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At least 1,747 records · Page 97

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗

Designing Cellular Metal Structures for Thermal Insulation

This project focused on developing topology optimization software to design advanced metal thermal insulators. Initially, solid designs were created that matched the thermal performance of current baseline designs but were significantly heavier. To address this, cellular materials were incorporated, specifically the octet structure which is known for its high strength-to-weight ratio and thermal properties. By leveraging these cellular designs at various densities, superior thermal and mechanical performance was achieved without added weight. This novel approach enhances thermal management and structural integrity under extreme conditions, offering promising advancements for thermal protection systems.

36 MATERIALS SCIENCE↗

FY24 Advancements in PFLOTRAN Development for GDSA Framework

The Spent Fuel & Waste Science and Technology (SFWST) Campaign of the Office of Spent Fuel & Waste Disposition of U.S. Department of Energy Office of Nuclear Energy (DOE-NE) is conducting research and development on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). This report describes fiscal year 2024 accomplishments in the Geologic Disposal Safety Assessment (GDSA) PFLOTRAN Development work package, which is charged with developing subsurface simulation software for postclosure performance assessment of deep geologic disposal of SNF and HLW.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

An Update on Microreactor Automated Control System (MACS)

Automation of control systems is expected to be important in the economic and safe operation of microreactors. There is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a microreactor automated control system (MACS) testbed developed to test control system automation. While a future goal is to demonstrate this system using a prototypic microreactor such as MARVEL, the present focus is on developing and testing within a non-nuclear testbed. The testbed, developed in collaboration with Idaho National Laboratory, includes hardware-in-the-loop simulation and uses a Modelica-based model of a prototypic microreactor for use in testing control automation. Research to date at Oak Ridge National Laboratory has focused on the development of prototypic software for automating plant-level control under selected scenarios. Empirical testing on the integrated MACS testbed was performed to quantify key characteristics of the integrated testbed and to demonstrate the use of the software for automating the calculation and use of actuation setpoints for selected load-following scenarios. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Inspecta Technical Report

Sandia National Laboratories (SNL) is in the process of creating Inspecta (International Nuclear Safeguards Personal Examination and Containment Tracking Assistant), an Artificial Intelligence (AI)-powered smart digital assistant (SDA) with robotic capabilities, aimed at enhancing the effectiveness, efficiency, and safety of international nuclear safeguards inspections. This innovative tool is designed to assist inspectors on-site by supporting or automating tasks that are typically mundane, hazardous, or susceptible to errors. In 2021, the development team established the specifications for Inspecta by analyzing International Atomic Energy Agency (IAEA) documents and consulting with former IAEA inspectors and subject matter experts. This process involved aligning in-field inspection tasks with existing commercial or open-source technologies to outline a roadmap for the initial prototype of Inspecta, while also identifying areas needing further research and development. From 2022 – 2024, the focus has shifted to integrating a critical inspection activity, the examination of seals, into an early version of Inspecta. This has involved developing both the software and hardware capabilities necessary for this task. This report outlines the ongoing advancements in Inspecta's functionalities, specifically those supporting the seal examination process.

97 MATHEMATICS AND COMPUTING↗

GE 1.5 ESS Wind Turbine Retrofit Controller Development (CRADA Final Report)

National Renewable Energy Laboratory (NREL) and Bachmann electronic corp. will collaborate on the development of a software application to be used on an existing aftermarket Bachmann controller, utilizing and existing Bachmann software platform, which will be used on the General Electric (GE) 1.5 ESS wind turbine. This retrofit will significantly enhance NREL’s ability to control experiments it is planning to conduct on the GE 1.5 wind turbine as part of the Gearbox Reliability Collaborative, Atmosphere to Electrons and other future R&D. The proposed work is leveraging ongoing Department of Energy (DOE) Annual Operating Plan activities on the GE 1.5 ESS wind turbine at the National Wind Technology Center.

