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At least 343 records · Page 19

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DOE OSTI2023

Final Report On Non-Intrusive Load Monitoring Of Welding Processes

The conventional method of weld process monitoring is to monitor the process output electrical power close to the point of welding. Non-Intrusive Load Monitoring (NILM) describes the method of monitoring primary or utility electrical power into a welding process well away from the point of welding. The objective of this project was to determine if there is sufficient information within the welding process input power to understand process output power characteristics, and, if so, determine if there is sufficient resolution within the input electrical characteristics to infer some measures of weld quality. To understand the relationship between process input and output power, both input and output power were monitored for two welding processes (GMAW and GTAW) and two different power source types (inverter and SCR). Welds were made with and without intentional disturbances. The results showed that there is a strong correlation between input and output power and that the influence of process disturbances are evident within the input power. A simple method using input power only was devised and successfully demonstrated to discriminate between a weld made with no intentional disturbance (a nominal weld) from a weld made with an intentional disturbance (off-nominal weld). The primary conclusions of this work is that NILM of process input power is sensitive to process disturbances that could influence weld quality and that the approach warrants additional study.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Joint physics-based and data-driven time-lapse seismic inversion: Mitigating data scarcity

In carbon capture and sequestration (CCS), developing rapid and effective imaging techniques is crucial for real-time monitoring of the spatial and temporal dynamics of CO 2 propagation during/after injection. With continuing improvements in computational power and data storage, data-driven techniques based on machine learning (ML) have been effectively applied to seismic inverse problems. In particular, ML helps alleviate the ill-posedness and high computational cost of full-waveform inversion (FWI). However, such data-driven inversion techniques require massive high-quality training data sets to ensure prediction accuracy, which hinders their application to time-lapse monitoring of CO 2 sequestration. We propose an efficient “hybrid” time-lapse workflow that combines physics-based FWI and data-driven ML inversion. The scarcity of the available training data is addressed by developing a new data-generation technique with physics constraints. The method is vali dated on a synthetic CO 2 -sequestration model based on the Kimberlina storage reservoir in California. The proposed approach is shown to synthesize a large volume of high-quality, physically realistic training data, which is critically important in accurately characterizing the CO 2 movement in the reservoir. In conclusion, the developed hybrid methodology can also simultaneously predict the variations in velocity and saturation and achieve high spatial resolution in the presence of realistic noise in the data.

58 GEOSCIENCES↗

DOE OSTI2024

Precision Polishing of Ablator Capsules via in situ Process Monitoring and Machine Learning–Based Optimization

In inertial confinement fusion (ICF) experiments seeking output gains of unity and beyond, the quality of the ablator capsule is paramount for minimizing the hydrodynamic mix that quenches the central hot spot. Defects in the form of foreign particles or missing mass on the surface and within the wall of the capsule are primary offenders. High-density carbon capsules made for ICF experiments at the National Ignition Facility are precision polished to achieve surface smoothness on the order of a few nanometers as well as to minimize isolated defects in the form of pits. Given the critical role of this process, we are developing smart manufacturing techniques with the goal of elevating the efficiency of this process. Our approach is to use MEMS (micro-electromechanical systems)–based sensors to capture the fine vibration signals generated during the polishing process and combine them with synchronized visual feedback as needed. Beyond using these sensors for process monitoring, we use specific deep learning methods to analyze the data and extract correlations with both the process parameters and the final performance of the polishing run. Here, in this work, we describe the multiple fronts we have explored in this regard and the results we have gotten so far. This approach promises to have the potential to ultimately provide real-time feedback that can be used to ensure the progress of the run as well as a means for faster optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Integrating field observations and process-based modeling to predict watershed water quality under environmental perturbations

