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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Tre-DST: A Drug Susceptibility Test for Mycobacterium tuberculosis Using Solvatochromic Trehalose Probes

In 2024, an estimated 10 million people developed Tuberculosis (TB), nearly half a million of whom were infected with drug-resistant tuberculosis (DR-TB). Early detection of infection and drug resistance enables rapid engagement in effective care. Bacterial culture and nucleic acid testing remain the primary diagnostic methods, with smear microscopy being phased out. However, these methods present significant limitations for diagnosing drug resistance, such as lengthy time-to-result for phenotypic tests, as well as the need for prior knowledge of resistance mutations and prohibitive cost for molecular tests. To address this, we developed a rapid phenotypic TB drug susceptibility test, termed Tre-DST, based on novel metabolically incorporated trehalose probes, which specifically detect live mycobacteria. We used the nonpathogenic Mycobacterium smegmatis and the virulence-attenuated Mycobacterium tuberculosis (Mtb) H37Ra or auxotrophic Mtb to demonstrate a strong correlation between cost-effective plate reader results and flow cytometry data, suggesting that the plate reader is a suitable fluorescence detector for Tre-DST. We determined that adding a 1-week incubation step allowed Mtb samples originally seeded at 10 4 CFU/mL to become detectable, over 2 weeks earlier than colony-forming unit analysis. We found that Tre-DST reports on drug susceptibility in a drug-agnostic manner, demonstrating loss of fluorescence with frontline TB drugs as well as the newer drug bedaquiline. Tre-DST distinguished RIF- and INH-resistant auxotrophs from susceptible controls and accurately reported the resistance activity. Ultimately, because Tre-DST is agnostic to mechanisms of drug resistance, this assay is likely compatible with all WHO-recommended and future DR-TB drugs as a diagnostic in reference laboratories.

diagnostics↗
DOE OSTI2025

Open World Dempster-Shafer Theory/The Transferable Belief Model with Intervals: A Practitioner's Guide to DST and TBM

Dempster-Shafer theory (DST) is a mathematical framework that allows for uncertainty or ignorance to be quantified and included when making predictions from evidence. This is in contrast to Bayesian theory, which does not allow for any quantification of ignorance. The framework is described in great detail in [7]. DST is particularly useful for problems where the inclusion of additional evidence (for example, data from another sensor) could lead to a different conclusion. Thus, it is a useful data fusion method, especially in applications not suited to maximum likelihood or maximum a posteriori estimations due to limited samples or incomplete prior knowledge.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

NDE Technology Development Program for Hanford DST Non-Visual Volumetric Inspection Technology – Phase II; Technical Letter Report on Air-slot NDE Sensor Maturation Testing

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Phase II Flaw Detection Performance Tests in August 2018 that allowed the newly matured ultrasonic guided wave phased-array (GWPA) air-slot NDE sensor—“Hanford-Probe A”—developed by Guidedwave to be evaluated for its flaw detection capability and repeatability. A portion of the Phase II Flaw Detection Performance Tests was performed on a subset of test flaws on which the original GWPA sensor was evaluated during Phase I Sensor Effectiveness Testing (SET) to facilitate a comparison in flaw detection performance between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I. The objective of the performance comparison was to determine the extent to which GWPA sensor design changes impacted the flaw detection performance upon which selection of the sensor technology was originally based for the purpose of determining whether the flaw detection performance of the newly matured Hanford-Probe A GWPA air-slot NDE sensor is at least equal to that of the original GWPA sensor evaluated under Phase I SET. This technical letter report presents the results produced by the new Hanford-Probe A on the Phase I test flaws and the results of the flaw detection performance comparison between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

NDE Technology Engineering Program for Hanford DST Non-Visual Volumetric Inspection Technology: Phase II RAVIS Radiation Tolerance Test Report

