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DOE OSTI2022

3DBFSVBF (3D BatFinder Smart Video BioFilter and Multi-class BatFinder Smart Video BioFilter) [SWR-22-88]

Bats are notoriously difficult to study, therefore, identifying specific behavioral trends and the precise environmental conditions at the time of collision requires a monitoring solution that can reliably collect relevant data. To date, thermal infrared video surveillance has been extensively applied to study bats and has proven to be a powerful yet cumbersome tool. Current analytical approaches are time consuming because data processing data has not been fully automated. In the past, steps have been taken to record avian and bat activity in conjunction with complicated image processing techniques that separate species from other moving objects within the field of view (i.e. clouds and portions of the wind turbine). Once the videos are collected, the post-processing does not allow real time monitoring and identification, leading to a delay in both studying the behavior of these species and determining the effectiveness of any impact reduction strategy being studied. Moreover, object identification capability is lacking, thus limiting the usefulness of video data. To resolve these issues, we are using open source 3D computer vision and machine learning techniques allowing for automatic detection of objects in real-time with the ability to correlate these objects with environmental variables and recording the flight paths of each object. The machine learning has been trained on 3D data and allows for automated real-time data collection, identification and tracking, thereby eliminating the need for long and tedious post-analysis processing of the videos. This machine learning model is an added feature to the previous BatFinder Smart Video BioFilter and increases the accuracy of that systems classification by increasing the accuracy of identifying bats (90% accuracy) and insects (69% accuracy) to a 97% accuracy. There are two object classifier machine learning models, Binary and multi-classification. Binary object classifier labeled BatFinder_Smart_Video_BioFilter.h5 distinguishes between biological objects and non-biological objects. The main goal of this object classifier is to ignore the turbine blades while detecting biological object flying withing the rotor swept area of the turbine. Non-biological objects have a probability of 0 and biological objects have a probability of 1. Multi-classifier labeled Multiclass_BatFinder_Smart_Video_BioFilter.h5 distinguishes between bats, birds, insects and non-biological.

Yarbrough, John↗

DOE OSTI2022

BFSVBF (BatFinder Smart Video BioFilter) [SWR-22-87] and Multi-class BatFinder Smart Video BioFilter Keras

Bats are notoriously difficult to study, therefore, identifying specific behavioral trends and the precise environmental conditions at the time of collision requires a monitoring solution that can reliably collect relevant data. To date, thermal infrared video surveillance has been extensively applied to study bats and has proven to be a powerful yet cumbersome tool. Current analytical approaches are time consuming because data processing data has not been fully automated. In the past, steps have been taken to record avian and bat activity in conjunction with complicated image processing techniques that separate species from other moving objects within the field of view (i.e. clouds and portions of the wind turbine). Once the videos are collected, the post-processing does not allow real time monitoring and identification, leading to a delay in both studying the behavior of these species and determining the effectiveness of any impact reduction strategy being studied. Moreover, object identification capability is lacking, thus limiting the usefulness of video data. To resolve these issues, we are using open source computer vision and machine learning techniques allowing for automatic detection of objects in real-time with the ability to correlate these objects with environmental variables and recording the flight paths of each object. The code has gone through five rounds of development with images used to train the models. This advancement allows for automated real-time data collection, identification, and tracking, thereby eliminating the need for long and tedious post-analysis processing of the videos. We will discuss the two open source and publicly available machine learning models developed within this scope of this work: 1) a binary model with a 97.5% accuracy in identifying the difference between an object and an empty scene, including wind turbine and clouds; and 2) a multiple classification model with the capability of identifying the type of object detected: bats (90% accuracy), birds (83% accuracy), insects (69% accuracy) and non-biological (99% accuracy).

Yarbrough, John↗

DOE OSTI2018

Evaluation of microstructure stability at the interfaces of Al-6061 welds fabricated using ultrasonic additive manufacturing

