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Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗

Adapting Traditional Hazards Analysis Methods to Address Cyber Risks

Traditional hazards analysis (HA) methods, originally developed to address physical and operational risks, often fall short when it comes to identifying and mitigating cyber threats. These cyber threats pose unique and evolving risks to critical infrastructure and industrial control systems (ICS). This report explores the integration of Cyber-Informed Engineering (CIE) principles into existing HA methods to enhance their ability to address cyber-induced risks. CIE provides organizations with a practical, cost-effective approach to closing the gap between traditional HA methods and the need for cyber risk mitigation. By leveraging existing safety processes and controls, CIE allows users to examine and mitigate cyber vulnerabilities without overhauling existing HA methods. This report identifies areas where HA and CIE naturally align and where their approaches diverge. It emphasizes how CIE principles can be used to adapt HA methods, broadening their scope to include cyber risks and enabling the mitigation of cyber- induced impacts alongside traditional hazards and failure scenarios. This report examines how CIE can be applied across various HA methods—such as Hazard and Operability Studies (HAZOP), Probabilistic Risk Assessment (PRA), Failure Modes and Effects Analysis (FMEA), Systems-Theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), and Layers of Protection Analysis (LOPA). It provides strategies for integrating CIE to strengthen the identification, assessment, and mitigation of cyber-induced risks. The findings offer a structured entry point for organizations to embed CIE concepts into hazards and safety analyses, as well as broader engineering processes, ultimately supporting the design and operation of a more resilient infrastructure.

42 ENGINEERING↗

Spread Spectrum Digital Communications Modeling in Electronic Warfare Modeling and Simulation Software

This artifact is an intern project poster. The subject matter is modeling spread spectrum digital communications in electronic warfare modeling and simulation software produced by National and Homeland Security. It contains images of communications coverage analysis from the software, link budget terms, and image depicting the Wireless Spectrum Communications (WSComm) underlay control channel (UCC), and an image of a filter bank multicarrier spread spectrum (FBMCSS) signal. INL National and Homeland Security Electronic Warfare Modeling and Simulation software (EWMSS) is capable of modeling several digital and analog signal types, but it does not currently support spread spectrum techniques such as filter bank multicarrier spread spectrum (FBMCSS). FBMCSS modeling requires "processing gain," which is not present in EWMSS' link budget. Wireless Spectrum Communications (WSComm) Underlay Control Channel (UCC), a product of INL, employs FBMCSS and is modeled in EWMSS for this project. This research shows that by manually accounting for FBMCSS processing gain, EWMSS calculates a link margin that is within 0.023 dB of a link margin in an existing WSComm link budget. These link margins were based on free space path loss, an ideal propagation model. EWMSS has the capability to include terrain and other sophisticated propagation models in its calculations, giving it the potential to provide realistic, location-specific models of WSComm UCC if processing gain is accounted for.

97 MATHEMATICS AND COMPUTING↗

Laser scanner data processing and 3D modeling using a free and open source software

The laser scanning is a technology that allows in a short time to run the relief geometric objects with a high level of detail and completeness, based on the signal emitted by the laser and the corresponding return signal. When the incident laser radiation hits the object to detect, then the radiation is reflected. The purpose is to build a three-dimensional digital model that allows to reconstruct the reality of the object and to conduct studies regarding the design, restoration and/or conservation. When the laser scanner is equipped with a digital camera, the result of the measurement process is a set of points in XYZ coordinates showing a high density and accuracy with radiometric and RGB tones. In this case, the set of measured points is called “point cloud” and allows the reconstruction of the Digital Surface Model. Even the post-processing is usually performed by closed source software, which is characterized by Copyright restricting the free use, free and open source software can increase the performance by far. Indeed, this latter can be freely used providing the possibility to display and even custom the source code. The experience started at the Faculty of Engineering in Catania is aimed at finding a valuable free and open source tool, MeshLab (Italian Software for data processing), to be compared with a reference closed source software for data processing, i.e. RapidForm. In this work, we compare the results obtained with MeshLab and Rapidform through the planning of the survey and the acquisition of the point cloud of a morphologically complex statue.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Complexity and error potential of digital I and C - 135

