Engineering topics

Bruckman, Laura S.

Publications and source records attributed to Bruckman, Laura S..

5 records

DOE OSTI2024

Image-Based Fracture Surface Defect Characterization Methods for Additively Manufactured Ti-6Al-4V Tested in Fatigue

Abstract Fatigue initiation in additively manufactured samples/parts often occurs at processed-induced defects such as lack-of-fusion (LoF), keyhole, or other morphological/microstructural defects that have unique characteristics and measurable qualities. Attempts at identifying and minimizing such defects have utilized optimized processing conditions along with in situ and ex situ characterization that includes metallography and/or X-ray computed tomography (XCT). This paper highlights the benefits of using fracture surface analyses to detect and quantify defects that may not be detected by metallography/XCT due to sectioning and resolution limits. In addition to using manual quantification of fatigue initiating LoF and keyhole defects on fracture surfaces, image-based machine learning using convolutional neural networks such as U-Net were also used to automate the process. Statistical analyses were used to identify the extreme cases of defects that initiated and accelerated fatigue and to model the distribution of defect size and shape characteristics to distinguish the type of defect. Initial results show agreement between trained machine learning models and ground truth data in defect segmentation, and the distributions of defect characteristics are distinguishable to particular process-induced defect types.

Materials Science↗

DOE OSTI2024

Using spatio-temporal graph neural networks to estimate fleet-wide photovoltaic performance degradation patterns

Accurate estimation of photovoltaic (PV) system performance is crucial for determining its feasibility as a power generation technology and financial asset. PV-based energy solutions offer a viable alternative to traditional energy resources due to their superior Levelized Cost of Energy (LCOE). A significant challenge in assessing the LCOE of PV systems lies in understanding the Performance Loss Rate (PLR) for large fleets of PV systems. Estimating the PLR of PV systems becomes increasingly important in the rapidly growing PV industry. Precise PLR estimation benefits PV users by providing real-time monitoring of PV module performance, while explainable PLR estimation assists PV manufacturers in studying and enhancing the performance of their products. However, traditional PLR estimation methods based on statistical models have notable drawbacks. Firstly, they require user knowledge and decision-making. Secondly, they fail to leverage spatial coherence for fleet-level analysis. Additionally, these methods inherently assume the linearity of degradation, which is not representative of real world degradation. To overcome these challenges, we propose a novel graph deep learning-based decomposition method called the Spatio-Temporal Graph Neural Network for fleet-level PLR estimation (PV-stGNN-PLR). PV-stGNN-PLR decomposes the power timeseries data into aging and fluctuation components, utilizing the aging component to estimate PLR. PV-stGNN-PLR exploits spatial and temporal coherence to derive PLR estimation for all systems in a fleet and imposes flatness and smoothness regularization in loss function to ensure the successful disentanglement between aging and fluctuation. We have evaluated PV-stGNN-PLR on three simulated PV datasets consisting of 100 inverters from 5 sites. Experimental results show that PV-stGNN-PLR obtains a reduction of 33.9% and 35.1% on average in Mean Absolute Percent Error (MAPE) and Euclidean Distance (ED) in PLR degradation pattern estimation compared to the state-of-the-art PLR estimation methods.

14 SOLAR ENERGY↗

DOE OSTI2023

Rear-Side Irradiance Simulation of Field PV Modules

Assessing the durability of photovoltaic (PV) module backsheet is critical to increasing module lifetime. Historically, laboratory-based accelerated testing has insufficient in predicting large-scale failures of commercial polymeric materials. Additionally, there is growing concern that standard condition tests do not reflect non-uniformities in field exposure, and that certain modules experience more severe degradation due to their location. Anisotropy in field exposures is installation-dependent and reflects different levels of exposure to irradiance due to mounting geometry, ground surface albedo, and climatic zone. "Bificial_Radiance" [1], simulates the amount of reflected irradiance on the Polyethylene Naphthalate (PEN) backsheet of a PV array located in Maryland. In our work, site specific weather data are gathered for the entire length of exposure for the modules. The total full-spectrum dose for the incident irradiance on the backsheet was then determined. The simulation results are integrated with historical field survey data to better understand real orld outdoor degradation.

backsheet↗

DOE OSTI2023

Image Processing Pipeline for Fluoroelastomer Crystallite Detection in Atomic Force Microscopy Images

Phase transformations in materials systems can be tracked using atomic force microscopy (AFM), enabling the examination of surface properties and macroscale morphologies. In situ measurements investigating phase transformations generate large datasets of time-lapse image sequences. The interpretation of the resulting image sequences, guided by domain-knowledge, requires manual image processing using handcrafted masks. Here this approach is time-consuming and restricts the number of images that can be processed. Her in this study, we developed an automated image processing pipeline which integrates image detection and segmentation methods. We examine five time-series AFM videos of various fluoroelastomer phase transformations. The number of image sequences per video ranges from a hundred to a thousand image sequences. The resulting image processing pipeline aims to automatically classify and analyze images to enable batch processing. Using this pipeline, the growth of each individual fluoroelastomer crystallite can be tracked through time. We incorporated statistical analysis into the pipeline to investigate trends in phase transformations between different fluoroelastomer batches. Understanding these phase transformations is crucial, as it can provide valuable insights into manufacturing processes, improve product quality, and possibly lead to the development of more advanced fluoroelastomer formulations.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Lifetime and Degradation Study of Poly(Methyl Methacrylate) via a Data-Driven Study Protocol Approach

We report to optimize and extend the service life of polymeric materials in outdoor environments, a domain knowledge-based and data-driven approach was utilized to quantitatively investigate the temporal evolution of degradation modes, mechanisms, and rates under various stepwise accelerated exposure conditions. Six formulations of poly(methyl methacrylate) (PMMA) with different combinations of stabilizing additives, including one unstabilized formulation, were exposed in three accelerated weathering conditions. Degradation was dependent on wavelength as samples in UV light at 340 nm (UVA) exposure showed the most yellowing. The unstabilized PMMA formulation showed much higher yellowness index values (59.5) than stabilized PMMA formulations (2–12). Urbach edge analysis shows a shift toward longer wavelength from 285 to 500 nm with increasing exposure time and an increased absorbance around 400 nm of visible region as the unstabilized samples increase in yellowing. The degradation mechanisms of PMMA were tracked using induced absorbance to dose at specific wavelengths that correspond to known degradation mechanisms. The degradation pathway of PMMA was modeled in a framework using network structural equation modeling (netSEM). netSEM showed changes in degradation pathway as PMMA transition stages of degradation.

36 MATERIALS SCIENCE↗