Ultrasonic additive manufacturing (UAM) is a solid-state additive manufacturing process that uses fundamental principles of ultrasonic welding and sequential layering of tapes to fabricate complex three-dimensional (3-D) components. One of the factors limiting the use of this technology is the poor tensile strength along the z-axis. Recent work has demonstrated the improvement of the z-axis properties after post-processing treatments. The abnormally high stability of the grains at the interface during post-weld heat treatments is, however, not yet well understood. In this work we use multiscale characterization to understand the stability of the grains during post-weld heat treatments. Aluminum alloy (6061) builds, fabricated using ultrasonic additive manufacturing, were post-weld heat treated at 180, 330 and 580 °C. The grains close to the tape interfaces are stable during post-weld heat treatments at high temperatures (i.e., 580 °C). This is in contrast to rapid grain growth that takes place in the bulk. Transmission electron microscopy and atom-probe tomography display a significant enrichment of oxygen and magnesium near the stable interfaces. Based on the detailed characterization, two mechanisms are proposed and evaluated: nonequilibrium nano-dispersed oxides impeding the grain growth due to grain boundary pinning, or grain boundary segregation of magnesium and oxygen reducing the grain boundary energy.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Grinding of additively manufactured silicon carbide surfaces for optical applications

Many of the properties of Silicon carbide (SiC) are advantageous for optical applications, such as telescope mirrors and industrial laser systems. However, the base shapes of complex components are costly and difficult to manufacture. Leveraging additive manufacturing, near net complex components are readily processed. In this work, we investigate the post processing of additively manufactured SiC (AM SiC) compared to chemical vapor deposited (CVD) SiC. The specific grinding energy for the AM SiC was lower than CVD, however the trends were the same. A specular finish was observed on both materials but the AM SiC finish was limited due to residual porosity.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Using GIS for Processing, Analysis and Visualization of Hydrological Model Data - 16202

The Applied Research Center at Florida International University (ARC-FIU) is supporting the soil and groundwater remediation efforts of the U.S. Department of Energy's (DOE's) Savannah River Site (SRS) by developing a surface water model to simulate the hydrology and the fate and transport of contaminants and sediment in the Tims Branch watershed. Advances in ArcGIS software through the development of spatial GIS database (geo-database) technology, coupled with the development of data models such as ArcHydro which possesses a spatial relational database management system (RDMS) schema and relationship structure specific to hydrologic systems, provides modelers with tools and applications to assist in the processing, analysis and visualization of flow and contaminant transport data. In addition, the coupling of this type of geo-database structure with a numerical modeling package such as MIKE SHE/MIKE 11 can serve as an efficient tool that significantly reduces the time needed for data preparation. The MIKE modeling system has a geographic information systems (GIS) user interface built into its system that can directly use GIS data for model inputs. GIS-based hydrologic models can provide a spatial element that other hydrologic models lack. GIS is important for processing and analysis of large spatio-temporal datasets derived from multiple sources that are being used for setting up of models, model calibration and simulation of flow and contaminant fate and transport. GIS-based approaches in hydrological modeling can also provide the benefit of combining different layers of geographic data to create new integrated information which can be quite useful for creating dependent or independent hydrological variables. ARC-FIU has developed an ArcGIS geo-database to support the hydrological modeling work being conducted at SRS. The SRS geo-database was developed based on the ArcHydro and ArcGIS Base Map data models with modifications made for project specific input parameters. The significance of this approach was to ensure its replicability for potential application at other DOE sites. The SRS geo-database assists in the storage and management of GIS and time series data being used for hydrological model development at Savannah River Site. Other GIS tools such as ArcGIS Model Builder coupled with Python scripting have enabled the automation of many of the repetitive geo-processing tasks required for pre- and post-processing of the hydrological modeling data. Automation of many of the data processing tasks has facilitated faster and hence more complex analyses of field test data. The toolbox created is also a scalable and reusable application that can be implemented in other watersheds. This paper describes the use of ArcGIS tools for the pre-processing, spatial delineation and analysis of hydrological model data; for automation of repetitive geo-processing tasks; and for visualization of different hydrological components of the Tims Branch watershed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

NSTXU Diagnostic Disruption Dynamic Loading Represented by Response Spectra

This article presents the results of transient dynamic simulations of loads due to disruption eddy currents on the NSTXU vacuum vessel. Dynamic loading at diagnostic mounting locations is expressed as response spectra derived from the time history results of the dynamic structural simulations of a variety of disruption scenarios. The disruption simulations draw on a history of the project assessments of worst case disruptions for specific components. Major efforts to assess disruption loading have included the vacuum vessel which is the major structural support for the machine, as well as the passive plates (PPs), high harmonic fast wave (HHFW) antenna, and centerstack casing. Each one of these efforts included transient electromagnetic simulations producing time-dependent eddy current Lorentz loads (and in some cases halo loads) which then were applied to time-dependent structural dynamic analyses intended to obtain the proper dynamic amplification factors. In some instances, the EM model and structural model were identical allowing direct transfer of EM forces to the structural model. In other cases, the EM and structural model were not identical and the vector potential (VP) transfer method was used. The results files from these analyses were available (or re-run) to post process in ANSYS Classic time history postprocessor. In conclusion, the ANSYS command is used to create response spectra from time history data at desired points on the vessel.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

