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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2025

5G integrated edge computing platform for efficient component monitoring in coal-fired power plants

This project developed a cutting-edge 5G-integrated edge computing framework to enhance operational efficiency and reliability in coal-fired power plants through real-time component monitoring and anomaly detection. The initiative focused on leveraging distributed machine learning, federated learning, and 5G-based dynamic network slicing to support scalable, fault-tolerant monitoring environments to meet the operational requirements in industrial control systems. With a Distributed Edge Computing Service (DECS) orchestration, this project enabled federated learning at edge for condition monitoring and introduced adaptive client selection strategies to minimize communication overhead. Scalable distributed training was achieved using the Horovod framework, thus enhancing performance across edge nodes. In the realm of 5G networking, the project designed and deployed reconfigurable, QoS-aware network slicing tailored for operational technology (OT) environments, integrating software-defined networks to bolster cyber-resilience and enabling dynamic slicing for federated learning workloads. A significant milestone was the development of a virtualized ICS environment with 5G core integration—which allowed elastic and fault tolerant distributed training on real-world datasets such as NASA Bearings, Hydraulic Systems, and TEP. To broaden the impact of the project, a TRL-3 virtualized ICS testbed for research and education was designed. This project engaged several graduate and undergraduate students to conduct research on the cutting-edge technology, and it resulted in one PhD dissertation, one MS thesis, and over 14 peer-reviewed publications. With the support of this project students also participated in national cybersecurity competitions to improve their professional development skills.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Southwest Wind Power R&D Test Site Development at the National Wind Technology Center (CRADA CRD-12-00472 Final Report)

Southwest Windpower, Inc. (SWWP) has been designing and distributing small wind turbines for more than 22 years and is the recognized global leader in the design, manufacturing and distribution of small wind systems (400-3000 watts). The company has been a pioneer in the development of wind technology and has built and shipped more than 170,000 wind turbines to over 120 countries worldwide. Headquartered in Flagstaff AZ, SWWP has sales representatives in over 88 countries. Applications for SWWP systems include residential homes, commercial properties, micro grids, remote cabins, telecom transmitters, offshore platforms, water pumping and sailboats. In addition, U.S. Department of Defense uses SWWP’s products in Forward Operating Bases (FOB’s), USGS uses them for remote monitoring of glacier movements and the CIA uses them to provide power seismic monitoring. Today, SWWP plans development of new technologies to address distributed energy market needs and become even more aggressive in international markets. This strategy includes extensive Research, Development, Demonstration & Deployment (RDD&D) activities to improve existing production line into more simple, reliable, and cost-effective wind turbine systems. Important part of such activities is the field testing of the new systems, which should provide: (i) validation of the reliable operation of hardware and software; (ii) validation of numerical models of the system and its components; (iii) field comparison of various control and optimization strategies; (iv) customized reliability testing; (v) customized monitoring and analysis testing; and (vi) IEC certification testing (vii) filed demonstration of system performance and reliability. Such field testing facility should encompass multiple towers and appropriate data acquisition systems. SWWP is exploring to move part of the engineering department to Colorado, and execute its RDD&D strategies in this new location. Partnership with NREL will provide great insights into SWWP’s RDD&D processes and more efficient commercialization by utilizing NWTC as the field testing site, and working close with NREL personnel. NWTC is ideally suited to strain the design. NREL is very experienced with customized and IEC testing. During this project, Southwest Windpower aims to improve the value proposition of distributed renewable energy, and make it a competitive choice in the energy markets. As of today, more then 170,000 small wind turbines, manufactured in the U.S., are installed in more then 180 countries. With the improved value proposition, Southwest Windpower wants to create and address new market needs, substantially increase its sales domestically and internationally, which should have positive impact on the creation of American jobs, competitiveness of U.S. economy, export or U.S. products, and the use of renewable energy.