Utilization of digital I and C for application in nuclear power plants led to a growing discussion on how to create methods for a probabilistic evaluation on such systems. Issues arise on the one hand due to a lack of commonly accepted models for quantitative evaluation of availability and reliability and on the other hand due to the integration of such models into the evaluation of reliability of an overall system. Nevertheless programmable and even more complex systems are implemented to satisfy growing functionality requirements. Therefore the question for a method to evaluate the reliability of systems based on software or on programmable logic became even more urgent. The approach described is based on the commonly accepted assumption that more complex designs are less reliable. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

WE-AB-209-05: Development of an Ultra-Fast High Quality Whole Breast Radiotherapy Treatment Planning System

Purpose: To enable near-real-time (<20sec) and interactive planning without compromising quality for whole breast RT treatment planning using tangential fields. Methods: Whole breast RT plans from 20 patients treated with single energy (SE, 6MV, 10 patients) or mixed energy (ME, 6/15MV, 10 patients) were randomly selected for model training. Additional 20 cases were used as validation cohort. The planning process for a new case consists of three fully automated steps:1. Energy Selection. A classification model automatically selects energy level. To build the energy selection model, principle component analysis (PCA) was applied to the digital reconstructed radiographs (DRRs) of training cases to extract anatomy-energy relationship.2. Fluence Estimation. Once energy is selected, a random forest (RF) model generates the initial fluence. This model summarizes the relationship between patient anatomy’s shape based features and the output fluence. 3. Fluence Fine-tuning. This step balances the overall dose contribution throughout the whole breast tissue by automatically selecting reference points and applying centrality correction. Fine-tuning works at beamlet-level until the dose distribution meets clinical objectives. Prior to finalization, physicians can also make patient-specific trade-offs between target coverage and high-dose volumes.The proposed method was validated by comparing auto-plans with manually generated clinical-plans using Wilcoxon Signed-Rank test. Results: In 19/20 cases the model suggested the same energy combination as clinical-plans. The target volume coverage V100% was 78.1±4.7% for auto-plans, and 79.3±4.8% for clinical-plans (p=0.12). Volumes receiving 105% Rx were 69.2±78.0cc for auto-plans compared to 83.9±87.2cc for clinical-plans (p=0.13). The mean V10Gy, V20Gy of the ipsilateral lung was 24.4±6.7%, 18.6±6.0% for auto plans and 24.6±6.7%, 18.9±6.1% for clinical-plans (p=0.04, <0.001). Total computational time for auto-plans was < 20s. Conclusion: We developed an automated method that generates breast radiotherapy plans with accurate energy selection, similar target volume coverage, reduced hotspot volumes, and significant reduction in planning time, allowing for near-real-time planning.

60 APPLIED LIFE SCIENCES↗

2015 Summary Report on Industrial and Regulatory Engagement Activities

The Advanced Instrumentation, Information, and Control (II&C) Systems Technologies pathway of the Light Water Reactor Sustainability(LWRS) Program conducts a vigorous engagement strategy with the U.S. nuclear power industry, including the nuclear operating companies, major support organizations, the Nuclear Regulatory Commission (NRC), and suppliers. The goal of this engagement strategy is to develop a shared vision and common understanding across the nuclear industry of the need for II&C modernization, the performance improvement that can be obtained, and the opportunities for collaboration to enact this vision. The primary means of engaging the nuclear operating companies is through a Utility Working Group (UWG), composed of utility representatives that participate in formal meetings and bi-monthly phone calls to provide input on nuclear plant needs and priorities for II&C technologies. Two working groups were initiated during FY 2015 to provide a means for UWG members to focus on particular technologies of interest. The Outage Improvement Working Group consists of eight utilities that participate in periodic conference calls and have access to a share-point web page for acccess to project materials developed in the Advanced Outage Control Center pilot project. In the area of computer-based procedures and automated work packages, the II&C Pathway has worked with the Nuclear Information Technology Strategic Leadership (NITSL) to set up a monthly conference call with interested utility members to discuss various aspects of mobile worker technologies. Twenty one technical and project reports were delivered to the UWG during FY 2015, reflecting the work of the II&C Pathway pilot projects during the year. Distribution of these reports is one of the primary means of transferring to the nuclear industry the knowledge and experience gained during the development of advanced II&C technologies in support of LWR sustainability. Site visits to discuss pilot project activities and future plans were made to Arizona Public Service, Exelon, Duke Energy, Pacific Gas & Electric, SCANA, Southern Nuclear, South Texas Project, STARS Alliance, Tennessee Valley Authority, and Xcel. Discussions were also held on the pathway goals and activities with major industry support organizations during FY 2102, including the Institute of Nuclear Power Operations (INPO), the Nuclear Information Technology Strategic Leadership (NITSL), the Nuclear Energy Institute (NEI), and the Electric Power Research Institute. The Advanced II&C Pathway work was presented at five major industry conferences and Informal discussions were held with key NRC managers at industry conferences. In addition, discussions were held with NRC senior managers on digital regulatory issues through participation on the NEI Digital I&C Working Group. Meetings were held with major industry suppliers and consultants, to explore opportunities for collaboration and to provide a means of pilot project technology transfer. In the international area, discussions were held with Electricite’ de France (EdF) concerning possible collaboration in the area NPP configuration control using intelligent wireless devices.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A novel adaptive discrete cosine transform-domain filter for gap-inpainting of high resolution PET scanners

