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DOE OSTI2022

Local Thermomechanical Processing for Improving Formability of High Strength Aluminum Sheets

Limited room temperature formability hinders the wide-spread use of high strength aluminum alloys in structural body-in-white parts. Stamping or extrusion at warm temperatures or from softer tempers are the current solutions. In this work, our approach is to start with age-hardened sheets from 7xxx and 6xxx family of alloys and improve their formability using local thermomechanical processing only in the regions demanding highest ductility in the forming processes. We achieved local formability improvements with friction stir processing and introduce another process named roller-bending as a concept and showed its feasibility through finite element simulations. Initial results from FSP indicated significant deformation in the processed zones with minimal sheet distortion. FSP also resulted in dynamically recrystallized, fine grained (d < 5 µm) microstructures in the processed regions with textures significantly different from the base material. This resulted in formability improvements of > 30% in 7085-T76 and > 50% in 6111-T6 alloys as measured by minimum bend radius (r/t) ratios established with V-bending tests performed at 90° and 180° bend angles. Based on the encouraging initial results, we envision applicability of these processes in both pre- and post-stamping stages through integration of the process tools as end-effectors to robotic arms.

Nasim, Wahaz↗

DOE OSTI2020

Aging of Concrete for the Evaluation of Repair Materials to Protect the Walls of the HCAEX Tunnel at Savannah River - 20301

H-Canyon, located in the Savannah River site, is a unique facility for chemical reprocessing of plutonium, highly-enriched uranium, and other radioactive materials. The exhaust gases of the H-Canyon are sent through the H-Canyon Exhaust (HCAEX) tunnel for contamination removal. Robotic inspections of the tunnel revealed significant degradation of the reinforced concrete structure that was associated with acid attack, and could compromise the structural stability of the tunnel. Thus, the identification and evaluation of potential repair materials that could be applied on the degraded walls to mitigate and prevent further degradation is of significant interest to the Department of Energy and the Savannah River representatives. This research effort has been divided into two phases: 1) Development and evaluation of aged concrete under accelerated aging conditions (which is the focus of this paper) and 2) Evaluation of potential repair materials applied on aged and non-aged concrete under simulated aggressive conditions. In order to develop and evaluate concrete samples exposed to accelerated aging conditions in simulated aggressive environments, a literature review of the HCAEX tunnel was conducted that included 1) characterization and extent of the concrete damage, 2) environmental conditions inside the tunnel and 3) primary deterioration mechanisms. In addition, potential coatings and/or repair materials for degraded concrete surfaces exposed to aggressive environments (primarily acidic) were selected from the literature review and the most common testing and measurements for evaluating acid attack phenomena, erosion, etc. were reviewed. From the literature review findings, a preliminary bench-scale test plan for the concrete aging was developed, including accelerated aging tests with aggressive conditions (acid fumes, humidity, etc.). Concrete samples were exposed to the aging accelerated conditions (e.g. immersion in acid solutions) and visual inspection, mass loss and pH change (acid solution) were recorded over time. Correlations between the visual inspection, mass loss and pH changes results and the aging time or the aging conditions were developed. Specimens submitted to the highest acid concentration showed the fastest and most intense degradation. The type of coarse aggregate (limestone) used for the concrete seemed to be the cause of the fastest aging observed, compared to the cement paste. The research findings created the foundation for the ongoing investigation, in which new concrete samples with a mix design similar to the HCAEX tunnel will be tested and will serve as the substrate for testing the selected coatings and /or repair materials. In this paper, the literature review and preliminary results from the aging tests are provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Detecting optical transients using artificial neural networks and reference images from different surveys

ABSTRACT We present a technique to detect optical transients based on an artificial neural networks method. We describe the architecture of two networks capable of comparing images of the same part of the sky taken by different telescopes. One image corresponds to the epoch in which a potential transient could exist; the other is a reference image of an earlier epoch. We use data obtained by the Dr. Cristina V. Torres Memorial Astronomical Observatory and archival reference images from the Sloan Digital Sky Survey. We trained a convolutional neural network and a dense layer network on simulated source samples and then tested the trained networks on samples created from real image data. Autonomous detection methods replace the standard process of detecting transients, which is normally achieved by source extraction of a difference image followed by human inspection of the detected candidates. Replacing the human inspection component with an entirely autonomous method would allow for a rapid and automatic follow-up of interesting targets of opportunity. The toy-model pipeline that we present here is not yet able to replace human inspection, but it might provide useful hints to identify potential candidates. The method will be further expanded and tested on telescopes participating in the Transient Optical Robotic Observatory of the South Collaboration.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

