Fabrication and Testing of Thick Film CVD Niobium-Lined Copper SRF Cavities for High-Gradient Applications, Phase II
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36 MATERIALS SCIENCE↗
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Applied Metrology for the Assembly of the Nb3Sn MQXFA Quadrupole Magnets for the HL-LHC AUP
The US HL-LHC Accelerator Upgrade Project (AUP) is building Nb3Sn quadrupole magnets, called MQXFA, with plans to install 16 of them in the HL-LHC Interaction Regions. Variability in coil size must be dealt with at the assembly level, which requires timely and repeatable measurement of each coil. In this paper we will present the methodology used for coil measurements and the geometrical size data for the coils that have been measured thus far. We will also show the coil measurements of 8 coils before and after cold test. The Leica AT960-MR laser tracker with Spatial Analyzer software acquired to achieve these measurements has been used elsewhere in the project to great effect.
43 PARTICLE ACCELERATORS↗
Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel
This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.
36 MATERIALS SCIENCE↗
Development of Multi-Filament Textured-Powder Bi-2212/Ag Wire With Enhanced Local Area Ratio
The performance and cost of Bi-2212/Ag wire is limited by the large fraction of Ag matrix (~3:1) that is required in the oxide-powder-in-tube fabrication process. An alternative fabrication process is being developed in which fine-powder Bi-2212 is uniaxially compressed to form bars with a thin Ag foil sheath. The fine powder naturally textures (aligns the a-b planes perpendicular to the direction of compaction) with texture >80% using 200 MPa compression. A billet is formed by stacking trapezoidal- cross-section bars in a symmetric 8-12-16 pattern around an Ag rod and enclosed in an Ag-wall extrusion can. Here, the billet is extruded and drawn to fine wire. Results are presented on present status of the development and testing.
17 WIND ENERGY↗
High pressure rinse simulations for PIP-II SRF cavities
The implementation of High Pressure Rinse (HPR) not only ensures thorough cleaning of the inner high purity niobium surface of Superconducting Radio Frequency (SRF) cavities but also unlocks their full potential for achieving peak performance. By effectively removing contaminants and impurities, HPR sets the stage for enhanced superconducting properties, improved energy efficiency, and superior operational stability. A simulation tool has been developed, facilitating the accurate prediction of both the quality and effectiveness of the rinsing process before its execution in the cleanroom. This tool, the focus of this paper, stands as a pivotal advancement in optimizing Superconducting Radio Frequency (SRF) cavity preparation. Furthermore, our paper will also present correlations with cavity cold testing results, demonstrating the practical applicability and reliability of the simulation predictions in real-world scenarios.
43 PARTICLE ACCELERATORS↗
Challenges and Lessons Learned from fabrication, test and analysis of ~10 MQXFA Low Beta Quadrupoles for HL-LHC [Slides]
Topics of the presentation include: MQXFA magnets; Fabrication and test status; Analysis of magnets with limited performance; Lessons learned and corrective actions; MQXFA endurance and toughness; and, conclusions.
42 ENGINEERING↗
Flow Measurements in Pressurized Helium Gas Cooling Channels: Rev. 1
Compressed helium gas is used to cool the NorthStar Medical Radioisotope (NMR) target system, also called the trident, chosen due to its superior heat transfer capabilities and its inability to react with Molybdenum-100 (Mo-100) during irradiation. To test the housing and NMR target stack at Los Alamos National Laboratory (LANL), two sets of helium gas flow loop facilities have been set-up and tested. One system is used for bench-top experiments to systematically investigate individual components of the NMR target, and the other, larger system is more representative of the system at NMR and is used for testing the full NMR target stack.
43 PARTICLE ACCELERATORS↗
Design Challenges in High-Current Pulsed Striplines
The Long Baseline Neutrino Facility (LBNF) will produce the worlds most intense neutrino beam. Three series connected magnetic horns will require 5 kV, 300 kA, 800 $\mu$s pulses at a rate of 1.4 Hz to focus the beam. Connecting a single power supply to these focusing horns will require a low impedance connection measuring over 60 m in length. To meet the challenging requirements of connecting the horns to the power supply, this connection is engineered as a nine-conductor, high-current pulsed stripline. It must pass through a harsh radiation environment, be passively cooled, and have an operational lifetime of at least 30 years. This paper discusses mechanical and electrical considerations such as high-voltage holdoff, clamped joint performance, and Lorentz force mitigations in order to meet the specified requirements. The results of tests and experiments on several prototypes of key design features will be presented and discussed.
43 PARTICLE ACCELERATORS↗
Final Design of the LB650 Cryomodule for the PIP-II Linear Accelerator
The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and its scope covers the supply of the 650 MHz low-beta cryomodule section, with the design of the cryostat (i.e the cryomodule without the cavities, the power couplers and the frequency tuning systems) and the manufacturing of its components, the assembly and tests of the pre-production cryomodule and 9 production modules. An important milestone was reached in April 2023 with the Final Design Review. This paper presents the detailed design of the 650 MHz low-beta cryomodules.
