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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Improving the stellarator through advances in plasma theory

Improvements to the stellarator concept can be realized through advancements in theoretical and computational plasma physics. Herein, recent advances are reported in the topical areas of: (1) improved energetic ion confinement, (2) the impact of three-dimensional (3D) shaping on turbulent transport, (3) reducing coil complexity, (4) novel optimization and design methods, and (5) computational magnetohydrodynamic tools. Furthermore, these advances enable the development of new stellarator configurations with improved confinement properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Integral analysis of the effect of material dimension and composition on tokamak neutronics *

Abstract The neutronics performance of a tokamak has been identified as an important factor in designing a fusion power plant. The design of the tokamak should not only meet operational parameters such as sufficient tritium breeding, but also safety parameters such as low structural material activation. This paper investigates the impacts of the neutronics metrics for the ARC-class tokamak, a compact tokamak with an immersion blanket, by perturbing the first five layers of structural material—first wall, inner vacuum vessel, coolant salt channel, neutron multiplier, and outer vacuum vessel. The goal of this work is to provide insight into shaping and scaling the flux on each layer to obtain optimized operational and safety metrics through quantification of the responses from each perturbation. Results show that increased first wall thickness can increase the tritium breeding ratio (TBR) in specific configurations with high 6 Li enrichments and that vacuum vessels decrease TBR for low- 6 Li enrichment configurations. It was also found that the neutron multiplier can either increase or decrease TBR depending on the configuration. The response of metrics to the change in layer thickness and enrichment also varies depending on the vacuum vessel material. The integral impacts of 6 Li enrichment, layer thicknesses, and vacuum vessel material choice are investigated and presented in this paper.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Multi-Factor-Coupled, Ahead-of-Time Aggregation of Power Flexibility Under Forecast Uncertainty

The increasing penetration of distributed energy resources (DERs) is significantly reshaping the role of distribution systems under active energy management. To aggregate the active-reactive power flexibility of DERs dispersed at the feeder and provide capacity support to the transmission system, it is essential to efficiently identify feasible substation power injection trajectories. This paper introduces a novel ahead-of-time flexibility characterization method to address it. First, a polyhedral non-feeder-level power flexibility region (PFR) is constructed, accounting for various time-dependent, power-coupled, and forecast error uncertainties. Then, a polyhedral feeder-level PFR is analytically derived through a coordinate transformation, which can reveal the uncertainty propagation path, i.e., how uncertainty applies to the feeder-level PFR. To facilitate the high-level application, a tractable chance-constrained Chebyshev centering optimization model is further developed to find a ball-shaped inner approximation of the feeder-level PFR. Finally, the proposed method is validated on a modified IEEE 123-bus test system. Here, both theoretical and experimental results show that, with appropriate robustness parameter settings, the proposed method can make the approximated PFR less conservative with abundant robustness against forecast error uncertainty.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Programmable, direct space-to-time picosecond resolution pulse shaper with nanosecond record

In this work, we demonstrate a novel, to the best of our knowledge, extension of optical arbitrary waveform generation capable of picosecond resolution over nanosecond duration. The method, called space–time induced linearly encoded transcription for temporal optimization, is based on direct space-to-time pulse shaping and is extended here to single-mode output with a programmable temporal profile. We develop the theory of operation and discuss ultimate limits on resolution, record length, and efficiency. We report on the results of an experimental demonstration showing ~1ps resolution over 600 ps.

42 ENGINEERING↗
DOE OSTI2018

Additive Manufacturing of Sensors and Components for Non-Destructive Evaluation Applications

