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DOE OSTI2025

Brine Availability Test in Salt (BATS) (FY25 Final Closeout)

This fiscal year 2025 (FY25) closeout report summarizes the final experiments conducted and data collected in phase 2 of the Brine Availability Test in Salt (BATS 2). The design and interpretation of the test was previously funded by the US Department of Energy’s Office of Nuclear Energy (DOE-NE) Spent Fuel and Waste Disposition Program, under the Disposal Research and Development (R&D) program of the Office of Spent Fuel & Waste Science and Technology (SFWST) but they are not funding it anymore (since May 2025). The experiment was located underground at the Waste Isolation Pilot Plant (WIPP), southeastern New Mexico, which is a DOE Office of Environmental Management (DOE-EM) site managed by the Carlsbad Field Office (CBFO). DOE-EM funds the WIPP Test Coordination Office (TCO), which provided critical implementation support for the continued execution of BATS. A high-level summary of processes expected in a salt repository are given in Kuhlman & Mills (2025).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Initial Results of PostProcess NDE Using Advanced Techniques

The U.S. Department of Energy, Office of Nuclear Energy Advanced Materials and Manufacturing Technologies Program is developing advanced materials and manufacturing technologies that will enable the safe and economical operation of both the current fleet and the next generation of advanced nuclear reactors. Post-process nondestructive evaluation capabilities are a key enabling technology that will be required to qualify and verify the condition of components produced using advanced materials and manufacturing technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

DistOPF: Advanced Solutions for Distribution Optimal Power Flow Analysis - DistOPF v0.2 Documentation

To achieve an affordable and reliable energy system, research on power distribution system is often focused on integration of distributed generators, energy storage solution, EV charging, smart meters, and other advanced assets that may benefit from or require more advanced control and optimization techniques. Despite this focus on advanced distribution system topics, early researchers and grid scientists often start from scratch when developing optimization programs for power distribution systems. This report introduces DistOPF, a Python package that consolidates years of research into a versatile and modular tool. DistOPF provides researchers with essential capabilities to solve distribution system Optimal Power Flow (OPF) problems using standard network models. Additionally, it offers a platform to benchmark both new and existing algorithms against established test systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2011

Melter Testing for Technetium Removal Using Goethite Precipitation

During vitrification of low activity waste (LAW) at the Hanford Tank Waste Treatment and Immobilization Plant (WTP), liquid effluents are produced in the primary off-gas treatment system that processes the exhaust gases from the LAW melters. That effluent stream, which contains captured hazardous and radioactive species from the melter exhaust, is then recycled and eventually becomes part of subsequent melter feed batches. Other constituents, such as sulfur and halides, are also recycled in this process and this can impact the LAW glass loadings that are achievable. Thus, breaking the melter recycle loop could have advantages with respect to reducing LAW glass volumes. However, this recycle stream cannot currently be diverted to liquid secondary waste treatment because of the levels of several constituents in the scrub solutions, particularly technetium. Researchers at Pacific Northwest National Laboratory (PNNL) have been investigating a process whereby the technetium could be precipitated from the off-gas recycle stream in the mineral goethite ((Tc, Fe)OOH). It could then be diverted to the high level waste (HLW) stream through the WTP pretreatment facility and the decontaminated liquid stream could be sent to secondary waste treatment. As part of the test program to develop the goethite precipitation process, it is necessary to assess the impacts of including this material in the HLW melter feed and the extent to which the captured technetium is volatilized during HLW vitrification. To support such testing, sufficiently large batches of material were prepared at PNNL using rhenium as a surrogate for technetium. These materials were shipped to the Vitreous State Laboratory (VSL) of the Catholic University of America (CUA) for testing on a DuraMelter 10 (DM10) small-scale joule-heated ceramic melter system. This report describes the testing that was performed with those materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

CRADA Number NFE-22-09375 with Vitriform3D, Inc. (CRADA Final Report)