This test report provides the results of radiation tolerance robustness testing that was performed on samples of robotic components and an ultrasonic guided wave air-slot sensor that represent components/sub-systems of the Robotic Air-slot Volumetric Inspection System (RAVIS) that has been engineered for volumetric inspection of Hanford tank bottom plates via under-tank refractory pad air-slots. The specific components tested for 1) functionality during active irradiation and 2) tolerance to cumulative radiation dose (until failure or upon reaching a cumulative dose test limit) were: • four samples each of a printed circuit board (PCB) and direct current (DC) motor, which are robotic components, and • 26 ultrasonic piezoelectric elements (samples) inside an air-slot sensor. The robotic components are part of the RAVIS air-slot inspection crawler drive control system that is responsible for remote communication with and actuation of the air-slot inspection crawler. The failure of either of these components during under-tank deployment would require manual retrieval via the crawler’s tether, which risks damage to the robot/refractory/tank. Preemptive replacement of the components at appropriately conservative dose/time intervals informed by failure dose would reduce the likelihood of under-tank failure. The components were included in radiation tolerance testing to quantify their failure doses to inform replacement intervals. The air-slot sensor is responsible for collecting ultrasonic inspection data (scan images) for the tank bottom plates during under-tank deployment. Compromised signal quality due to elevated noise levels caused by gamma radiation would compromise inspection performance. The air-slot sensor was included in radiation tolerance testing to quantify the impact of active irradiation on sensor signal quality. The irradiation and in-situ functional tests of the PCBs, DC motors and air-slot sensor took place in June and July 2020 at the Pacific Northwest National Laboratory. Testing was performed at a gamma dose rate near 300 rad/hr., which, in the absence of under-tank dose rate data, has been conservatively estimated to be the upper-bound dose rate beneath the primary tanks at Hanford. Irradiation took place at elevated temperatures of 150-200°F to determine failure doses that reflect the compounding effects of gamma radiation and heat. The test results revealed: • The DC motors can tolerate being actively irradiated at the high dose rate at 200°F and can tolerate a cumulative dose of 300,000 rad, that which would be incurred after 5 years of service at the 300 rad/hr dose rate. The component therefore meets minimum and preferred radiation tolerance and lifecycle requirements for robotic components. • The air-slot sensor can tolerate being actively irradiated at the high dose rate at 150°F and can tolerate a cumulative dose of 60,000 rad, that which would be incurred after 1 year of service at the 300 rad/hr dose rate. The sensor therefore meets minimum radiation tolerance and lifecycle requirements. • The PCB can tolerate being actively irradiated at the high dose rate, but can only tolerate a cumulative dose of 19,000 rad at 150-200°F. The PCB does not meet minimum radiation tolerance and lifecycle requirements; however, because the component is considered replaceable, it can be replaced before a cumulative dose of 19,000 rad is reached, determined through either monitoring with a dosimeter or scheduled time intervals that are calculated based on conservative estimates of under-tank dose rates.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Beam Spill in Downstream Transport due to Injector Faults [PowerPoint]

We have investigated injector faults with numerical experiments. For this investigation we used the nominal tune that is also being used to assess beam stability. Beam spill in the DST due to a serious injector fault was evaluated using the LSP slice algorithm. Only the most serious fault investigated (-350 keV) caused beam spill in the DST. DST transport focusing solenoids limit the beam spill. Beam spill in the DST is the result of large halo caused by betatron oscillations of the mismatched beam. Bremsstrahlung radiation from the DST beam spill was estimated from Tom Martin scaling normalized to DARHT-I. In conclusion, Scorpius is reasonably safe from beam spill radiation in the DST due to injector faults.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Electron Dropout Events and Flux Enhancements Associated With Geomagnetic Storms Observed by PROBA-V/Energetic Particle Telescope From 2013 to 2019

Electron flux variations for E > 500 keV during geomagnetic storms are investigated using the Energetic Particle Telescope (EPT). This detector launched in May 2013 on board the satellite PROBA-V at an altitude of 820 km was designed to provide uncontaminated spectra of electrons, protons, and alpha particles. Electron flux dropout events are observed during the main phase of each storm and even during substorms: a rapid reduction of the electron flux is noted throughout the outer electron radiation belt at all energies above about 0.5 MeV on timescales of a few hours. The electron spectrograms measured by the EPT between 2013 and 2019 show that after each geomagnetic storm, dropout events are followed by a flux enhancement starting first at low L values, and reaching the slot or even the inner belt for the strongest storms. We determine the link between Disturbed Storm Time (Dst) and the minimum value of the L-shell where the dropouts deplete the outer belt, as well as the nonlinear relation between Dst and the minimum L-shell where the flux penetrates in the slot region or even the inner belt during the storms. Dropouts appear at all energies measured by EPT and penetrate down to $\textit{L}$~3.5 for the strongest events. Dropouts are observed at Low Earth Orbit each time Dst has an inverted peak < –40 nT. Flux enhancements appear at lower L only for big storm events with Dst < –50 nT. They penetrate down to an impenetrable barrier with a minimum L-shell related to Dst and to the energy. For E > 1 MeV, this limit is also linked to the plasmapause position.