Watersheds play a critical role in supplying water resources needed for human use and ecosystem health. Understanding and predicting how, when, and where changes in the quantity and quality of water resources occur under different environmental stresses including extreme events is crucial for sustainable management of water resources under a changing environment. However, few studies have attempted to quantify or identify the factors and process interactions controlling the impact of extreme events across water-shed systems. Only few large-scale studies include coordinated monitoring and modeling efforts, which limits our ability to assess the large-scale impact of extreme events on water supply and quality. Methods are lacking to propagate uncertainty in process understanding through an integrated hydro-biogeochemical model framework and evaluate its importance, thus failing to take full advantage of the information potentially available through transformative advances in characterization technologies from high-resolution mass spectrometry to airborne and satellite-based remote sensing. There are consequent risks to our nations water security and to human and ecosystem health that may become exacerbated with the increasing frequency of extreme events that is projected for the coming decades. This paper reviews the current status of watershed science for both water quantity and quality and identifies critical gaps in our current knowledge and modeling capability in addressing the emergent needs in predicting watershed hydrologic and biogeochemical responses (i.e., water quantity and quality) under natural and anthropogenic perturbations. We highlight the need to (1) understand how environmental perturbations including extreme events like floods and droughts propagate through watershed systems and assess their short- and long-term impacts on watershed biogeochemistry, water quality and their recovery pathways; (2) develop and improve a watershed water quality model that reflects the state of scientific understanding gained from observations; and (3) construct a data-model fusion system for watershed characterization, process identification, and mechanistic model parameterization. A large base of modeling, monitoring and data capabilities have been built by various federal government agencies given the relevance of water to their critical missions. An emerging need is to build an integrated national capability for watershed water availability and quality that can address water-related missions across multiple federal agencies.

13 HYDRO ENERGY↗

DOE OSTI2024

Real-time In-process Monitoring for Additive Manufacturing (Final CRADA Report)

Phase 3D has invented a real-time in-process monitoring system which can retrofit any industrial 3D printer to provide actionable part quality data. Designed to provide value to builders through dimensional measurements of several in-situ part features, the system reduces lost schedule time and wasted energy via allowing for earlier part scrap.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Risk to ecological resources following remediation can be due mainly to increased resource value of successful restoration: A case study from the Department of Energy's Hanford Site

Several nations are faced with the need to remediate large contaminated sites following World War II, the Cold War, and abandoned industrial sites, and to return them to productive land uses. In the United States, the Department of Energy (DOE) has the largest cleanup challenge, and its Hanford Site in the state of Washington has the most extensive and most expensive cleanup task. Ideally, the risk to ecological resources on remediation sites is evaluated before, during, and after remediation, and the risk from, or damage to, ecological resources from contaminants should be lower following remediation. In this paper, we report the risk to ecological resources before, during, and as a consequence of remediation on contaminated units requiring cleanup, and then examine the causes for changes in risk by evaluating 56 cleanup evaluation units (EUs) at the Hanford Site. In this case, remediation includes a restoration phase. In general, the risk to ecological and eco-cultural resources is currently not discernible or low at most contaminated units, increases during remediation, and decreases thereafter. Remediation often causes physical disruption to ecosystems as it reduces the risk from exposure to contaminants. Most new remediation projects at the Hanford Site include ecological restoration. Ecological restoration results in the potential for the presence of higher quality resources after remediation than currently exists on these contaminated lands and facilities. Although counter-intuitive, our evaluation of the risk to ecological resources following remediation indicated that a significant percentage of units (61%) will be at increased risk in the post-remediation period. This increased risk is due to DOE's successful remediation and restoration that results in a higher percent of native vegetation and higher ecological value on the sites in the post-remediation period than before. These newly-created resources can then be at risk from post-remediation activities. Risks to these new higher quality resources include the potential for spread of invasive species and of noxious grasses used in previous cleanup actions, disruption of ecosystems (including those with state or federally listed species and unique ecosystems), compaction of soil, use of pesticides to control invasive species, and the eventual need for continued monitoring activities. Thus, by greatly improving the existing habitat and health of eco-receptors, and maintaining habitat corridors between high quality habitats, the ecological resources in the post-remediated units are at risk unless care is taken to protect them. Many of the negative effects of both remediation and future monitoring (or other future land uses) can be avoided by planning and management early in the remediation process. We suggest DOE and other agencies convene a panel of managers, remediation scientists, regulators, environmental and ecological scientists, Native Americans, economists, and the public to develop a generic list of performance metrics for the restoration phase of remediation, including evaluation of success, which could be applied across the DOE complex.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Sizing Accuracy of Low-Cost Optical Particle Sensors Under Controlled Laboratory Conditions

