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Neutron computed tomography of B12W and M8N socket sections of the Arecibo telescope

From neutron user principal investigator: We kindly request the public release of three neutron imaging datasets through ONCat. All datasets were collected from two forensic specimens, B12W and M8N, sectioned from zinc-filled steel-wire sockets recovered from the collapsed Arecibo Telescope. The dataset titled “Neutron radiographs of B12W and M8N socket sections of the Arecibo telescope” contains normalized two-dimensional (2D) neutron radiographs of the specimens, showing the geometry and spatial distribution of the steel wires embedded within the zinc matrix, as well as internal features such as voids and cracks. The dataset titled “Neutron computed tomography of B12W and M8N socket sections of the Arecibo telescope” contains normalized 2D neutron projection images acquired over a range of specimen rotation angles for one selected region of each specimen. These projection images were used to reconstruct three-dimensional (3D) tomographic volumes that reveal the embedded-wire geometry and internal defects. The dataset titled “Bragg edge imaging (BEI) of B12W and M8N socket sections of the Arecibo telescope” contains six time-of-flight (TOF) neutron imaging datasets, three from each specimen, acquired at regions of interest selected based on the radiographs. The spatially resolved 2D TOF images show the zinc matrix and embedded steel wires, and the wavelength-dependent neutron transmission data were used to characterize crystallographic texture within the zinc. All components and their condition are in the public domain as they are the property of the National Science Foundation (NSF). The neutron imaging data, part geometries, and detailed forensic information have been widely published in the Arecibo Telescope Collapse Forensic Report by Thornton Tomasetti Engineers and others (NASA report and NASEM report).

Bilheux, Hassina↗

Rare Earth Adsorption and Desorption with PEGDA Beads

We synthesized PEGDA polymer hydrogel beads for cell embedding and compared REE biosorption with these beads via a gravity-driven flow through setup. One way to set up a flow through system is by cell encapsulation into polymer beads with a column setup similar to that used in the chromatography industry. To achieve this, we tested PEGDA for cell encapsulation, and tested REE biosorption under both batch mode and a follow through setup based on gravity . For making the cell embedded polymer beads, we used a fluidic device by which homogenous spherical particles of 0.5 to1 mm in diameter were synthesized. The beads are made relatively quickly, and the size of the beads can be controlled. PEGDA beads were polymerized by UV. Tb adsorption experiment was performed with beads with or without cells embedded.

15 GEOTHERMAL ENERGY↗

Experimental Investigation of Low-Frequency Distributed Acoustic Strain-Rate Responses to Propagating Fractures

Summary Low-frequency distributed acoustic sensing (LF-DAS) responds to strain changes due to far-field fracture propagation. To better understand the LF-DAS response to fracture propagation, we performed laboratory-scale hydraulic fracture experiments with embedded optical strain sensors. The objectives of this research are to generate hydraulic fractures of known geometry, measure the strain response along the embedded fiber-optic cable comparable to LF-DAS measurements, and use the results to inform the interpretation of field-derived LF-DAS data. The experiments were conducted in unconfined transparent cubic blocks with a dimension of 8 in. on each side. The block was made of transparent epoxy to visualize the fracture propagation. Fiber-optic sensing cables were embedded in the block at different distances to the source of injection. We injected dyed water through an injection tubing to generate a transverse, radial fracture along an initial flaw. An optical interrogator recorded the response of offset fiber Bragg grating (FBG) strain sensors normal to the plane of the fracture. The strain data were visualized on a waterfall plot, akin to visualizations of field-derived LF-DAS data. Dimensional analysis was used to scale the laboratory results to field conditions. We compared the evolution of the strain response at the fiber-optic cable, injection pressure, and rate with known fracture geometry. The measured strains were compared with Sneddon’s (1946) linear elastic solution for a penny-shaped crack and found to follow this behavior. The generated radial fractures in transparent media can be modeled with Sneddon’s linear elastic radial fracture model and a Mode I critical stress intensity factor. The LF-DAS characteristic response of a narrowing region of extension surrounded by compression was exhibited as a fracture that approached and intersected the fiber-optic cable. The experimentally derived strain and strain-rate waterfall plots with known fracture geometry, injection rate, and pressure response provide insight in understanding LF-DAS responses in the field. Furthermore, we developed a method to estimate fracture geometry evolution from the fiber-optic strain data and validated the method against the experimental data.

