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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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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Exploring PV Circularity by Modeling Socio-Technical Dynamics of Modules' End-of-Life Management: Preprint

The circular economy (CE) tackles environmental and resource scarcity issues by maximizing value retention in the economy. The concept implies design strategies such as reducing the use of materials or improving products’ durability and end-of-life (EOL) strategies such as reusing products and components and recycling materials. With an estimated 80 million tons of global cumulative EOL photovoltaic (PV) modules, applying CE principles to the PV industry could alleviate resource scarcity issues while also providing economic benefits. However, transitioning to a CE may imply changes in organizations and consumer behaviors. In this context, assessment of CE strategies may require accounting for behavioral change, a requirement that methods from complex system science such as agent-based modeling meet. Thus, this paper uses an agent-based modeling (ABM) approach to study circularity in the photovoltaics supply chain. Four types of agents are represented in the ABM: PV owners, installers, recyclers, and manufacturers. Moreover, five possible EOL options – including three CE strategies – are modeled. Departing from traditional techno-economic analysis, the model includes techno-economic factors as well as social factors to model EOL management decisions. Results show that each dollar decrease in the recycling fees improves the recycling rate by roughly 1.1%. However, excluding social factors underestimates the effect that lower recycling prices have on material circularity.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2022

Reconciling and Improving Formulations for Thermodynamics and Conservation Principles in Earth System Models (ESMs)

Abstract This paper provides a comprehensive derivation of the total energy equations for the atmospheric components of Earth System Models (ESMs). The assumptions and approximations made in this derivation are motivated and discussed. In particular, it is emphasized that closing the energy budget is conceptually challenging and hard to achieve in practice without resorting to ad hoc fixers. As a concrete example, the energy budget terms are diagnosed in a realistic climate simulation using a global atmosphere model. The largest total energy errors in this example are spurious dynamical core energy dissipation, thermodynamic inconsistencies (e.g., coupling parameterizations with the host model) and missing processes/terms associated with falling precipitation and evaporation (e.g., enthalpy flux between components). The latter two errors are not, in general, reduced by increasing horizontal resolution. They are due to incomplete thermodynamic and dynamic formulations. Future research directions are proposed to reconcile and improve thermodynamics formulations and conservation principles.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1979

Analysis of multiple pulse NMR in solids. III

The paper introduces principles which greatly simplify the process of designing and analyzing compound pulse cycles. These principles are demonstrated by applying them to the design and analysis of several cycles, including a 52-pulse cycle; this pulse cycle combines six different REV-8 cycles and has substantially more resolving power than previously available techniques. Also, a new 24-pulse cycle is introduced which combines three different REV-8 cycles and has a resolving ability equivalent to that of the 52-pulse cycle. The principle of pulse-cycle decoupling provides a method for systematically combining pulse groups into compound cycles in order to achieve enhanced performance. This method is illustrated by a logical development from the two-pulse solid echo sequence to the WAHUHA (Waugh et al., 1968), the REV-8, and the new 24-pulse and 52-pulse cycles, along with the 14-pulse and 12-pulse cycles. Proton chemical shift tensor components for several organic solids, measured by using the 52-pulse cycle, are reported without detailed discussion.

Burum, D. P.↗
DOE OSTI2022

A spatial superstructure approach to the optimal design of modular processes and supply chains

Modularity is a design principle that aims to provide flexibility for spatio-temporal assembly/disassembly and reconfiguration of systems. This design principle can be applied to multiscale (hierarchical) manufacturing systems that connect units, processes, facilities, and entire supply chains. Designing modular systems is challenging because of the need to capture spatial interdependencies that arise between system components due to product exchange/transport between components and due to product transformation in such components. In this work, we propose an optimization framework to facilitate the design of modular manufacturing systems. Central to our approach is the concept of a spatial superstructure, which is a graph that captures all possible system configurations and interdependencies between components. The spatial superstructure is a generalization of the notion of a superstructure and of a p-graph used in process design, in that it encodes spatial (geographical) context of the system components. Here, we show that this generalization facilitates the simultaneous design and analysis of processes, facilities, and of supply chains. Our framework aims to select the system topology from the spatial superstructure that minimizes design cost and that maximizes design modularity. We show that this design problem can be cast as a mixed-integer, multi-objective optimization formulation. We demonstrate these capabilities using a case study arising in the design of a plastic waste upcycling supply chain.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Small Reactors in Microgrids: Technology Modeling and Selection (Net-Zero Microgrid Program Project Report)