Purpose: Several positron emission tomography (PET) scanners with special detector block arrangements have been developed in recent years to improve the resolution of PET images. However, the discontinuous detector blocks cause gaps in the sinogram. This study proposes an adaptive discrete cosine transform-based (aDCT) filter for gap-inpainting. Methods: The gap-corrupted sinogram was morphologically closed and subsequently converted to the DCT domain. A certain number of the largest coefficients in the DCT spectrum were identified to determine the low-frequency preservation region. The weighting factors for the remaining coefficients were determined by an exponential weighting function. The aDCT filter was constructed and applied to two digital phantoms and a simulated phantom introduced with various levels of noise. Results: For the Shepp-Logan head phantom, the aDCT filter filled the gaps effectively. For the Jaszczak phantom, no secondary artifacts were induced after aDCT filtering. The percent mean square error and mean structure similarity of the aDCT filter were superior to those of the DCT2 filter at all noise levels. For the simulated striatal dopamine innervation study, the aDCT filter recovered the shape of the striatum and restored the striatum to reference activity ratios to the ideal value. Conclusions: The proposed aDCT filter can recover the missing gap data in the sinogram and improve the image quality and quantitative accuracy of PET images.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

Cybersecurity for distributed energy resources and smart inverters

The increased penetration of distributed energy resources (DER) will significantly increase the number of devices that are owned and controlled by consumers and third parties. These devices have a significant dependency on digital communication and control, which presents a growing risk from cyber attacks. This paper proposes a holistic attack-resilient framework to protect the the integrated DER and the critical power grid infrastructure from malicious cyber attacks, helping ensure the secure integration of DER without harming the grid reliability and stability. Specifically, we discuss the architecture of the cyber-physical power system with a high penetration of DER and analyze the unique cybersecurity challenges introduced by DER integration. Next, we summarize important attack scenarios against DER, propose a systematic DER resilience analysis methodology, and develop effective and quantifiable resilience metrics and design principles. Lastly, we introduce attack prevention, detection, and response measures specifically designed for DER integration across cyber, physical device, and utility layers of the future smart grid.

97 MATHEMATICS AND COMPUTING↗

Primitive quantum gates for an S U ( 3 ) discrete subgroup: Σ ( 36 × 3 )

We construct the primitive gate set for the digital quantum simulation of the 108-element Σ ( 36 × 3 ) group. This is the first time a non-Abelian crystal-like subgroup of S U ( 3 ) has been constructed for quantum simulation. The gauge link registers and necessary primitives—the inversion gate, the group multiplication gate, the trace gate, and the Σ ( 36 × 3 ) Fourier transform—are presented for both an eight-qubit encoding and a heterogeneous three-qutrit plus two-qubit register. For the latter, a specialized compiler was developed for decomposing arbitrary unitaries onto this architecture. Published by the American Physical Society 2024

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Independent Review of the Proof-of-Concept Cyber100 Compass Cybersecurity Risk Tool