Engineering↗

Remote Monitoring of the Structural Health of Hydrokinetic Composite Turbine Blades (Final Report)

A health monitoring approach is investigated for hydrokinetic turbine blade applications. In-service monitoring is critical due to the difficult environment for blade inspection and the cost of inspection downtime. Composite blade designs have advantages that include long life in marine environments and great control over mechanical properties. Experimental strain characteristics are determined for static loads and free-vibration loads. These experiments are designed to simulate the dynamic characteristics of hydrokinetic turbine blades. Carbon/epoxy symmetric composite laminates are manufactured using an autoclave process. Four-layer composite beams, eight-layer composite beams, and two-dimensional eight-layer composite blades are instrumented for strain. Experimental results for strain measurements from electrical resistance gages are validated with theoretical characteristics obtained from in-house finite-element analysis for all sample cases. These preliminary tests on the composite samples show good correlation between experimental and finite-element strain results. A health monitoring system is proposed in which damage to a composite structure, e.g. delamination and fiber breakage, causes changes in the strain signature behavior. The system is based on embedded strain sensors and embedded motes in which strain information is demodulated for wireless transmission. In-service monitoring is critical due to the difficult environment for blade inspection and the cost of inspection downtime. Composite blade designs provide a medium for embedding sensors into the blades for in-situ health monitoring. The major challenge with in-situ health monitoring is transmission of sensor signals from the remote rotating reference frame of the blade to the system monitoring station. In the presented work, a novel system for relaying in-situ blade health measurements in hydrokinetic systems is described and demonstrated. An ultrasonic communication system is used to transmit sensor data underwater from the rotating frame of the blade to a fixed relay station. Data are then broadcast via radio waves to a remote monitoring station. Results indicate that the assembled system can transmit simulated sensor data with an accuracy of ±5% at a maximum sampling rate of 500 samples/sec. A power investigation of the transmitter within the blade shows that continuous max-sampling operation is only possible for short durations (~days), and is limited due to the capacity of the battery power source. However, intermittent sampling, with long periods between samples, allows for the system to last for very long durations (~years). Finally, because the data transmission system can operate at a high sampling rate for short durations or at a lower sampling rate/higher duty cycle for long durations, it is well-suited for short-term prototype and environmental testing, as well as long-term commercially-deployed hydrokinetic machines.

13 HYDRO ENERGY↗

Subtask 1.8 - Investigation of Improved Conductivity and Proppant Applications in the Bakken Formation

Given the importance of hydraulic fracturing and proppant performance for development of the Bakken and Three Forks Formations within the Williston Basin, a study was conducted to evaluate the key factors that may result in conductivity loss within the reservoirs. Various proppants and reservoir rock cores were exposed to several different fracturing and formation fluids at reservoir conditions. The hardness of the rock cores and the strength of the proppants were evaluated prior to and following fluid exposure. In addition, the conductivity of various proppants, as well as formation embedment and spalling, was evaluated at reservoir temperatures and pressures using actual reservoir rock cores. The results of this work suggest that certain fluids may affect both rock and proppant strength, and therefore, fluid exposure needs to be considered in the field. In addition, conductivity decreases within the Bakken Formation appear to be a function of a variety of factors, including proppant and rock strength, as well as formation embedment and spalling. The results of this study highlight the need for advanced conductivity testing, coupled with quantification of formation embedment and spalling. Given the importance of proppant performance on conductivity loss and, ultimately, oil recovery, better understanding the effects of these various factors on proppant and rock strength in the field is vital for more efficient production within unconventional oil and gas reservoirs.

02 PETROLEUM↗

Nanoscale Kondo Physics and Nanomechanics of Metallic Systems from First Principles