Additively manufactured machine components were designed for use in non-destructive evaluations. Additive manufacturing (3D printing) enables rapid production of simple or complex objects at a low cost for use in many fields of research and industry. 3D printed components were used to optimize an eddy current array probe to inspect various complex shaped objects, such as gears. Preliminary eddy current inspections were conducted to test the functionality and compatibility of the 3D printed components to the array probe and existing system. These were done by wrapping replica 3D printed gears with aluminum foil. The results were as expected, rough, uneven surface of the aluminum foil. Calibration scans were also executed to enable proper measurement of defect size in metal structures. For use in waveguide-based distributive sensing technologies, additively manufactured custom waveguides were designed for use in liquid environments to collect pressure and flow data. Waveguides were designed with membranes, thin sections of the walls, which would be pressed inward due to fluid pressure. Waveguide models continue to be developed and revised for most functional utility in liquid environments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Shaping Micro-Bunched Electron Beams for Compact X-ray Free-Electron Lasers with Transverse Gradient Undulators

Laser-modulator-based micro-bunching of electron beams has been applied to many novel operating modes of X-ray free-electron lasers from harmonic generation to attosecond pulse production. Recently, it was also identified as a key enabling technology for the production of a compact XFEL driven by a relatively low-energy beam. In traditional laser modulator schemes with low-energy and high-current bunches, collective effects limit the possible working points that can be employed, and thus it is difficult to achieve optimal XFEL performance. We propose to utilize transverse longitudinal coupling in a transverse gradient undulator (TGU) to shape micro-bunched electron beams so as to optimize their performance in a compact X-ray free-electron laser. We show that a TGU added to a conventional laser modulator stage enables much more flexibility in the design, allowing one to generate longer micro-bunches less subject to slippage effects and even lower the slice emittance of the micro-bunches. We present a theoretical analysis of laser-based micro-bunching with an added TGU, simulation of compression with collective effects in such systems, and finally XFEL simulations demonstrating the gains in peak power enabled by the TGU. Although we focus on the application to compact XFELs, what we propose is a general phase space manipulation that may find utility in other applications as well.

eSASE↗
DOE OSTI2024

Explosively driven Richtmyer–Meshkov instability jet suppression and enhancement via coupling machine learning and additive manufacturing

The ability to control the behavior of fluid instabilities at material interfaces, such as the shock-driven Richtmyer–Meshkov instability, is a grand technological challenge with a broad number of applications ranging from inertial confinement fusion experiments to explosively driven shaped charges. In this work, we use a linear-geometry shaped charge as a means of studying methods for controlling material jetting that results from the Richtmyer–Meshkov instability. A shaped charge produces a high-velocity jet by focusing the energy from the detonation of high explosives. The interaction of the resulting detonation wave with a hollowed cavity lined with a thin metal layer produces the unstable jetting effect. By modifying the characteristics of the detonation wave prior to striking the lined cavity, the kinetic energy of the jet can be enhanced or reduced. Modifying the geometry of the liner material can also be used to alter jetting properties. We apply optimization methods to investigate several design parameterizations for both enhancing or suppressing the shaped-charge jet. This is accomplished using 2D and 3D hydrodynamic simulations to investigate the design space that we consider. We also apply new additive manufacturing methods for producing the shaped-charge assemblies, which allow for the experimental testing of complicated design geometries obtained through computational optimization. We present a direct comparison of our optimized designs with experimental results carried out at the High Explosives Application Facility at Lawrence Livermore National Laboratory.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A combined experimental and numerical approach that eliminates the non-uniqueness associated with the Johnson-Cook parameters obtained using inverse methods

Abstract Johnson-Cook constitutive model is a commonly used material model for machining simulations. The model includes five parameters that capture the initial yield stress, strain-hardening, strain-rate hardening, and thermal softening behavior of the material. These parameters are difficult to determine using experiments since the conditions observed during machining (such as high strain-rates of the order of $$10^5$$ 10 5 /sec - $$10^6$$ 10 6 /sec) are challenging to recreate in the laboratory. To address this problem, several researchers have recently proposed inverse approaches where a combination of experiments and analytical models are used to predict the Johnson-Cook parameters. The errors between the measured cutting forces, chip thicknesses and temperatures and those predicted by analytical models are minimized and the parameters are determined. In this work, it is shown that only two of the five Johnson-Cook parameters can be determined uniquely using inverse approaches. Two different algorithms, namely, Adaptive Memory Programming for Global Optimization (AMPGO) and Particle Swarm Optimization (PSO), are used for this purpose. The extended Oxley’s model is used as the analytical tool for optimization. For determining a parameter’s value, a large range for each parameter is provided as an input to the algorithms. The algorithms converge to several different sets of values for the five Johnson-Cook parameters when all the five parameters are considered as unknown in the optimization algorithm. All of these sets, however, yield the same chip shape and cutting forces in FEM simulations. Further analyses show that only the strain-rate and thermal softening parameters can be determined uniquely and the three parameters present in the strain-hardening term of the Johnson-Cook model cannot be determined uniquely using the inverse method. A combined experimental and numerical approach is proposed to eliminate this determine all parameters uniquely.

