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DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Ameliorating Global Challenges: Globalization, Geopolitics, Basic & Applied Research, and Research Security

We are confronted with a myriad of global challenges, from extreme weather events, occurring at higher frequencies than at any point in history, to pollution, food insecurity, clean water shortages, and fundamentally limited natural resources and materials. The largest number of people inhabit our planet today and enjoy the highest standard of living - though not equally distributed across the world - compared to any prior moment in history. To sustain this quality of life, we are largely reliant on fossil fuel sources, which are responsible for more greenhouse gas emissions by weight each day than the collective weight of all humans that inhabit the planet. Ameliorating these global challenges will require elements of solutions that include advances in basic and applied research, innovative global engineering, materials discovery, new technologies, manufacturing at scale, resilient and adaptable infrastructure, carbon-free energy sources and storage technologies, and new supply chain networks and markets. Success will require constructive collaborative efforts between researchers in countries located in every continent of this planet. For any of these goals to be realized in a timely fashion, geopolitical leaders must become better educated about this existential challenge and incentivized to act.

applied research↗

DOE OSTI2025

Grid Resiliency with a 100% Renewable Microgrid

San Diego Gas & Electric Company (SDG&E) installed America’s first and largest utility-scale microgrid in Borrego Springs in 2013. The first generation Borrego Springs Microgrid utilized diesel generators to form and stabilize the microgrid island, with support from grid-scale batteries and local solar photovoltaic (PV) generation. In this project, SDG&E in partnership with National Renewable Energy Laboratory (NREL) demonstrated through modeling, simulation and utility field testing that blackstart and islanding of the microgrid can be led with 100% renewable, inverter based resources (IBRs), to help reduce community reliance on conventional generation resources. Through equipment upgrades, grid-forming island leader capability was transitioned to a battery IBR instead of the Borrego Springs Microgrid diesel generators. A new microgrid controller was integrated to the microgrid and programmed to control and manage multiple energy storage systems. Synchrophasor and other power quality data verified autonomous, high-speed response of the IBRs through blackstart, islanding, and load step testing. Results of project field evaluations provide distribution systems operators (DSO) with increased confidence that renewable, IBR can replace traditional generators to blackstart and island microgrids and rapidly establish stable island frequency with rapid changes in peak power demand. Importantly, the project validated the integration feasibility of a distributed energy resource management system (DERMS) controller that manages multiple grid-forming and grid-following IBRs, establishing a standard design interface to reduce the complexity of integrating new DERs in the future and supporting replication by the industry. As a result of learnings in this project, SDG&E has implemented the microgrid controller strategy at multiple other microgrid sites, thereby validating the replicability of the solution. Hardware-in-the-loop (HIL) simulations including power and controller HIL hardware — along with electromagnetic transient (EMT) simulations of Borrego Springs Microgrid —informed adjustments to inverter parameters and were important to characterize the performance of the IBRs in relevant operating conditions before deployment. The EMT and HIL simulations of islanding the entire community are important contributions in providing confidence in IBR performance prior to future islanding of the community in the field. High-fidelity EMT and/or HIL simulation of IBRs can de-risk field operations, and its relevance and importance as a tool is increasing as distribution grids and microgrids become more complex and dynamic with an increasing proportion of renewable generation, distributed energy storage, and two-way power and energy flows.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Satellite-based aerosol optical depth estimates over the continental U.S. during the 2020 wildfire season: Roles of smoke and land cover

