Defense, Defense Threat Reduction Agency tunnel defeat tests. The U16a Tunnel complex is on the top and slopes of Shoshone Mountain, encompassing an area of approximately 16.7 hectares (41.1 acres). Major modifications to the landscape are a result of three principal activities, road construction and maintenance, mining activities related to development of the tunnel complex, and site preparation for activities related to testing. Forty-seven cultural features were recorded at the portal and on the slopes of Shoshone Mountain. At the portal area, features relate to the mining, construction, testing, and general every day operational support activities within the tunnel. These include concrete foundations for buildings, equipment pads, and rail lines. Features on the slopes above the tunnel relate to tunnel ventilation, borehole drilling, and data recording. Feature types include soil-covered bunkers, concrete foundations, instrument cable holes, drill holes, and ventilation shafts. The U16a Tunnel complex is eligible to the National Register of Historic Places under criteria a and c, consideration g of 36 CFR Part 60.4 as a historic landscape. Scientific research conducted at the tunnel has made significant contributions to the broad patterns of our history, particularly in regard to the Cold War era that was characterized by competing social, economic, and political ideologies between the former Soviet Union and the United States. The tunnel also possesses distinctive construction and engineering methods for conducting underground nuclear tests. The Desert Research Institute recommends that the U16a Tunnel area be left in place in its current condition and that the U16a Tunnel historic landscape be included in the Nevada National Security Site monitoring program and monitored on a regular basis.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

A Historical Evaluation of the U16a Tunnel, Nevada National Security Site, Nye County, Nevada Volume 2

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2015

Systematic assessment of wellbore integrity for geologic carbon storage projects using regulatory and industry information

Under this three year project, the condition of legacy oil and gas wells in the Midwest United States was evaluated through analysis of well records, well plugging information, CBL evaluation, sustained casing pressure (SCP) field testing, and analysis of hypothetical CO 2 test areas to provide a realistic description of wellbore integrity factors. The research included a state-wide review of oil and gas well records for Ohio and Michigan, along with more detailed testing of wells in Ohio. Results concluded that oil and gas wells are clustered along fields in areas. Well records vary in quality, and there may be wells that have not been identified in records, but there are options for surveying unknown wells. Many of the deep saline formations being considered for CO 2 storage have few wells that penetrate the storage zone or confining layers. Research suggests that a variety of well construction and plugging approaches have been used over time in the region. The project concluded that wellbore integrity is an important issue for CO 2 storage applications in the Midwest United States. Realistic CO 2 storage projects may cover an area in the subsurface with several hundred legacy oil and gas wells. However, closer inspection may often establish that most of the wells do not penetrate the confining layers or storage zone. Therefore, addressing well integrity may be manageable. Field monitoring of SCP also indicated that tested wells provided zonal isolation of the reservoirs they were designed to isolate. Most of these wells appeared to exhibit gas pressure originating from intermediate zones. Based on these results, more flexibility in terms of cementing wells to surface, allowing well testing, and monitoring wells may aid operators in completing CO 2 storage project. Several useful products were developed under this project for examining wellbore integrity for CO 2 storage applications including, a database of over 4 million items on well integrity parameters in the study areas, a systematic CBL evaluation tool for rating cement in boreholes, SCP field testing procedures and analysis methodology, a process for summarizing well integrity at CO 2 storage fields, a statistical analysis of well integrity indicators, and an assessment of practical methods and costs necessary to repair/remediate typical wells in the region based on assessment of six test study areas. Project results may benefit both CO 2 storage and improved oil recovery applications. This study of wellbore integrity is a useful precursor to support development of geologic storage in the Midwest United States because it sheds more light on the actual well conditions (rather than the perceived condition) of historic oil and gas wells in the region.

42 ENGINEERING↗

DOE OSTI2025

Comparative post-irradiation examination of high burnup U-19Pu-10Zr: Assessing steady-state irradiation behavior against historical and modeled fuel performance

Here, the development of next-generation sodium-cooled fast reactors necessitates comprehensive research on metallic fuels to maximize economic performance while ensuring safe operation. In this study, we investigated the steady-state irradiation behavior of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, in preparation for planned safety testing. Post-irradiation examination (PIE) was performed to quantify fuel column elongation, regions of low-density at the top of the fuel column, pin deformation, fission product distribution, fractional fission gas release, microstructural evolution, and fuel constituent redistribution. Benchmarking against existing PIE data from U-19Pu-10Zr fuel pins irradiated in EBR-II revealed consistent patterns in fuel column elongation and cladding diametral strain. However, both pins exhibited longer low-density structures, and destructive examination of DP-36 revealed more complex constituent redistribution patterns compared to previously reported data for ternary fuel pins. The steady-state irradiation of both pins was also modeled using BISON. Comparisons of PIE results with modeled predictions showed overall agreement in fractional fission gas release but consistent overestimation of axial and radial swelling due to gaseous and solid swelling models. These findings underscore the critical importance of pre-test characterization on test and sibling pins to accurately capture steady-state fuel behavior ahead of transient testing, thus establishing a baseline for post-test comparison. Additionally, these analyses identified key data gaps that warrant further investigation to improve the understanding and prediction of fuel swelling, thereby enhancing the synergy between modeling and experimental efforts in supporting accident testing.

BISON↗