43 PARTICLE ACCELERATORS↗
Multiscale Modeling of the Mechanical Response of Silicon Carbide Composite Within the Accelerated Fuel Qualification Framework
The accelerated fuel qualification (AFQ) framework has been used for the initial development of multiscale modeling of silicon carbide (SiC) fiber reinforced composite (SiC-SiC). The AFQ framework provides a methodology to leverage physics-informed multiscale modeling along with a reduced set of empirical test data to reduce the time and cost of licensing and qualification of new nuclear fuel systems while maintaining the overall nuclear power plant safety case. SiC-SiC is being proposed for in-core applications, most notably fuel cladding, for current and next-generation nuclear reactors because of its high temperature stability, irradiation tolerance, and ability to withstand many accident conditions. As these composites exhibit multiscale architectures and complex microstructure-based fracture mechanics, it is an appealing use case for the AFQ methodology. While the end goal of this work is a single multiscale model that can be used for predictive in-core performance, current focus is on the individual various length scale models. Four individual models have been initially developed from microscale to engineering system level to capture key physics-based effects across different length scales. These models include a microscale homogenized tow model, a mesoscale fast Fourier transform–based weave model that integrates the homogenized tow model, a mesoscale finite element–based weave model, and a system-level BISON fuel performance model. Results of these models have undergone an initial comparison with separate-effects test data showing a good match to experimental results. By using the AFQ framework during model development, several near-term benefits have been secured including a reduction in development time for the SiC-SiC cladding, more targeted irradiation testing, and a better understanding of uncertainty.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
CEA Contribution to the PIP-II Linear Accelerator
The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and will deliver 10 low-beta cryomodules as In-Kind Contribution to the PIP-II project, with cavities supplied by LASA-INFN and power couplers and tuning systems supplied by Fermilab. This paper presents the CEA scope of work that includes the design, manufacturing, assembly and tests of the cryomodules and the upgrade of the existing infrastructures to the PIP-II requirements.
43 PARTICLE ACCELERATORS↗
A parallel variable population multi-objective optimizer for accelerator beam dynamics optimization
The simultaneous optimization of multiple objective functions is needed in many particle accelerator applications. In this paper, we present a parallel evolution based multi-objective optimizer that uses a variable population from generation to generation and an external storage to save good solutions. Two heuristic optimization methods, one uses the unified differential evolution and the other uses the real-coded genetic algorithm, are included in the optimizer to generate next generation candidate solutions, and are compared in the test examples. Finally, as an application, we applied this optimizer to the beam dynamics design optimization of a photoinjector and attained the optimal front solutions after 200 generations with the unified differential evolution offspring production scheme.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Extended cycle life implications of fast charging for lithium-ion battery cathode
Enabling extreme fast charging (XFC, =10–15 min charging) requires a comprehensive understanding of its implications. While lithium plating is a key bottleneck for the anode, the full extent of limitations for the cathode are not well-understood, particularly in extended-cycle settings with well-defined battery designs and conditions. This article presents cycle-life implications of XFC on cathodes at multiple length scales, combining electrochemical analyses, degradation modeling, and post-test characterizations. The comprehensive test matrix includes 41 well-defined gr/NMC pouch cells under varied fast-charge rates (1–9C) and state-of-charges cycled up to 1000 times. Cathode issues remain minimal in early cycling, but begin to accelerate in later life, when distinct cracking is found and identified as a fatigue mechanism. The bulk structure of cathodes remains intact, but distinct particle surface reconstruction is observed; however, this shows less pronounced effect on cathode aging than does cracking.
25 ENERGY STORAGE↗
A cycle-jump acceleration method for the crystal plasticity simulation of high cycle fatigue of the metallic microstructure
For metallic materials, high-cycle fatigue life is sensitive to underlying microstructure features including secondary phases, textures, grains morphology, etc. The traditional, data-based safe-life approaches for modeling fatigue don’t explicitly consider the microstructure and can’t guide study in microstructure modification for improved fatigue property. Crystal plasticity-based simulation provides increased model fidelity at the expense of immense computation time, making it inapplicable for high cycle fatigue. In this work, an acceleration method based on cycle-jump approach (Lesne and Savalle, 1989) was developed for microstructure-based high-cycle FE simulation using crystal plasticity constitutive-model. We report this method demonstrated high efficiency in benchmark tests of various conditions.
