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DOE OSTI2022

TiNi-Based Bi-Metallic Shape-Memory Alloy by Laser-Directed Energy Deposition

In this study, laser-directed energy deposition was applied to build a Ti-rich ternary Ti–Ni–Cu shape-memory alloy onto a TiNi shape-memory alloy substrate to realize the joining of the multifunctional bi-metallic shape-memory alloy structure. The cost-effective Ti, Ni, and Cu elemental powder blend was used for raw materials. Various material characterization approaches were applied to reveal different material properties in two sections. The as-fabricated Ti–Ni–Cu alloy microstructure has the TiNi phase as the matrix with Ti2Ni secondary precipitates. The hardness shows no high values indicating that the major phase is not hard intermetallics. A bonding strength of 569.1 MPa was obtained by tensile testing, and digital image correlation reveals the different tensile responses of the two sections. Differential scanning calorimetry was used to measure the phase-transformation temperatures. The austenite finishing temperature of higher than 80 °C was measured for the Ti–Ni–Cu alloy section. For the TiNi substrate, the austenite finishing temperature was tested to be near 47 °C at the bottom and around 22 °C at the upper substrate region, which is due to the repeated laser scanning that acts as annealing on the substrate. Finally, the multiple shape-memory effect of two shape-memory alloy sides was tested and identified.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Institute for Clean Energy Technology Mississippi State University NSR&D Aged HEPA Filter Study Final Report

Data have demonstrated that filter media lose tensile strength and the ability to resist the effects of moisture as a function of age. Testing of new and aged filters needs to be conducted to correlate reduction of physical strength of HEPA media to the ability of filters to withstand upset conditions. Appendix C of the Nuclear Air Cleaning Handbook provides the basis for DOE’s HEPA filter service life guidance. However, this appendix also points out the variability of data, and it does not correlate performance of aged filters to degradation of media due to age. Funding awarded by NSR&D to initiate full-scale testing of aged HEPA filters addresses the issue of correlating media degradation due to age with testing of new and aged HEPA filters under a generic design basis event set of conditions. This funding has accelerated the process of describing this study via: (1) establishment of a Technical Working Group of all stakeholders, (2) development and approval of a test plan, (3) development of testing and autopsy procedures, (4) acquiring an initial set of aged filters, (5) testing the initial set of aged filters, and (6) developing the filter test report content for each filter tested. This funding was very timely and has moved the project forward by at least three years. Activities have been correlated with testing conducted under DOE-EM funding for evaluating performance envelopes for AG-1 Section FC Separator and Separatorless filters. This coordination allows correlation of results from the NSR&D Aged Filter Study with results from testing new filters of the Separator and Separatorless Filter Study. DOE-EM efforts have identified approximately 100 more filters of various ages that have been stored under Level B conditions. NSR&D funded work allows a time for rigorous review among subject matter experts before moving forward with development of the testing matrix that will be used for additional filters. The NSR&D data sets are extremely valuable in as much as establishing a selfimproving, NQA-1 program capable of advancing the service lifetime study of HEPA filters. The data and reports are available for careful and critical review by subject matter experts before the next set of filters is tested and can be found in the appendices of this final report. NSR&D funds have not only initiated the Aged HEPA Filter Study alluded to in Appendix C of the NACH, but have also enhanced the technical integrity and effectiveness of all of the follow-on testing for this long-term study.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2017

Validation of Material Models For Automotive Carbon Fiber Composite Structures Via Physical And Crash Testing (VMM Composites Project)

