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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Hydrodynamic Test Requirements Process Improvements

Hydrodynamic testing at Los Alamos National Laboratory would benefit from a process improvement for the requirements process. Cameo was used as a digital solution for requirements management to allow Lead Engineers to track requirements more effectively. This was identified as a process improvement throughout this Capstone project. This report includes a project proposal, business case, literature review, methodology, project plan, data analysis, decision-making report, financial analysis report, discussion, and conclusion. Initially, this project focused on figuring out a solution for the hydrotest requirement process improvements. The scope narrowed to focus on the use of Cameo for requirement capture and management. During this Capstone, four tests had digital models produced for requirements management in Cameo. The initial model was the baseline, with core requirements used across the tests. Commonalities in tests were used and the core requirements allowed for process efficiencies. In the data analysis, it was seen that overall, the implementation of using Cameo for requirements resulted in a decreasing trend for both schedule and normalized cost. Tests have different complexity levels which is also a factor in how long the requirements process will take. Additional data is needed to continue analyzing process improvements. Through decisionmaking and financial analysis, the recommendation was to use Cameo for requirements process improvement. Multiple experts provided feedback for requirements that were then captured within models. Numerous tangible and intangible benefits were identified with this process improvement. For return on investment, the metric of success was schedule reduction, which was overall seen. Four tests were analyzed, so future analysis will be needed. There is also not a great financial risk because the main cost would be purchasing more licenses. Individuals must generate requirements whether using this software or not. Overall, training is needed to help improve the skillsets of Lead Engineers but is already being supported on a regular frequency. A desktop guide was started associated with explaining the process, however, it is a work in progress. The team plans on adding additional information in the digital models to help status when requirements are met using verification methods and artifacts. From working on this project an improved understanding of Cameo and requirements was the result. There are future opportunities to extend the usage for requirements management and progress will continue after this project.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Prototype Development for MBSE-Driven Digital Environment at Fermilab

Complex projects like Fermilab s accelerators and detectors involve thousands of interdependent components and requirements, making traditional documentation hard to keep consistent and often causing rework. Model-Based Systems Engineering (MBSE) tackles this by representing the system as a digital, queryable model. While widely used in aerospace and safety-critical industries, MBSE adoption has been limited elsewhere due to steep learning curves and high costs. This project investigates how a web-first, low-code MBSE stack can reduce those barriers and offer an accessible, unified source of truth for engineers and physicists.

Valle, Diego Pedro (ORCID:0009000865900663)↗
DOE OSTI2022

Regulatory Considerations for Nuclear Energy Applications of Digital Twin Technologies

Digital twins (DTs) in complex industrial and engineering applications have potential benefits that include increased operational efficiencies, enhanced safety and reliability, improved security engineering, reduced errors, faster information sharing, and better predictions. The interest in DT technologies continues to grow, and many of these advanced technologies are expected to experience rapid and wide industry adoption in the near future. Some of the potential application areas for DTs in the nuclear industry are design, licensing, plant construction, training simulators, predictive operations and maintenance, autonomous operation and control, failure and degradation prediction, physical protection modeling and simulation, and safety and reliability analyses. The Office of Nuclear Regulatory Research at the U.S. Nuclear Regulatory Commission (NRC) has initiated a future-focused research project to assess the regulatory viability of DTs for nuclear power plants and other NRC-regulated activities, such as fuel cycle facilities and operations. This report explores the potential impact of DT technologies in nuclear applications on NRC-regulated activities of interest. This report describes a nuclear DT system and its capabilities for nuclear power plant applications, followed by identification and discussion of some regulated activities that merit special consideration and present opportunities in implementing DT-enabling technologies and capabilities.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

A SIMPLE TOOL TO EVALUATE COLOR FOR LEGIBILITY AND DISTINGUISHABILITY WHEN DESIGNING DIGITAL DISPLAYS

Color is important in helping users effectively process information like text and symbols when performing tasks on digital displays. Interface designers in safety- and mission-critical industries often utilize human factors design guidelines and standards to make important design decisions like the use of color for legibility and distinguishability. However, such guidance sometimes requires additional interpretation and calculation to readily apply to the design question at hand. This work describes a simple tool that can be used to evaluate the adequacy of color choices from a palette for being legible or distinguishable. The tool eliminates having to manually convert colors to a readable format while providing a specific set of colors that are acceptable from select human factors standards. This paper provides an exemplary case study applied to a digital modification at a nuclear power plant to highlight how the tool may be used in safety and mission-critical industries.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Cyber-Informed Engineering for Design and Operations

