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DOE OSTI2025

Advancing the STS Neutron Moderator Design with an Automated Optimization Workflow and Unstructured Mesh Modeling

With the Second Target Station approaching its final design phase, a detailed neutronics evaluation of its critical components is necessary. Optimizing the dimensions of the two cold-source moderators that are at the heart of this facility presents a multi-objective optimization problem for which an accurate geometric description is crucial. We have applied a fully automated optimization workflow in which a detailed unstructured mesh geometry is automatically generated with Attila4MC, starting from a parametrized CREO geometry followed by preprocessing with SpaceClaim. With this geometry, a MCNP run is performed to calculate the brightness metrics, which are subsequently provided to the optimization algorithm in DAKOTA that provides new parameters and drives the optimization loop until convergence. In this paper, we show the results of the analysis that are used for the final design of the cylindrical and tube moderator. The optimization simulations provide a refinement to and confirmation of the conclusions of the previous design iteration. Additional to the optimization, a sensitivity study is performed to study the effect of minor geometry changes, which is important for the final engineering design. In conclusion, with these studies, we demonstrate that the automated workflow and high-fidelity unstructured mesh modeling are efficient tools for a thorough design evaluation.

DAKOTA↗

NASA NTRS2014

Optimization of a Lunar Pallet Lander Reinforcement Structure Using a Genetic Algorithm

This paper presents a design automation process using optimization via a genetic algorithm to design the conceptual structure of a Lunar Pallet Lander. The goal is to determine a design that will have the primary natural frequencies at or above a target value as well as minimize the total mass. Several iterations of the process are presented. First, a concept optimization is performed to determine what class of structure would produce suitable candidate designs. From this a stiffened sheet metal approach was selected leading to optimization of beam placement through generating a two-dimensional mesh and varying the physical location of reinforcing beams. Finally, the design space is reformulated as a binary problem using 1-dimensional beam elements to truncate the design space to allow faster convergence and additional mechanical failure criteria to be included in the optimization responses. Results are presented for each design space configuration. The final flight design was derived from these results.

Burt, Adam O.↗

DOE OSTI2022

Development of fast-running eighth core nodal solution

A fast-running, eighth-core solution technique has been developed for the quick core calculations in ANC, the Westinghouse core analysis code based on the nodal expansion method, and the BEACON{sup TM} Core Monitoring System (BEACON). This technique, referred to as 'Fast Eighth' (Fast8), enables users to obtain satisfactory macroscopic core calculation results such as reactivity, axial offset and assembly power much more quickly than calculations performed in the standard full-core or quarter-core geometry. Fast8 uses three techniques: folding the radial geometry into eighth-core geometry, reducing the axial geometry into a coarse axial mesh geometry, and smearing the spacer grids into nodes on-the-fly after the first calculation in the standard geometry. These geometry adjustments in Fast8 contribute to the reduction of the number of neutronic and material nodes while maintaining the reaction rates in each node. The axial mesh condition dependency in Fast8 is investigated in a xenon transient calculation in single assembly geometry, and the Fast8 maximum axial mesh size is determined based on these results. Fast8 is then applied to the load swing calculation, and the results are compared with the reference, full-core geometry, solution. The critical boron concentration and axial offset of Fast8 show good agreement with the reference solutions, and that Fast8 is a good technique for obtaining macroscopic core calculation results in significantly shorter time. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Historical review and proof-of-concept future method demonstration of adaptive mesh refinement in nuclear engineering for increased fidelity and computational efficiency

As the nuclear industry's use of computational tool increases, the need for increased fidelity and computational efficiency is well known. While most approaches to increased fidelity rely on applying a fine mesh over the problem domain, a more efficient method is to apply an adaptive mesh refinement (AMR) algorithm to the mesh definition. In the field of nuclear engineering, AMR has previously been used in conjunction with deterministic methods, including: S{sub N} transport methods, Lattice Boltzmann Methods, and COMSOL. The future of AMR in nuclear engineering is to couple it to a Monte Carlo code with the goal of reducing calculation time. A proof-of-concept example yielded positive results for using the gradient of the flux as a refinement criteria. The refinement criteria was varied from 0.01 to 0.10, which yielded a recommended range of 0.01 to 0.04, and the number of refinement iterations was varied from 0 to 7, with diminishing returns seen after 5 iterations. After the success of the proof-of-concept exercise, work began on creating a full program coupling MCNP6.2 and the AMR algorithm in the deal.II library. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2024