17 WIND ENERGY↗

SLIA Reference Architecture Models

The SLIA Reference Architecture Models project, sponsored by the DOE CESER Energy CyberSense Program (Oct 2024–Sep 2025), advanced LLNL’s PySCES simulation tool to better support CyTRICS Prioritization and Initial Risk Assessment (PIRA) reference architectures. Key achievements include enhancements to the PySCES transmission substation facility model, expanded asset coverage, and enhancements to the PySCES code base. Software improvements reduced code complexity, migrated PySCES to Python version 3.11, introduced an object-oriented design, and added a schema database for easier updates and validation. New features support device criticality assessments and a more precise parametric simulation mode. Remaining gaps include model validation, workflow limitations, Monte Carlo convergence issues, full device criticality metric implementation, model fidelity, and general software improvements. Continued development is recommended to address these gaps and fully align PySCES with CyTRICS PIRA requirements.

97 MATHEMATICS AND COMPUTING↗

Clean Water Production in Cooling Towers

This project developed and demonstrated a novel technology that produces clean water from cooling tower recirculating water by using the natural evaporation and condensation cycle inside cooling towers. The system captures the escaping plume and converts blowdown quality water into high purity water suitable for on-site reuse such as boiler feed. The technology uses electric fields to ionize exhaust plumes, charge the entrained droplets, and direct them toward collection electrodes where they coalesce and flow downward. This allows water recovery at a low energy cost while reducing visible plume emissions. In addition, we developed a complementary software platform that improves overall cooling tower performance. The system uses wireless sensors and physics-based machine learning algorithms to optimize key parameters of the cooling process. For power generation facilities, this increases the thermal efficiency of the cooling loop and condenser, resulting in measurable cycle efficiency gains. Improvements of one percent or more can deliver significant increases in electricity production for the same fuel input.

01 COAL, LIGNITE, AND PEAT↗

Apex Study: Compensating Transient Beam Loading in the RHIC 28 MHZ

With the EIC on the way, it is important that developments and strategies are in place to deal with the very high beam currents that the machine will feature. Specifically, the EIC will collide beams of up to 2.5 A, three times the beam current in RHIC. This higher beam current will cause significant voltage transients in the cavity fields which can lead to longitudinal instabilities and beam loss. In anticipation of these negative effects, studies were carried out on the RHIC 28 MHz cavities using newly developed firmware and software to diagnose and combat beam loading. Diagnostic tools such as the bunch-by-bunch (BbyB) ADC firmware and digital network analyzer (DNA) were used to characterize the closed loop system and transient on the cavity voltage magnitude and phase. Then, a one-turn delay feedback (OTFB) and adaptive feed-forward (aFFWD) were used to minimize the transient beam loading. The studies were carried out with beam during 2 accelerator physics experiements (APEXs) using one of the 28 MHz accelerating cavities here at RHIC.

43 PARTICLE ACCELERATORS↗

VERA Core Physics Benchmark Progression Problem Specifications

Provided are the detailed specifications for the AMA Core Physics Benchmark Progression Problems 1 through 5. These problems were selected to assist software and methods developers and analysts in progressing through capabilities needed to model U.S. nuclear power reactors and their operations. The problems provide a prioritization of the VERA requirements for the virtual reactor, beginning at the fuel pin level and progressing to full core, multi-physics problems. They also enable clear and concise communication about what capabilities have been achieved. In addition to the specifications, reference solutions are provided, if available, from a continuous energy Monte Carlo transport solution.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Inspecta Technical Report

Sandia National Laboratories (SNL) has developed Inspecta (International Nuclear Safeguards Personal Examination and Containment Tracking Assistant), an AI-powered smart digital assistant (SDA) equipped with robotic capabilities. This innovative tool aims to enhance the effectiveness, efficiency, and safety of international nuclear safeguards inspections. Inspecta is designed to assist inspectors on-site by supporting or automating tasks that are often mundane, hazardous, or prone to errors. In 2021, the development team established the specifications for Inspecta by thoroughly analyzing International Atomic Energy Agency (IAEA) documents and consulting with former IAEA inspectors and subject matter experts. This process involved aligning in-field inspection tasks with existing commercial and open-source technologies, thereby creating a roadmap for the initial prototype of Inspecta and identifying areas requiring further research and development. From 2022 to 2025, the focus shifted to integrating a critical inspection activity—the examination of seals—into an early version of Inspecta. This phase has involved the development of both software and hardware capabilities essential for this task. This report outlines the advancements in Inspecta’s functionalities, particularly those that support the seal examination process.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

What's New in ParaView

This presentation is on ParaView development activities and software releases for the year prior to the DOE CGF in April of 2025.