Pursuant to the National Cyber-Informed Engineering (CIE) Strategy published in 2022, INL is leading the development of philosophy and practices to identify and mitigate the inherent risks of digital technology by including cybersecurity as a core element of engineering risk management. This presentation will provide an overview of why we need CIE and what it is, a discussion of the major implications of CIE for electric power systems design and operations, and an update on significant milestones and resources from the CIE program.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Synopsis of NREL's Automated Mobility District (AMD) Research Program and Associated Publications

An automated mobility district (AMD) envisions a system of integrated mobility options that serves major activity centers such as campuses, central business districts, and large medical facilities. The National Renewable Energy Laboratory (NREL) has been investigating the implementation prospects for fully automated passenger transport systems that are deployed to operate within dense urban settings. This document provides a synopsis of findings revealed over the last three phases of work, which have yielded insights into the creation and management of AMDs anticipated to use automated vehicle (AV) technology over the next decade. Phase I and Phase II tracked the deployment and lessons learned from 10 early-stage demonstrations of automated shuttle deployments, and their associated insights into the challenges for automated driving systems to achieve safe operations within district-scale deployments. Phase III began in-depth investigations of critical subsystem components, as automation, electrification, and on-demand service continue to converge within initial AMD operations. These directed studies focus on elements of electrification, curbfront/station management, the role of infrastructure sensing, and overall integration of AMD safety management in central, simultaneous coordination of multiple AMD fleets. Future research in AMDs includes systems engineering methodology (more frequently referred to as "digital twins") for planning, design, testing, and ongoing operation of AMDs; location (or co-location) of management functions; and human supervision and passenger communications for safety and security in unattended vehicles. The synopsis references the foundational research products (papers and presentations) that have been published through conference proceedings, journal articles, and NREL reports.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Digital Tuning of the Transition Temperature of Epitaxial VO 2 Thin Films on MgF 2 Substrates by Strain Engineering

Abstract Straining the vanadium dimers along the rutile c ‐axis can be used to tune the metal‐to‐insulator transition (MIT) of VO 2 but has thus far been limited to TiO 2 substrates. In this work VO 2 /MgF 2 epitaxial films are grown via molecular beam epitaxy (MBE) to strain engineer the transition temperature ( T MIT ). First, growth parameters are optimized by varying the synthesis temperature of the MgF 2 (001) substrate ( T S ) using a combination of X‐ray diffraction techniques, temperature dependent transport, and soft X‐ray photoelectron spectroscopy. It is determined that T S values greater than 350 °C induce Mg and F interdiffusion and ultimately the relaxation of the VO 2 layer. Using the optimized growth temperature, VO 2 /MgF 2 (101) and (110) films are then synthesized. The three film orientations display MITs with transition temperatures in the range of 15–60 °C through precise strain engineering.

Howard, Sebastian A.↗
DOE OSTI2024

Anomaly Detection in Materials Digital Twins with Multiscale ICME for Additive Manufacturing

Detecting anomaly in fatigue and fracture experimental materials science is an interesting yet challenging topic. The reasons are threefold. First, the anomalous microstructure feature that gives rise to structural failure is small, sometimes in the order of 10 -7 of the interrogated volume. This, in turn, results in a highly imbalanced classification problem in machine learning (ML). Second, the consequence is high, in the sense that the test specimen is destructed in such case. Third, the convolution between microstructure stochasticity and the small probability of void nucleation, growth, and coalescence makes failure and fracture a hard-to-predict and challenging problem in materials science due to its irreproducibility, even experimentally. In this paper, we developed a materials digital twin and applied anomaly detection methods to detect voids and anomaly in additive manufacturing (AM). The materials digital twin is driven by two integrated computational materials engineering (ICME) models, which are kinetic Monte Carlo (kMC) and crystal plasticity finite element method (CPFEM). In conclusion, we demonstrated that by using anomaly detection, it is possible to detect voids and other defects in materials digital twin, which paves way for future research in integrating materials digital twin with its physical counterpart.