As automotive fuel economy requirements increase, the push for reducing overall vehicle weight will likely include the consideration of materials that have not previously been part of mainstream vehicle design and manufacturing, including carbon fiber composites. Vehicle manufacturers currently rely on computer-aided engineering (CAE) methods as part of the design and development process, so going forward, the ability to accurately and predictably model carbon fiber composites will be necessary. If composites are to be used for structural components, this need applies to both, crash and quasi-static modeling. This final report covers the results of a five-year, $6.89M, 50% cost-shared research project between Department of Energy (DOE) and the US Advanced Materials Partnership (USAMP) under Cooperative Agreement DE-EE-0005661 known as “Validation of Material Models for Automotive Carbon Fiber Composite Structures Via Physical and Crash Testing (VMM).” The objective of the VMM Composites Project was to validate and assess the ability of physics-based material models to predict crash performance of automotive primary load-carrying carbon fiber composite structures. Simulation material models that were evaluated included micro-mechanics based meso-scale models developed by the University of Michigan (UM) and micro-plane models by Northwestern University (NWU) under previous collaborations with the DOE and Automotive Composites Consortium/USAMP, as well as five commercial crash codes: LS-DYNA, RADIOSS, VPS/PAM-CRASH, Abaqus, and GENOA-MCQ. CAE predictions obtained from seven organizations were compared with experimental results from quasi-static testing and dynamic crash testing of a thermoset carbon fiber composite front-bumper and crush-can (FBCC) system gathered under multiple loading conditions. This FBCC design was developed to demonstrate progressive crush, virtual simulation, tooling, fabrication, assembly, non-destructive evaluation and crash testing advances in order to assess the correlation of the predicted results to the physical tests. The FBCC was developed to meet a goal of 30-35% mass reduction while aiming for equivalent energy absorption as a steel component for which baseline experimental results were obtained from testing in the same crash modes. The project also evaluated crash performance of thermoplastic composite structures fabricated from commercial prepreg materials and low cost carbon fiber sourced from Oak Ridge National Laboratory. The VMM Project determined that no set of predictions from a CAE supplier were found to be universally accurate among all the six crash modes evaluated. In general, crash modes that were most dependent on the properties of the prepreg were more accurate than those that were dependent on the behavior of the joints. The project found that current CAE modeling methods or best practices for carbon fiber composites have not achieved standardization, and accuracy of CAE is highly reliant on the experience of its users. Coupon tests alone are not sufficient to develop an accurate material model, but it is necessary to bridge the gap between the coupon data and performance of the actual structure with a series of subcomponent level tests. Much of the unreliability of the predictions can be attributed to shortcomings in our ability to mathematically link the effects of manufacturing and material variability into the material models. This is a subject of ongoing research in the industry. The final report is organized by key technical tasks to describe how the validation project developed, modeled and compared crash data obtained on the composite FBCC to the multiple sets of CAE predictions. Highlights of the report include a discussion of the quantitative comparison between predictions and experimental data, as well as an in-depth discussion of remaining technological gaps that exist in the industry, which are intended to spur innovations and improvements in CAE technology.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Excited-state uncertainties in lattice-QCD calculations of multi-hadron systems

Excited-state effects lead to hard-to-quantify systematic uncertainties in lattice quantum chromodynamics (LQCD) spectroscopy calculations when computationally accessible imaginary times are smaller than inverse excitation gaps, as often arises for multi-hadron systems with signal-to-noise problems. Lanczos residual bounds address this by providing two-sided constraints on energies that do not require assumptions beyond Hermiticity, but often give very conservative systematic uncertainty estimates. Here, a more-constraining set of gap bounds is introduced for hadron spectroscopy. These bounds provide tighter constraints whose validity requires an explicit assumption about an energy gap. Exactly solvable lattice field theory correlators are used to test the utility of residual and gap bounds at finite and infinite statistics. Two-sided bounds and other analysis methods are then applied to a high-statistics LQCD calculation of nucleon-nucleon scattering at $m_π\sim 800$ MeV. Generalized eigenvalue problem (GEVP) and Lanczos energy estimators are compatible when applied to the same correlator data, but analyses including different interpolating operators show statistically significant inconsistencies. However, two-sided bounds from all operators are consistent. Under the assumption that the number of energy levels below $NΔ$ and $ΔΔ$ thresholds is the same as for non-interacting nucleons, gap bounds are sufficient to constrain nucleon-nucleon scattering amplitudes at phenomenologically relevant precision. Lanczos methods further reveal that energy-eigenstate estimates from previously studied asymmetric correlators have not converged over accessible imaginary times. Nevertheless, data-driven examples demonstrate why assumptions are required to draw conclusions about the natures of two-nucleon ground states at these masses.