Wildfires produce smoke that can affect an area >1000 times the burn extent, with far-reaching human health, ecologic, and economic impacts. Accurately estimating aerosol load within smoke plumes is therefore crucial for understanding and mitigating these impacts. We evaluated the effectiveness of the latest Collection 6.1 MODIS Multi-Angle Implementation of Atmospheric Correction (MAIAC) algorithm in estimating aerosol optical depth (AOD) across the U.S. during the historic 2020 wildfire season. We compared satellite-based MAIAC AOD to ground-based AERONET AOD measurements during no-, light-, medium-, and heavy-smoke conditions identified using the Hazard Mapping System Fire and Smoke Product. This smoke product consists of maximum extent smoke polygons digitized by analysts using visible band imagery and classified according to smoke density. We also examined the strength of the correlations between satellite- and ground-based AOD for major land cover types under various smoke density levels. MAIAC performed well in estimating AOD during smoke-affected conditions. Correlations between MAIAC and AERONET AOD were strong for medium- (r = 0.91) and heavy-smoke (r = 0.90) density, and MAIAC estimates of AOD showed little bias relative to ground-based AERONET measurements (normalized mean bias = 3 % for medium, 5 % for heavy smoke). During two high AOD, heavy smoke episodes, MAIAC underestimated ground-based AERONET AOD under mixed aerosol (i.e., smoke and dust; median bias = −0.08) and overestimated AOD under smoke-dominated (median bias = 0.02) aerosol. MAIAC most overestimated ground-based AERONET AOD over barren land (mean NMB = 48 %). Our findings indicate that MODIS MAIAC can provide robust estimates of AOD as smoke density increases in coming years. Increased frequency of mixed aerosol and expansion of developed land could affect the performance of the MAIAC algorithm in the future, however, with implications for evaluating wildfire-associated health and welfare effects and air quality standards.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Scalable/Secure Cooperative Algorithms and Framework for Extremely-high Penetration Solar Integration (SolarExPert) (Final Technical Report)

This SolarExPert project has developed a Sustainable Grid Platform (SGP) with scalable architecture of distributed control and optimization. The SGP consists of the following major functions: 1) an advanced grid architecture with hierarchical and distributed communication and control, combined with the OpenFMB standard and implemented on the Multi-Agent OpenDSS (MA-OpenDSS) platform; 2) an online distributed stochastic optimal power flow; 3) an online distributed system state estimation algorithm; 4) the distributed Volt/VAR optimization and frequency control algorithms; 5) the distributed distribution system restoration strategy. The developed SGP together with advanced functions are tested in 1 million (1M)-node distribution system on the MA-OpenDSS platform. Furthermore, the models and algorithms are tested in 100,000-node system HiL simulation, and also in P-HiL implementation with 100 physical devices. The developed functions haven been validated and tested on the selected actual distribution feeder with the data collected from the field of Maui Meadows in Hawaii. The distributed PV hosting capacities with cooperative Volt/VAR and Volt/VAR/Watt control are estimated and compared to provide recommendations for customers and the utility company.

14 SOLAR ENERGY↗

DOE OSTI2024

Power Sharing-Based Framework for Allocating Automatic Generation Control in Distributed Energy Resources: Preprint

The recent proliferation of distributed energy resources (DERs) in the power network along with the retirement of conventional generators has made it challenging to regulate system frequency. In this paper, we present a centralized control framework to leverage the potential of DERs in the distribution network in provisioning secondary frequency control services to the grid. The proposed framework is based on network volt-watt sensitivity analysis and takes into account DER operational and network-imposed constraints to allocate the automatic generation control (AGC) request among the aggregated units. The proposed framework was implemented on the IEEE 8500-node test feeder and results were validated against a standard linear programming-based scheme. Numerical results indicate that the proposed framework can successfully utilize the available power production headroom of the network to meet the AGC request while maintaining nodal voltages within acceptable limits.

distributed energy resources↗

DOE OSTI2022

NIR fluorescence lifetime macroscopic imaging with a time-gated SPAD camera

The performance of SwissSPAD2 (SS2), a large scale, widefield time-gated CMOS SPAD imager developed for fluorescence lifetime imaging, has recently been described in the context of visible range and fluorescence lifetime imaging microscopy (FLIM) of dyes with lifetimes in the 2.5 – 4 ns range. Here, we explore its capabilities in the NIR regime relevant for small animal imaging, where its sensitivity is lower and typical NIR fluorescent dye lifetimes are much shorter (1 ns or less). We carry out this study in a simple macroscopic imaging setup based on a compact NIR picosecond pulsed laser, an engineered diffuser-based illumination optics, and NIR optimized imaging lens suitable for well-plate or small animal imaging. Because laser repetition rates can vary between models, but the synchronization signal frequency accepted by SS2 is fixed to 20 MHz, we first checked that a simple frequency-division scheme enables data recording for different laser repetition rates. Next, we acquired data using different time gate widths, including gates with duration longer than the laser period, and analyzed the resulting data using both standard nonlinear least-square fit (NLSF) and phasor analysis. We show that the fixed synchronization rate and large gate widths characterizing SS2 (10 ns and over) are not an obstacle to accurately extracting lifetime in the 1 ns range and to distinguishing between close lifetimes. As a result, SS2 and similar very large gated SPAD imagers appear as a versatile alternative to other widefield time-resolved detectors for NIR fluorescence lifetime imaging, including preclinical molecular applications.