ICME↗
DOE OSTI2022

Evaluation of Joint Cyber/Safety Risk in Nuclear Power Systems

This report presents an analysis of the Emergency Core Cooling System (ECCS) for a generic Boiling Water Reactor (BWR)-4 NPP. The Electric Power Research Institute (EPRI) developed Hazards and Consequences Analysis for Digital Systems (HAZCADS) process is applied to the ECCS and its subsystems to identify unsafe control actions (UCAs) which act as possible cyber events of concern. The analysis is performed for two design basis events: Small-break Loss of Coolant Accident (SLOCA) and general transients (TRANS), such as unintended reactor trip. In previous work, HAZCADS UCAs were combined with other cyber-attack analysis to develop a risk-informed approach; however, this was for a single system. This report explores advanced systems engineering modeling approaches to model the interactions between digital assets across multiple systems which may be targeted by cyber adversaries. The complex and interdependent design of digital systems has the potential to introduce emergent cyber properties that are generally not covered by hazard analyses nor formal nuclear Probabilistic Risk Assessment (PRA). The R&D and supporting analysis presented here explores approaches to predict and manage how interdependent system properties effect risk. To show the potential impact of a successful cyber-attack to formal PRA event tree probabilities, HAZCADS analysis was also used. HAZCADS was also used to model the automatic depressurization system (ADS) automatic actuation. This analysis extended to an integrated system analysis for common-cause failure (CCF). In this aspect, the HAZCADS analysis continued by analyzing plant design details for system connectivity in support of critical plant functions. A dependency matrix was developed to depict the integrated functionality of the interconnected systems. Areas of potential CCF are indicated. Future work could include adversary attack development to show how CCF could be caused, resulting in PRA events. Across the multiple systems that comprise the ECCS, the analysis shows that the change in such probabilities was very different between systems. This indicates that some systems have a larger potential risk impact from successful cyber-attack or digital failure, which indicates a need for these systems to have a higher priority for design and defensive measures. Furthermore, we were able to establish that a risk analysis using any arbitrary threat model establishes an ordering of components with regard to cyber-risk. This ordering can be used to influence the overall system design with an eye to lowering risk, or as a way to understand real-time risk to operational systems based on a current threat landscape. Expert knowledge of both the analysis process and the system being analyzed is required to perform a HAZCADS analysis. The need for a tiered risk analysis is demonstrated by the results of this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

AI-Enabled Discovery and Physics-Based Optimization of Energy Efficient Processing Strategies for Advanced Turbine Alloys (Final Technical Report)

In this project, the multi-organizational team of academic and industrial researchers from the University of Kentucky an aerospace and energy generation OEM partner has leveraged novel Digital Process Twin (DPT) models of process/structure interactions (i.e., process-induced surface integrity) to advance a paradigm of fully integrated computational materials engineering (ICME). Using efficient process models as the core of a digital process simulator for a reinforcement learning algorithm, the team has integrated industrial data and metrics of structure/performance/energy relationships and manufacturing-related energy metrics to optimize dynamic processing parameters for significantly improved life-cycle energy efficiency of advanced γ-TiAl low-pressure turbine (LPT) alloys, as indicated by a set of design relevant parameters (e.g., residual stresses and scrap rate). The key objective and anticipated outcome of the project was at least a 10% reduction in life-cycle embodied energy for a recently developed, γ-TiAl low-pressure turbine (LPT) alloy and nickel-based superalloy Inconel 718, through the adoption of the proposed AI-enabled process optimization approach. The final project outcomes significantly exceeded this original target, realizing manufacturing-related energy efficiency improvements of more than 130% for TiAl and up to 80% for Inconel 718. Rather than following the prevailing and highly inefficient empirical paradigm, the proposed study demonstrated the feasibility of adopting a digital, physics-based process design and optimization paradigm. The recurring need for manual intervention, rework, reinspection causes significant production bottlenecks and unnecessary expense associated with delivering the requisite component quality. The OEM partner, and turbine industry in general, expect to reap significant cost and resource savings if an AI-optimized set of parameters can be applied to specific machining operations. The technical scope of the proposed project involved the paving of a realistic path towards model-based and AI-enabled Integrated Computational Materials Engineering (ICME), and away from inefficient empirical process optimization and legacy manufacturing practices, which are no longer able to efficiently process novel high-performance turbine alloy materials. The project team will address the fundamental knowledge gap that currently exists within the ICME paradigm with respect to the process/structure/performance/energy impacts of finishing processes. While significant resources have been devoted to the ‘early stages’ of manufacturing, such as alloy design, primary and secondary processing, finishing processes have not been adequately integrated within ICME. To provide an actionable path towards model-based finishing process design (e.g., machining, burnishing, grinding, polishing), we will employ a novel AI-enabled process optimization paradigm, based on a computationally efficient, physics-based process simulator. Through limited experimental work to calibrate and validate our process simulator model via an advanced in-situ characterization technique and process optimization via reinforcement learning, the project will seek to demonstrate a viable alternative to the inefficient ‘legacy’ processing strategies, empirical testing and broad scope machining learning approaches, all of which fail to adequately consider complex process physics. The project team has identified an intermetallic γ-TiAl LPT alloy, which is currently being used as part of the OEM partner’s advanced gas turbine designs. This particular alloy poses significant manufacturing challenges during finishing operations, which limit the degree to which the current turbine design can be manufactured in an energy- and cost-efficient manner. Empirical testing and numerical modeling efforts to optimize processing parameters for γ-TiAl have not been able to resolve these manufacturing challenges, so the proposed physics-based AI-enabled optimization technology would offer a truly novel and transformative capability. The multi-organizational team of academic and industry experts from the UKY and the OEM partner will work together closely to demonstrate the analytical and experimental critical function and characteristic proof of concept of this novel approach.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Cross-domain digital twin architecture for predictive maintenance via machine learning and Large Language Models