Otahal, Thomas Jay [Sandia National Laboratories (↗

Integrated Transmission-and-Distribution System Modeling of Power Systems: State-of-the-Art and Future Research Directions

Integrated transmission-and-distribution (T&D) modeling is a new and developing method for simulating power systems. Interest in integrated T&D modeling is driven by the changes taking place in power systems worldwide that are resulting in more decentralized power systems with increasingly high levels of distributed energy resources. Additionally, the increasing role of the hitherto passive energy consumer in the management and operation of power systems requires more capable and detailed integrated T&D modeling to understand the interactions between T&D systems. Although integrated T&D modeling has not yet found widespread commercial application, its potential for changing the decades-old power system modeling approaches has led to several research efforts in the last few years that tried to (i) develop algorithms and software for steady-state and dynamic modeling of power systems and (ii) demonstrate the advantages of this modeling approach compared with traditional, separated T&D system modeling. In this paper, we provide a review of integrated T&D modeling research efforts and the methods employed for steady-state and dynamic modeling of power systems. We also discuss our current research in integrated T&D modeling and the potential directions for future research. This paper should be useful for power systems researchers and industry members because it will provide them with a critical summary of current research efforts and the potential topics where research efforts are needed to further advance and demonstrate the utility of integrated T&D modeling.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Automated Process Planning for Embossing and Functionally Grading Materials via Site-Specific Control in Large-Format Metal-Based Additive Manufacturing

The potential for site-specific, process-parameter control is an attribute of additive manufacturing (AM) that makes it highly attractive as a manufacturing process. The research interest in the functionally grading material properties of numerous AM processes has been high for years. However, one of the issues that slows developmental progress in this area is process planning. It is not uncommon for manual programming methods and bespoke solutions to be utilized for site-specific control efforts. This article presents the development of slicing software that contains a fully automated process planning approach for enabling through-thickness, process-parameter control for a range of AM processes. The technique includes the use of parent and child geometries for controlling the locations of site-specific parameters, which are overlayed onto unmodified toolpaths, i.e., a vector-based planning approach is used in which additional information, such as melt pool size for large-scale metal AM processes, is assigned to the vectors. This technique has the potential for macro- and micro-structural modifications to printed objects. A proof-of-principle experiment is highlighted in which this technique was used to generate dynamic bead geometries that were deposited to induce a novel surface embossing effect, and additional software examples are presented that highlight software support for more complex objects.

36 MATERIALS SCIENCE↗

Methodology for the Incorporation of Passive Component Aging Modeling into the RAVEN/ RELAP-7 Environment

Passive system, structure and components (SSCs) will degrade over their operation life and this degradation may cause to reduction in the safety margins of a nuclear power plant. In traditional probabilistic risk assessment (PRA) using the event-tree/fault-tree methodology, passive SSC failure rates are generally based on generic plant failure data and the true state of a specific plant is not reflected realistically. To address aging effects of passive SSCs in the traditional PRA methodology [1] does consider physics based models that account for the operating conditions in the plant, however, [1] does not include effects of surveillance/inspection. This paper represents an overall methodology for the incorporation of aging modeling of passive components into the RAVEN/RELAP-7 environment which provides a framework for performing dynamic PRA. Dynamic PRA allows consideration of both epistemic and aleatory uncertainties (including those associated with maintenance activities) in a consistent phenomenological and probabilistic framework and is often needed when there is complex process/hardware/software/firmware/ human interaction [2]. Dynamic PRA has gained attention recently due to difficulties in the traditional PRA modeling of aging effects of passive components using physics based models and also in the modeling of digital instrumentation and control systems. RAVEN (Reactor Analysis and Virtual control Environment) [3] is a software package under development at the Idaho National Laboratory (INL) as an online control logic driver and post-processing tool. It is coupled to the plant transient code RELAP-7 (Reactor Excursion and Leak Analysis Program) also currently under development at INL [3], as well as RELAP 5 [4]. The overall methodology aims to: • Address multiple aging mechanisms involving large number of components in a computational feasible manner where sequencing of events is conditioned on the physical conditions predicted in a simulation environment such as RELAP-7. • Identify the risk-significant passive components, their failure modes and anticipated rates of degradation • Incorporate surveillance and maintenance activities and their effects into the plant state and into component aging progress. • Asses aging affects in a dynamic simulation environment 1. C. L. SMITH, V. N. SHAH, T. KAO, G. APOSTOLAKIS, “Incorporating Ageing Effects into Probabilistic Risk Assessment –A Feasibility Study Utilizing Reliability Physics Models,” NUREG/CR-5632, USNRC, (2001). 2. T. ALDEMIR, “A Survey of Dynamic Methodologies for Probabilistic Safety Assessment of Nuclear Power Plants, Annals of Nuclear Energy, 52, 113-124, (2013). 3. C. RABITI, A. ALFONSI, J. COGLIATI, D. MANDELLI and R. KINOSHITA “Reactor Analysis and Virtual Control Environment (RAVEN) FY12 Report,” INL/EXT-12-27351, (2012). 4. D. ANDERS et.al, "RELAP-7 Level 2 Milestone Report: Demonstration of a Steady State Single Phase PWR Simulation with RELAP-7," INL/EXT-12-25924, (2012).