Kohn-Sham density functional theory (DFT) is a powerful, well-established tool for the study of condensed phase electronic structure. However, there are still a number of situations where its applicability is limited. The basic theme of our research is the development of first principles electronic structure approaches for condensed matter that goes beyond what can currently be done with standard implementations of Kohn-Sham DFT. Our efforts to this end have focused on two classes of methods. The first addresses the well-known inability of DFT to handle strong, many-body electron correlation effects. Our approach is a DFT-based embedding theory, to treat localized features (e.g. impurity, adsorbate, vacancy, etc.) embedded in a periodic, metallic crystal. A description for the embedded region is provided by explicitly correlated, ab initio wave function methods. DFT, as a formally ground state theory, does not give a good description of excited states; an additional feature of our approach is the ability to obtain excitations localized in this region. We apply our method to a first-principles study of the adsorption of a single magnetic Co adatom on non-magnetic Cu(111), a known Kondo system whose behavior is governed by strong electron correlation. The second class of methods that we are developing is an orbital-free density functional theory (OFDFT), which addresses the speed limitations of Kohn-Sham DFT. OFDFT is a powerful, 0(A) scaling method for electronic structure calculations. Unlike Kohn-Sham DFT, OFDFT goes back to the original Hohenberg-Kohn idea of directly optimizing an energy functional which is an explicit functional of the density, without invoking an orbital description. This eliminates the need to manipulate orbitals, which leads to O(N 3 ) scaling in the Kohn-Sham approach. The speed of OFDFT allows direct electronic structure calculations on large systems on the order of thousands to tens of thousands of atoms, an expensive feat within Kohn-Sham. Due to our incomplete knowledge of the exact, universal energy density functional, this speedup comes at the cost of some accuracy with respect to Kohn-Sham methods. However, OFDFT has been shown to be remarkably accurate with respect to Kohn-Sham when used in the study of nearly-free-electron-like metals, e.g., Al, for which good density functionals have been derived. Examples of past applications of OFDFT include the prediction of properties of bulk crystals, surfaces, vacancies, vacancy clusters, nanoclusters, and dislocations, as well as OFDFT-based multiscale simulations of nanoindentation in Al and Al-Mg alloys.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Using the D-Wave 2X Quantum Computer to Explore the Formation of Global Terrorist Networks

Social networks with signed edges (+/-) play an important role in an area of social network theory called structural balance. In these networks, edges represent relationships that are labeled as either friendly (+) or hostile (-). A signed social network is balanced only if all cycles of three or more nodes in the graph have an odd number of hostile edges. A fundamental property of a balanced network is that it can be cleanly divided into 2 factions, where all relationships within each faction are friendly, and all relationships between members of different factions are hostile. The more unbalanced a network is, the more edges will fail to adhere to this rule, making factions more ambiguous. Social theory suggests unbalanced networks should be unstable, a finding that has been supported by research on gangs, which shows that unbalanced relationships are associated with greater violence, possibly due to this increased ambiguity about factional allegiances (Nakamura et al). One way to estimate the imbalance in a network, if only edge relationships are known, is to assign nodes to factions that minimize the number of violations of the edge rule described above. This problem is known to be computationally NP-hard. However, Facchetti et al. have pointed out that it is equivalent to an Ising model with a Hamiltonian that effectively counts the number of edge rule violations. Therefore, finding the assignment of factions that minimizes energy of the equivalent Ising system yields an estimate of the imbalance in the network. Based on the Ising model equivalence of the signed-social network balance problem, we have used the D-Wave 2X quantum annealing computer to explore some aspects of signed social networks. Because connectivity in the D-Wave computer is limited to its particular native topology, arbitrary networks cannot be represented directly. Rather, they must be “embedded” using a technique in which multiple qubits are chained together with special weights to simulate a collection of nodes with the required connectivity. This limits the size of a fully connected network in the D-Wave to about 50 simulated nodes, using all of the approximately 1150 qubits in the machine. In order to keep within this limitation, while exploring a problem of potential social relevance, we constructed time series of historical network snapshots from Stanford’s Mapping Militants Project, where nodes represent militant organizations, and edges represent either alliances or rivalries between organizations. We constructed two series from different theaters – Iraq and Syria – spanning timelines from about 2000 to 2016, each with networks whose maximum size was in the 20-30 node range. Computationally, our experience suggests D-Wave technology is promising, providing fast, nearly constant scaling of computational effort in the main part of the calculation that relies on the quantum annealing cycle. However, the cost of embedding an arbitrary network of interest in the D-Wave native topology scales poorly. If the embedding cost can be amortized relative to the annealing cycle, it may be possible to gain a substantial advantage over classical computing methods, provided a large enough network can be accommodated by partitioning into subnetworks or some similar strategy. In terms of our application to networks of militant organizations, we found a rise in network imbalance in the Syrian theater that appears to correspond roughly with the entrance of the Islamic State into a milieu already populated with other groups, a phenomenon we plan to explore in more detail. In these very preliminary results, we also noticed that during at least one period where both the size and imbalance of the network increased substantially, the imbalance per edge seemed to remain fairly steady. This may suggest some adaptive behavior among the participating factions, which may also warrant further exploration.