Low-cost particulate matter sensors have seen increased use for monitoring at personal and local levels due to their affordability, ease of operation, and high time resolution. However, the quality of data reported by these sensors can be questionable, and a thorough evaluation of their performance is necessary. This study evaluated the particle sizing accuracy of several commonly used optical sensors, including the Alphasense optical particle counter (OPC), TSI DustTrak DRX aerosol monitor, Plantower PMS5003 sensor, and Sensirion SPS30 sensor, using laboratory-generated monodisperse particles. The OPC and DRX agreed partially with reference instruments and showed promise in detecting coarse-size particles. However, the PMS5003 and SPS30 did not correctly size fine and coarse particles. Furthermore, their reported mass distributions do not directly correspond to their number distribution. Despite these limitations, field measurements involving a dust storm period showed that the SPS30 correlated reasonably well with reference instruments for both PM2.5 and PM10, though the regression slopes differed significantly. These findings underscore the need for caution when interpreting data from low-cost optical sensors, particularly for coarse particles. Recommendations for improving the performance of these sensors are also provided.

Gautam, Prakash↗

DOE OSTI2026

Precision Polishing of Spheres Via In-Situ Process Monitoring and Machine-Learning-Based Optimization

In inertial confinement fusion (ICF) experiments seeking output gains of unity and beyond, the quality of the ablator capsule is paramount for minimizing hydrodynamic mix that quenches the central hot spot. Defects in the form of foreign particles or missing mass on the surface and within the wall of the capsule are primary offenders. High density carbon capsules made for ICF experiments on the National Ignition Facility (NIF) are precision polished to achieve the surface smoothness in the order of a few nm as well as to minimize isolated defects in the form of pits. Given the critical role of this process, we are developing smart manufacturing techniques with goal of elevating the efficiency of this process. Our approach is to use MEMS-based sensors to capture the fine vibrational signals generated during the polishing process and combine it with synchronized visual feedback as needed. Beyond using these sensors for process monitoring, we use specific deep learning methods to analyze the data and extract correlations with both the process parameters and the final performance of the polishing run. Here, we describe the multiple fronts that we have explored in this regard and the results we have gotten so far. This approach promises to have the potential to ultimately provide real-time feedback that can be used for ensuring the progress of the run as well as a means for faster optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Sensors with Intelligent Measurement Platform and Low-cost Equipment (SIMPLE) for Monitoring and Control of Medium Voltage Distribution Systems with High Penetration of Intermittent Distributed Energy Resources

The primary focus of the SIMPLE project was to develop, commission, test and introduce intelligent voltage and current sensor platform with enhanced characteristics (accuracy, bandwidth and harmonic range) and high measurement granularity for medium voltage distribution system monitoring, protection and control. The enhancements incorporated existing (commercially available) sensors and made them suitable for applications such as voltage regulation, frequency support, fault detection and location, distribution system state estimation, power quality measurements and electrical distribution network topology processing. The development of the intelligent sensor platform was driven by the need for high-fidelity monitoring and control of medium voltage distribution feeder to enable higher penetration of renewable resources and microgrid operation.

14 SOLAR ENERGY↗

DOE OSTI2023

Environmental risks and opportunities of orphaned oil and gas wells in the United States

Abstract Hundreds of thousands of documented and undocumented orphaned oil and gas wells exist in the United States (U.S.). These wells have the potential to contaminate water supplies, degrade ecosystems, and emit methane and other air pollutants. Thus, orphaned wells present risks to climate stability and to environmental and human health, which can be reduced by plugging. To quantify environmental risks and opportunities of well plugging at the national level, we analyze data on 81 857 documented orphaned wells across the U.S. We find that > 4.6 million people live within 1 km of a documented orphaned well. 35% of the documented orphaned wells are located within 1 km of a domestic groundwater well, yet only 8% of the wells have groundwater quality data within a 1 km radius. Methane emissions from the documented orphaned wells represent approximately 3%–6% of total U.S. methane emissions from abandoned oil and gas wells, but this estimate is based on measurements at < 0.03% of U.S. abandoned wells. 91% of the documented orphaned wells overlie formations favorable for geologic storage of carbon dioxide and hydrogen, meaning that orphaned well plugging can reduce leakage risks from future storage projects. Finally, we estimate plugging costs for documented orphaned wells to exceed the $4.7 billion federal funding by 30%–80%, emphasizing the importance of prioritizing federal spending on wells with large remediation benefits. Overall, environmental monitoring data are not extensive enough to quantify risks, especially those related to air and water quality and human health. Plugging orphaned wells can provide opportunities for geologic storage of carbon dioxide and hydrogen and geothermal energy development, thereby facilitating efforts to transition to net-zero energy systems. Our analysis on environmental risks and opportunities of orphaned wells provides a framework that can be used to manage the millions of documented and undocumented orphaned wells in the U.S. and abroad.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Development of an Electrochemical Hydrogen Contaminant Detector