FLIM↗

DOE OSTI2024

Practical procedures for sensor quality assessment

Sensors are increasingly deployed for process monitoring and control. These produce on-line measurements at a high frequency, in parallel with low-frequency laboratory measurements. Compared to laboratory practices, sensor data quality assessment and control practices are far less structured at most utilities. This leads to inaccurate sensor data with unknown uncertainty factors.This chapter shows how to establish standard operating procedures (SOPs) to support sensor data quality assessment and control and subsequent maintenance actions by producing relevant sensor metadata. Furthermore, SOPs are provided for the most commonly used wastewater quality sensors, inspired by utility and academic best practices. This chapter builds on definitions provided in Chapter 3 and provides additional definitions specifically related to sensors maintenance. Chapter 6 complements the methods in this chapter, which are based on reference measurements, with data-analytical techniques.

Alferes, Janelcy↗

DOE OSTI2022

H-Canyon Jumper Gasket Sealing Evaluation

H-Canyon Documented Safety Analysis approved December 2019 credits the leak integrity of HCanyon (HCA) process tanks, piping, and jumpers in preventing the release of radioactive material in a post seismic environment. Demonstration of leak tightness capability for this equipment was achieved through substantial analytical effort. However, one potential weak point that affects leak integrity exists at the gasketed joint between Hanford Connectors (HC) and nozzles. Review of the HCA Crane Log over a three-year period indicates the HCs periodically leak. Savannah River National Laboratory (SRNL) was requested to perform gasket compression tests that evaluate gasket relaxation characteristics, i.e., creep, and provide improvements to the HC installation process that can reduce or eliminate the frequency of leaks at HCs. A HC torque value of 312 ft-lbf is the target value used because it is the minimum torque value, with 95% confidence, when an unlubricated HC is impacted for standard sealing period of 9 seconds.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

H-Canyon Jumper Gasket Sealing Evaluation

H-Canyon Documented Safety Analysis approved December 2019 credits the leak integrity of H-Canyon (HCA) process tanks, piping, and jumpers in preventing the release of radioactive material in a post seismic environment. Demonstration of leak tightness capability for this equipment was achieved through substantial analytical effort. However, one potential weak point that affects leak integrity exists at the gasketed joint between Hanford Connectors (HC) and nozzles. Review of the HCA Crane Log over a three-year period indicates the HCs periodically leak. Savannah River National Laboratory (SRNL) was requested to perform gasket compression tests that evaluate gasket relaxation characteristics, i.e., creep, and provide improvements to the HC installation process that can reduce or eliminate the frequency of leaks at HCs. A HC torque value of 312 ft-lbf is the target value used because it is the minimum torque value, with 95% confidence, when an unlubricated HC is impacted for standard sealing period of 9 seconds. In the HCA pipe-jumper connections are installed remotely by using HCs. HCs inherently add to the uncertainty of a gasketed joint because a calibrated torque value cannot be applied. The gasket material is a special material made of asbestos-fiber impregnated with Teflon. This material has been used for decades and generally performs well but does leak intermittently as gaskets creep and preloaded torque is lost. Gasket types are either snap-ring (SR) or lampshade (LS). Both gasket types cover the same seating area. The SR gasket is designed to remain with the jumper when the jumper is removed leaving the nozzle faces clean of any debris. SR gaskets are initially installed when the jumper is fabricated. Changing gaskets is time consuming and the radioactive environment presents risks to personnel. When jumpers are removed LS gaskets could be used to better seal the connection to reduce down time and ALARA concerns. That is, an LS gasket would be remotely positioned over the nozzle and the HC reinstalled. Testing also included two situations not typical of plant operation. One situation was the use of the non-standard double-layered gaskets (DG), and the other situation was the use of a LS without removal of the installed SR gasket. The DG was used when the supply of LS gaskets ended, so that testing could continue. It was of interest to demonstrate this gasket’s creep response because the DG, which was two gaskets glued together, was thicker than the LS gasket and the thicker material was expected to elicit a greater creep characteristics. The second situation of using two gaskets together by installing an LS gasket without removing the installed gasket is not allowed by the ASME Codes. However, by demonstrating the creep history of such a gasket arrangement it could be considered as an option that could possibly seal a connection while significantly reducing operational down time and personnel risk. Forty tests were conducted, and the overall results demonstrate the initial applied force and how the gasket changes with time. The change in sealing force, in terms of torque, was then measured to obtain a force history as the gaskets creep. This report documents the results of those tests as well as the method used to perform the tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Buoy - California - Wind Sentinel (120), Humboldt - Processed Data