97 MATHEMATICS AND COMPUTING↗

AOI [3]: Smart Refractory Sensor Systems for Wireless Monitoring of Temperature, Health, and Degradation of Slagging Gasifiers

The objective of the work was to develop refractory “smart bricks”, which would contain embedded temperature, strain/stress, and spallation sensors throughout the volume of highchromia (-Cr 2 O 3 ) refractory brick. The proposed work included work to interconnect the sensors to the reactor exterior, where the sensor signals may be processed by low-power electronics and transmitted wirelessly to a central processing hub. The data processing and wireless transmitter hardware was specifically designed to be isolated (with low power consumption) and to be adaptable to future implementation of energy-harvesting strategies for extended life. Finally, the collected data was incorporated into a model to estimate refractory degradation, a technique that could help monitor the health of the refractory in real-time. The long-term goal of this program was to demonstrate high-temperature, wireless sensor arrays for in situ three-dimensional (3-D) refractory monitoring or mapping for slagging gasification systems. The research was in collaboration with HarbisonWalker International (HWI) Technology Center in West Mifflin, PA. HWI is a leading developer and manufacturer of ceramic refractory products for high-temperature applications. The work completed focused on the following areas: 1) Investigation of the chemical stability, microstructural evolution, grain growth kinetics, degree of homogeneity (quantitative image analysis), and electrical properties of refractory oxide-silicide composites at temperatures between 750-1450ºC; 2) Fabrication of silicide-alumina composite and oxide thermocouples and thermistor preforms and the development of techniques to embed them into high-chromia refractory bricks to form “smart bricks”; 3) Utilization of commercial off-the-shelf discrete components to prototype circuits for interfacing between smart brick sensors and the wireless sensor network. The prototypes were then used to design an integrated circuit for thermistor, thermocouple, and capacitive-based smart brick sensor interfacing; 4) Interfacing of the smart bricks with embedded sensors with wireless motes thus yielding a complete signal chain. This end-to-end data collection system was tested on a furnace heated to 1350°C; 5) Development of a slag penetration model and a nonlinear unknown input filter for the data from the embedded sensors for estimating temperature and extent of slag penetration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NDT System for Metal Components in Concrete Structures (Final Report)

Steel reinforcements embedded within concrete can corrode and crack, leading to weakening of the structures, and existing NDT (non-destructive testing) techniques do not provide the full picture. Condition assessment is critical in evaluating these structures in order to ensure safe, long-term operation of the nuclear power plants. Improved NDT techniques are needed as the nation’s generating stations age and require action based on increasingly critical inspection data. The power industry uses eddy current test (ECT) during in-service inspections to detect and monitor defects such as cracks and corrosion in metals, particularly metal pipes. However, the detection of defects in the reinforcing steel embedded in concrete is far more challenging for numerous reasons. Primary among them is the concrete layer’s thickness, which prevents the ability to have a close proximity between sensor and metallic sample. One solution to this problem is to create a higher sensitivity technique which can inspect at depth, with good spatial resolution and excellent directional sensitivity, to isolate the metal buried deep in the concrete and characterize defects in the metal. The goal of the phase II research program was to study and develop a new reinforced concrete NDT technology based on anisotropic magnetoresistive (AMR) sensors designed specifically for ECT of steel reinforcements in concrete. The first technical objective was to demonstrate the capability of inspecting steel reinforcement structures, including metal rebar and tensioning cable at or below 6” of depth embedded in concrete. Another objective was to be able to confidently identify multiple layers of reinforcements at varying depths. In addition, the technique needed to be able to provide condition assessment of the metal, providing data on the structure and positioning of the steel members, material loss, and detection of the presence of breaks. An important part of the research and development was aimed at achieving superior performance compared to existing technology. The ability to detect corrosion breaks in unbonded multi-wire and multi-strand tendons was another important objective. The final objective that led to a successful program was to build a complete prototype portable scanning system capable of demonstrating the probe performance in the field. All of these objectives were met, which provided data for the system development work going forward. RMD worked with the engineering firm Simpson Gumpertz & Heger to develop a detailed problem definition for concrete structures and the necessary sensor specifications. In addition, we developed finite element simulation models for the eddy current based NDT system through the analysis of the electromagnetic (EM) properties of sample materials and the orientation of the transmitter, sensor array (receivers), metal, and intervening materials like concrete and air. Based on the modeling and specifications, we designed and fabricated prototype sensor modules. We then acquired and fabricated test samples to characterize and optimize the sensors. Finally, we built a complete prototype for testing on actual concrete structures. This new NDT technology has high promise for greatly improving capabilities in the inspection of steel reinforcements within concrete structures, such as rebar, liners, anchors, and prestressing cables. This method could be valuable in the maintenance of nuclear power plants, and many other structures critical to our nation’s infrastructure.