97 MATHEMATICS AND COMPUTING↗

Advanced Multiphysics Thermal-Hydraulics Models for the High Flux Isotope Reactor

Engineering design studies to determine the feasibility of converting the High Flux Isotope Reactor (HFIR) from using highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel are ongoing at Oak Ridge National Laboratory (ORNL). This work is part of an effort sponsored by the US Department of Energy (DOE) Reactor Conversion Program. HFIR is a very high flux pressurized light-water-cooled and moderated flux-trap type research reactor. HFIR s current missions are to support neutron scattering experiments, isotope production, and materials irradiation, including neutron activation analysis. Advanced three-dimensional multiphysics models of HFIR fuel were developed in COMSOL software for safety basis (worst case) operating conditions. Several types of physics including multilayer heat conduction, conjugate heat transfer, turbulent flows (RANS model) and structural mechanics were combined and solved for HFIR s inner and outer fuel elements. Alternate design features of the new LEU fuel were evaluated using these multiphysics models. This work led to a new, preliminary reference LEU design that combines a permanent absorber in the lower unfueled region of all of the fuel plates, a burnable absorber in the inner element side plates, and a relocated and reshaped (but still radially contoured) fuel zone. Preliminary results of estimated thermal safety margins are presented. Fuel design studies and model enhancement continue.

COMSOL↗

Landscape Environmental Assessment Framework

LEAF Version 2.0 is a framework comprising of three models RUSLE2, WEPS, and AGNPS. The framework can predict row crop, crop residue, and energy crop yields at a sub-field resolutions for various combinations of soil, climate and crop management and residue harvesting practices. It estimates the loss of soil, carbon, and nutrients to the atmosphere, to the groundwater, and to runoff. It also models the overland flow of water and washed-off sediments, nutrients and other chemicals to provide estimates of sediment, nutrient, and chemical loadings to water bodies within a watershed. AGNPS model and wash-off calculations are the new additions to this version of LEAF. Development of LEAF software is supported by DOE's BETO program.

Nair, Shyam↗

Hybrid Geothermal Heat Pumps for Cooling Telecommunications Data Centers

The technical and economic performance of geothermal heat pump (GHP) systems supplying year-round cooling to representative small data centers with cooling loads less than 500 kWth were analyzed and compared to air-source heat pumps (ASHPs). A numerical model was developed in TRNSYS software to simulate the operation of air-source and geothermal heat pumps with and without supplementary air cooled heat exchangers - dry coolers (DCs). The model was validated using data measured at an experimental geothermal system installed in Ithaca, NY, USA. The coefficient of performance (COP) and cooling capacity of the GHPs were calculated over a 20-year lifetime and compared to the performance of ASHPs. The total cost of ownership (TCO) of each of the cooling systems was calculated to assess its economic performance. Both the length of the geothermal borehole heat exchangers (BHEs) and the dry cooler temperature set point were optimized to minimize the TCO of the geothermal systems. Lastly, a preliminary analysis of the performance of geothermal heat pumps for cooling dominated systems was performed for other locations including Dallas, TX, Sacramento, CA, and Minneapolis, MN.

15 GEOTHERMAL ENERGY↗