A New Method for Aerosol Measurement Using Wide-field Photometry

We present a new method to measure the vertical aerosol optical depth (VAOD) during clear nights using a wide-field imager—a CCD camera with a photographic lens on an equatorial mount. A series of 30 s exposures taken at different altitudes above the horizon can be used to measure the VAOD with a precision better than 0.008 optical depths within a few minutes. Such a measurement does not produce any light and is thus suitable for use at sites where other astronomical instruments are located. The precision of the VAOD measurement depends on the laboratory calibration of spectral properties of the system and of the response of the camera electronics to varying illumination levels, as well as careful considerations of the details of stellar photometry and modeling of the dependence of the measured stellar flux, the star color, and the position within the field of view. The results obtained with robotic setups at the future sites of the Cerenkov Telescope Array show good internal consistency and agreement with simultaneous measurements from a Sun/Moon photometer located at the same sites.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Dynamic Charging Rendezvous and Motion Planning for a Multi-AGV Team Including a Mobile Charging Host

Teams of automated battery-powered electric vehicles have the potential to execute complex mission tasks in off-road environments for agriculture, military, and other applications. Limited onboard energy reserves hinder their adoption in large-scale resource-constrained environments, where recharging is a necessity. It may be infeasible to install a network of static charging stations in off-road environments. For this reason, dedicated mobile host vehicles with charging capabilities are proposed as a means to increase range and capabilities of the multivehicle team. Here, in this study, we consider an ad hoc planning framework, where results from a high-confidence trajectory planner are leveraged to plan charging rendezvous between a host and other worker vehicles in a receding horizon fashion to provide high confidence that energy reserves will not be prematurely exhausted. The core problem is posed so as to minimize the impact of recharging on the mission in terms of task delays, overall energy utilization, and costs of fast charging. Through extensive Monte Carlo simulations of an off-road mission, we show a decrease in task delays without substantial increases in energy needs by updating the charging rendezvous plan during the mission. However, if updates are made too often, model mismatch may cause unnecessary cycling and mission failure.

Energy constraints↗

DOE OSTI2026

A compact, low-power epithermal neutron counter for lunar water detection

The detection and characterization of lunar water are critical for enabling sustainable human and robotic exploration of the Moon. Orbital neutron spectrometers, such as instruments on Lunar Prospector and the Lunar Reconnaissance Orbiter, have revealed hydrogen-rich regions near the poles but are limited by coarse spatial resolution and low counting efficiency. We present a compact, lightweight, and low-power epithermal neutron detector based on boron-coated silicon imagers, designed to probe subsurface hydrogen at decimeter scales from mobile platforms such as lunar rovers. This instrument leverages the high neutron capture cross-section of 10 B to convert epithermal neutrons into detectable α and 7 Li ions in a fully-depleted silicon imager, providing a unique event topology to identify neutrons while suppressing backgrounds. Monte Carlo simulations demonstrate that a 3 μm boron layer achieves optimal neutron detection efficiency, further enhanced with polyethylene moderation to improve sensitivity to the 0.4 eV–500 keV epithermal energy range. For a 10 cm 2 active area, the detector achieves sensitivity to H 2 O weight fractions as low as 0.01 wt% in a 15 minute measurement. This scalable, portable, low-mass design is well-suited for integration into upcoming Artemis and commercial lunar rovers, providing a transformative capability for in-situ resource prospecting and ground-truth validation of orbital measurements.

Detector modelling and simulations I (interaction ↗

DOE OSTI2015

Additive manufacturing of materials: Opportunities and challenges

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2026

A Robotic High-Throughput Grid-Search Platform for Mapping Phase Behavior in Triblock Copolymer–Homopolymer Blends

We present a high-throughput experimental investigation of the phase behavior in triblock copolymers (PS-b-PB-b-PS and PS-b-PI-b-PS) and polystyrene (PS) homopolymer blends as a function of homopolymer molecular weight (MW) and blend ratio. Using a robotic thin-film processing platform (NOVA) integrated with Grazing Incidence Small-Angle X-ray Scattering (GISAXS) and Atomic Force Microscopy (AFM), we systematically mapped the order–disorder transition (ODT) boundaries and domain spacing evolution across a broad MW range (4.0–101.3 kDa) with varying homopolymer loadings (10% to 90%). The results reveal three distinct regimes: low-MW homopolymers, corresponding to the wet-brush regime produced only gradual domain swelling before disordering at high blend ratios (weight fraction); medium-MW homopolymers, corresponding to thedry-brush regime induced significant domain spacing increase up to 80% followed by earlier disordering, while high-MW homopolymers led to macrophase separation with minimal changes in domain spacing. Additionally, coarse-grained molecular dynamics simulations confirmed our experimental finding that in the low-MW region, the PS homopolymer uniformly distributed in the PS domain. These findings demonstrate that homopolymer molecular weight critically governs both the extent of domain swelling and the onset of disorder in triblock copolymer systems. This high-throughput platform enables the rapid mapping of composition–morphology relationships and can be integrated with AI/ML tools for designing next-generation nanostructured polymers.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Binary operations on neuromorphic hardware with application to linear algebraic operations and stochastic equations