42 ENGINEERING↗

Metal 3D Printing of Low-NOX Fuel Injectors with Integrated Temperature Sensors (Final Technical Report)

This technical report presents the exploration of design and prototyping of an Oxy-fuel injector with integrated temperature sensing capabilities using Additive Manufacturing (AM) technology. The AM process has proven itself as a viable method to fabricate complex shapes for custom-designed metallic components rapidly. The lack of assembly requirements and the virtually unlimited geometrical complexity renders the AM process particularly attractive for fabricating complex energy system components. The unique layer-by-layer fabrication technique allows the embedding of sensors within complex components early in the design process. Sensors can be embedded (without post-production component modifications) in AM-fabricated components through two distinct processes: Stop and Go or Post-Integration. The Stop and Go fabrication process allows sensor placement within a cavity during fabrication; where the process is allowed to continue upon sensor placement. Post-integration process supports selective build of customized compartments for sensors within the part. The Stop and Go process requires an extremely accurate re-alignment of the powder-bed during the restart process. Additionally, metallization and shorting of sensors due to a considerably high temperature of the AM process creates significant fabrication challenges and limit the types of sensors that can be embedded. The Post-Integration of sensors is a practical alternative for components that can be effectively designed and fabricated with pre-built complex sensor compartments without the need for post-production component modifications. The proposed effort aimed at exploring the fabrication of an oxy-fuel injector designed for high-pressure Oxy-Combustion applications (Combustor for Directly Heated Supercritical Power Cycle) with integrated temperature measurement capabilities using the AM technique. Since the current design methodology of injectors is based on conventional fabrication techniques (e.g., multi-step machining and welding processes), a new paradigm of design methodology needs to be developed for their adaptation in the AM fabrication process. One of the most challenging issues addressed in powder bed fusion is the removal of powder from internal channels/cavities as the powder to be removed has been lightly sintered during the fabrication process. In this research, a major task has been assigned to developing and evaluating powder removal techniques that will ultimately be used when removing sintered powder from cavities/channels used for sensor placement. Achieving thorough powder removal will permit the incorporation of intricate cavities, integrated fasteners, or other novel features to incorporate sensors into parts directly post-fabrication – allowing for the novel, AM-based design practices to be developed and employ for sensor integration. The designed injector was initially tested at atmospheric conditions to review its successful operation. The tests were carried out for different firing inputs; with a minimum of 55 kW and a maximum of 275 kW. Later tests were carried out for pressurized conditions between 82 kW to 275 kW firing input. A pressure of 16.35bar was observed in the combustion chamber pressure during the pressurized test of 275 kW firing input; test duration was 15 seconds. Integrated thermocouples within the injector provided temperature data for test operations. The data revealed during the atmospheric condition the injector temperature is almost unaffected by the combustion. However, during the pressurized condition, the injector temperature rapidly up to 205°C within 15 seconds; at a 275 kW firing input.

42 ENGINEERING↗

Advanced Analytics Studies Applied to US Department of Veterans Affairs' Corporate Data Warehouse (Initial Draft)