Hydrogen refueling stations (HRSs) that dispense hydrogen to fuel cell vehicles need to ensure the quality of hydrogen to avoid contamination of the vehicle’s expensive fuel cell stacks. Currently, stations verify their fuel quality only periodically to ensure that they meet the strict fuel quality standards specified by either International Organization for Standards (ISO) or Society for Automotive Engineers (SAE). The development of hydrogen contaminant detectors (HCDs) that can provide low cost continuous monitoring at the HRS can be an invaluable asset in protecting fuel cell vehicles from any fuel contamination in-between infrequent expensive analysis of hydrogen fuel quality. An HCD capable of detecting < 200 ppb of CO in hydrogen is presented in this paper. The HCD is based on an electrochemical hydrogen pumping cell whose ultra-low loaded working electrode is poisoned by the contaminant, thus reducing its hydrogen oxidation reaction rate. The hydrogen pumping cell consists of a Nafion® membrane, a sputtered Pt working electrode, a Pt/Ru counter/pseudo-reference electrode and an internal water wicking system that provides humidification to the membrane and electrodes. When this HCD is operated in a pulsed voltammetry mode, it can provide stable CO response for thousands of hours in a HRS.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Quantitative imaging and automated fuel pin identification for passive gamma emission tomography

Compliance of member States to the Treaty on the Non-Proliferation of Nuclear Weapons is monitored through nuclear safeguards. The Passive Gamma Emission Tomography (PGET) system is a novel instrument developed within the framework of the International Atomic Energy Agency (IAEA) project JNT 1510, which included the European Commission, Finland, Hungary and Sweden. The PGET is used for the verification of spent nuclear fuel stored in water pools. Advanced image reconstruction techniques are crucial for obtaining high-quality cross-sectional images of the spent-fuel bundle to allow inspectors of the IAEA to monitor nuclear material and promptly identify its diversion. In this work, we have developed a software suite to accurately reconstruct the spent-fuel cross sectional image, automatically identify present fuel rods, and estimate their activity. Unique image reconstruction challenges are posed by the measurement of spent fuel, due to its high activity and the self-attenuation. While the former is mitigated by detector physical collimation, we implemented a linear forward model to model the detector responses to the fuel rods inside the PGET, to account for the latter. The image reconstruction is performed by solving a regularized linear inverse problem using the fast-iterative shrinkage-thresholding algorithm. We have also implemented the traditional filtered back projection (FBP) method based on the inverse Radon transform for comparison and applied both methods to reconstruct images of simulated mockup fuel assemblies. Higher image resolution and fewer reconstruction artifacts were obtained with the inverse-problem approach, with the mean-square-error reduced by 50%, and the structural-similarity improved by 200%. We then used a convolutional neural network (CNN) to automatically identify the bundle type and extract the pin locations from the images; the estimated activity levels finally being compared with the ground truth. The proposed computational methods accurately estimated the activity levels of the present pins, with an associated uncertainty of approximately 5%.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Measurements of fusion reaction history in inertially confined burning plasmas

Direct evidence of inertially confined fusion ignition appears in the abrupt temperature increase and consequent rapid increase in the thermonuclear burn rate as seen in the reaction history. The Gamma Reaction History (GRH) and Gas Cherenkov Detector (GCD) diagnostics are γ-based Cherenkov detectors that provide high quality measurements of deuterium–tritium fusion γ ray production and are, thus, capable of monitoring the thermonuclear burn rate. Temporal shifts in both peak burn time and burn width have been observed during recent high-yield shots (yields greater than 1017 neutrons) and are essential diagnostic signatures of the ignition process. While the current GRH and GCD detectors are fast enough to sense the changes of reaction history due to alpha heating, they do not have enough dynamic range to capture the onset of alpha heating. The next generation of instrumentation, GRH-15m, is proposed to increase the yield-rate coverage to measure the onset of alpha-heating.