Abstract Non-von Neumann computational hardware, based on neuron-inspired, non-linear elements connected via linear, weighted synapses—so-called neuromorphic systems—is a viable computational substrate. Since neuromorphic systems have been shown to use less power than CPUs for many applications, they are of potential use in autonomous systems such as robots, drones, and satellites, for which power resources are at a premium. The power used by neuromorphic systems is approximately proportional to the number of spiking events produced by neurons on-chip. However, typical information encoding on these chips is in the form of firing rates that unarily encode information. That is, the number of spikes generated by a neuron is meant to be proportional to an encoded value used in a computation or algorithm. Unary encoding is less efficient (produces more spikes) than binary encoding. For this reason, here we present neuromorphic computational mechanisms for implementing binary two’s complement operations. We use the mechanisms to construct a neuromorphic, binary matrix multiplication algorithm that may be used as a primitive for linear differential equation integration, deep networks, and other standard calculations. We also construct a random walk circuit and apply it in Brownian motion simulations. We study how both algorithms scale in circuit size and iteration time.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

On Distributed Model-Free Reinforcement Learning Control with Stability Guarantee

Distributed learning can enable scalable and effective decision making in numerous complex cyber-physical systems such as smart transportation, robotics swarm, power systems, etc. However, the stability of the system is usually not guaranteed in most existing learning paradigms; and this limitation can hinder the wide deployment of machine learning in decision making of safety-critical systems. This paper presents a stability guaranteed distributed reinforcement learning (SGDRL) framework for interconnected linear subsystems, without knowing the subsystem models. While the learning process requires data from a peer-to-peer (p2p) communication architecture, the control implementation of each subsystem is only based on its local state. The stability of the interconnected subsystems will be ensured by a diagonally dominant eigenvalue condition, which will then be used in a model-free RL algorithm to learn the feedback control gains. The RL algorithm structure follows an off-policy iterative framework, with interleaved policy evaluation and policy update steps. We numerically validate our theoretical results by performing simulations on four interconnected sub-systems.

Mukherjee, Sayak↗

DOE OSTI2025

Dynamic Analysis of a Six-Cable Parallel Robot for Automated Panelized Building Retrofits

Cable-Driven Parallel Robots (CDPRs) are highly suitable for automated panelized building retrofits, thanks to their compact footprint and high payload-to-weight ratio. A common CDPR configuration featuring eight cables, where the anchors form a rectangular prism in front of the building facade, offers a large wrench feasible workspace and good control versatility. However, installing upper anchor points requires additional support structures, such as towers or beams, increasing setup complexity and posing logistical challenges in construction settings. To mitigate these challenges, we propose a six-cable CDPR model specifically designed for automated panelized building retrofits. Although the feasible workspace is limited, our analysis shows that the proposed CDPR adequately covers the critical areas required for panel installation. To validate that the six-cable system can effectively transport the end effector to the desired installation pose, we calculated optimal trajectories based on a constrained dynamic model. The simulation results of the six-cable CDPR demonstrate promising potential for automated panelized building retrofits, effectively balancing simplicity, cost-effectiveness, and functionality.

Liu, Yifang [ORNL] (ORCID:0000000190817417)↗

DOE OSTI2024

Mechanochemically responsive polymer enables shockwave visualization

Abstract Understanding the physical and chemical response of materials to impulsive deformation is crucial for applications ranging from soft robotic locomotion to space exploration to seismology. However, investigating material properties at extreme strain rates remains challenging due to temporal and spatial resolution limitations. Combining high-strain-rate testing with mechanochemistry encodes the molecular-level deformation within the material itself, thus enabling the direct quantification of the material response. Here, we demonstrate a mechanophore-functionalized block copolymer that self-reports energy dissipation mechanisms, such as bond rupture and acoustic wave dissipation, in response to high-strain-rate impacts. A microprojectile accelerated towards the polymer permanently deforms the material at a shallow depth. At intersonic velocities, the polymer reports significant subsurface energy absorption due to shockwave attenuation, a mechanism traditionally considered negligible compared to plasticity and not well explored in polymers. The acoustic wave velocity of the material is directly recovered from the mechanochemically-activated subsurface volume recorded in the material, which is validated by simulations, theory, and acoustic measurements. This integration of mechanochemistry with microballistic testing enables characterization of high-strain-rate mechanical properties and elucidates important insights applicable to nanomaterials, particle-reinforced composites, and biocompatible polymers.