This research introduces a comprehensive framework for creating and deploying a digital twin platform for continuous monitoring and predictive maintenance within industrial settings. Through utilizing advanced technologies, including Unreal Engine 5, Unity 3D, the Message Queue Telemetry Transport protocol, Random Forest machine learning algorithms, and Large Language Models (LLMs), we establish a platform that digitally reproduces physical equipment and translates digital controls into real-world actions. This facilitates preventive maintenance approaches and improves operational effectiveness. The digital twin platform gathers sensor data from operational equipment, analyzes it using machine learning, and delivers practical insights to prevent potential malfunctions and enhance equipment performance. Furthermore, the incorporation of a web portal enables efficient monitoring and access to historical data, educational materials, and equipment status information. Preliminary findings indicate that digital twins can transform industrial equipment management and maintenance methodologies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Experimental and theoretical study of the restrained shrinkage cracking of early age well cement

The shrinkage cracking occurring in oil & gas well cement material is a major factor that reduces the cement sheath integrity and impairs the durability of an underground well. Shrinkage mainly takes place in the early hydration period of the cement, and the resulting restrained shrinkage cracking can form a leaking network for oil & gas or carbon dioxide stored in an underground reservoir. It is thus important to understand the early age behavior of well cement and the leaking pathway formation in the well. This study describes the application of the digital image correlation (DIC) method as a tool to measure the strain development and crack distributions of well cement in the lab during early phase changes. A theoretical model is presented to calculate the stress distribution built up in the cement sheath during early ages of well cement hydration, which helps to interpret the experimental observations and determine the major factors influencing the cracking sequences. This study presents the whole hydration – drying shrinkage – and cracking mechanism of early age well cement under restrained ring conditions experimentally and theoretically. Finally, the results offer useful insights on the key material and geometric parameters which control the fracture of a well cementing structure.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Prioritizing ICS Beachhead Systems for Cyber Vulnerability Testing

Cyber Testing for Resilient Industrial Control Systems™ (CyTRICS™) is the Department of Energy’s (DOE’s) program for cybersecurity vulnerability testing, digital subcomponent enumeration, and forensic assessment. CyTRICS leverages best-in-class test facilities and analytic capabilities at six DOE National Laboratories and strategic partnerships with key stakeholders including technology developers, manufacturers, asset owners and operators, and interagency partners. During the program’s development, CyTRICS established a unique methodology for prioritizing digital components within operational technology (OT) and industrial control systems (ICS) in the Energy Sector Industrial Base (ESIB) for cyber vulnerability testing. The CyTRICS Prioritization Process leverages multiple characteristics of systems, components, and their contextual deployment to calculate a quantification of individual digital components for CyTRICS testing. The initial version of the CyTRICS Prioritization Process was premised largely upon the impact which could result to an industrial control system if the digital component under testing was compromised, either through malicious means, faulty engineering, or other modes. The worldwide compromise of the SolarWinds Orion platform, first reported in December 2020, through malicious interference with the digital patching cycle was a watershed event in cyber supply chain security. The SolarWinds compromised demonstrated the strategic importance of certain types of ubiquitous software, and the ability to generate widespread cybersecurity effects. To address this challenge and as a part of the Department of Energy’s response to the SolarWinds compromise, DOE’s Office of Cybersecurity, Energy Security, and Emergency Response (CESER) directed the National Laboratories to evolve the CyTRICS Prioritization Process methodology to encompass additional factors related to the strategic importance of digital components. CESER directed CyTRICS researchers to identify, characterize, and append strategic factors to the CyTRICS Prioritization Process to provide additional weight to these characteristics. National Laboratory expert researchers identified functionality, distribution, and platform characteristics for digital components in ICS and OT that they assessed would be likely targeted in strategic initial-access cyber attack. CyTRICS has termed these factors “ICS Beachhead Systems,” leveraging a definition first advanced by Schneider Electric, which is intended as a blanket term to encompass digital components, products, and systems in OT. This paper describes the ICS Beachhead Systems identified and the rationale for inclusion. As a next step in the research and refinement process, the National Laboratories will validate this initial set of characteristics against digital components evaluated by the CyTRICS program and current implementation of the CyTRICS Prioritization Process. After validation, CyTRICS researchers will then develop a scoring methodology to generate a quantitative score to assess the degree to which a digital component is characterized as an ICS Beachhead System. Finally, the National Laboratories will append this scoring to the existing CyTRICS Prioritization Process algorithm.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Detuned synchronized waveform averaging for reducing distortions due to sample interleaving