42 ENGINEERING↗

DOE OSTI2020

Implementing Environmental Requirements

The purpose of this document is to describe the processes for identifying, communicating, and implementing environmental requirements at the Los Alamos National Laboratory (LANL) for Triad National Security, LLC (Triad). References to LANL or the Laboratory refer to the Department of Energy, National Nuclear Security Administration (DOE/NNSA) managed portion of LANL. References to the Prime Contract refer to the contract between DOE/NNSA and Triad and does not apply to the portion of Technical Area 54 now managed and operated by DOE Environmental Management (EM-LA).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

xSDK-batched Subcontract - Ginkgo Batched Iterative Solver Development (Final Report)

Iterative solvers are fundamentally different from direct solvers in terms of execution as they generally do not execute a pre-defined sequence of operations or steps, but adapt the number of iterations to the specific problem and the preset solution quality. Generally, the adaptation of the iteration count to the problem is realized by monitoring the solver convergence and stopping the iteration process once the monitored metric, e.g., the residual norm, hits a pre-defined threshold. When addressing a set of problems with different properties, it is necessary to monitor the threshold for each problem individually and break up the SIMD execution style to avoid excess iterations for “easier” problems. Ginkgo integrates a simple but customizable stopping criterion for the residual norm and generally uses a pre-defined (relative or absolute) residual norm as the stopping criterion. In order to avoid the overhead of launching a kernel at every iteration, the iteration convergence and iteration control is part of the solver kernel. Each thread maintains its own copy of the iteration count.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Stability of Floodplain Subsurface Microbial Communities Through Seasonal Hydrological and Geochemical Cycles

Riparian floodplains represent an interaction zone between the terrestrial subsurface and rivers, where regional groundwater flows, infiltration, and evapotranspiration drive mixing of water and import/export of nutrients and contaminants. These dynamics create seasonally transient redox conditions that drive biogeochemical transformations, which strongly modify groundwater quality. Microbial responses to changing hydrological conditions are perhaps the critical step connecting hydrology to geochemical transformations and groundwater quality, yet are not well understood. We aimed to address this knowledge gap by monitoring seasonal transitions at the U.S. Department of Energy legacy uranium ore processing site in Riverton, WY, through spring-summer-fall hydrological transitions. Our goal was to characterize the microbial community throughout the soil profile, down to the saturated aquifer, and observe its response to wet-dry transitions across a full season and compare to changes in geochemistry and hydrology. Next-generation sequencing was employed to identify biogeochemically-relevant microbial taxa based on the 16S rRNA gene; we found a broad diversity of microbial clades including taxa involved in sulfur and metal cycling, as well as nitrification. These data were paired with measurements of soil moisture, major nutrients and cations, and trace elements. Overall microbial community composition was dependent on soil depth or type, with seasonal effects only observed in the topsoil or subsurface aquifer. This finding indicates that microbial communities in the transiently-reduced center of the soil profile at the Riverton, WY site are remarkably stable, despite moisture and redox inversions. In addition, these communities likely impact the communities in surrounding soil horizons through export of metabolites and solutes as the water table rises and falls throughout the season.

16S rRNA↗

DOE OSTI2021

Towards Learning-Based Architectures for Sensor Impact Evaluation in Building Controls

Advanced control algorithms for building systems are known to have significant potential in reducing energy consumption while optimizing thermal comfort. The success of such algorithms is critically contingent on several different types of sensor systems, which are in turn, used for continuous monitoring, identification and estimation of several important building states, such as temperatures, humidity, air quality, power consumption and occupancy status. Nonidealities in any of these sensors can lead to significant performance degradation of the control functionalities, and may lead to unwanted sub-optimal building operation. In this paper, we provide a simulation example with a high-fidelity building model, for a particular use-case of advanced optimization-based control in buildings, i.e., occupancy-based controls. We show how imperfections in occupancy sensing can offset performance. Subsequently, we discuss a novel learning-based architecture to efficiently evaluate the impact of sensor nonidealities for building systems, in context of advanced control algorithms.

Bhattacharya, Saptarshi↗