In this report, we describe our experience of applying several advanced analytics algorithms to the US Department of Veterans Affairs’ (VA’s) Corporate Data Warehouse (CDW) electronic health records datasets during FY2017-18. While various algorithms were applied to the CDW data, the main goal of this effort was to provide useful insights into the operational aspects (as opposed to the purely clinical aspect) of this specific implementation. Since there are not many reports in the public literature on advanced analytics applied to this data, this report provides unique insight in this regard. We focused on two machine learning (ML) applications: (1) clinical pathway inference (patterns dominating clinical pathways applied to a male dataset of Stable Ischemic Heart Disease patients as use case) and (2) medical-concept representation learning’s capability to inform and refine cohort membership based on probable patient outcomes. During our study on clinical pathway inference, we used two main modeling techniques: (a) topic probabilistic modeling (latent Dirichlet allocation [LDA]) and (b) feature imbedding. We observed that the applicability of LDA to the pathway inference remains in question. LDA provides results that are intuitive and easy for humans to comprehend; however, when applied to the pathway inference, it also generates pathway patterns that consist of a few dominant pathway components. In addition, LDA provides no information regarding the relationships among components in the same pathway. The outputs of LDA are also found to categorize patients based on their trace data of clinical procedures. However, the results suggest that LDA is biased toward statistically dominant components. This makes it particularly hard to discriminate pathway subbranches. To address the issue, we designed a new pathway inference methodology that integrates temporal ordering of pathway components into LDA results, as existing feature embedding tools such as word2vec are not readily applicable to our task. In addition, we developed our own feature embedding tool customized for patient traces. We conclude this study by suggesting two approaches to use embedding representation of a component into LDA and briefly list our lessons learned and recommendations for future work. For our study on medical-concept representation learning ability to inform and refine cohort membership based on probable patient outcomes, during our empirical evaluation we compared methods from medical-concept learning to standard one of a kind (one-of-K) encoding to evaluate the change in effectiveness as done in Choi, Schuetz, Stewart, and Sun (2016). We performed two primary empirical evaluations. The first evaluation was on a curated collection of 60,000 patients with no more than 1 year of medical history included. The second was a collection of patients with no restriction to the amount of medical history included. The hypothesis across both evaluations is that representation learning is broadly useful independent of downstream processing models; thus, for each experiment, we trained three models—a logistic regression model, a two-layer neural network model, and a nearest-neighbor model—and then averaged the results. Each model was trained using fivefold cross validation. We provided evidence that medical-representation learning improves predictions of the primary diagnosis category of a short patient history through 12 experiments. In addition, we provided evidence that medical-representation learning fails to improve prediction of the primary diagnosis category of an arbitrarily long patient history through 12 experiments. We conclude this study with a brief list of our lessons learned and recommendations for future work. We conclude the report with a discussion of recent technology trends as they relate to our artificial intelligence and, more specifically, to our ML research and approaches as described previously.

97 MATHEMATICS AND COMPUTING↗

Skid Testing Report (FY 2019)

The Skid Test is an experiment that impacts an explosive charge obliquely upon a gritty target in order to deliver a frictional ignition stimulus. At Los Alamos, the Skid Test has been used since 2011 to test myriad explosives, drop heights, impact angles, target materials, target coatings, and other variables. In FY19, forty-four tests were performed. The focus was twofold: 1) investigate the possibility that grit pre-embedded into PBX 9501 can create ignitions when impacting a gritty soft-rubber surface, via grit-grit interactions; 2) test the HMX-based UK explosive EDC37 in typical Skid Test conditions. Thirty-one tests were performed with grit pre-embedded in PBX 9501, dropped onto gritty soft rubber targets. No ignitions were observed in any of the tests. Previously, nominally identical tests were performed, except lacking the pre-embedded grit, and no ignitions were observed in those tests. Post-mortem analysis suggests that grit-grit collisions are common, yet still fail to produce ignitions. We hypothesize that the softness of the rubber target fails to provide sufficient normal force for frictional heating, regardless the grit-grit collisions. Eleven tests with EDC37 were conducted in total, at drop heights of 9 in, 6 ft, and 9 ft and with grit diameters of 75-150 µm, 150-250 µm, 250-500 µm, and 500-1000 µm. Ignition of hotspots followed by quench was observed in a single test at an incident angle of 14° and effective drop height of 9 ft. These results demonstrate that EDC37 is safer—i.e. less prone to ignition—than other conventional high explosives tested to date, including PBX 9501.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Reactor Pressure Vessel Fracture Mechanics Development and Concrete Application Testing for Grizzly

The Grizzly code is being developed to address degradation issues in nuclear reactor structures and components. For light-water reactors, Grizzly currently has capabilities to simulate degradation processes and their effects on structural integrity in two key areas: reactor pressure vessels (RPVs) and reinforced concrete structures. This report documents improvements made to Grizzly’s ability to address both of these structural systems. For RPVs, the reduced-order models (ROMs) used in fracture mechanics calculations have been expanded to allow their application over a broader range of the parameter space than was permitted by the previous models. The ROMs currently used in Grizzly for the evaluation of flaws that are fully embedded within the RPV (as opposed to surface-breaking flaws) are based on a model that is known to be conservative, indicating higher stress intensity factors than would be obtained from direct simulations. A more accurate model that eliminates these excess conservatisms has been recently included in the American Society of Mechanical Engineers Boiler and Pressure Vessel Code but was not applicable for flaws near the RPV surface, which is where the most critical flaws are usually located. That model has recently been extended for increased applicability in this near-surface region. The ROMs for embedded flaws in the Grizzly code have been expanded to include these recent extensions, which permit their use in a much broader set of cases than previously possible. Direct 3D simulations have been used to check these ROMs and have shown good agreement in most cases, although there are still some cases that need further investigation. There are considerable benefits to using these these more accurate and less conservative ROMs for embedded flaws. On a benchmark probabilistic fracture mechanics problem tested here, the conditional probability of fracture initiation computed for a population of flaws in a single plate in an RPV decreased by over a factor of 3. To address aging in reinforced concrete structures, a capability to simulate multiple degradation mechanisms, including alkali-silica reaction and radiation-induced volumetric expansion has been developed in Grizzly over the past several years. This had previously been demonstrated on laboratory-scale specimens but not on full-scale nuclear concrete structures with reinforcement. To demonstrate the applicability of Grizzly to the analysis of large-scale structures of interest, a full 3D model of a representative reinforced concrete structure, including a complex arrangement of reinforcing bars, was developed and demonstrated in Grizzly.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Printed Strain Gauges for Anthropomorphic Test Dummies for Vehicle Crash Testing