Each year, roughly 8 million tons of glass are landfilled in the United States. Vitriform3D, in collaboration with Oak Ridge National Laboratory through the Innovation Crossroads program, is developing an additive manufacturing approach to transform post-consumer glass into engineered stone building materials. A custom UV-curable binder jetting system was commissioned to enable recycled glass printing without energy-intensive oven curing. While this printer is still under development, the team pursued a parallel research track using ORNL equipment and a polyethyleneimine (PEI) binder. Printed parts were thermally post-cured and infiltrated with epoxy, with the resulting material exceeding fiber cement board performance. Silane treatment of the glass particles further improved glass–epoxy adhesion, yielding an additional 24% strength gain over the epoxy-glass composite, achieving nearly 3x the fiber cement benchmark. Ongoing research is focused on reducing epoxy content to improve cost and recycled content while retaining mechanical performance. This work demonstrates a scalable, low-carbon pathway to convert glass waste into high-value, locally produced construction materials.

36 MATERIALS SCIENCE↗

DOE OSTI2026

FINAL PROJECT REPORT SBIR Phase II Next Generation Power Converters for Distributed Wind Applications

Intergrid, LLC, based in Temple, New Hampshire, conducted an 24-month DOE SBIR Phase II research program to develop next-generation electronic power inverters and converters for the United States distributed wind (DW) market. The distributed wind segment is defined as turbines rated from 10 kW to 1 MW, a market segment that has been almost entirely blocked by the absence of UL1741-certified, commercially available inverters.

17 WIND ENERGY↗

DOE OSTI2025

Regional Energy Hardware Innovation Accelerator

E4 Carolinas, Inc., along with the Joules Accelerator and Savannah River National Laboratory received a grant from the DOE Office of Technology Commercialization as part of its Energy Program for Innovation Clusters (EPIC) program to develop a Regional Energy Hardware Innovation Accelerator. The project objective was to create a regional energy hardware cluster innovation and accelerator ecosystem (Accelerator) to enhance commercialization opportunities for U.S. energy startups (Ventures) and Corporate Ventures (a new venture originating within an established company).

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗

DOE OSTI2026

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗

DOE OSTI2018

Automated Calculation of Bulk-Stamping Matrices for Circular Blanks

The bulk stamping of circular blanks is considered. There is a clear need for automatic stamping. The input and output data for calculating the working part of the bulk-stamping matrix are analyzed. Software for automated calculation of bulk-stamping matrices is developed. The program code and a possible interface for the calculation of matrix parameters and construction of 3D models by means of the Object Pascal language are presented.

42 ENGINEERING↗

DOE OSTI2023

Chlorophyll fluorescence is a potential indicator to measure photochemical efficiency in early to late soybean maturity groups under changing day lengths and temperatures

In this study, we employed chlorophyll a fluorescence technique, to indicate plant health and status in response to changing day lengths (photoperiods) and temperatures in soybean early and late maturity groups. Chlorophyll a fluorescence study indicates changes in light reactions in photosystem II. Experiments were performed for 3-day lengths (12.5, 13.5, and 14.5 h) and five temperatures (22/14°C, 26/18°C, 30/22°C, 34/26°C, and 40/32°C), respectively. The I-P phase declined for changing day lengths. Active reaction centers decreased at long day length for maturity group III. We observed that low temperatures impacted the acceptor side of photosystem II and partially impacted electron transport toward the photosystem I end electron acceptor. Results emphasized that higher temperatures (40/32°C) triggered damage at the oxygen-evolving complex and decreased electron transport and photosynthesis. We studied specific leaf areas and aboveground mass. Aboveground parameters were consistent with the fluorescence study. Chlorophyll a fluorescence can be used as a potential technique for high-throughput phenotyping methods. The traits selected in the study proved to be possible indicators to provide information on the health status of various maturity groups under changing temperatures and day lengths. These traits can also be deciding criteria for breeding programs to develop inbreed soybean lines for stress tolerance and sensitivity based on latitudinal variations.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2011

Switchgrass (Panicum virgatum L.) Intraspecific Variation and Thermotolerance Classification Using in Vitro Seed Germination Assay