Science & Technology - Other Topics↗

DOE OSTI2016

Forecasting the northern African dust outbreak towards Europe in April 2011: A model intercomparison

In the framework of the World Meteorological Organisation's Sand and Dust Storm Warning Advisory and Assessment System, we evaluated the predictions of five state-of-the-art dust forecast models during an intense Saharan dust outbreak affecting western and northern Europe in April 2011. We assessed the capacity of the models to predict the evolution of the dust cloud with lead times of up to 72 h using observations of aerosol optical depth (AOD) from the AErosol RObotic NETwork (AERONET) and the Moderate Resolution Imaging Spectroradiometer (MODIS) and dust surface concentrations from a ground-based measurement network. In addition, the predicted vertical dust distribution was evaluated with vertical extinction profiles from the Cloud and Aerosol Lidar with Orthogonal Polarization (CALIOP). To assess the diversity in forecast capability among the models, the analysis was extended to wind field (both surface and profile), synoptic conditions, emissions and deposition fluxes. Models predict the onset and evolution of the AOD for all analysed lead times. On average, differences among the models are larger than differences among lead times for each individual model. In spite of large differences in emission and deposition, the models present comparable skill for AOD. In general, models are better in predicting AOD than near-surface dust concentration over the Iberian Peninsula. Models tend to underestimate the long-range transport towards northern Europe. In this paper, our analysis suggests that this is partly due to difficulties in simulating the vertical distribution dust and horizontal wind. Differences in the size distribution and wet scavenging efficiency may also account for model diversity in long-range transport.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Extremum seeking for optimal control problems with unknown time-varying systems and unknown objective functions

We consider the problem of optimal feedback control of an unknown, noisy, time-varying, dynamic system that is initialized repeatedly. Examples include a robotic manipulator which must perform the same motion, such as assisting a human, repeatedly and accelerating cavities in particle accelerators which are turned on for a fraction of a second with given initial conditions and vary slowly due to temperature fluctuations. In this paper, we present an approach that applies to systems of practical interest. The method presented here is model independent; does not require knowledge of the objective function; is robust to measurement noise; is applicable for any set of initial conditions; is applicable to simultaneously controlling an arbitrary number of parameters; and may be implemented with a broad range of continuous or discontinuous functions such as sine or square waves. For systems with convex cost functions we prove that our algorithm will produce controllers that approach the minimal cost. For linear systems we reproduce the cost minimizing linear quadratic regulator optimal controller that could have been designed analytically had the system and cost function been known. We demonstrate the effectiveness of the algorithm with simulation studies of noisy and time-varying systems.

42 ENGINEERING↗

DOE OSTI2025

Sunny.jl: A Julia Package for Spin Dynamics

Sunny is a Julia package designed to serve the needs of the quantum magnetism community. It supports the specification of a very broad class of spin models and a diverse suite of numerical solvers. These include powerful methods for simulating spin dynamics both in and out of equilibrium. Uniquely, it features a broad generalization of classical and semiclassical approaches to SU(N) coherent states, which is useful for studying systems exhibiting strong spin-orbit coupling or local entanglement effects. Sunny also offers a well-developed framework for calculating the dynamical spin structure factor, enabling direct comparison with scattering experiments. Ease of use is a priority, with tools for symmetry-guided modeling and interactive visualization.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Time-of-Flight Estimation for Nondestructive Evaluation