Utah FORGE: Phase 2C Seismic Observation and Ground Water Well Data and Well Locations

This submission contains the following data associated with Utah FORGE Phase 2C within the Roosevelt Hot Springs geothermal area: - An ArcGIS shapefile with well locations for wells 58-32, 78-32, 68-32, OH-3, OH-4, WOW-2, and WOW-3. Well 58-32 is the deep test well, wells 68-32 and 78-32 are seismic test wells, and the OH and WOW wells were used for ground water monitoring and temperature gradient logging. - Drilling reports, lithologic logs, daily drilling reports, cuttings logs, and drilling photos for seismic monitoring wells 78-32 and 68-32. - Raw and post-processing temperature logs for wells OH-3, OH-4, WOW-2, and WOW-4. The archive also includes a README.txt file, which contains an explanation of the data and how it was acquired, and a text file with coordinates for the logged wells.

15 GEOTHERMAL ENERGY↗

DOE OSTI2018

A study of microstructural evolution of Fe-18Cr-8Ni, Fe-17Cr-12Ni, and Fe-20Cr-25Ni stainless steels after mechanical alloying and annealing

In this study, high-energy mechanical alloying technique was used to produce nanocrystalline stainless steels of three different compositions from elemental powders. The microstructural evolution (grain growth and phase transformation) as a function of alloy compositions and annealing temperatures were investigated by room and high temperature x-ray diffraction experiments, transmission electron microscopy and focused ion beam microscopy. The results revealed that stainless steels with low nickel content (i.e., Fe-18Cr-8Ni) underwent a deformation-induced martensitic transformation during room temperature mechanical alloying. Deformation-induced martensitic transformation with increasing nickel content (i.e., Fe-17Cr-12Ni and Fe-20Cr-25Ni) would not be possible by room temperature milling but was created by high strain rate cryogenic processing, the degree to which was compositional dependent. Post process annealing induced the reverse transformation from martensite-to-austenite the ratio of which was found to be a factor of alloy composition and annealing temperature. The real time in-situ x-ray studies showed that the martensite-to-austenite reverse transformation was completed at around 600 °C and 800 °C for Fe-18Cr-8Ni and Fe-20Cr-25Ni steels, respectively. Microscopy studies revealed a significant enhancement in the resistance to grain growth for Fe-17Cr-12Ni steel over other compositions at elevated temperatures as high as 1200 °C. As such, cryogenic processing following by reverse martensitic transformation of high Ni containing alloys provides a pathway for developing higher heat resistant stainless steel alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact of the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii) systems development, (iv) material feedstock, (v) process planning, (vi) residual stress & distortion, (vii) post-processing, (viii) qualification of parts, (ix) supply chain and (x) business case. Furthermore, an open innovation network methodology was proposed to accelerate the development and deployment of new large-scale metal additive manufacturing technology with the goal of creating a new generation of high deposition rate equipment, affordable feed stocks, and large metallic components to enhance America’s economic competitiveness.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Cesium Ion Exchange with Crystalline Silicotitanate Literature Review

Crystalline silicotinante (CST) is planned for use as the ion exchange media to accomplish the cesium (Cs) decontamination of low-activity waste (LAW) in the current evolution of the Direct Feed Low-Activity Waste flowsheet. CST has yet to be deployed in a production-scale operating waste treatment facility on the Hanford Site. However, CST was used nearly 20 years ago to successfully treat approximately 270,000 gallons of supernatant waste in modular columns at Oak Ridge National Laboratory. As part of the technical maturation of the media for use at Hanford, an assessment of the state-of-the-art was performed by reviewing work in the technical literature. The review considered work from the U.S. Department of Energy (DOE) complex (i.e., national laboratories and government documents), the CST manufacturer, and the open technical literature nationally and internationally. The review focused on information most relevant to the caustic, high-sodium chemical environment typical of Hanford LAW. The topic areas explored in this literature review document include the following: CST structural and physical properties; Isotherm and batch contact data; Mass transport: intraparticle, interparticle, dispersion in the column; Column performance at multiple scales; Hydraulic performance; The effect of process conditions; Gas generation and retention behavior; Post-processing options for spent CST media The reviewed literature demonstrates that CST is well-suited for Cs decontamination of Hanford LAW. However, after consideration of the available literature data in these subject areas, some uncertainties regarding the application of CST for the treatment of Hanford LAW are identified and summarized. These uncertainties are areas where additional information may permit better prediction of CST performance or provide margin to facility operations and safety basis analyses.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