58 GEOSCIENCES↗
DOE OSTI2019

Chemistry Envelope for Pitting and Stress Corrosion Cracking Mitigation

The present waste chemistry controls for the Hanford double-shell tanks (DSTs) were established in the 1980s in response to tank failures caused by stress corrosion cracking (SCC) at the DOE Savannah River Site (SRS). Portions of the SRS chemistry limits were coupled with corrosion testing results from Pacific Northwest Laboratory (PNL) and adopted for corrosion control of the DST waste at the Hanford Site. Since that time, the temperatures of many DST wastes have decreased to less than 50 °C as the radioactive material has decayed, the testing program in Argentina demonstrated that chloride ion in Hanford Site waste could cause pitting, and other work showed that dilute solutions could cause pitting at the liquid air interface (LAI). Moreover, future transfers from the single shell tanks and the waste treatment plant and process changes may shift the DST waste chemistries to a broader range of compositions with higher aggressive anion concentrations than the wastes that are presently stored. The decreasing temperatures led to the formulation of new chemistry controls for the minimization of SCC risks for operations below 50 °C in 2010, and these controls were partially adopted. The Tank Integrity Expert Panel (TIEP) Corrosion Subgroup (CSG) recommended that additional testing be performed to assess the potential for pitting and LAI corrosion. Since 2015, DNV-GL, SRNL, and the Hanford Site laboratory have investigated pitting and LAI corrosion at current and anticipated DST chemistries and Savannah River National Laboratory (SRNL) undertook a statistically based investigation of the role of nitrate and halide ion induced pitting corrosion. The objective was to develop a comprehensive waste chemistry envelope for the simultaneous minimization of the pitting and SCC risks caused by halide and nitrate ions. This report summarizes the technical basis for the new waste chemistry envelope to minimize the potential for both pitting and cracking corrosion induced by nitrate and halide ions, and the strategies used for the validation of the new controls.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

A constitutive model for sheared dense suspensions of rough particles

In a concentrated suspension, particles come into contact due to the presence of asperities on their surfaces. As a result, the contact forces and interparticle friction become one of the important factors governing the rheology of rigid particle suspensions at high concentrations. We show that a load-dependent friction model can be used to reproduce the experimentally observed shear thickening [ST—continuous and discontinuous (DST)] behavior with an increase in the asperity size. Increasing the particle surface roughness size leads to a decrease in the critical shear rate above which shear-thickening takes place, a reduction in the critical volume fraction for DST and an increase in the viscosity jump across non-shear-thickened to shear-thickened regime. In this paper, we propose a constitutive model to quantify the effect of increasing the roughness size on the rheology of dense ST suspensions as well as on the critical shear rate for ST and the critical volume fraction for DST. We fit this model to our simulation data for stress controlled shear flow of dense rough particle suspensions. Once the fitting is complete, these equations are used to predict exact volume fractions and shear stress values for transitions between three regimes on the shear stress-shear rate flow state diagram for different roughness values. Furthermore, the results of this study can be used to tune the particle surface roughness for manipulating the dense suspension rheology according to different applications.