Cardinal temperatures for plant processes have been used for thermotolerance screening of genotypes, geoclimatic adaptability determination and phenological prediction. Current simulation models for switchgrass (Panicum virgatum L.) utilize single cardinal temperatures across genotypes for both vegetative and reproductive processes although in-tra-specific variation exists among genotypes. An experiment was conducted to estimate the cardinal temperatures for seed germination of 14 diverse switchgrass genotypes and to classify genotypes for temperature tolerance. Stratified seeds of each genotype were germinated at eight constant temperatures from 10 °C to 45 °C under a constant light intensity of 35 μmol m -2 s -1 for 12 hd -1 . Germination was recorded at 6-h intervals in all treatments. Maximum seed germination (MSG) and germination rate (GR), estimated by fitting Sigmoidal function to germination-time series data, varied among genotypes. Quadratic and bilinear models best described the MSG and GR responses to temperature, respectively. The mean cardinal temperatures, T min , T opt , and T max , were 8.1, 26.6, and 45.1 °C for MSG and 11.1, 33.1, and 46.0 °C for GR, respectively. Cardinal temperatures for MSG and GR; however, varied significantly among genotypes. Genotypes were classified as sensitive (Cave-in-Rock, Dacotah, Expresso, Forestburg, Kanlow, Sunburst, Trailblazer, and Tusca), intermediate (Alamo, Blackwell, Carthage, Shawnee, and Shelter) and tolerant (Summer) to high temperature based on cumulative temperature response index (CTRI) estimated by summing individual response indices estimated from the MSG and GR cardinal temperatures. Similarly, genotypes were also classified as sensitive (Alamo, Blackwell, Carthage, Dacotah, Shawnee, Shelter and Summer), moderately sensitive (Cave-in-rock, Forestburg, Kanlow, Sunburst, and Tusca), moderately tolerant (Trailblazer), and tolerant (Expresso) to low temperatures. The cardinal temperature estimates would be useful to improve switchgrass models for field applications. Additionally, the identified cold- and heat-tolerant genotypes can be selected for niche environments and in switchgrass breeding programs to develop new genotypes for low and high temperature environments.

09 BIOMASS FUELS↗

DOE OSTI2026

Farm Practice Typologies as a Strategy for Management-Relevant Land Use and Land Cover Mapping in the Great Lakes Region (Version 1) [Dataset]

Dataset overview and development This dataset provides spatially explicit agricultural land-use and land-management typologies developed for the Great Lakes Region (GLR) at the farm-parcel level. The typologies were designed to characterize not only the land-use and land-cover (LULC) associated with individual agricultural farm parcels, but also the land-management practices (LMPs), including irrigation, tile drainage, and conservation easements, occurring within those parcels and how these characteristics change through time. The dataset contains four related typology products: Annual integrated typology – describes the combined LULC and land-management characteristics for each farm parcel for individual years. LULC transition typology – describes the temporal pattern of LULC change for each farm parcel across the study period (2008-2023). LMP trend typology – describes the temporal pattern in the occurrence of LMPs for each farm parcel across the study period. Multi-year integrated typology – combines the LULC transition typology and LMP trend typology to provide an integrated characterization of long-term land-use and management patterns. Purpose of the dataset The purpose of these products is to provide a management-relevant integrated and consistent framework for evaluating the spatial and temporal organization of agricultural landscapes across the GLR. The resulting typologies can: support landscape-scale environmental and land-use analysis; provide spatial information relevant to land-management strategies, conservation planning, policy development, and program evaluation; characterize spatial patterns of agricultural land use and management; examine changes in agricultural landscapes through time; and identify persistent, transitional, and changing agricultural systems. Please refer to the README file provided in Files for more details.

Agriculture↗

DOE OSTI2011

STATISTICAL SAMPLING FOR IN-SERVICE INSPECTION OF LIQUID WASTE TANKS AT THE SAVANNAH RIVER SITE

Savannah River Remediation, LLC (SRR) is implementing a statistical sampling strategy for In-Service Inspection (ISI) of Liquid Waste (LW) Tanks at the United States Department of Energy's Savannah River Site (SRS) in Aiken, South Carolina. As a component of SRS's corrosion control program, the ISI program assesses tank wall structural integrity through the use of ultrasonic testing (UT). The statistical strategy for ISI is based on the random sampling of a number of vertically oriented unit areas, called strips, within each tank. The number of strips to inspect was determined so as to attain, over time, a high probability of observing at least one of the worst 5% in terms of pitting and corrosion across all tanks. The probability estimation to determine the number of strips to inspect was performed using the hypergeometric distribution. Statistical tolerance limits for pit depth and corrosion rates were calculated by fitting the lognormal distribution to the data. In addition to the strip sampling strategy, a single strip within each tank was identified to serve as the baseline for a longitudinal assessment of the tank safe operational life. The statistical sampling strategy enables the ISI program to develop individual profiles of LW tank wall structural integrity that collectively provide a high confidence in their safety and integrity over operational lifetimes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2011