17 WIND ENERGY↗

DOE OSTI2020

Parametric Design Study of a Power Electronics Package for Improving Solder Joint Reliability

The lifetime of a power electronics package is, to a large extent, determined by the reliability of its bonded interfaces under major loading conditions in an operational environment. Based on the application-level requirements of the package, bonded interface material is selected based on the results obtained from accelerated tests such as thermal cycling and power cycling. In addition to evaluating the reliability through accelerated tests, it is important to consider the impact of other component layers on the thermomechanical performance of the interface material, both from a material and geometric perspective. The co-efficient of thermal expansion (CTE) mismatch introduced by the use of different materials within a package and its structural design plays a critical role in determining the interface material reliability. In this paper, we present the results of a parametric modeling study of a power electronics package under thermal cycling in which the materials and geometric design of the different component layers were varied with respect to a baseline design to understand their impact on the reliability of the interface material. We chose the volume-averaged strain energy density per cycle computed at the corner region of the interface material as the metric for the reliability comparisons. Our results indicate that in addition to the CTE mismatch, the stiffness of individual component layers has a major impact on reliability. Among the different baseplates that we studied, aluminum silicon-carbide baseplates offered superior reliability over their copper and aluminum counterparts. We also found that the magnitude of the impact of stiffness variation—amongst the adjacent layers—on the reliability of the solder joint is dependent on the inherent CTE mismatch between the layers.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Parametric Design Study of a Power Electronics Package

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Enhancing Surface Finish of Additively Manufactured 316L Stainless Steel with Pulse/Pulse Reverse Electropolishing

To improve the reliable integration of additively manufactured (AM) metal components, there is an urgent need for surface finishing methods capable of processing rough, “as-printed” surfaces. Here, we present a new and scalable electropolishing (EP) technique for use on AM 316L stainless steel (SS) that is capable of achieving a surface roughness equivalent to a machined finish, with arithmetic mean heights (S a ) as low as 1.0 µm. This technique utilizes the sequential application of a new, NaCl/H 2 O pulse/pulse reverse (P/PR) EP step along with a conventional DC (direct current) EP step, where P/PR expands the capability of EP by removing roughness features > 1 µm, which has been previously unattainable with DC EP alone without substantial material removal. This is achieved by independently varying pulse parameters, such as pulse width and height, allowing more control over electrodynamic processes at the part-electrolyte interface. Additionally, P/PR EP resulted in higher smoothing efficiency, where a higher degree of smoothing was achieved with less material removal when compared with conventional DC EP alone. This minimizes unwanted change in geometry from excessive metal dissolution.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Component Identification of Solid Biomass Fuels Using Reflected Light Microscopy: Interlaboratory Study 2

As nations transition toward sustainable energy systems, biomass has become a vital component of global energy portfolios. Derived from organic materials such as wood, agricultural residues, forestry byproducts, and organic waste, biomass is a renewable energy source with significant environmental and economic benefits. Responsible biomass energy production can improve waste management, reduce emissions of greenhouse gases, and mitigate environmental pollution. However, as the diversity of biomass-derived fuels increases, robust quality assessment methods are essential to ensure their efficiency, safety, and minimal environmental impact. Reflected light microscopy (RLM) is one such technique with the potential to complement conventional physico-chemical analyses by enabling a rapid identification of material constituents and impurities. To refine this methodology and evaluate the reproducibility of solid biomass component identification using RLM, an interlaboratory study (ILS) was conducted. The study involved the recognition of 58 components across 45 photomicrographs, with the participation of 65 scientists and students from 25 countries. The participants faced high difficulty identifying some of the marked components, and as a result, the percentage of correct answers ranged from 19.0 % to 98.3 %, with an average correct identification rate of 62.7 %. The most challenging aspects of the identification process included distinguishing between woody and non-woody (agro) biomass, accurately identifying petroleum-derived materials, and differentiating agro biomass from inorganic matter. The results suggest that while RLM is an important tool for characterizing solid biomass, further development of methodology guidelines and training are necessary to enhance its effectiveness. Future research should prioritize preparing detailed, image-rich, microscopic morphological descriptions of biomass fuel components, which could improve the accuracy and reliability of using RLM in biomass fuel characterization.