42 ENGINEERING↗
DOE OSTI2021

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

NLR HPC Kestrel Jobs Data

Overview: Anonymized job-level records from the Kestrel HPC system at the National Laboratory of the Rockies (NLR). Each record represents a Slurm batch job with scheduling metadata, resource requests, utilization, energy estimates, and efficiency metrics. Sensitive fields (user, account, job name, submit line, working directory, submit script, and job type) are replaced with 7-character cryptographic hashes. System & Timeframe: Kestrel is located at the NLR campus. Standard compute nodes have 104 cores and 256 GB RAM; bigmem nodes have 2,000 GB. GPU nodes (gpu-h100 partition) use NVIDIA H100 GPUs. Data covers jobs submitted August 2023 through December 2025. Funding provided by the U.S. Department of Energy, EERE. Files: esif.hpc.kestrel.job-anon.zip — Anonymized job records (Hive-partitioned Parquet) datacard.md — Full dataset documentation ~11 million rows, 50 variables. Readable with PyArrow, pandas, DuckDB, Apache Spark, or any Parquet-compatible tool. Data Collection: Jobs collected via sacct with timezone-aware export (SLURM_TIME_FORMAT="%Y-%m-%dT%H:%M:%S%z"), loaded into PostgreSQL. Calculated columns updated via database triggers and batch functions. All timestamps use timestamptz and correctly handle DST transitions. Preprocessing: Anonymization of name, user, account, submit_line, work_dir, submit_script, and job_type via 7-char hex hashes Derived columns: queue_wait, cpu_eff, max/min/avg_mem_eff, energy estimates Simplified job state mapping (e.g., "CANCELLED by 132357" → "CANCELLED") Boolean flags: python_job, reframe_job Temporal decomposition: year, month, day, day_of_week, hour, minute from submit_time Shared node tracking: shared_job_count, nodes_shared, jobs_shared Key Variables: Scheduling: job_id, partition, state_simple, submit_time, start_time, end_time, queue_wait Resources: nodes_req/used, processors_req/used, memory_req, wallclock_req/used, gpus_requested Efficiency: cpu_eff, max/min/avg_mem_eff Energy: cpu_energy_tdp_estimated_max/used_watt_hours, consumed_energy_raw_joules, consumed_energy_raw_watt_hours Sharing: shared_job_count, nodes_shared, jobs_shared Partitions: short, standard, debug, gpu-h100 Job States: CANCELLED, COMPLETED, FAILED, PENDING, RUNNING QoS Levels: normal, high Important Notes: Timestamps include timezone offsets; DST transitions are handled correctly, though adding intervals across DST boundaries requires offset adjustment shared_job_count reflects physical node co-residency, not use of the shared partition Job step records and raw Slurm JSONB fields are excluded Do not attempt to re-identify individuals from hashed fields

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

Waste Chemistry Envelope for the Determination of Pitting Corrosion Susceptibility - 19554

Liquid radioactive wastes at the Hanford and Savannah River sites are stored in large underground carbon steel tanks. The high-level wastes are processed in several of the tanks and then transferred by piping to other site facilities for further processing before they are stabilized in a vitrified or grout waste form. Based on waste removal and processing schedules, many of the tanks, will be required to be in service for times exceeding the initial intended life (i.e., greater than 60 years). Until the waste is removed from storage, transferred, and processed, the materials and structures of the tanks must maintain a confinement function by providing a barrier to the environment and by maintaining acceptable structural stability during design basis events, which include loadings from both normal service and abnormal (e.g., earthquake) conditions. Administrative programs are in place to mitigate potential corrosion mechanisms and thereby maintain the structural and leak integrity functions of these waste tanks throughout their intended service life. Waste chemistry and temperature control are the means by which corrosion degradation of the waste tanks is minimized. Chemistry controls are based on in-situ coupon tests, waste tank experience, and laboratory testing. These requirements comprise the technical standards for corrosion control. The standards are utilized then as guidelines for operational procedures. The present waste chemistry controls for the Hanford DSTs were established in the 1980's in response to tank failures caused by stress corrosion cracking (SCC) at the DOE Savannah River Site (SRS). Portions of the SRS chemistry limits, which were developed at the Savannah River National Laboratory (SRNL) were coupled with corrosion testing results from Pacific Northwest National Laboratories (PNNL) and adopted for corrosion control of the double-shell tank (DST) waste at the Hanford Site. Since that time, the temperatures of the waste in the DSTs have decreased to less than 50 deg. C in most cases as the radioactive material has decayed. As a consequence, new chemistry controls were formulated for SCC in 2010. This testing however, did not address that potential for pitting in the supernatant and at the liquid-air interface. Indeed, initial tests indicated that the inhibitor requirements for SCC would be insufficient for the prevention of pitting. In addition to lower waste temperatures, future retrieval and process changes may impact the DST waste chemistry. Initial projections suggest that the waste chemistry of the DSTs may shift to a broader range of pH and higher aggressive anion concentrations (e.g., chloride, sulfate, etc.) than the wastes that are presently stored. Additionally, processes within the vitrification facility may result in streams that are returned to the tank farm for evaporation. These streams may also contain high concentrations of aggressive species. SRNL investigated the propensity for pitting of the carbon steel waste tanks at current and projected DST waste chemistries. A statistically designed series of tests provided a pitting factor that relates the ratio of the inhibitor species to the aggressive species and the probability of observing pitting. An acceptable pitting factor was determined and was utilized for the development of a new chemistry envelope. The new chemistry envelope was compared to the envelope that was established for SCC and was determined to be bounding. Validation of the new chemistry envelope was performed via model simulations and comparison with historical experimental results and approaches to establishing chemistry envelopes. The new chemistry envelope will eventually be part of an overall assessment of the condition of the tanks and any changes made to the overall structural integrity program for the Hanford DSTs. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Development of a Semi-autonomous Miniature Rover for Inspection of Double Shell Tank Floors - 19575