Detmold, William [MIT, Cambridge, CTP]↗

DOE OSTI2019

Optimization of enhanced law correlation glasses for processing

Primary objectives of this work are given below. Review past test data to identify potential causes for poor processing characteristics of some glass compositions generated by the Enhanced LAW Glass Correlation and conduct tests to investigate these effects. Evaluate strategies to ameliorate processing characteristics of poorly performing Enhanced LAW Glass Correlation compositions through manipulation of glass compositions and GFC additives. Characterize new glass compositions to be processed on the DM100 with respect to properties affecting processability and product quality for melt viscosity, melt electrical conductivity, VHT, PCT, crystallization, refractory corrosion, and sulfate incorporation. Conduct Inconel 690 corrosion tests for various compositions designed by the Enhanced LAW Glass Correlation. Characterize melter feeds to be processed on the DM100 to verify that they have physical and rheological properties that are acceptable for melter feed processing at the WTP. Further refine the Enhanced LAW Glass Correlation based on the results from the rheology, feed VGF, Inconel 690 corrosion, crucible and melter tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Divergent taxonomic and functional responses of microbial communities to field simulation of aeolian soil erosion and deposition

Aeolian soil erosion and deposition have worldwide impacts on agriculture, air quality and public health. Yet, ecosystem responses to soil erosion and deposition remain largely unclear in regard to microorganisms, which are the crucial drivers of biogeochemical cycles. Using integrated metagenomics technologies, we analysed microbial communities subjected to simulated soil erosion and deposition in a semiarid grassland of Inner Mongolia, China. As expected, soil total organic carbon and plant coverage were decreased by soil erosion, and soil dissolved organic carbon (DOC) was increased by soil deposition, showing that field simulation was reliable. Soil microbial communities were altered ( p < .039) by both soil erosion and deposition, with dramatic increase in Cyanobacteria related to increased stability in soil aggregates. amyA genes encoding α-amylases were specifically increased ( p = .01) by soil deposition and positively correlated ( p = .02) to DOC, which likely explained changes in DOC. Surprisingly, most of microbial functional genes associated with carbon, nitrogen, phosphorus and potassium cycling were decreased or unaltered by both erosion and deposition, probably arising from acceleration of organic matter mineralization. These divergent responses support the necessity to include microbial components in evaluating ecological consequences. Moreover, Mantel tests showed strong, significant correlations between soil nutrients and functional structure but not taxonomic structure, demonstrating close relevance of microbial function traits to nutrient cycling.

16S rRNA sequencing↗

DOE OSTI2015

An Experimental Study of Shear-Dominated Failure in the 2013 Sandia Fracture Challenge Specimen

This report presents an experimental study motivated by results obtained during the 2013 Sandia Fracture Challenge. The challenge involved A286 steel, shear-dominated compression specimens whose load-deflection response contained a load maximum fol- lowed by significant displacement under decreasing load, ending with a catastrophic fracture. Blind numerical simulations deviated from the experiments well before the maximum load and did not predict the failure displacement. A series of new tests were conducted on specimens machined from the original A286 steel stock to learn more about the deformation and failure processes in the specimen and potentially improve future numerical simulations. The study consisted of several uniaxial tension tests to explore anisotropy in the material, and a set of new tests on the compression speci- men. In some compression specimen tests, stereo digital image correlation (DIC) was used to measure the surface strain fields local to the region of interest. In others, the compression specimen was loaded to a given displacement prior to failure, unloaded, sectioned, and imaged under the microscope to determine when material damage first appeared and how it spread. The experiments brought the following observations to light. The tensile tests revealed that the plastic response of the material is anisotropic. DIC during the shear- dominated compression tests showed that all three in-plane surface strain components had maxima in the order of 50% at the maximum load. Sectioning of the specimens revealed no signs of material damage at the point where simulations deviated from the experiments. Cracks and other damage did start to form approximately when the max- imum load was reached, and they grew as the load decreased, eventually culminating in catastrophic failure of the specimens. In addition to the steel specimens, a similar study was carried out for aluminum 7075-T651 specimens. These specimens achieved much lower loads and displacements, and failure occurred very close to the maximum in the load-deflection response. No material damage was observed in these specimens, even when failure was imminent. In the future, we plan to use these experimental results to improve numerical simu- lations of the A286 steel experiments, and to improve plasticity and failure models for the Al 7075 stock. The ultimate goal of our efforts is to increase our confidence in the results of numerical simulations of elastic-plastic structural behavior and failure.