CFD Analysis of RLUOB Zone 1 HEPA Filter Plenum and Testing Manifolds

The purpose of this computational fluid dynamics (CFD) analysis is to ensure that Camfil Farr’s upstream and downstream injection and sampling manifolds can meet or exceed the requirements outlined in the ASME AG-1 1997 a(2000) Code on Nuclear Air and Gas Treatment for the testing of HEPA and adsorbent filters. This paper will present a numerical simulation of airflow in the Radiological Laboratory Utility Office Building (RLUOB) zone 1 HEPA filter plenum and testing manifolds using the commercial CFD software ANSYS FLUENT 2020R1. The CFD analysis focuses on the investigation of the air flow distribution and air-aerosol mixing uniformity. The evaluation was done for all steps of the modeling process: grid generation, physics setup, simulation, and post-processing. The mass flow rate in each section of the zone 1 injection and sampling manifolds is also reported.

42 ENGINEERING↗

DOE OSTI2023

TRACER Lightning Mapping Array Field Campaign Report

Our observational contribution to the U.S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility’s Tracking Aerosol Convection Interactions Experiment (TRACER) was the deployment of additional Lightning Mapping Array sensors to provide enhanced capability to the Houston Lightning Mapping Array (HLMA) during the TRACER intensive operational period. To that end, the Texas Tech University personnel (Professor Bruning and Dr. Brunner, and graduate students Jessica Souza, David Singewald, Stephanie Weiss, and Matthew Miller) deployed two portable LMA antennae at locations G and B shown in the map below. The map also shows the predicted lightning flash detection efficiency in black contours, as well as color-shaded very-high-frequency (VHF) source detection efficiency, which roughly corresponds to the sensitivity to lightning channel detail. Feeds from these sensors were integrated in the HLMA processing in real-time and in post-processing, partially leveraging National Science Foundation support through the TRACER campaign that supported the core HLMA, operated by Timothy Logan.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

A Python Tool for Reconstructing MCNP6 Particle Histories from an HDF5 PTRAC File [Slides]

A Python tool for converting the MCNP6 HDF5 PTRAC file to a list of Python trees is presented. The particle trees store MCNP6 simulated events for each history using parent-child relationships, which ensures that branching processes are accurately reproduced. A variety of post-processing scripts are presented and used in conjunction with the Python particle trees to make special tallies that are currently not available in the MCNP6 software and visualize the particle tracks.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Challenges in Postprocessing of Hybrid Manufacturing of Magnet Polymer Composites to Enhance the Energy Product of NdFeB Bonded Magnets

Bonded permanent magnets need to process magnetic filler particles and binder together which is a form of hybrid or composite manufacturing that needs to simultaneously process multimaterials. Polymer bonding of the permanent magnets decreases the energy product of the bonded magnets which varies with square of loading fraction of magnetic materials. However, due to high viscosity of bonding polymer prohibits loading higher than 80 volume % of magnetic materials in most efficient loading process such as compression molding. To further increase the loading of magnetic fraction in the bonded permanent magnets, it is expected to be beneficial to introduce a fraction of nonreacting thermally sacrificial polymer along with permanent bonding polymer in the least permissible of about 20 volume % of the polymer. This process of first adding the sacrificial polymer for higher processability for composites and later removing it via post processing such as heat treatment provides a simple example of inclusion of both the additive and the subtractive stages of hybrid manufacturing. These hybrid composite magnets can be heat treated to remove the sacrificial polymer to further increase the density and energy product which might require to implement hot isostatic pressing for compaction. Although the identification of such ideal polymer requires an extensive polymer chemistry research, we have compression molded several permanent bonding polymers such as nylon, polycarbonate (PC) and polyphenyl sulfide (PPS) and potential sacrificial polymer such as polyoxymethylene (POM), polystyrene (PS), and Acrylonitrile Butadiene Styrene (ABS) and heat treated to remove the sacrificial polymers. It is discovered that oxygen free low temperature pyrolizable polymers could be the potential candidates for increasing the magnet particles loading for achieving high energy products.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Large Scale Metal Additive Techniques Review

In recent years additive manufacturing made long strides toward becoming a main stream production technology. Particularly strong progress has been made in large-scale polymer deposition. However, large scale metal additive has not yet reached parity with large scale polymer. This paper is a review study of the metal additive techniques in the context of building large structures. Current commercial devices are capable of printing metal parts on the order of several cubic feet compared to hundreds of cubic feet for the polymer side. In order to follow the polymer progress path several factors are considered: potential to scale, economy, environment friendliness, material properties, feedstock availability, robustness of the process, quality and accuracy, potential for defects, and post processing as well as potential applications. This paper focuses on current state of art of large scale metal additive technology with a focus on expanding the geometric limits.