This report demonstrates the capabilities of the net-zero microgrid (NZM) Xendee platform for modeling an SR module with electricity, heat extraction and thermal storage in microgrids configurations. The model effectively captures the most important technical and economic considerations for SR technology specific analysis: cost and operational characteristics of SR technology and financial costs and incentives. The model can analyze multiple scenarios to establish metrics for cost-competitive and zero-carbon microgrids connected to the grid or completely isolated. The model is fully integrated within the Xendee platform for modeling and analysis of clean energy microgrids with storage and generation from renewable energy sources. The model captures the capabilities, constraints, and nuances of SR by incorporating parameters related to plant economics, design efficiency and performance, plant operation and component and fuel lifespan. The cost and operational parameters modeled in the SR module are specific to the technology selected for integration in the microgrid. Cost parameters recognize advanced nuclear technology for modular production and installation based on economies of scale from factory manufacture and related commissioning, and cost reduction through technology maturation—first-of-a-kind (FOAK) and nth-of-a-Kind (NOAK). The cost parameters include installation, operations and maintenance (O&M), fuel refueling cycle, and reactor life. Installation cost reflects economies of scale due to unit sizing at scale and colocation. O&M economies of scale for both fixed- and variable-cost fuel life-cycle costs are incurred at every refueling interval, with separate front- and back-end fuel costs, as well as waste-handling and disposition costs. This report investigates key characteristics of different SR technologies suitable for microgrid applications, including design principles, sizing, coolant properties, temperature ratings, fuel structures, and life-cycle considerations. This also includes fuel technologies applicable to these SR systems, alongside strategies for nuclear-waste and spent-fuel management and approaches to address safety, security, and proliferation challenges. Four primary groups of SR technologies are examined: water-cooled, liquid-metal-cooled, high-temperature gas-cooled, and molten-salt-cooled systems. In this report, an initial guideline for technology selection is established, aligning the characteristics of the technologies with the requirements of microgrids. The selection of technology in a microgrid is influenced by various factors, including financial capacity, location and accessibility, demand type and characteristics, reliability and resilience requirements, area constraints, and the lifespan of the microgrid. The types of electrical and non-electrical applications within the microgrid also play a significant role in technology selection. The characteristics of SRs, such as their smaller size, modularity, transportability, long refueling interval, improved safety features, ability to operate in autonomous or semi-autonomous mode, and provision of high-grade heat, are particularly appealing for microgrids. Furthermore, a list of considerations for implementing SRs in microgrids is outlined. The SR model is created to be continuously improved with the acquisition of actual data on investment and operational costs, experience with supply chains, production at scale, and field deployments. In the near term, performance data on applications in microgrids will become available from lessons learned from laboratory tests, such as those planned for the Microreactor Applications Research Validation and Evaluation Project (MARVEL), led by Idaho National Laboratory (INL). The SR model incorporates scenario data and known SR design specifications, enabling technoeconomic analysis for SR deployment in microgrids. It specifically considers the distinctive attributes of SRs as generators in technoeconomic studies. SRs can be modeled and analyzed with generation from renewable-energy sources, energy storage, and flexible loads over a range of functionality and applications. This offers a comprehensive tool for feasibility studies, scenario development, and sensitivity analysis for “what-if” consideration of any range of assumptions about SRs in microgrids and other aggregations of distributed-energy resources, including virtual power plants.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1989

Mobility power flow analysis of an L-shaped plate structure subjected to acoustic excitation