36 MATERIALS SCIENCE↗

DOE OSTI2014

H{sub α} SPECTRAL DIVERSITY OF TYPE II SUPERNOVAE: CORRELATIONS WITH PHOTOMETRIC PROPERTIES

We present a spectroscopic analysis of the H{sub α} profiles of hydrogen-rich Type II supernovae. A total of 52 Type II supernovae having well-sampled optical light curves and spectral sequences were analyzed. Concentrating on the H{sub α} P-Cygni profile we measure its velocity from the FWHM of the emission and the ratio of absorption to emission (a/e) at a common epoch at the start of the recombination phase, and search for correlations between these spectral parameters and photometric properties of the V-band light curves. Testing the strength of various correlations we find that a/e appears to be the dominant spectral parameter in terms of describing the diversity in our measured supernova properties. It is found that supernovae with smaller a/e have higher H{sub α} velocities, more rapidly declining light curves from maximum during the plateau and radioactive tail phase, are brighter at maximum light, and have shorter optically thick phase durations. We discuss possible explanations of these results in terms of physical properties of Type II supernovae, speculating that the most likely parameters that influence the morphologies of H{sub α} profiles are the mass and density profile of the hydrogen envelope, together with additional emission components due to circumstellar interaction.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2017

Baryon acoustic oscillations from the complete SDSS-III Lyα-quasar cross-correlation function at z = 2.4

We present a measurement of baryon acoustic oscillations (BAO) in the cross-correlation of quasars with the Lyα-forest flux-transmission at a mean redshift z = 2.40. The measurement uses the complete SDSS-III data sample: 168,889 forests and 234,367 quasars from the SDSS Data Release DR12. In addition to the statistical improvement on our previous study using DR11, we have implemented numerous improvements at the analysis level allowing a more accurate measurement of this cross-correlation. We also developed the first simulations of the cross-correlation allowing us to test different aspects of our data analysis and to search for potential systematic errors in the determination of the BAO peak position. We measure the two ratios D H (z = 2.40)=r d = 9.01 ± 0.36 and D M (z = 2.40)=r d = 35.7 ±1.7, where the errors include marginalization over the non-linear velocity of quasars and the metal - quasar cross-correlation contribution, among other effects. These results are within 1.8σ of the prediction of the flat-ΛCDM model describing the observed CMB anisotropies.We combine this study with the Lyα-forest auto-correlation function (Bautista et al. 2017), yielding D H (z = 2.40)=r d = 8.94 ± 0.22 and D M (z = 2.40)=r d = 36.6 ± 1.2, within 2.3σ of the same flat-ΛCDM model.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Correlating energy density induced residual stress, porosity, and mechanical property variations in directed energy deposition using neutron diffraction and imaging techniques

In a directed energy deposition (DED) process, the energy density deposited into the materials drives the structure and properties. The energy density is influenced by several printing parameters, such as laser power, hatch spacing, scanning speed, etc. In this study, 316L stainless steels samples were fabricated with varying hatch spacing aiming to induce variations in sample microstructure and properties. A combination of techniques including engineering neutron diffraction, neutron computed tomography, and tensile testing, were employed to correlate the structure and macroscopic properties. Porosity was predominantly observed at the bottom of the deposited materials and was effectively reduced by decreased hatch spacing. Correlatively, compressive residual stress was observed at the bottom of the specimens, while internal stress is largely determined by the hatch spacing. The residual stress in general decreases as the hatch spacing decreases. The maximum ultimate tensile strength (UTS) was found to increase from 517.4 to 528.6 MPa with a strain increased from 0.847 to 0.897 as the hatch spacing decreased from 0.45 to 0.42 mm. However, further increase in energy density by reducing the hatch spacing resulted in a significant decrease in UTS (as low as 452 MPa). This work provides new insights from bulk non-destructive techniques into correlating energy density induced residual stress, porosity, and mechanical property variations in directed energy deposition.

316L stainless steel↗

DOE OSTI2023

First test of the consistency relation for the large-scale structure using the anisotropic three-point correlation function of BOSS DR12 galaxies

