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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

The Release of the Simplified Radionuclide Transport (SRT) Code (V.2.1)

Reactor licensing centers on the protection of the public and environment from the inadvertent release of radioactive material. Therefore, mechanistic source term analysis, or the realistic evaluation of radionuclide transport from the source to the environment for specific transient scenarios, is vital to reactor licensing efforts. Developed to resolve a gap in mechanistic source term modeling capabilities for sodium fast reactors (SFRs), the Simplified Radionuclide Transport (SRT) code created by Argonne National Laboratory (Argonne) is now utilized by advanced reactor vendors, universities, and research institutions to support a multitude of design, licensing, and research efforts. Recently, SRT version 2.1 was released, which includes improvements to code models and verification and validation (V&V) suite to support the SRT user community. The following work provides an overview of the improvements made as part of the release of SRT version 2.1. This effort is supported by the U.S. Department of Energy Office of Nuclear Energy (DOE:NE) Advanced Reactor Technologies (ART) Fast Reactor Program (FRP), as part of the program’s support of national laboratory design and safety analysis computer codes utilized by the fast reactor industry. The expansion of SRT code capabilities and improvements to code V&V associated with version 2.1 are in response to user requests and lessons learned from recent source term analyses performed by Argonne and advanced reactor vendors. They also align with the evolving role of SRT, from research and development tool to software utilized for reactor licensing calculations. The report is structured in alignment with the code improvements, as outlined in Figure 1-1. Section 2 provides background information on SRT, including its history, capabilities, and utilization. Section 3 details new code capabilities as part of version 2.1, while Section 4 focuses on the expansion of the code’s V&V suite. Lastly, Section 5 provides a summary and discussion of next steps.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Ristra Project FY23 L2 Milestone Report, Rev.1: MRT #8541: Multiphysics Scaling on EAS-3

The findings of this report were used to close out the ATDM milestone MRT# 8541, which was designed to demonstrate readiness of ATDM multiphysics codes for mission-relevant work on ATS-4, El Capitan. To this end, the closure criteria were to run a 3D shaped charge problem at scale up to 50% of the El Capitan early-access system, RZVernal (AMD Trento CPUs and AMD MI-250X GPUs), demonstrate scalability, and document challenges with the software stack and environment. LANL’s approach to this milestone was to test our modular software capability by developing an entirely new code, Moya, built upon our FleCSI framework. The physics capability and the GPU infrastructure needed for the shaped charge problem on GPUs was added to Moya, and the required calculations were performed at scale. Moya showed good scaling without any fine-tuning of GPU kernels; there is still significant room for performance enhancements, especially for the Legion backend. Tied up in this L2 milestone was a closeout of KPP-3s for the ECP ST Projects at LANL; this material will be covered in a separate document.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

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↗
DOE OSTI2024

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↗
DOE OSTI2024

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↗
DOE OSTI2024

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↗
DOE OSTI2024

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↗
DOE OSTI2025

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↗
DOE OSTI2025

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↗
DOE OSTI2025

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↗
DOE OSTI2026

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↗
DOE OSTI2013

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↗
DOE OSTI2025

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↗
DOE OSTI2025

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 (↗
DOE OSTI2020

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↗
DOE OSTI2022

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↗
DOE OSTI2014

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↗