An analytical investigation based on the Mobility Power Flow method is presented for the determination of the vibrational response and power flow for two coupled flat plate structures in an L-shaped configuration, subjected to acoustical excitation. The principle of the mobility power flow method consists of dividing the global structure into a series of subsystems coupled together using mobility functions. Each separate subsystem is analyzed independently to determine the structural mobility functions for the junction and excitation locations. The mobility functions, together with the characteristics of the junction between the subsystems, are then used to determine the response of the global structure and the power flow. In the coupled plate structure considered here, mobility power flow expressions are derived for excitation by an incident acoustic plane wave. In this case, the forces (acoustic pressures) acting on the structure are dependent on the response of the structure because of the scattered pressure component. The interaction between the structure and the fluid leads to the derivation of a corrected mode shape for the plates' normal surface velocity and also for the structure mobility functions. The determination of the scattered pressure components in the expressions for the power flow represents an additional component in the power flow balance for the source plate and the receiver plate. This component represents the radiated acoustical power from the plate structure.

Cuschieri, J. M.↗
NASA NTRS1994

Compression strength of composite primary structural components

The linear elastic response is determined for an internally pressurized, long circular cylindrical shell stiffened on the inside by a regular arrangement of identical stringers and identical rings. Periodicity of this configuration permits the analysis of a portion of the shell wall centered over a generic stringer-ring joint; i.e., a unit cell model. The stiffeners are modeled as discrete beams, and the stringer is assumed to have a symmetrical cross section and the ring an asymmetrical section. Asymmetery causes out-of-plane bending and torsion of the ring. Displacements are assumed as truncated double Fourier series plus simple terms in the axial coordinate to account for the closed and pressure vessel effect (a non-periodic effect). The interacting line loads between the stiffeners and the inside shell wall are Lagrange multipliers in the formulation, and they are also assumed as truncated Fourier series. Displacement continuity constraints between the stiffeners and shell along the contact lines are satisfied point-wise. Equilibrium is imposed by the principle of virtual work. A composite material crown panel from the fuselage of a large transport aircraft is the numerical example. The distributions of the interacting line loads, and the out-of-plane bending moment and torque in the ring, are strongly dependent on modeling the deformations due to transverse shear and cross-sectional warping of the ring in torsion. This paper contains the results from the semiannual report on research on 'Pressure Pillowing of an Orthogonally Stiffened Cylindrical Shell'. The results of the new work are illustrated in the included appendix.

Johnson, Eric R.↗
NASA NTRS2004

Variable Step Integration Coupled with the Method of Characteristics Solution for Water-Hammer Analysis, A Case Study

One-dimensional water-hammer modeling involves the solution of two coupled non-linear hyperbolic partial differential equations (PDEs). These equations result from applying the principles of conservation of mass and momentum to flow through a pipe, and usually the assumption that the speed at which pressure waves propagate through the pipe is constant. In order to solve these equations for the interested quantities (i.e. pressures and flow rates), they must first be converted to a system of ordinary differential equations (ODEs) by either approximating the spatial derivative terms with numerical techniques or using the Method of Characteristics (MOC). The MOC approach is ideal in that no numerical approximation errors are introduced in converting the original system of PDEs into an equivalent system of ODEs. Unfortunately this resulting system of ODEs is bound by a time step constraint so that when integrating the equations the solution can only be obtained at fixed time intervals. If the fluid system to be modeled also contains dynamic components (i.e. components that are best modeled by a system of ODEs), it may be necessary to take extremely small time steps during certain points of the model simulation in order to achieve stability and/or accuracy in the solution. Coupled together, the fixed time step constraint invoked by the MOC, and the occasional need for extremely small time steps in order to obtain stability and/or accuracy, can greatly increase simulation run times. As one solution to this problem, a method for combining variable step integration (VSI) algorithms with the MOC was developed for modeling water-hammer in systems with highly dynamic components. A case study is presented in which reverse flow through a dual-flapper check valve introduces a water-hammer event. The predicted pressure responses upstream of the check-valve are compared with test data.