ABSTRACT We present, for the first time, an observational test of the consistency relation for the large-scale structure (LSS) of the Universe through a joint analysis of the anisotropic two- and three-point correlation functions (2PCF and 3PCF) of galaxies. We parameterize the breakdown of the LSS consistency relation in the squeezed limit by Es, which represents the ratio of the coefficients of the shift terms in the second-order density and velocity fluctuations. Es ≠ 1 is a sufficient condition under which the LSS consistency relation is violated. A novel aspect of this work is that we constrain Es by obtaining information about the non-linear velocity field from the quadrupole component of the 3PCF without taking the squeezed limit. Using the galaxy catalogues in the Baryon Oscillation Spectroscopic Survey (BOSS) Data Release 12, we obtain $E_{\rm s} = -0.92_{-3.26}^{+3.13}$, indicating that there is no violation of the LSS consistency relation in our analysis within the statistical errors. Our parameterization is general enough that our constraint can be applied to a wide range of theories, such as multicomponent fluids, modified gravity theories, and their associated galaxy bias effects. Our analysis opens a new observational window to test the fundamental physics using the anisotropic higher-order correlation functions of galaxy clustering.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2018

Determining the Concentration of Free Electrons in n-InSb from Far-Infrared Reflectance Spectra with Allowance for Plasmon–Phonon Coupling

Contactless nondestructive testing is a means for determining the concentration of free electrons N in indium antimonide (InSb) samples from far-infrared reflectance spectra recorded at room temperature. A computer program capable of determining the characteristic wave number from the Kramers–Kronig relation is developed. The calculated calibration dependence makes it possible to determine the electron concentration from the known characteristic wave number. It is shown that this dependence is described by a cubic polynomial. In the calculations, the energy dependence of the electron effective mass is taken into account. It is established that, in determining the electron concentration, account must be taken of plasmon–phonon coupling, specifically at N ≤ 5 × 10{sup 17} cm{sup –3}. The systematic error introduced into the determination of N by disregard of plasmon–phonon coupling is estimated. The software elaborated here makes it possible to calculate the electron concentration N from experimental reflectance spectra and to store and process the results. The software is tested by the example of the reflectance spectrum of heavily doped n-InSb.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

Optimization of an exchange-correlation density functional for water

We describe a method, that we call data projection onto parameter space (DPPS), to optimize an energy functional of the electron density, so that it reproduces a dataset of experimental magnitudes. Our scheme, based on Bayes theorem, constrains the optimized functional not to depart unphysically from existing ab initio functionals. The resulting functional maximizes the probability of being the “correct” parameterization of a given functional form, in the sense of Bayes theory. The application of DPPS to water sheds new light on why density functional theory has performed rather poorly for liquid water, on what improvements are needed, and on the intrinsic limitations of the generalized gradient approximation to electron exchange and correlation. Finally, we present tests of our water-optimized functional, that we call vdW-DF-w, showing that it performs very well for a variety of condensed water systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2014

SSL and LED life prediction and assessment of CCT shift

Solid-state lighting (SSL) products can have a predicted life of 70% lumen output (L70) from 26,000 to 40,000 hours using the LM-80-08 testing standards. Chromaticity shift, correlated color temperature (CCT) and lumen maintenance (LM) will dramatically reduce the nominal life of SSL luminaires. In this work, an off-the-shelf luminaire from Philips (AmbientLED) has been aged in a standard wet hot temperature operating life (WHTOL) of 85% relative humidity and 85°C (85/85) in order to assess reliability of prolonged exposer in a harsh environment. Failure criterion has been derived using the Arrhenius equation from the LM-80-08 standard, as well as the 60W LED Lamp test report from an isothermal environment of 45°C. This is a similar luminaire to the test vehicle used in this research. Data characterization between the two data sets has been carried out to determine the luminaires reliability and life under the 85/85 test conditions. This characterization allows for the determination of poor quality luminaire products in the market place. The distribution properties of the shifting mean values of CCT and LM were incorporated into the Bayesian Linear Regression (BLR) to determine the degradation pattern, in order to predict the remaining useful life (RUL) of the system due to aging before the end-of-life (EoL).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Complete Status Report Documenting Weld Development for Thin Wall Tubing of ODS Ferritic Alloys