Nycz, Andrzej↗

DOE OSTI2024

Gas pore correlations in laser powder bed fusion of Al6061

Additive manufacturing (AM) of metal materials based on powder bed fusion technology is widely used now in many industries. A known limitation of this type of manufacturing is the formation of gas pores in the bulk material. Here we present a combined X-ray imaging and mid-infrared pyrometry study of pore formation in side-by-side tracks of Al6061 for different processing conditions using both in-situ and post-processing analysis. By carefully quantifying the distributions and correlations of pore positions, we show that an existing pore in one track often catalyzes the formation of another pore in an adjacent track. In a raster scan strategy commonly used to construct bulk material, this phenomenon has the result of forming subsurface perforations, or lines of pores transverse to the scanning direction in a rastered patch. If controlled, this effect can be eliminated to improve the yield strength of the build, or exploited to create programmable failures for specific purposes.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Microstructural heterogeneities in additively manufactured refractory alloy C103 and their implications for room and elevated temperature mechanical behavior

Considering the vast component design space enabled by fusion-based additive manufacturing (F-BAM) processes, e.g., directed energy deposition (DED), the scale-up manufacturing of Nb-alloys with F-BAM is advantageous for structural applications. However, varying thermokinetic parameters-induced microstructural heterogeneities are prevalent within the F-BAM processed alloys. Such microstructural heterogeneities can have significant implications for the room and elevated temperature mechanical behavior. While a few studies investigating F-BAM processed alloy C103 are available, none of these studies investigate the microstructural heterogeneities – including those associated with solidification growth modes and second phase particles – and the effect thereof on the mechanical behavior. To this end, we investigate the microstructurally heterogeneous regions with varying solidification growth morphologies, segregation behavior, and second phase particle attributes within the laser-DED processed alloy C103. The implications of such heterogeneous regions for room- and elevated-temperature tensile behavior and damage mechanisms are revealed. Particularly, the interface between the cellular and planar region is identified as susceptible to deformation localization. The implications of hot isostatic pressing (HIP) for the consolidation behavior, microstructural evolution, and resulting mechanical behavior are also discussed. Although the recrystallization and grain growth led to a reduced yield strength in the HIPed condition, the homogenization of microstructure alleviated the deformation localization sites, such as the planar/cellular interface within the melt pool. The homogenized microstructure alongside the enhanced consolidation upon HIP led to an enhanced elongation to failure. Findings establish microstructural design considerations in F-BAM processed Nb alloys and also facilitate design of post-processing heat treatments for achieving improved mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Bragg Spot Finder (BSF): a new machine-learning-aided approach to deal with spot finding for rapidly filtering diffraction pattern images

Macromolecular crystallography contributes significantly to understanding diseases and, more importantly, how to treat them by providing atomic resolution 3D structures of proteins. This is achieved by collecting X-ray diffraction images of protein crystals from important biological pathways. Spotfinders are used to detect the presence of crystals with usable data, and the spots from such crystals are the primary data used to solve the relevant structures. Having fast and accurate spot finding is essential, but recent advances in synchrotron beamlines used to generate X-ray diffraction images have brought us to the limits of what the best existing spotfinders can do. This bottleneck must be removed so spotfinder software can keep pace with the X-ray beamline hardware improvements and be able to see the weak or diffuse spots required to solve the most challenging problems encountered when working with diffraction images. In this paper, we first present Bragg Spot Detection (BSD), a large benchmark Bragg spot image dataset that contains 304 images with more than 66 000 spots. We then discuss the open source extensible U-Net-based spotfinder Bragg Spot Finder (BSF), with image pre-processing, a U-Net segmentation backbone, and post-processing that includes artifact removal and watershed segmentation. Finally, we perform experiments on the BSD benchmark and obtain results that are (in terms of accuracy) comparable to or better than those obtained with two popular spotfinder software packages ( Dozor and DIALS ), demonstrating that this is an appropriate framework to support future extensions and improvements.

36 MATERIALS SCIENCE↗