The purpose of the dataset is to provide preliminary filtered, averaged lidar data and standardize the data format of various datastreams from the buoy into NetCDF. The attached Lidar Buoy Data Dictionary provides further details on the various instruments mounted on the buoys, parameters measured by each instrument, and the frequency of data collection.

17 WIND ENERGY↗

DOE OSTI2024

Hawaii - Wind Sentinel (120), Oahu, Hawaii / Processed Data

17 WIND ENERGY↗

DOE OSTI2026

Control and Real-Time Simulation of Microgrids with EV Fast-Charging and Grid-Forming Resources

Fast charging stations (FCSs) for electric vehicles (EVs) can behave as constant power loads, which is problematic for the operation of grid-forming (GFM) inverter-based resources (IBRs). To tackle this problem, this paper proposes a control suite that makes FCSs responsive to ac voltage and frequency disturbances. To test the performance of the FCS controls, the paper also sets forth theory to compensate for time-delays appearing in the real-time simulation of microgrid models divided into several central processing units (CPUs). Furthermore, these contributions are showcased via multi-CPU real-time simulations of a faulted microgrid having EV FCSs and GFM IBRs powered by photovoltaic solar arrays as well as power hardware-in-the-loop experiments. These contributions are significant to address NERC recommendations and IEEE standards.

14 SOLAR ENERGY↗

DOE OSTI2025

A Novel Measurement of the Anomalous Muon Spin Precession Frequency in the Muon $g-2$ Experiment at Fermilab

The Muon $g-2$ Experiment operated at Fermi National Accelerator Laboratory (FNAL, or Fermilab) between 2018 and 2023 to produce the world's most precise measurement of the muon's \textit{anomalous magnetic moment}, $a_\mu = \frac{g_\mu - 2}{2}$, which expresses the relative deviation in the muon's $g$-factor from a baseline theoretical expectation that $g_\mu = 2$. In the Standard Model of particle physics, $g_\mu > 2$ and hence $a_\mu > 0$ by a calculable amount that depends on all possible interactions between the muon and all other fundamental particles, including any potentially undiscovered interactions beyond the Standard Model. For this reason, measurements of the electron anomaly $a_e$ and later the muon anomaly $a_\mu$ have helped guide the development of the Standard Model since the inception of quantum field theory, and the measured value of $a_\mu$ provides a valuable constraint for new hypotheses that extend the Standard Model. As of 2006, the leading measurement and Standard Model prediction for $a_\mu$ exhibited tension at the level of about three standard deviations, motivating an improved measurement at Fermilab that could test the tension more precisely. The experiment functions by storing a polarized beam of $\mu^+$ in a uniform magnetic field, which simultaneously induces circular motion and spin precession. As the stored muons undergo the Michel decay $\mu^+ \to e^+ + \nu_e + \bar{\nu}_\mu$, mediated by the parity-violating weak interaction, the rest-frame $e^+$ emission direction is correlated with the parent $\mu^+$ spin orientation. Boosting into the laboratory frame encodes this correlation in the decay $e^+$ energy, which is higher when the emission (i.e. $\mu^+$ spin direction) is aligned with the $\mu^+$ momentum, and lower when opposite. Detectors then count the rate of high-energy decay $e^+$, which modulates at the difference between the $\mu^+$ revolution and spin precession frequencies. This observed frequency, called the \textit{anomalous spin precession frequency} $\omega_a$, is directly proportional to $a_\mu$. The extraction of $\omega_a$ proceeds by fitting the time spectrum of detected $e^+$, which requires precise modeling of the $\omega_a$ oscillation as well as any perturbations from beam dynamics and detector acceptance. Using the $\omega_a$ analysis presented in this work, based on Runs 4 -- 6 of the Muon $g-2$ Experiment at Fermilab, we find that $a_\mu = 0.001\,165\,920\,738(162)$ with a relative uncertainty of 139 parts per billion.