In Phase 1 of the technical collaboration between Oak Ridge National Laboratory (ORNL) and Humanetics, additive manufacturing was studied as a method to produce high strain – strain gauges that are embedded in an additively manufactured (AM) anthropomorphic crash test dummy (ATD) to provide high fidelity data to significantly improve vehicle safety. In this study commercially available conductive filament was acquired and the mechanical properties were tested for use in this application. The design space of embedded printed strain gauges was explored with multiple configurations printed and tested for performance. The testing resulted in finding that commercially available filament materials were unable to meet the performance requirements. Finally, an extensive literature survey was performed on advanced manufacturing techniques and novel high strain conductive materials to manufacture strain gauges that can be embedded in to the AM ATD. Humanetics have taken the literature survey and have reached out to material suppliers such as Techmer to provide custom blends of materials for testing. Humanetics will continue to build off of the research that was performed and test custom materials for use in AM ATDs.

36 MATERIALS SCIENCE↗

Doped Lanthanum Chromite-refractory Based Composites Sensors for High Temperature Monitoring in Harsh Environments Systems

In order to test and monitor the operational stability and conditions of various energy, and manufacturing systems and their components, development of accurate sensors capable of operating at temperatures in excess of 1000 °C in various environments for long durations is required. In addition, many of these harsh-environment systems do not permit sensors to be directly inserted, so these sensors need to be embedded into thermal protective materials. In this work were developed high-temperature embedded thermocouples composed of various doped lanthanum chromites-refractory based composites synthesized by a mixed-oxide route and directly embedded into a Al2O3 based refractory. The electrical properties were specifically manipulated by altering the level of percolation of the conductive phase within the refractory constituent. Chemical stability of sensors was determined by phase development analysis by X-ray diffraction and X-ray photoelectron spectroscopy; Seebeck coefficients were determined by thermoelectric voltages measurements at temperature up to 1400 oC.

Perovskite LaCrO3, High-temperature conductivity, ↗

CIE Curriculum Guide (V.2.0)

The Cyber-Informed Engineering (CIE) Curriculum Guide offers a comprehensive framework, guidance, and resources for integrating CIE into university-level engineering programs and related educational activities. The primary goal is to help educators adopt CIE principles into their teaching to produce future engineers and technicians who understand digital risks in modern engineered systems, thereby addressing the nation’s infrastructure resilience needs. This guide outlines practical integration examples, links to resources to accelerate CIE adoption, and shares insights from partner academic institutions on various implementation strategies. CIE is a framework for embedding engineered controls that mitigate the impact of cyber-attacks in any cyber-physical system used in critical energy infrastructure and other sectors. Developed by the U.S. Department of Energy’s Office of Cybersecurity, Energy Security, and Emergency Response (CESER), the National Cyber-Informed Engineering Strategy emphasizes embedding CIE into formal education, training, and credentialing. This guide supports this strategic objective by providing examples of integrating CIE concepts into engineering curricula, from class activities to new courses and certificate programs. The importance of educating cyber-informed engineers is underscored by the evolving cybersecurity threats facing engineered systems. As industrial control systems (ICS) increasingly incorporate digital technologies, the responsibility for security extends to both cyber professionals and engineers. CIE addresses critical gaps in designing and protecting physical systems with digital components against cyber risks, ensuring engineers consider digital risk throughout the engineering design lifecycle. Currently, engineering education does not routinely include cyber-informed principles, highlighting a gap in addressing modern engineering system risks. This guide advocates for updating engineering curricula to include digital risk management as a fundamental element. By doing so, future engineers will be equipped to design resilient systems that mitigate digital risks from the outset. Through this guide, engineering faculty can integrate CIE into their curricula, bridging the gap between digital risk and engineering. This approach prepares a cyber-informed workforce capable of safeguarding the cyber-physical systems crucial to national security and public welfare. By embedding CIE into education and training, institutions can produce engineers and technicians who can effectively mitigate cyber impacts throughout the engineering design lifecycle, resulting in more secure critical infrastructures.