Turpin, Jason B.↗
DOE OSTI2020

Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Creation of pores and defects during laser powder bed fusion (LPBF) can lead to poor mechanical properties and thus must be minimized. Post-build inspection is required to ensure the printed parts contain acceptably low defect concentrations. These inspections are time consuming and costly, especially for large or complex parts. As a potential solution, in situ process monitoring can be used to detect the creation of defects, characterize local material behavior and predict expected component properties. However, the precise relationship between pore creation and in situ process monitoring still needs to be understood. In this work, high-speed infrared diode-based pyrometry and high-speed optical imaging signals were used to monitor LPBF printing of 446 stainless steel 316 L single tracks with varying laser power and velocity. Results indicate an increase in pyrometer signal and melt pool dimensions with increasing laser power and decreasing velocity in agreement with previous work. In addition, careful analysis of pyrometer signal reveals a distinct signature of the conduction-to-keyhole mode transition which was confirmed by metallography. Critically, pore defect initiation as characterized by ex situ X-ray radiography was correlated with in situ thermal monitoring signals to derive the probability of defect creation. Our results show that, in principle, a probabilistic prediction of pore formation can be achieved based on in situ high-speed pyrometry monitoring of the LPBF melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Unveiling X-ray absorption signatures of boron nitride via first-principles simulation and machine learning

Boron nitride (BN) allotropes hold great promise in many advanced applications ranging from optical and photonic devices to energy storage and battery systems to tribological components. The diverse functionalities of this material stem from BN’s highly tunable structural and electronic properties, which are governed by the versatile boron–nitrogen bonding configurations. Exploring the structural landscape of BN can unveil novel structures possessing unique properties suited for specific applications, therefore accelerating the design of next-generation advanced functional materials. In this work, we leverage boron K-edge X-ray absorption spectroscopy (XAS) as an effective probe for local structural features and chemical environments. A total of 210 BN crystal structures are generated via analogies to the extensive array of carbon allotropes, and XAS is simulated for each unique local motif within the resulting collection of structures. A mapping between structural features and spectral signatures was established by synergizing first-principle simulations with data-driven based post-analysis approaches. Specifically, we developed a neural network model that can satisfactorily predict spectra line shapes from local structural descriptors. Toward automatic spectroscopic interpretation of any new BN structures, supervised machine learning models, trained on this structure–spectrum dataset, can accurately infer local coordination environments from simulated XAS, highlighting the strength of this unique approach of combining high-fidelity first-principles simulation and machine-learning to accelerate target design of novel BN materials via rational understanding of local structure-spectrum correlations.

36 MATERIALS SCIENCE↗
NASA NTRS1950

Theoretical Investigation of a Proportional-Plus-Flicker Automatic Pilot

The proportional-plus-flicker automatic pilot operates by a nonlinear principle whereby a fast-acting flicker servomotor response is combined with a low-speed proportional servomotor response for the purpose of obtaining supersonic stability and control. Essentially, the autopilot maintains a zero reference about which the output is proportional to the input. However, a flicker response overrides this proportional response at a fixed angle of gimbal displacement on either side of the zero gyroscope reference. Therefore, in contrast to other high speed control systems, the design requirements are simplified because the two components of the proportional-flicker control system are easy to build separately and they can be combined in a relatively simple manner. By application of the proportional-flicker principle, satisfactory stability can be obtained by the proper adjustment of the variable factors in the autopilot mechanism; namely, the proportional gain, the amplitude of flicker control deflection, the autopilot time-lag factor (the time-lag between flicker and proportional operation), and the point in the range that the autopilot switches from a flicker to a proportional system. There is a possibility that these factors can be adjusted so that a more rapid response time (the time to reach steady state) is obtained with the non-linear proportional-flicker autopilot than with a purely linear proportional autopilot. For the main part of this analysis, the proportional part of the system is approximated by a zero-phase-lag proportional autopilot with the assumption that the control surface moves instantaneously at the point where the system switches from flicker to proportional. Good correlation is shown between the results obtained by this method and results obtained by using a close approximation of an actual autopilot transfer function for proportional autopilot operation.