42 ENGINEERING↗
DOE OSTI2019

Artificial Intelligence Design of Nuclear Systems

Advanced manufacturing applications in the nuclear industry have the potential to revolutionize nuclear design. While current engineering design objectives may be consistent with objectives from the past, such as those intended to minimize the fuel cost or to limit the maximum fuel temperature for a given power level, the possible geometries which can be considered as candidate designs have changed. Optimizations applied to current designs in nuclear engineering are limited by traditional geometric shapes that are easy to manufacture with traditional processes: slabs as fuel plates, cylinders as fuel rods, spheres as fuel pebbles, axis-aligned coolant channels, and more. Advanced manufacturing allows for an approach to the nuclear design problem with arbitrary geometries that can enable previously unrealized optimizations in performance and cost. This work explores the application of arbitrary geometry to the nuclear engineering design process.

42 ENGINEERING↗
DOE OSTI2020

Data optimization for large batch distributed training of deep neural networks

Distributed training in deep learning (DL) is common practice as data and models grow. The current practice for distributed training of deep neural networks faces the challenges of communication bottlenecks when operating at scale, and model accuracy deterioration with an increase in global batch size. Present solutions focus on improving message exchange efficiency as well as implementing techniques to tweak batch sizes and models in the training process. The loss of training accuracy typically happens because the loss function gets trapped in a local minima. We observe that the loss landscape minimization is shaped by both the model and training data and propose a data optimization approach that utilizes machine learning to implicitly smooth out the loss landscape resulting in fewer local minima. Our approach filters out data points which are less important to feature learning, enabling us to speed up the training of models on larger batch sizes to improved accuracy.

Gahlot, Shubhankar↗
DOE OSTI2021

Shape evolution and growth mechanisms of 3D-printed nanowires

3D printing of nanowires using Focused Electron Beam Induced Deposition (FEBID) enables the direct-write fabrication of complex 3D objects on almost any substrate surface. The physical properties of such freestanding structures are determined by the dimensions of constituent nanowires. However, little knowledge is available about the exact shape of the nanowires, which is indispensable for calculations and simulations as well as for optimization in applications. In this study, we evaluate the thicknesses and widths of freestanding segments as a function of the inclination angles, primary electron energy, beam currents, and precursor flux. Furthermore, the cross-sectional shape, the cross-sectional area, and the evolution along the length of the wire are investigated. Basing on detailed scanning electron microscopy measurements and Monte Carlo/Finite Differences simulations, the effects that the growth parameters have on the segment growth are elucidated. Furthermore, the results shed light on the growth evolution of the structures and form the basis for future studies on the fabrication of high-precision, arbitrarily shaped nanowires.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization

This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.

03 NATURAL GAS↗
DOE OSTI2023

An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

additive manufacturing↗
DOE OSTI2026

Pushing the Limits of Pulse Shape Discrimination in a Large Liquid Xenon Detector