Beginning in 2015, research in the FCRD program began the development of FSW for joining thin sections of 14YWT in the form of thin (0.5 mm) plate and ultimately thin wall tubing. In the previous fiscal year, a ~1 mm thick plate, or sheet, of 14YWT was produced by hot rolling with no edge cracking. The initial FSW experiment was performed on the 1 mm thick plate and involved a bead-on-plate weld in which the spinning pin tool is plunged into the plate surface, but does not penetrate the thickness of the plate, and then travels the length of the plate. The FSW run successfully produced a bead-on-plate stir zone on the 1 mm thick plate of 14YWT, but no characterization studies of the stir zone were performed by the end of FY15. Therefore, the results presented in this report cover the microstructural analysis of the bead-on-plate stir zone and the initial research task on obtaining tensile properties of the stir zone using the digital image correlation (DIC) approach during testing of miniature tensile specimens to assess the quality of the FSW parameters used in the initial experiment. The results of the microstructural characterization study using optical, scanning electron and scanning transmission electron microscopies showed the grain structure in the SZ to have isotropic and irregular shape but very similar size compared to the highly elongated grains oriented horizontally with the plane of the plate that were observed in the unaffected zone of 14YWT. Several cracks oriented horizontally were observed mostly on the retreating side of the SZ in both the SZ and TMAZ. These cracks may have formed due to insufficient pressure being exerted on the top surface of the plate by the shoulder and pin tool during the FSW run. High resolution STEM-EDS analysis showed the presence of the Y-Ti-O particles in the SZ, but that some particles exhibited coarsening. Overall, the FSW parameters used to produce the bead-on-plate SZ in the 0.1 cm thick plate of 14YWT were nearly optimized. The results of the digital image correlation (DIC) analysis of the two SS-Mini-2 tensile specimens fabricated from the 0.1 cm thick plate of 14YWT showed that the specimens exhibited high strength and good ductility. However, strain localization occurred in one of the specimens during the tensile test that was too close to the grips, which invalidated the data from the DIC analysis. This was surprising since the abrupt crack pop-in that occurred in the 0.1 cm thick plate of 14YWT during fabrication by wire EDM suggested that residual stresses were high. Residual stress measurements and the effects of post weld heat treatment on the FSW quality of joined 14YWT plates will be investigated in the next FW work package.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

State-of-the-art and review of condensation heat transfer for small modular reactor passive safety: Computational studies

The small modular reactor (SMR) is a promising option with added safety features, economical manufacturing, reliable parts, portability, and scalable energy capacity that emits no greenhouse gas during its operating lifespan. The SMR safety systems, however, need to be evaluated for design and licensing. Thus, they require the verification and validation of the physics models and correlations. This study focuses on state-of-the-art condensation heat transfer analysis and a review of previous studies related to the passive containment cooling system (PCCS) of a SMR. In the PCCS of a SMR, due to its smaller size containment, filmwise condensation is dominant and therefore emphasized in this study. Furthermore, previous condensation heat transfer studies for PCCSs did not make the SMR the primary focus, so a critical review for formulating the state-of-the-art is necessary. A previous review covered experimental condensation heat transfer studies with a brief overview of associated test facilities and empirical correlations. This review covers the empirical, resistance-layer and theoretical (numerical and commercial CFD) approaches.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

MaLTESE: Large-Scale Simulation-Driven Machine Learning for Transient Driving Cycles

Optimal engine operation during a transient driving cycle is the key to achieving greater fuel economy, engine efficiency, and reduced emissions. In order to achieve continuously optimal engine operation, engine calibration methods use a combination of static correlations obtained from dynamometer tests for steady-state operating points and road and/or track performance data. As the parameter space of control variables, design variable constraints, and objective functions increases, the cost and duration for optimal calibration become prohibitively large. In order to reduce the number of dynamometer tests required for calibrating modern engines, a large-scale simulation-driven machine learning approach is presented in this work. A parallel, fast, robust, physics-based reduced-order engine simulator is used to obtain performance and emission characteristics of engines over a wide range of control parameters under various transient driving conditions (drive cycles). We scale the simulation up to 3,906 nodes of the Theta supercomputer at the Argonne Leadership Computing Facility to generate data required to train a machine learning model. The trained model is then used to predict various engine parameters of interest, and the results are compared with those predicted by the engine simulator. Our results show that a deepneural-network-based surrogate model achieves high accuracy: Pearson product-moment correlation values larger than 0.99 and mean absolute percentage error within 1.07% for various engine parameters such as exhaust temperature, exhaust pressure, nitric oxide, and engine torque. Once trained, the deep-neural-network-based surrogate model is fast for inference: it requires about 16 mu s for predicting the engine performance and emissions for a single design configuration compared with about 0.5 s per configuration with the engine simulator. Moreover, we demonstrate that transfer learning and retraining can be leveraged to incrementally retrain the surrogate model to cope with new configurations that fall outside the training data space.

deep learning↗