Usage of ChatGPT for Engineering Design and Analysis Tool Development

ChatGPT, a generative AI large language model, has recently captured significant attention in both the computer science community and the broader public domain. It has demonstrated a wide range of capabilities, from answering simple questions to writing fully functional computer code. This study spotlights both the capabilities and limitations of ChatGPT when addressing engineering problems. The model's capacity to generate practical engineering tools is highlighted through an example of a prompt that leads to an interactive plotting tool, enabling the examination of the fluid boundary layer around a fan blade. Subsequently, the paper also uncovers potential pitfalls in ChatGPT’s application, shown through an unsuccessful attempt to use ChatGPT to automate a process in Ansys Workbench through scripting. The research further investigates ChatGPT's proficiency in addressing inquiries and providing explanations about the functionalities of OpenMDAO, an open-source, multidisciplinary design, analysis, and optimization tool developed at NASA Glenn Research Center. Finally, an optimization methodology, developed with ChatGPT’s help, is applied to the structural optimization of a fan blade. The developed optimization method utilizes T-Blade3 for geometry generation, Ansys Mechanical for meshing and finite element analysis, and sci-kit learn’s MLPRegressor method to generate a trained neural network model of the design space. OpenMDAO is then used to find the optimal point within the design space. The outcome is a significant reduction in stress in the optimized model—less than one-fifth of the stress value in the baseline model.

Design↗

NASA NTRSDate not supplied

Usage of ChatGPT for Engineering Design and Analysis Tool Development

Design↗

DOE OSTI2025

Magnetic mesh generation and field line reconstruction for scrape-off layer and divertor modeling in stellarators

The design of divertor targets and baffles for optimal heat and particle exhaust from magnetically confined fusion plasmas requires a combination of fast, low-fidelity models (such as EMC3-Lite (Feng 2022 Plasma Phys. Control. Fusion 64 125012)) for scoping studies and high-fidelity ones (such as EMC3-EIRENE (Feng et al 2014 Contrib. Plasma Phys. 54 426–31)) for verification. Both of those approaches benefit from a magnetic flux tube mesh for fast interpolation and mapping of field line segments (Feng et al 2005 Phys. Plasmas 12 052505). A new automated mesh generator for unstructured quadrilateral flux tubes with adaptive refinement is presented and integrated into FLARE (Frerichs 2024 Nucl. Fusion 64 106034). For HSX with an extended first wall, it is found that several layers of flux tubes can span the entire half field period before splitting is required. This is an advantage over the traditional setup of the EMC3-EIRENE mesh where careful construction of several sub- domains is required already for the much tighter present first wall. In particular, there is no longer the need to manually construct a suitable outer boundary for the mesh. The divide and conquer paradigm with unstructured mesh layout offers a powerful alternative for fast head load approximation that is suitable for integration into optimization workflows. Further examples for W7-X and CTH demonstrate the versatile application range.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2005

A Program to Improve the Triangulated Surface Mesh Quality Along Aircraft Component Intersections

A computer program has been developed for improving the quality of unstructured triangulated surface meshes in the vicinity of component intersections. The method relies solely on point removal and edge swapping for improving the triangulations. It can be applied to any lifting surface component such as a wing, canard or horizontal tail component intersected with a fuselage, or it can be applied to a pylon that is intersected with a wing, fuselage or nacelle. The lifting surfaces or pylon are assumed to be aligned in the axial direction with closed trailing edges. The method currently maintains salient edges only at leading and trailing edges of the wing or pylon component. This method should work well for any shape of fuselage that is free of salient edges at the intersection. The method has been successfully demonstrated on a total of 125 different test cases that include both blunt and sharp wing leading edges. The code is targeted for use in the automated environment of numerical optimization where geometric perturbations to individual components can be critical to the aerodynamic performance of a vehicle. Histograms of triangle aspect ratios are reported to assess the quality of the triangles attached to the intersection curves before and after application of the program. Large improvements to the quality of the triangulations were obtained for the 125 test cases; the quality was sufficient for use with an automated tetrahedral mesh generation program that is used as part of an aerodynamic shape optimization method.

Cliff, Susan E.↗

DOE OSTI2025

Coupled beam-target-moderator optimization for the Second Target Station

To support the design of the Second Target Station, that aims to provide the world’s highest peak brightness of cold neutrons, studies that optimize the dimensions of the target and moderators are invaluable. In this work, we investigate the influence of the target dimensions and beam profile on the performance and optimal size of the moderators. We perform optimization runs with detailed MCNP6.2 simulations using high-fidelity unstructured mesh geometries generated from parametrized CAD models. We demonstrate that small changes in target height do not influence the moderator performance if the beam dimensions are chosen adequately. We quantify the effect of beam footprint and target width on the moderator performance and show that the optimal moderator dimensions are insensitive to limited changes in target and beam profile.