FEASIBILITY STUDY FOR THE DEVELOPMENT OF A TEST BED PROGRAM FOR NOVEL DETECTORS AND DETECTOR MATERIALS AT SRS H-CANYON SEPARATIONS FACILITY

Researchers at the Savannah River National Laboratory (SRNL) have proposed that a test bed for advanced detectors be established at the H-Canyon separations facility located on the DOE Savannah River Site. The purpose of the proposed test bed will be to demonstrate the capabilities of emerging technologies for national and international safeguards applications in an operational environment, and to assess the ability of proven technologies to fill any existing gaps. The need for such a test bed has been expressed in the National Nuclear Security Administration's (NNSA) Next Generation Safeguards Initiative (NGSI) program plan and would serve as a means to facilitate transfer of safeguards technologies from the laboratory to an operational environment. New detectors and detector materials open the possibility of operating in a more efficient and cost effective manner, thereby strengthening national and international safeguards objectives. In particular, such detectors could serve the DOE and IAEA in improving timeliness of detection, minimizing uncertainty and improving confidence in results. SRNL's concept for the H Canyon test bed program would eventually open the facility to other DOE National Laboratories and establish a program for testing national and international safeguards related equipment. The initial phase of the test bed program is to conduct a comprehensive feasibility study to determine the benefits and challenges associated with establishing such a test bed. The feasibility study will address issues related to the planning, execution, and operation of the test bed program. Results from the feasibility study will be summarized and discussed in this paper.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2011

Model NbTi Helical Solenoid Fabrication and Test Results

A program to develop model magnets for a helical cooling channel is under way at Fermilab. In the first steps of a planned sequence of magnets, two four-coil helical solenoid models with 300 mm aperture have been fabricated and tested. These two models, HSM01 and HSM02, used insulated NbTi Rutherford cable wound onto stainless steel rings with spliceless transitions between coils. Strip heaters were included for quench protection of each coil, and the coils were epoxy-impregnated after winding inside the support structures. Based on the results of the first model the second model was made using a cable with optimized cross-section, improved winding and epoxy-impregnation procedures, enhanced ground insulation, and included heat exchange tubing for a test of conduction cooling. We report on the results and lessons learned from fabrication and tests of these two models.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Design and Fabrication of a Single-Aperture 11T Nb3Sn Dipole Model for LHC Upgrades

The planned upgrade of the LHC collimation system includes additional collimators to be installed in the dispersion suppressor areas of points 2, 3 and 7. To provide the necessary longitudinal space for the collimators, a replacement of 8.33 T Nb-Ti LHC main dipoles with 11 T dipoles based on Nb{sub 3}Sn superconductor compatible with the LHC lattice and main systems is being considered. To demonstrate this possibility FNAL and CERN have started a joint program to develop a 2 m long single-aperture dipole magnet with the nominal field of 11 T at {approx}11.85 kA current and 60 mm bore. This paper describes the demonstrator magnet magnetic and mechanical designs and analysis, coil fabrication procedure. The Nb{sub 3}Sn strand and cable parameters and test results are also reported.

43 PARTICLE ACCELERATORS↗

DOE OSTI2012

Linac Energy Management for LCLS

Linac Energy Management (LEM) is a control system program that scales magnet field set-point settings following a change in beam energy. LEM is necessary because changes in the number, phase, and amplitude of the active klystrons change the beam's rigidity, and therefore, to maintain constant optics, one has to change focusing gradients and bend fields accordingly. This paper describes the basic process, the control system application programs we developed for LEM, and some of the implementation lessons learned at the Linac Coherent Light Source (LCLS).

43 PARTICLE ACCELERATORS↗