36 MATERIALS SCIENCE↗
NEML2: An efficient and modular multiphysics constitutive modeling library for hybrid computing environments
This paper presents NEML2, an open-source, high-performance library developed for constitutive material modeling, designed to support the flexible and modular development of models for complex material behavior. Building on the foundational structure of its predecessor, NEML, the NEML2 library introduces significant improvements, including enhanced vectorization, automatic differentiation, and seamless integration with PyTorch, facilitating the application of machine learning techniques in material simulations. NEML2 provides a C++ backend with Python bindings, enabling users to create custom material models that can be executed efficiently on both CPU and GPU platforms. The library also supports coupling with Multiphysics simulation frameworks like MOOSE, making it suitable for realistic simulations involving coupled physical processes. Rigorous quality assurance through unit and regression testing ensures the reliability of results, while the extensible, user-friendly design encourages collaboration and reproducibility across the scientific community. This paper provides an overview of NEML2’s architecture, core features, and applications, highlighting its impact on accelerating material qualification and advancing computational methods in materials science.
GPU↗
Mitigating the Impacts of Uncertain Geomagnetic Disturbances on Electric Grids: A Distributionally Robust Optimization Approach
Severe geomagnetic disturbances (GMDs) increase the magnitude of the electric field on the Earth’s surface (E-field) and drive geomagnetically-induced currents (GICs) along the transmission lines in electric grids. These additional currents can pose severe risks, such as current distortions, transformer saturation and increased reactive power losses, each of which can lead to system unreliability. Today several mitigation actions (e.g., changing grid topology) exist that can reduce the harmful GIC effects on the grids. Making such decisions can be challenging, however, because the magnitude and direction of the E-field are uncertain and non-stationary. In this paper, we model uncertain E-fields using the distributionally robust optimization (DRO) approach that determines optimal transmission grid operations such that the worst-case expectation of the system cost is minimized. We also capture the effect of GICs on the nonlinear AC power flow equations. For solution approaches, we develop an accelerated column-and-constraint generation (CCG) algorithm by exploiting a special structure of the support set of uncertain parameters representing the E-field. Extensive numerical experiments based on “epri-21” and “uiuc-150” systems, designed for GMD studies, demonstrate (i) the computational performance of the accelerated CCG algorithm, (ii) the superior performance of distributionally robust grid operations that satisfy nonlinear, nonconvex AC power flow equations and GIC constraints, in comparison with standard stochastic programming-based methods during the out-of-sample testing.
42 ENGINEERING↗
A new method for measuring refractory corrosion of ceramics in glass
Abstract Nuclear waste glass vitrification furnaces are lined with refractory ceramic blocks to contain the molten glass. The refractory liner is susceptible to corrosion and has a finite service lifetime. For this reason, predicting the refractory corrosion in contact with molten glass is integral to estimating melter service lifetime. Standardized laboratory tests varying time and temperature are commonly performed to estimate refractory material loss as a function of glass composition. These data are time and resource‐intensive to collect and are susceptible to considerable measurement error. In order to accelerate glass formulation and design for nuclear waste vitrification, methods are needed to increase laboratory‐scale throughput while maintaining data quality. In this work, a method to remove the residual glass from a corroded coupon using hydrofluoric acid is presented that accelerates the throughput of sample analysis while simultaneously facilitating more accurate measurements.
Amoroso, Jake W. [Savannah River National Laborato↗
Dense Seismic Array Study of a Legacy Underground Nuclear Test at the Nevada National Security Site
The complex postdetonation geologic structures that form after an underground nuclear explosion are difficult to constrain because increased heterogeneity around the damage zone affects seismic waves that propagate through the explosion site. Generally, a vertical rubble-filled structure known as a chimney is formed after an underground nuclear explosion that is composed of debris that falls into the subsurface cavity generated by the explosion. Compared with chimneys that collapse fully, leaving a surface crater, partially collapsed chimneys can have remnant subsurface cavities left in place above collapsed rubble. The 1964 nuclear test HADDOCK, conducted at the Nevada test site (now the Nevada National Security Site), formed a partially collapsed chimney with no surface crater. Understanding the subsurface structure of these features has significant national security applications, such as aiding the study of suspected underground nuclear explosions under a treaty verification. In this study, we investigated the subsurface architecture of the HADDOCK legacy nuclear test using hybrid 2D–3D active source seismic reflection and refraction data. The seismic data were acquired using 275 survey shots from the Seismic Hammer (a 13,000 kg weight drop) and 65 survey shots from a smaller accelerated weight drop, both recorded by ~1000 three-component 5 Hz geophones. First-arrival, P-wave tomographic modeling shows a low-velocity anomaly at ~200 m depth, likely an air-filled cavity caused by partial collapse of the rock column into the temporary postdetonation cavity. A high-velocity anomaly between 20 and 60 m depth represents spall-related compaction of the shallow alluvium. Hints of low velocities are also present near the burial depth (~364 m). The reflection seismic data show a prominent subhorizontal reflector at ~300 m depth, a short-curved reflector at ~200 m, and a high-amplitude reflector at ~50 m depth. Comparisons of the reflection sections to synthetic data and borehole stratigraphy suggest that these features correspond to the alluvium–tuff contact, the partial collapse cavity, and the spalled layer, respectively.
58 GEOSCIENCES↗