Leaks in the primary liner of double-shell tank (DST) 241-AY-102 at Hanford have prompted the need for the development of inspection tools that are able to access confined spaces around and underneath the tanks. Last year, Florida International University (FIU) has continued to improve inspection tools that were developed in the previous years, to ensure that the resultant tools are able to overcome the challenges posed by the DSTs. Experimental testing conducted last year at the full-scale sectional mock-up of the DST's refractory slots revealed some shortcomings of the miniature rover, particularly in traversing over weld seams of different heights. The weld seams are the results of welded steel plate-joints for the DST. It was advised by the site engineers that the weld seams height could range from 6.35 mm - 9.525 mm (1/4 to 3/8 inches), and with 12.7 mm (1/2 inches) width. As the rover traverses over a weld seam, the gap between the rover's magnets and tank surface increases, causing the adhesive force to drop. The rover loses its surface contact if this adhesive force drops below its weight, jeopardizing the inspection tasks. In this paper, we present the numerical studies to calculate the minimum magnetic force required for the miniature rover to traverse over weld seams with different heights and the corresponding modifications to the rover design. Initial bench scale tests were conducted using a steel bar with 5 welds of varying heights. The testing validated the results from the simulation studies and established the rover's capability in traversing weld seams. Another challenge for the miniature rover is the use of a joystick or keypad for manual control. Utilizing these controls will likely be difficult for the operators due to the tight channels underneath the tank. Having a semi-autonomous navigational capability would alleviate the complexity of the inspection tasks and allow the operator to focus on the channel inspection. The goal is to implement lane-keeping capability, akin to that of a driverless car, for the inspection tool, so that it will maintain its relative position with respect to the wall of the channels. Am image processing pipeline has been developed using both the Robot Operating System (ROS) and OpenCV to process the image stream coming from the onboard camera, for the purpose of lane identification. Additionally, a PID controller has been implemented to navigate the miniature rover along the central location of the detected lane, while allowing the operator to control the tool's forward and backward motion. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Assessment of Cold Spraying Mild-Steel Powder onto Mild-Steel Substrate for Development of Waste Tank Repair System - 20515

Infrastructure for nuclear waste storage and processing (e.g., waste tanks, transfer pipelines, evaporators) at the U.S. Department of Energy (DOE) Hanford Site has been in service well beyond its original design life. Past corrosion control methods at Hanford for waste tanks have not been fully successful, as evidenced by leaks forming in tank AY-102, the first double-shell tank (DST) constructed, and significant degradation detected in the primary tanks of AP-102 and AY-101. Failure of infrastructure components can pose a significant risk to the environment, worker safety, and project schedules. Therefore, remotely deployable methods for repairing and extending the service life of the existing tank waste infrastructure are needed. Cold spray has been identified as a potential technique for performing in situ repairs and material buildup for life extension of waste storage and processing infrastructure. Cold-spray repair methods and technology are well-established and are used extensively by industry and the military for making repairs using dissimilar materials. Pacific Northwest National Laboratory is evaluating the process of making repairs using mild-steel powder applied to a mild-steel substrate to minimize the galvanic corrosion potential. This paper presents the initial results for a feasibility ('go/no-go') assessment as to whether low-density deposits with sound metallurgic bonds, to build-back steel plate material, can be achieved using existing commercial cold-spray equipment. An assessment of steel-on-steel deposit is necessary to determine if cold spray is a viable candidate for DST carbon steel plate restoration/repair and thus DST service life extension. Powder properties and preparation requirements have been investigated and operating conditions and parameters for depositing a cold-spray buildup of mild steel on a mild-steel substrate have been determined. Soundness of metallurgic bonding as a function of the operating parameters exercised and results from applying cold spray to lay a deposit over simulated small-diameter flaws in 1/2-inch mild-steel plate are presented. Application of in situ cold-spray repair to the DOE complex has the potential to reduce cost and schedule impacts associated with component failures and the need to procure and construct replacement infrastructure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Feasibility Study for Cathodic Protection of Waste Tanks at Hanford