09 BIOMASS FUELS↗

DOE OSTI2022

Piezo-optomechanical cantilever modulators for VLSI visible photonics

Visible-wavelength very large-scale integration photonic circuits have a potential to play important roles in quantum information and sensing technologies. The realization of scalable, high-speed, and low-loss photonic mesh circuits depends on reliable and well-engineered visible photonic components. Here, we report a low-voltage optical phase shifter based on piezo-actuated mechanical cantilevers, fabricated on a CMOS compatible, 200 mm wafer-based visible photonics platform. We show linear phase and amplitude modulation with 6 V π cm in differential operation, −1.5 to −2 dB insertion loss, and up to 40 dB contrast in the 700–780 nm range. By adjusting selected cantilever parameters, we demonstrate a low-displacement and a high-displacement device, both exhibiting a nearly flat frequency response from DC to a peak mechanical resonance at 23 and 6.8 MHz respectively, which, through resonant enhancement of Q ∼ 40, further decreases the operating voltage down to 0.15 V π cm.

Dong, Mark↗

DOE OSTI2023

Refined room-temperature equation of state of Bi up to 260 GPa

At room temperature, bismuth undergoes several structural transitions with increasing pressure before taking on a body-centered cubic (bcc) phase at approximately 8 GPa. The bcc structure is stable to the highest measured pressure and its simplicity, along with its high compressibility and atomic number, makes it an enticing choice as a pressure calibrant. Here, we present three data sets on the compression of bismuth in a diamond anvil cell in a neon pressure medium, up to a maximum pressure of about 260 GPa. The use of a soft pressure medium reduces deviatoric stress when compared to previous work. With an expanded pressure range, a higher point density, and a decreased uniaxial stress component, we are able to provide more reliable equation of state parameters. We also conduct density functional theory electronic-structure calculations that confirm that the bcc phase is energetically favored at high pressure.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Speckle correlation as a monitor of X-ray free-electron laser induced crystal lattice deformation

X-ray free-electron lasers (X-FELs) present new opportunities to study ultrafast lattice dynamics in complex materials. While the unprecedented source brilliance enables high fidelity measurement of structural dynamics, it also raises experimental challenges related to the understanding and control of beam-induced irreversible structural changes in samples that can ultimately impact the interpretation of experimental results. This is also important for designing reliable high performance X-ray optical components. In this work, X-FEL beam-induced lattice alterations are investigated by measuring the shot-to-shot evolution of near-Bragg coherent scattering from a single crystalline germanium sample. It is shown that X-ray photon correlation analysis of sequential speckle patterns measurements can be used to monitor the nature and extent of lattice rearrangements. Additionally, abrupt, irreversible changes are observed following intermittent high-fluence monochromatic X-ray pulses, thus revealing the existence of a threshold response to X-FEL pulse intensity.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

An Operational Resilience Metric for Modern Power Distribution Systems

The electrical power system is the backbone of our nations critical infrastructure. It has been designed to withstand single component failures based on a set of reliability metrics which have proven acceptable during normal operating conditions. However, in recent years there has been an increasing frequency of extreme weather events. Many have resulted in widespread long-term power outages, proving reliability metrics alone do not provide adequate energy security. As a result, researchers have focused their efforts on a new set of metrics based on the concept of resilience to ensure efficient operation of power systems during extreme events. A resilient system has the ability to resist, adapt, and recover from disruptions. Therefore, resilience has demonstrated itself as a promising concept for currently faced challenges in power distribution systems. In this work, we propose a real-time resilience metric for modern power distribution systems. The metric is an aggregation of the controllable assets adaptive capacity, or their temporal flexibility in real and reactive power. This metric gives information to the magnitude and duration of a disturbance which the system can respond to without having to drop loads or have stability issues in voltage or frequency. We demonstrate the impact to resilience in a case study under normal operation and during a power contingency on a microgrid. In the future, this information can be used by operators to make more informed decisions based on system resilience in an effort to prevent power outages.