The U.S. Department of Energy (DOE) Office of Cybersecurity, Energy Security, and Emergency Response (CESER), and Office of Electricity (OE) commissioned the National Renewable Energy Laboratory (NREL) to develop a method and tool to enable electric utilities to understand and manage the risk of cybersecurity events that can lead to physical effects like blackouts. This tool, called Cyber100 Compass, uses cybersecurity data elicited from cybersecurity experts, then incorporates that data into a tool designed to be usable by cybersecurity non-experts who understand the system itself. The tool estimates dollar-valued risks for a current or postulated future electric power digital control configuration, in order to enable utility risk planners to prioritize among proposed cybersecurity risk mitigation options. With the development of the Cyber100 Compass tool for quantification of future cyber-physical security risks, NREL has taken an initial bold step in the direction of enabling and indeed encouraging electric utilities to address the potential for cybersecurity incidents to produce detrimental physical effects related to electric power delivery. As part of the Cyber100 Compass development process, DOE funded NREL to seek out an independent technical review of the risk methodology embodied in the tool. NREL requested this review from Sandia National Laboratories, and made available to Sandia a very late version of the project report, as well as NREL personnel to provide clarification and to respond to questions. This paper provides the result of the independent review activity.

97 MATHEMATICS AND COMPUTING↗

Transport Simulations on Scanning Transmission Electron Microscope Images of Nanoporous Shale

Digital rock physics is an often-mentioned approach to better understand and model transport processes occurring in tight nanoporous media including the organic and inorganic matrix of shale. Workflows integrating nanometer-scale image data and pore-scale simulations are relatively undeveloped, however. In this paper, a workflow is demonstrated progressing from sample acquisition and preparation, to image acquisition by Scanning Transmission Electron Microscopy (STEM) tomography, to volumetric reconstruction to pore-space discretization to numerical simulation of pore-scale transport. Key aspects of the workflow include (i) STEM tomography in high angle annular dark field (HAADF) mode to image three-dimensional pore networks in µm-sized samples with nanometer resolution and (ii) lattice Boltzmann method (LBM) simulations to describe gas flow in slip, transitional, and Knudsen diffusion regimes. It is shown that STEM tomography with nanoscale resolution yields excellent representation of the size and connectivity of organic nanopore networks. In turn, pore-scale simulation on such networks contributes to understanding of transport and storage properties of nanoporous shale. Interestingly, flow occurs primarily along pore networks with pore dimensions on the order of tens of nanometers. Smaller pores do not form percolating pathways in the sample volume imaged. Apparent gas permeability in the range of 10−19 to 10−16 m2 is computed.

42 ENGINEERING↗

Real-Time Digital Simulation of Inertial Response with Hardware-in-the-Loop Implementation on the CART3 Wind Turbine at the National Wind Technology Center

With increasing penetrations of wind power on electric grids, the stability and reliability of interconnected power systems may be impacted. In some countries that have developed renewable energy sources and systems, grid codes have been revised to require wind power plants (WPPs) to provide ancillary services to support the power system frequency in case of severe grid events. To do this, wind turbine generators (WTGs) should be deloaded to reserve a certain amount of active power for primary frequency response; however, deloading curtails annual energy production, and the market for this type of service needs to be further developed. In this report, we focus on the temporary frequency support provided by WTGs through inertial response. WTGs have potential to provide inertial response, but appropriate control methods should be implemented. With the implemented inertial control methods, wind turbines are capable of increasing their active power output by releasing some of their stored kinetic energy when a frequency excursion occurs. Active power can be temporarily boosted above the maximum power points, after which the rotor speed decelerates, and subsequently an active power output reduction restores the kinetic energy. In this report, we develop two types of models for wind power systems: the first is common, based on the wind power aerodynamic equation, and the power coefficient can be regressed using nonlinear functions; the second is much more complicated, wherein the wind turbine system is modeled using the Fatigue, Aerodynamics, Structures, and Turbulence Modeling (FAST) tool with several degrees of freedoms. A nine-bus test power system is built in Simulink and the Real-Time Digital Simulator, respectively, which are used to evaluate the frequency support performance of the WPPs. We implement two distinct types of inertial control methods in the modeled wind turbines: frequency-based inertial control (FBIC) and stepwise inertial control (SIC). We compare the performances of the two methods in terms of their frequency nadirs, rates of change of frequency, and recovery times. We conclude the results under various wind speeds and penetration cases, which provide insight into designing the inertial response of WTGs. Further, we discuss the impact of the parameters on the performance of the inertial control methods. We evaluate both the scaling factors for the FBIC method and the slope values for the TLIC methods. The simulation work shows the characteristics of different inertial responses compared to conventional synchronous generators. Based on the simulation results, we modify, improve, and test the inertial control methods under a more realistic wind turbine model based on FAST. We then validate the inertial responses under highly turbulent wind conditions generated by TurbSim, and we examine their influences on the turbine mechanical components. The extensive simulation proves the effectiveness of the proposed inertial control methods as well as the nine-bus test power system. We then reconsider the parameters. We rebuild the same test power system using Real time Simulator Computer Aided Design (RSCAD), and we implement the inertial control methods in the real Controls Advanced Research Turbine (CART3), which is prepared for the hardware-in-the-loop field-test simulation. After the setups for the hardware and software hybrid simulation platform are complete, the inertial response is further tested on a real wind turbine for the first time, in which CART3 release the controlled inertial response against the emulated frequency excursion, provided by the real-time simulated power system test bed in RTDS.