This invention introduces a method for optimally detuning the ratio of analog-to-digital (ADC) sample rate and trigger rate during waveform averaging to minimize the deleterious effects from sample interleaving. A prescription is described for determining the optimal detuning factor for the ADC or trigger rate in any scenario, depending on the number of ADC cores used and the limited tuning resolution of the clock rates for a specific implementation.

42 ENGINEERING↗
DOE OSTI2021

A Redundancy-Guided Approach for the Hazard Analysis of Digital Instrumentation and Control Systems in Advanced Nuclear Power Plants

We report digital instrumentation and control (I&C) upgrades are a vital research area for the nuclear industry. Despite their performance benefits, deployment of digital I&C in nuclear power plants (NPPs) has been limited. Digital I&C systems exhibit complex failure modes including common cause failures (CCFs), which can be difficult to identify. This paper describes the development of a redundancy-guided application of the Systems-Theoretic Process Analysis and fault tree analysis for the hazard analysis of digital I&C in advanced NPPs. The resulting Redundancy-Guided Systems-Theoretic Hazard Analysis (RESHA) is applied for the case study of a representative state-of-the-art digital reactor trip system. The analysis qualitatively and systematically identifies the most critical CCFs and other hazards of digital I&C systems. Ultimately, the RESHA can help researchers make informed decisions for how, and to what degree, defensive measures such as redundancy, diversity, and defense in depth can be used to mitigate or eliminate the potential hazards of digital I&C systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

How the NRC modernized its digital I&C infrastructure and where it goes from here

The NRC first formally developed infrastructure for the review of digital instrumentation and control (I&C) systems in the 1990’s. Although, the current U.S. fleet of nuclear power plants were originally designed and constructed with analog systems, the U.S. nuclear industry has for more that thirty years been working to upgrade these older systems with modern digital systems. Digital systems have many advantages but also pose different engineering challenges and need to be reviewed by the Nuclear Regulatory Commission (NRC) in a different way. Because of this the NRC started looking at its regulatory infrastructure to see if changes needed be made to support the expanded safe use of digital systems in nuclear power plants. Several efforts in the 1990’s included a review by the National Academies’ National Research Council, a review of the impact of potential new digital systems by the NRC staff as a result of advanced reactor designs and the NRC staff’s update to the I&C section of the Standard Review Plan (SRP) (Ref 1).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Digital Multiphase Composites via Additive Manufacturing

Abstract Mechanical properties of traditional engineering materials are typically coupled to each other, presenting a challenge to practitioners with multi‐dimensional material property requirements. In this work, continuous, independent control over multiple mechanical properties is demonstrated in composite materials realized using additive manufacturing. For the first time, composites additively manufactured from rigid plastic, soft elastomer, and liquid constituents are experimentally characterized, demonstrating materials which span four orders of magnitude in modulus and two orders of magnitude in toughness. By forming analytical mappings between relative concentrations of constituents at the microscale and resulting macroscale material properties, inverse material design is enabled; the method is showcased by printing artifacts with prescribed toughness and elasticity distributions. The properties of these composites are placed in the context of biological tissues, showing they have promise as mechanically plausible tissue mimics.

Smith, Lawrence T.↗