42 ENGINEERING↗

DOE OSTI2024

System and Component Development of Particle-Based Pumped Thermal Energy Storage

Reliable power supply from variable renewable resources requires energy storage at various scales to overcome resource intermittency. Long-duration energy storage (LDES, 10-100 hours) can improve dispatchability and grid reliability with increasing levels of renewable power supply. Thermal energy storage (TES) has siting flexibility and the ability to store a large capacity of energy, and thus has the potential to meet the LDES need and provide charging and discharging durations beyond the economic capacity of conventional batteries. TES technology has evolved from concentrating solar thermal power (CSP) generation and is recognized as an economic large-scale energy storage method. A standalone electric-thermal energy storage system supporting renewable integration of wind and solar power without CSP solar field can firm renewable generation and boost overall grid resilience and security.

concentrating solar thermal power↗

DOE OSTI2020

Next Generation Hydrogen Station Composite Data Products: Retail Stations (Data through Quarter 3 of 2019)

This publication includes 98 composite data products (CDPs) produced for next generation hydrogen stations, with data through the third quarter of 2019. These CDPs include data from retail stations only and represent the following analysis categories: deployment, safety, maintenance and reliability, performance, cost, utilization, hydrogen quality, and component energy.

08 HYDROGEN↗

DOE OSTI2021

Next Generation Hydrogen Station Composite Data Products: Retail Stations; Summer 2020 (Q2 FY2020)

This publication includes 102 composite data products (CDPs) produced for next generation hydrogen stations, with data through the second quarter of 2020. These CDPs include data from retail stations only and represent the following analysis categories: deployment, safety, maintenance and reliability, performance, cost, utilization, hydrogen quality, and component energy.

08 HYDROGEN↗

DOE OSTI2020

Radiological Monitoring Plan for the Oak Ridge Y-12 National Security Complex: Surface Water

DOE Order 458.1 requires that dose estimates consider contributions from all facilities. In the Y-12 Radiological Monitoring Plan (RMP), surface water is monitored at points that reflect individual facilities, as well as at points that reflect the combined contributions of all facilities. This monitoring plan does not consider other potential routes (i.e., airborne releases and food chains). Thus, a complete determination of total effective dose (TED) cannot be made based on this plan alone. The other routes from Y-12, and all routes from other DOE facilities on the Oak Ridge Reservation (e.g., Oak Ridge National Laboratory (ORNL) and The Heritage Center), must be considered in order to satisfy DOE Order 458.1 requirements. Determination of TED from all sites and pathways is done through the use of dose-assessment models and is documented in the Annual Site Environmental Report. This monitoring plan provides adequate monitoring goals for Y-12 surface water releases to provide input of sufficient sensitivity and accuracy to reliably determine the Y-12 surface water component of the TED. The routine radiological monitoring program is designed to monitor effluents at four types of locations: (1) treatment facilities, (2) other point and area source discharges, (3) instream locations, and (4) production building roof run-off. With this sampling and analysis program, data will be obtained on primary point sources as well as on locations that represent the composite of other potential sources. This plan will be reviewed periodically to determine necessary modifications to the sampling frequencies, parameters, and locations. Modifications, if any, will be based on the analysis of the previous data and its effectiveness in satisfying the objectives of this plan. Appendix A contains graphs of the sum of the DCS fractions for locations and frequencies contained in a previous version of this plan. The data was collected from January 2009 through December 2019. Each sample was analyzed, and each result was divided by the appropriate DCS to compute a DCS fraction. These fractions were summed for all isotopes. According to DOE –STD-1196-2011, the annual average of these sums should be below 1.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Statement of Work: Toward AI-driven additive manufacturing for metal-ceramic composite structures