The Hanford Nuclear Reservation site contains approximately 211 million liters of radioactive and chemically hazardous waste arising from nuclear weapons production, beginning with World War II, and continuing through the Cold War. The waste is stored in 177 carbon-steel underground storage tanks, of which 149 are single-shell tanks (SSTs) and the remaining are double-shell tanks (DSTs). The mission of an ongoing River Protection Project is to retrieve the waste from the underground storage tanks and then treat and immobilize (i.e., vitrify) it for disposal. Waste from the older SSTs is being progressively retrieved into the newer DSTs for storage pending treatment, immobilization, and disposal. Waste chemistry controls are in place to mitigate general corrosion, pitting corrosion, and stress corrosion cracking (SCC) and minimize corrosion risks to the carbon steel tank liners of DST at the Hanford Site. The chemistry control program focuses on preserving liner integrity while balancing the need for caustic/nitrite additions that have large downstream impacts on vitrification. Some of the DSTs store salt cake or sludge waste layers contain out-of-specification interstitial liquids that contact the primary tank bottom or sidewall. Remediation of such layers through chemical additions is not practical. At the present time, the most significant leak integrity concern at Hanford is for corrosion of the tank bottoms of DSTs where the solids layer is out of specification because of hydroxide ion depletion and consequently, pH values that are less than 12. Cathodic protection (CP) has been proposed as a possible way to protect the liners of such tanks against corrosion. The objective of this project was to investigate the feasibility of applying CP to Hanford DSTs to mitigate internal corrosion of the carbon steel tank primary liners. The scope of the project included (1) a literature review on the application of CP to storage tank systems, in general, and to waste tanks at the Savannah River Site (SRS) and Hanford, (2) a review of the finite element analysis (FEA) model recently developed to evaluate potentials for a DST, and (3) the development of a boundary element analysis (BEA) model for CP for a DST. Tank AN-107, one of the Hanford DSTs, was selected for this work because (1) the bottommost waste layer in the tank is out-of-specification, and (2) electrochemical and resistivity data, based on recent waste sampling and testing, are available for this tank. The overarching conclusion of this study is that, based on the available information, it is feasible to apply CP to mitigate internal corrosion of the primary liners of the Hanford DSTs. However, significant additional information and work are required before a CP system can be designed. Recommendations for next steps in the design of the CP system will be presented.

WIERSMA, BRUCE↗
DOE OSTI2026

Update on Integrity Monitoring, Prediction and Assessment, Corrosion Control, and Repair of the Hanford Storage Tanks

DOE has launched a multi-year research program with the focus of preserving and increasing available volume for waste storage at Hanford. The long-term availability and operability of the Hanford Double Shell Tanks (DST) is critical to the completion of the Hanford mission. Maintaining the integrity of the tank will involve having a technology for repair or refurbishment of a DST should the tank function be compromised by degradation, monitoring the tank for indications of accelerated degradation, developing a means for mitigating accelerated degradation, and evaluating options for increasing the storage capacity in the tank farm without constructing new tanks. The project work was started in the middle of 2024; significant progress has been made in the following four areas: (i) tank refurbishment using a high performance grout and an epoxy sealant layer system, (ii) developing a chemically and radiologically stable reference electrode, (iii) designing and implementing a cathodic protection system to mitigate underside corrosion of DST secondary shells, and (iv) exploring evaporation to increase waste storage capacity.

Shukla, Pavan [Savannah River National Laboratory ↗
DOE OSTI2026

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