42 - ENGINEERING↗

Thriving in the Carbon-Aware Market: How to Account for Emissions in the Era of Carbon-Centered Trade Policies

Emerging global policies, such as the European Union's enacted Carbon Border Adjustment Mechanism and similar policies under development in Canada, Australia and the United Kingdom, will place a premium on goods traded into their territories with higher embedded emissions than those produced domestically. U.S. manufacturers could stand to benefit from such policies; given the investments U.S. industry has made to reduce the energy and emission intensities of its operations. For example, the overall GHG intensity of U.S. steel production in 2019 was ~0.96 t CO2/t steel, less than half that of China (~1.97 t CO2/t steel), and bested only by Italy. To realize these benefits, transparent, accurate, interoperable and accepted embedded emissions accounting and calculation methods are required. Achieving this requires overcoming challenges related to data availability, boundary definitions, and product definitions among others, both at individual facilities as well as through value chains. We will present technical findings on methodology considerations and data-availability constraints for determining the emissions of traded goods, using steel as a pilot and leveraging publicly available data. Issues such as determining the appropriate scope for emissions accounting, implications of the specificity of product chosen, emissions allocation in multi-product facilities, and enumeration of emissions for products manufactured across multiple facilities will be discussed. By sharing the results of our efforts, we aim to inform the development and execution of embedded emissions accounting methods from a technical perspective such that U.S. manufacturers can thrive in emerging global markets.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers (Final Technical Report)

This report summarizes the carbon capture research and development conducted by The State University of New York at Buffalo (UB) and GTI Energy (GTI) for award “DE-FE0031969: Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers” sponsored by the U.S. Department of Energy (DOE). The objective of this project is to develop an innovative sorbent structure of trapped small amines in HNC embedded in PEF for DAC. This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An innovative sorbent structure of trapped small amines in hierarchical nanoporous capsules (HNC) embedded in porous electrospun fibers (PEF) was developed for direct air capture (DAC). This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An interfacial polymerization process was developed, which utilized loaded amines inside mesoporous silica and trimesoyl chloride (TMC) dissolved in organic solvents as the precursors, to generate a polyamide (PA) coating layer on mesoporous silica and thus trap amines. Reaction conditions, including TMC concentration, organic solvents, reaction time, etc., for interfacial polymerization were optimized to effectively trap loaded amines, and cyclic heating-cooling operation was conducted to evaluate the coating quality. Larger pore volume mesoporous silica was also synthesized to increase amine loading and thus increase CO 2 capacity. The optimized sorbent material exhibited CO 2 capacity as high as 4.88 mmol/g under humid DAC conditions and negligible loss (<1%) during 10 cyclic heating-cooling operations. The optimized PA-coated sorbent also showed fast adsorption and desorption kinetics, with <20% t1/2 increase compared to uncoated sorbent. PEF fabrication conditions, including organic solvents for dissolving core and shell polymers, voltage, distance from the nozzle to the collection panel, etc. were adjusted to better incorporate HNC. After incorporating the optimized sorbent material into PEF, the structured sorbent had a CO 2 capacity of approximately 4.0 mmol/g under humid DAC conditions, with capacity loss of 0.17% per cycle and t1/2 increase less than 10%. A techno-economic analysis (TEA) for the process design for a DAC system based on our developed sorbent structure of trapped small amines in HNC embedded in PEF was conducted. The process design included process description and major equipment sizing and energy and mass balances in addition to scale-up research results and estimated capture cost. Aspen Adsorption Simulator was used to fit the experimentally measured breakthrough curves and extract equilibrium and kinetic data of the optimized sorbent. Our results indicated that for a DAC plant with CO 2 productivity of 3,000 tonne/year, the levelized cost of CO 2 capture was $\$$612/tonne, with the largest contribution of 44.33% from the fixed operation cost. Increasing CO 2 productivity, while maintaining similar fixed operation cost, is expected to significantly reduce the CO 2 capture cost. A sensitivity study was also conducted to understand the influence of total plant cost, sorbent cost, CO 2 concentration in the feed, sorbent mat lifetime, sorbent regeneration electricity, and adsorption blower pressure drop on the levelized cost of CO 2 capture, revealing a capture cost range of $\$$520-870/tonne.

36 MATERIALS SCIENCE↗