The LUX-ZEPLIN (LZ) experiment is a direct-detection dark matter experiment, optimized to search for weakly interacting massive particles (WIMPs) through WIMP-nucleon interactions. The main challenge in dark matter detection is differentiating between WIMP signals and background events. In LZ, the ratio of ionization to scintillation signals (charge-to-light) is the primary method for rejecting electronic recoil (ER) background. Pulse shape discrimination (PSD) offers a method for additional ER backgrounds rejection in liquid xenon detectors. In this paper, the discrimination power of PSD with the LZ experiment is discussed. To precisely characterize the scintillation pulse shape, an analysis framework is developed to reconstruct the detection time of individual photons. Using LZ calibration data, the photon-timing prompt fraction discriminator is optimized and achieves ER leakage as low as $15\%$. For specific background processes such as $^{124}$Xe double electron capture, the leakage is reduced further to about $5\%$. PSD is combined with charge-to-light to form two-factor discrimination (TFD). The optimized TFD performance is compared with the performance of the charge-to-light method, with the corresponding false positive rate reduced by up to a factor of two for large scintillation pulses. Finally, PSD and TFD are applied to data from LZ's WS2024 run and their performance is summarized.

Akerib, D. S. [SLAC; KIPAC, Menlo Park]↗
DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2025

Solid State Additive Manufacturing of Oxide Dispersion Strengthened-FeCrAl Alloy Components for High-Temperature Supercritical CO2 Power Cycle Applications

In this research, material extrusion additive manufacturing (MEAM) has been explored as an SSAM method for fabrication of 3-D components using ODS-FeCrAl alloy. MEAM-printed 3-D parts go through a series of process steps, e.g., chemical treatment, thermal treatment etc. in order to create a high density fully metallic part. Final 3-D part quality is associated with various process steps, e.g., filament fabrication, print design, and thermal treatment optimization. In MEAM, a metal powder loaded filament is used for printing 3-D shapes. Composition of the filament is very important since it provides shape retention at low-to-medium temperature. There are a few commercially available metallic alloy filaments. However, FeCrAl alloy filaments are not commercially available. In this project, we came up with a method to fabricate high quality composite FeCrAl filaments that could be used for MEAM printing. Subsequently, we have optimized MEAM print methods to fabricate samples that are larger than 10 mm, by using a modular print design approach. Finally, we have been able to optimize the chemical and high temperature heat treatment steps to achieve very high density (>98%) in sintered MEAM-printed products.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Simulation of the NuScale SMR and Investigation of the Effect of Load-Following on Component Lifetimes

The NuScale SMR has been modelled using the Virtual Environment for Reactor Applications (VERA) multiphysics environment and the results compared with the publicly reported data in the Design Certification Application (DCA). The results show an excellent agreement for the compared axial and radial power distributions, temperature coefficients of reactivity, boron and control rod worths, and fast neutron flux. This NuScale model is then used to investigate the effect of different operational modes on reactor components to determine how flexible load-following operation may affect control rod and reactor pressure vessel (RPV) lifetimes. The control rod degradation is confirmed to primarily affect the silver-indium-cadmium (AIC) rod tip. The degradation rate is observed to follow a non-linear function of core power level where the increase in degradation decreases with insertion depth. For the variation in core power levels expected with current load-following schemes, the total control rod degradation is found to be mild, at 5-10% of usable life per cycle for a reactor operating at <80% power. Nonetheless, this enables load following strategies to be confirmed and/or modified to ensure that control rods do not need to be replaced during the 60+ year life of the reactor. The RPV degradation was found to be almost directly proportional to the core power level and was not overly sensitive to flux shape perturbations. Future work is planned using these damage functions to optimize operation over multiple NuScale SMR units and develop strategies for prognostics and health management.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Replication of x-ray blazed gratings by nano-inscribing.

A nano-inscribing technique was tested as a method of cost-effective replication of blazed diffraction gratings for x-rays. A saw-tooth mold for the nano-inscribing was fabricated by a double-replication process from a master blazed grating. The nano-inscribing was performed using a UV-curable resist of low viscosity to provide a small thickness of the resist replicas, required for a following transfer process. The nano-inscribing process was optimized to minimize surface relaxation and preserve the saw-tooth shape of the grooves, required for high diffraction efficiency. The quality of the replica gratings was evaluated via diffraction efficiency simulations. The simulations demonstrated that near theoretical efficiency can be achieved for the x-ray gratings made by the nano-inscribing approach.

blazed grating↗