Barrett, Tyler [Cornell U.]↗

DOE OSTI2025

PowderJet: Spherical metal powder production via multi-orifice droplet-on-demand metal jetting

Leading metal additive manufacturing techniques, such as laser powder bed fusion and directed energy deposition, rely on high-quality spherical metal powders. However, traditional powder production methods like gas atomization face limitations, including low in-spec yield, asphericity, and internal porosity. We introduce PowderJet, a powder production platform that uses electromagnetic pulses to eject liquid metal droplets from a multi-orifice nozzle. Unlike stochastic methods, PowderJet tightly controls powder size, distribution, and purity through a droplet-on-demand approach. We detail the system’s design, operation, and performance using a combined experimental and computational fluid dynamics (CFD) framework. Initial results with Al4008 and Cu110 alloys demonstrate successful production, yielding unsieved aluminum powder batches with a mean diameter of 200 µm and a narrow size distribution (15 µm standard deviation). The produced powders are highly spherical, achieving a roundness > 0.95. PowderJet operates with a small melt volume (3 mL) and supports continuous refilling, enabling production rates between 30 and 140 cm³/hr depending on jetting frequency, number of orifices and particle size. CFD simulations show that future systems could achieve rates exceeding 1000 cm³/hr for particle sizes as small as 40 µm. PowderJet’s high yield of in-spec powder makes it ideal for producing precious or hazardous materials that are inefficient to manufacture using conventional methods. This platform offers a scalable, precise, and efficient solution for producing high-quality powders tailored for advanced manufacturing applications.

Atomization↗

DOE OSTI2022

Superior Daily and Sub-Daily Precipitation Statistics for Intense and Long-Lived Storms in Global Storm-Resolving Models

Here, daily and sub-daily precipitation statistics are investigated from three global model ensembles: (a) global storm-resolving models (GSRMs) with typical horizontal resolutions of ~4 km, (b) “high”-resolution global models with typical resolutions of ~50 km and (c) “standard”-resolution global models with typical resolutions of ~100 km. Compared to two satellite rainfall datasets, GSRMs convincingly exhibit superior performance for statistics of heavier rain rate events including their diurnal cycle, spatial propagation and the amount contributed by intense precipitation, but not for statistics of weaker or shorter duration precipitation. Both high- and standard-resolution models fail to simulate the correct phase and amplitude of diurnal cycle of precipitation and the propagating convection in the Central US, but high-resolution models show relative improvement in the distribution of precipitation frequency and amount, especially for intense precipitation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Bulk photospin effect: Calculation of electric spin susceptibility to second order in an electric field

Here, we compute the electric spin susceptibility of Bloch electrons with spin-orbit coupling to second order. We find that it is possible to generate a nonequilibrium spin polarization in the bulk of nonmagnetic inversion-symmetric materials using linearly polarized electric fields, but the process depends on interband coherence and produces heating. It may be possible to avoid heating with circular polarization in certain scenarios. The standard Edelstein effect and spin orientation effects are recovered in appropriate limits within the formalism. Finally, the electric spin susceptibility of metals has contributions proportional to spin multipole moments of the Fermi sea that dominate the low frequency spin response.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2024

California - Leosphere Windcube 866 (120), Humboldt / Reviewed Data

The purpose of this dataset is to provide filtered, averaged lidar data and standardize the data format of various data streams from the buoy into NetCDF. The attached Lidar Buoy Data Dictionary provides further details on the various instruments mounted on the buoys, parameters measured by each instrument, and the frequency of data collection.

17 WIND ENERGY↗