Seaberg, Ernest C.↗
NASA NTRSDate not supplied

NASA Systems Engineering and Safety Culture: Aerospace Project Design and Implementation Challenges

Using Systems Engineering principles and the NASA Glenn Safety procedures and protocols, a rigorous method was developed to ensure safe testing and operation of a small, commercial off the shelf turbofan engine at the Aero-Acoustic Propulsion Laboratory (AAPL). The DGEN380 is a small, ~500-lbf thrust class, high-bypass, geared- turbofan engine with a separate flow nozzle. It is a modular, compact, lightweight turbofan with Full-Authority Digital Engine Control. It’s general characteristics make it an ideal candidate for utilization as a testbed for engine aero-acoustic technology maturation in a relevant performance environment. The DGEN380 is the core component of the DGEN Aero-propulsion Research Turbofan (DART) mobile test rig. The full presentation will describe the risk assessment and mitigation process applied to the DART by the project team. The identification and analysis of failure modes led to the development of risk mitigation plans, which include administrative, engineering, and physical controls for the safe operation of the DART test rig at the AAPL facility.

Systems Engineering, Aeronautics, safety↗
DOE OSTI2021

Open Radiation Monitoring: Histogram Builder Module Design

The Open Radiation Monitoring Project seeks to develop and demonstrate a modular radiation detection architecture designed specifically for use in arms control treaty verification (ACTV) applications that will facilitate rapid development of trusted systems to meet the needs of potential future treaties. A modular architecture can be used to reduce more complex systems to a series of single purpose building blocks, thereby facilitating equipment inspection and in turn building trust in the equipment by all treaty parties. Furthermore, a modular architecture can be used to control data flow within the measurement system, reducing the risk of "hidden switches" and constraining the amount of sensitive information that could potentially be inadvertently leaked. This report details the first revision of a prototype circuit that will convert analog pulses directly into a histogrammed data set for further processing. The circuit was designed with both spectroscopy and multiplicity analysis in mind but can, in principle, be used to reduce any raw data stream into a histogram. The number of output channels is limited, and the histogram bin ranges are user configurable to allow for non-uniform and discontinuous bins, which makes it possible to restrict the information being passed down stream if desired. Pulse processing relies entirely on analog circuitry and non- programmable logic, which enables operation without the need for a central processor or other programmable control unit. The circuit remains untested under the Open Radiation Monitoring project due to the closure of the sponsoring program. However, further development and testing is scheduled to take place in support of a purpose-built trusted verification system development effort known as COGNIZANT, which demonstrates the potential benefit of developing a suite of modular trusted system components.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1978

Stress analysis for structures with surface cracks

Two basic forms of analysis, one treating stresses around arbitrarily loaded circular cracks, the other treating stresses due to loads arbitrarily distributed on the surface of a half space, are united by a boundary-point least squares method to obtain analyses for stresses from surface cracks in places or bars. Calculations were for enough cases to show how effects from the crack vary with the depth-to-length ratio, the fractional penetration ratio, the obliquity of the load, and to some extent the fractional span ratio. The results include plots showing stress intensity factors, stress component distributions near the crack, and crack opening displacement patterns. Favorable comparisons are shown with two kinds of independent experiments, but the main method for confirming the results is by wide checking of overall satisfaction of boundary conditions, so that external confirmation is not essential. Principles involved in designing analyses which promote dependability of the results are proposed and illustrated.

Bell, J. C.↗
DOE OSTI2019

Effect of Ce{sup 3+} Ion on Structural and Hyperfine Interaction Studies of Co{sub 0.5}Ni{sub 0.5}Fe{sub 2−x}Ce{sub x}O{sub 4} Ferrites: Useful for Permanent Magnet Applications