Ultrasonic testing (UT) for nondestructive evaluation (NDE) is a critical entity necessary to resolve both the quality and precision questions of complex parts evolving from the classical approaches to the innovative additive manufacturing (AM) process. This modality provides the essential quantitative information for acceptance and potential flaw detectionof apart under investigation. A primary ingredient in UT besides the required precision robotic hardware for theacquisition of high-qualitymeasurement data is the underlying signal processing. It is here that much of the system performance capability resides. In this report,we discuss the basic steps in UT signal processing along with current capabilities that must be achieved in order to satisfy the criticaldemands of the various LLNL programs.In itsbasic foundations, signal processing is essentially the “extraction of critical information (signals) from noisy, uncertain data.” Clearly, in a perfect world the best signal processing is none---just make a reliable, noise-free, uncertainty-free, measurement. Unfortunately, even the best of systems is still straddled within the confines and limitations of physical instrumentation. With this in mind, we discuss the development of signal processing techniques toextract the desired UT information from noisy measurement data. We start with a discussion of a simple homogeneous representation of a “part” under investigation and its insonification by an ultrasonicexcitation from a physics-based perspective. Once developed, we briefly discussthe various choices of excitation signals and their tradeoffs.Next,we discuss a simulation approach employing simple models from the signal processing perspective and then move on to the development of the basic signal processing approach to ultrasonic signal processing all based on estimating the pulse arrival estimation. Starting with simple peak detection techniques, progressing to the processing workhorse so-called “matched-filter” and finally to the more sophisticated “model-based matched filter.”The underlying pre-and post-processing of noisy measurement data along with the application of these techniques are subsequently demonstrated on experimental ultrasonic data.Finally, we present some results for processing “weld” data when the ultrasonic excitation signal is not directly available.

42 ENGINEERING↗

DOE OSTI2023

Certifiably Correct Range-Aided SLAM

We present the first algorithm capable of efficiently computing certifiably optimal solutions to range-aided simultaneous localization and mapping (RA-SLAM) problems. Robotic navigation systems are increasingly incorporating point-to-point ranging sensors, leading state estimation which takes the form of RA-SLAM. However, the RA-SLAM problem is more difficult to solve than traditional pose-graph SLAM; ranging sensor models introduce additional non-convexity, unlike pose-pose or pose-landmark measurements, a single range measurement does not uniquely determine the relative transform between the involved sensors, and RA-SLAM inference is highly sensitive to initial estimates. Our approach relaxes the RA-SLAM problem to a semidefinite program (SDP), which we show how to solve efficiently using the Riemannian staircase methodology. The solution of this SDP provides a high-quality initialization for our original RA-SLAM problem, which is subsequently refined via local optimization, as well as a lower-bound on the RA-SLAM problem's optimal value. Our algorithm, named certifiably correct RA-SLAM (CORA), applies to problems comprised of arbitrary pose-pose, pose-landmark, and ranging measurements. Evaluation on simulated and real-world marine examples shows that our algorithm frequently produces certifiably optimal RA-SLAM solutions; moreover, even suboptimal estimates are typically within 1-2\% of the optimal value.

Papalia, Alan↗

DOE OSTI2018

Model-Based Ultrasonic SignalProcessing for the Nondestructive Evaluation of Additive Manufacturing Components

Ultrasonic testing (UT) for nondestructive evaluation (NDE) is a critical entity necessary to resolve both the quality and precision questions of complex parts evolving from the innovative additive manufacturing (AM) process. This modality provides the essential quantitative information for acceptance and potential flaw detection of the part under investigation. A primary ingredient in UT besides the required precision robotic hardware for the acquisition of high quality measurement data is the underlying signal processing. It is here that much of the system performance capability resides. In this report, we discuss the basic steps in UT signal processing along with current and future capabilities that must be achieved in order to satisfy the critical demands created by the AM process. In its basic foundations, signal processing is essentially the “extraction of critical information (signals) from noisy, uncertain data.” Clearly, in a perfect world the best signal processing is none---just make a reliable, noise-free, uncertainty-free, measurement. Unfortunately, even the best of systems is still straddled within the confines and limitations of physical instrumentation. With this in mind, we discuss the development of signal processing techniques to extract the desired UT information from noisy measurement data. We start with a discussion of a simple homogeneous representation of a “part” under investigation and its insonification by an ultrasonic excitation from a physics-based perspective. Once developed, we briefly discuss the various choices of excitation signals and their tradeoffs. Next we discuss a simulation approach employing simple models from the signal processing perspective and then move on to the development of the basic signal processing approach to ultrasonic signal processing all based on estimating the pulse arrival estimation. Starting with simple peak detection techniques, progressing to the processing workhorse so-called “matched-filter” and finally to the more sophisticated “model-based matched filter.” The underlying pre- and post-processing of noisy measurement data along with the application of these techniques are subsequently demonstrated on experimental ultrasonic data. Finally, we discuss some open problems in UT and suggest a much more sophisticated model-based approach expanding these revolutionary ideas and encompassing more realistic signal models that incorporate noise, jitter and other pertinent uncertainties into the processor.

36 MATERIALS SCIENCE↗