17 WIND ENERGY↗

Derivation of the Statistical Distribution of the Mass Peak Centroids of Mass Spectrometers Employing Analog-to-Digital Converters and Electron Multipliers

Here, the mass peak centroid is a quantity that is at the core of mass spectrometry (MS). However, despite its central status in the field, models of its statistical distribution are often chosen quite arbitrarily and without attempts at establishing a proper theoretical justification for their use. Recent work has demonstrated that for mass spectrometers employing analog-to-digital converters (ADCs) and electron multipliers, the statistical distribution of the mass peak intensity can be described via a relatively simple model derived essentially from first principles. Building on this result, the following article derives the corresponding statistical distribution for the mass peak centroids of such instruments. It is found that for increasing signal strength, the centroid distribution converges to a Gaussian distribution whose mean and variance are determined by physically meaningful parameters and which in turn determine bias and variability of the m/z measurements of the instrument. Through the introduction of the concept of “pulse-peak correlation”, the model also elucidates the complicated relationship between the shape of the voltage pulses produced by the preamplifier and the mean and variance of the centroid distribution. The predictions of the model are validated with empirical data and with Monte Carlo simulations.

97 MATHEMATICS AND COMPUTING↗

Adaptive Anomaly Detection for Dynamic Clinical Event Sequences

Over the past decade, health information technology (IT) has enabled the amount of digital information stored in electronic health records (EHRs) to expand greatly. However, according to some studies, hazards in health IT can lead to changes in clinical decisions, care processes, and care outcomes, as well as other issues. Thus, the effects of health IT hazards on patient safety have been at the forefront of recent patient safety research. Nonetheless, hazard detection in health IT remains a challenge. In this paper, the authors assume that safety-related issues in health IT would exhibit anomalous characteristics in EHR data. Although all hazards will exhibit some anomalous characteristics, not all anomalies can be regarded as hazards. The authors hypothesize that errors in health IT could lead to interruptions in the sequence of clinical actions. To this end, the problem of detecting anomalous sequences in big EHR data is considered. This paper focuses on dynamic event sequences, which are a series of clinical actions in motion. The authors propose an adaptive anomaly detection approach that uses higher-order network representation to detect anomalous sequences. Furthermore, the authors propose a contiguous subsequence anomaly detection approach that identifies abnormal subsequences in the detected anomalous sequences. The proposed approaches are tested by using synthetic and real-world EHR data. The proposed methods outperform existing state of the art anomaly detection techniques. To reduce the computational complexity associated with the operational implementation of the proposed approaches, the Apache Spark environment was leveraged, and a much shorter run time together with improved performance were achieved, especially for data with more than 60,000 sequences.

Niu, Haoran↗

ChatGPT and Other Large Language Models for Cybersecurity of Smart Grid Applications

Cybersecurity breaches targeting electrical substations constitute a significant threat to the integrity of the power grid, necessitating comprehensive defense and mitigation strategies. Any anomaly in information and communication technology (ICT) should be detected for secure communications between devices in digital substations. This paper proposes large language models (LLMs), e.g., ChatGPT, for the cybersecurity of IEC 61850-based communications. Multi-cast messages such as generic object oriented system events (GOOSE) and sampled values (SV) are used for case studies. The proposed LLM-based cybersecurity framework includes, for the first time, data pre-processing of communication systems and human-in-the-loop (HITL) training (considering the cybersecurity guidelines recommended by humans). The results show a comparative analysis of detected anomaly data carried out based on the performance evaluation metrics for different LLMs. A hardware-in-the-loop (HIL) testbed is used to generate and extract a dataset of IEC 61850 communications.

ChatGPT↗

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