Nanoparticles of Co{sub 0.5}Ni{sub 0.5}Fe{sub 2−x}Ce{sub x}O{sub 4} (where x = 0.0, 0.01, 0.015 and 0.02) ferrites are prepared by the modified solution combustion method using a mixture of fuels and are characterized to understand their structural, microstructural and magnetic properties. The X-ray diffraction is used to confirm the formation of a single-phase cubic spinel structure. The average crystallite sizes are calculated using the Scherrer formula and are found to be less than 50 nm. The microstructural features are obtained by the scanning electron microscopy, and the compositional analysis is done by using the energy-dispersive spectroscopy. The transmission electron microscopy (TEM) investigations show that the synthesized ferrites are made up of very fine spherical nanoparticles. The influence of a rare-earth element (Ce{sup 3+}) on the magnetic properties of the samples was studied using the Mössbauer spectroscopy. The Mössbauer spectroscopy reveals the formation of broadened Zeeman lines and quadrupole-split lines and the presence of the Fe{sup 3+} charge state at B sites in the samples. The quadrupole splitting shows that the orientation of the magnetic hyperfine field with respect to the principle axes of the electric field gradient was random. The magnetic hyperfine field values indicate that the A sites have more A-O-B superexchange interactions than the B sites. The coexistence of magnetic sextet and a doublet component on the room-temperature spectra suggests superparamagnetic properties of the nanoparticles. The low-temperature (15 K) Mössbauer spectroscopy explores the paramagnetic relaxation in the nanoparticles. The area under the sextet refers to Fe{sup 3+} concentrations in the tetrahedral and octahedral sites of the ferrite. This study confirms that the Ce{sup 3+} substitution of Fe{sup 3+} only for octahedron sites causes the decrease in Fe-O-Fe arrangement. The effect of Ce{sup 3+} doping on the magnetic properties of Co{sub 0.5}Ni{sub 0.5}Fe{sub 2}O{sub 4} is examined from the vibrating sample magnetometry (VSM) spectra. Saturation magnetization values are decreased initially and then increased, as result of Ce{sup 3+} doping. This can be explained by Neel’s two-sub-lattice model. Further, the value of coercivity is found to be increasing with increasing Ce{sup 3+} concentration. The obtained results of M-H loop with improved coercivity (from 851 to 1039 Oe) by Ce{sup 3+} doping of Co{sub 0.5}Ni{sub 0.5}Fe{sub 2}O{sub 4} demonstrate the usefulness for permanent magnet applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2008

Object Recognition using Feature- and Color-Based Methods

An improved adaptive method of processing image data in an artificial neural network has been developed to enable automated, real-time recognition of possibly moving objects under changing (including suddenly changing) conditions of illumination and perspective. The method involves a combination of two prior object-recognition methods one based on adaptive detection of shape features and one based on adaptive color segmentation to enable recognition in situations in which either prior method by itself may be inadequate. The chosen prior feature-based method is known as adaptive principal-component analysis (APCA); the chosen prior color-based method is known as adaptive color segmentation (ACOSE). These methods are made to interact with each other in a closed-loop system to obtain an optimal solution of the object-recognition problem in a dynamic environment. One of the results of the interaction is to increase, beyond what would otherwise be possible, the accuracy of the determination of a region of interest (containing an object that one seeks to recognize) within an image. Another result is to provide a minimized adaptive step that can be used to update the results obtained by the two component methods when changes of color and apparent shape occur. The net effect is to enable the neural network to update its recognition output and improve its recognition capability via an adaptive learning sequence. In principle, the improved method could readily be implemented in integrated circuitry to make a compact, low-power, real-time object-recognition system. It has been proposed to demonstrate the feasibility of such a system by integrating a 256-by-256 active-pixel sensor with APCA, ACOSE, and neural processing circuitry on a single chip. It has been estimated that such a system on a chip would have a volume no larger than a few cubic centimeters, could operate at a rate as high as 1,000 frames per second, and would consume in the order of milliwatts of power.