The project scope is to investigate the compatibility of various ceramic and metal powder composite feedstock development, implement AI algorithms for in-situ monitoring and parameter optimization of binder jet 3D printing to achieve reliable and robust metal/ceramic and/or ceramic/ceramic composite components, and create a generative design framework for heterogeneous composite structures incorporating metals and ceramic-based materials to achieve specific mechanical properties. Funded is the effort and travel by the faculty advisor at University of California Berkeley in support of the work of their students and the related collaborative research and development effort.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

LAROMance Grade 91 Model Integration in NEML2

New reactor designs are targeting higher operating temperatures for increased thermal efficiency when compared to the current fleet of light water reactors. Designing structural components for these high temperature environments with reliable long-term operations requires material models that can accurately capture the deformation mechanisms active in these environments. The LAROMance surrogate material models are based on a database of mechanistic crystal plasticity simulations for high-temperature conditions. Inputs to the LAROMance models reflect the microstructural pedigree of the material, like dislocation densities and precipitate contents. Based on the evolution of these microstructural features, the LAROMance model provides the engineering scale constitutive model response. The LAROMance model was recently parameterized for Grade 91, a high temperature alloy. In the present work, the Grade 91 LAROMance model is implemented in the New Material Model Library, version 2 (NEML2). NEML2 provides a modular way to build material models from smaller blocks and was developed to vectorize the material update to efficiently run on modern computational architectures with graphics processing unit accelerators. NEML2 constitutive models can be used in simulations based on the multiphysics object-oriented simulation environment (MOOSE). This report provides details on the implementation of the Grade 91 LAROMance model in NEML2 and its verification of engineering scale finite element simulations in MOOSE.

42 - ENGINEERING↗

DOE OSTI2026

Introduction to the Demonstration of Pyroshock Response Prediction Methods Using NASA ShockSat Data Virtual Collection

Mechanical shocks, particularly pyroshocks, are environments that all spacecraft and launch vehicles experience. Pyroshocks can be challenging design environments for space hardware because these events are often high frequency, high intensity transients. Furthermore, since design decisions must be made relatively early in the design phase, understanding, and accurately defining pyroshock excitation and the loads that it imparts on components is important to ensure the high reliability required of spacecraft and rockets. Here, general guidelines about shock transmission through spacecraft structures are provided in NASA and MIL handbooks and standards, but these are relatively broad guidelines, and recent studies have shown that more accurate and less-conservative predictions are needed. However, predicting shock response accurately is still a challenge because of the high frequencies in a pyroshock excitation.

Babuska, Vit [Sandia National Laboratories (SNL-NM↗

DOE OSTI2020

A New Concept for Kilotonne Scale Liquid Argon Time Projection Chambers

We develop a novel Time Projection Chamber (TPC) concept suitable for deployment in kilotonne-scale detectors, with a charge-readout system free from reconstruction ambiguities, and a robust TPC design that reduces high-voltage risks while increasing the coverage of the light-collection system and maximizing the active volume. This novel concept could be used as a far detector module in the Deep Underground Neutrino Experiment (DUNE). For the charge-readout system, we used the charge-collection pixels and associated application-specific integrated circuits currently being developed for the liquid argon (LAr) component of the DUNE Near Detector design, ArgonCube. In addition, we divided the TPC into a number of shorter drift volumes, reducing the total voltage used to drift the ionization electrons, and minimizing the stored energy per TPC. Segmenting the TPC also contains scintillation light, allowing for precise trigger localization and a more expansive light-readout system. Furthermore, the design opens the possibility of replacing or upgrading components. These augmentations could substantially improve the reliability and the sensitivity, particularly for low-energy signals, in comparison to traditional monolithic LArTPCs with projective-wire charge readouts.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