Duong, Tuan↗
DOE OSTI2025

Radsource Mr: Mixed Reality Planning Tool For Radioactive Recovery

The RadSource MR system leverages Meta Quest 3's advanced mixed reality capabilities to create a comprehensive spatial planning platform for end-of-life sealed radioactive source recovery operations. The application utilizes the Quest 3's high-resolution passthrough cameras and spatial mapping algorithms to generate accurate 3D environmental models. Core technical components include: (1) Real-time spatial measurement algorithms calculating distances, angles, slopes, and surface areas with sub-centimeter accuracy; (2) Virtual object placement system allowing users to position digital representations of recovery equipment (trailers, containment vessels, protective barriers) within the real environment; (3) Voice recording and annotation system for hands-free documentation in protective equipment; (4) 3D mesh capture and storage capabilities for post-operation analysis and regulatory documentation. (5) Procedure documentation is available for viewing in Mixed Reality, providing an innovative and convenient way to access the information during pre-visit and inspection activities. (6) Support for screen capture for the view for real world and virtual objects together to use it later for planning. The system integrates computer vision techniques for environmental understanding, spatial mathematics for precise measurements, and human-computer interaction principles optimized for hazardous environment operations. Data persistence allows teams to save and share planning sessions across multiple stakeholders while maintaining operational security requirements.

Khadka, Rajiv [Idaho National Laboratory (INL), Id↗
DOE OSTI2022

A Multi-Scale Computational Platform for Predictive Modeling of Corrosion in Al-Steel Joints (Final Report)

The research team proposed to develop innovative multi-scale models to predict corrosion and the resulting mechanical performances in aluminum-steel joints. The methods of joining considered are resistance spot welding, self-piercing riveting, and rivet-welding, all suitable for mass production applications. The multi-scale models integrate high throughput first-principle calculations based on density functional theory (DFT), high throughput calculation of phase diagrams (CALPHAD) modeling, and finite element method (FEM) simulations. These models are to be validated through laboratory experiments. Furthermore, the models are available as open source so as to enable scientists and engineers in the community to adapt and contribute to the development and application. The approaches rely on the research team’s extensive experience on the prediction of properties of individual phases at finite temperatures and variable compositions through DFT calculations, and our broad expertise on dissimilar material joining and their corrosion. The proposed computational framework enables high throughput computations for improved predictions of corrosion and the associated mechanical performance in dissimilar material joints, resulting in significant reduction in computational time needed by the current state-of-the-art methods. With the participation of researchers from three universities, an auto manufacturer, two manufacturing technology/equipment suppliers, and a software developer/vendor, the interdisciplinary research team applies the technical development on both phase-based modeling and laboratory experiments into the automobile body joining processes for validation and technology demonstration. The global cost of corrosion was estimated at about 3.4% of the global GDP in 2013. By using available corrosion control practices, it is estimated a saving between 15-35% of the cost of corrosion. In the U.S., more than $276 billion is spent repairing corrosion damage. Prediction of the corrosion and its impact on performance of the dissimilar material joints is critical for reducing the massive number of the current corrosion-based recalls for automobiles. Thus, the project goal is to develop models to enable predictive maintenance and end-of-life planning of multi-metal joints with risk of corrosion under different conditions such as exposure to high temperatures in summer and salt solutions in winter, quantified through its pH. An academia-industry consortium led by the University of Michigan and including Pennsylvania State University, University of Illinois Urbana-Champaign, University of Georgia, General Motors Company, Livermore Software Technology Corporation, and Optimal Process Technologies, LLC. created multi-scale models for prediction of corrosion in aluminum-steel joint structures such of them used in vehicle subassemblies – chassis and transmission systems. Starting from the first principle calculations, the team developed mathematical and data-driven models to predict the metallic components, which are formed during joining of two metals, for example aluminum and steel - a lightweight multilateral system which is currently used in more than 60% car bodies. These models were used for simulating chemical reactions that are happening when the joining metallic components are exposed to high temperatures and different pH values. The team was able to predict how the corrosion installs on the metallic components and how they lead to a sudden failure of components in cars. Newly developed machine learning algorithms combining Science, Technology, Engineering and Math disciplines, advanced finite element simulation and experimental validations have been integrated in a platform for prediction of the corrosion evolution and prediction the failure of joints under mechanical loadings and fatigue. Moreover, based on machine learning and inverse analysis, the team proposed solutions for designing new metallic alloys less susceptible to corrosion when joining multi-material assembles. An average of 4% error compared with experiments was achieved for the most common joints that are used in vehicle subassemblies.

36 MATERIALS SCIENCE↗