Dakota↗

DOE OSTI2021

Preparing an Incompressible-Flow Fluid Dynamics Code for Exascale-Class Wind Energy Simulations

The U.S. Department of Energy has identified exascale-class wind farm simulation as critical to wind energy scientific discovery. A primary objective of the ExaWind project is to build high-performance, predictive computational fluid dynamics (CFD) tools that satisfy these modeling needs. GPU accelerators will serve as the computational thoroughbreds of next-generation, exascale-class supercomputers. Here, we report on our efforts in preparing the ExaWind unstructured mesh solver, Nalu-Wind, for exascale-class machines. For computing at this scale, a simple port of the incompressible-flow algorithms to GPUs is insufficient. To achieve high performance, one needs novel algorithms that are application aware, memory efficient, and optimized for the latest-generation GPU devices. The result of our efforts are unstructured-mesh simulations of wind turbines that can effectively leverage thousands of GPUs. In particular, we demonstrate a first-of-its-kind, incompressible-flow simulation using Algebraic Multigrid solvers that strong scales to more than 4000 GPUs on the Summit supercomputer.

algebraic multigrid↗

NASA NTRS2017

High-Fidelity Multidisciplinary Design Optimization of Aircraft Configurations

To evaluate new airframe technologies we need design tools based on high-fidelity models that consider multidisciplinary interactions early in the design process. The overarching goal of this NRA is to develop tools that enable high-fidelity multidisciplinary design optimization of aircraft configurations, and to apply these tools to the design of high aspect ratio flexible wings. We develop a geometry engine that is capable of quickly generating conventional and unconventional aircraft configurations including the internal structure. This geometry engine features adjoint derivative computation for efficient gradient-based optimization. We also added overset capability to a computational fluid dynamics solver, complete with an adjoint implementation and semiautomatic mesh generation. We also developed an approach to constraining buffet and started the development of an approach for constraining utter. On the applications side, we developed a new common high-fidelity model for aeroelastic studies of high aspect ratio wings. We performed optimal design trade-o s between fuel burn and aircraft weight for metal, conventional composite, and carbon nanotube composite wings. We also assessed a continuous morphing trailing edge technology applied to high aspect ratio wings. This research resulted in the publication of 26 manuscripts so far, and the developed methodologies were used in two other NRAs. 1

Martins, Joaquim R. R. A.↗

DOE OSTI2026

3D TRISO particle-explicit compact meshing

The TRI-structural ISOtropic (TRISO) layered fuel particle is a robust nuclear fuel form offering enhanced safety and performance for advanced reactor concepts, including high-temperature gas-cooled reactors and other Generation IV designs. These poppy-seed-sized particles are embedded in a graphite matrix to form fuel elements that must withstand elevated temperatures and high burn-up levels. The heterogeneous nature of these fuel elements — comprising thousands of randomly distributed TRISO particles — produces complex stress fields and thermal gradients that one- and two-dimensional models cannot accurately capture. While three-dimensional modeling has improved predictions of dimensional changes, internal pressure buildup, and fission product transport under irradiation, current approaches rely on homogenized material properties that are known to have considerable divergence from experimental observations. This work presents a methodology for optimized random packing of TRISO fuel compacts and full three-dimensional mesh generation within the BISON fuel performance code, with each particle coating layer individually discretized. The resulting mesh was demonstrated through heat conduction simulations under representative in-reactor operating conditions, showing strong agreement with expected behavior. This capability enables detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating layer failures — all of which directly govern fuel performance and safety margins.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1989

Integrated design optimization research and development in an industrial environment

An overview is given of a design optimization project that is in progress at the GE Research and Development Center for the past few years. The objective of this project is to develop a methodology and a software system for design automation and optimization of structural/mechanical components and systems. The effort focuses on research and development issues and also on optimization applications that can be related to real-life industrial design problems. The overall technical approach is based on integration of numerical optimization techniques, finite element methods, CAE and software engineering, and artificial intelligence/expert systems (AI/ES) concepts. The role of each of these engineering technologies in the development of a unified design methodology is illustrated. A software system DESIGN-OPT has been developed for both size and shape optimization of structural components subjected to static as well as dynamic loadings. By integrating this software with an automatic mesh generator, a geometric modeler and an attribute specification computer code, a software module SHAPE-OPT has been developed for shape optimization. Details of these software packages together with their applications to some 2- and 3-dimensional design problems are described.

Kumar, V.↗

NASA NTRS1985

Structural shape optimization - A survey

This paper is a survey of structural shape optimization with an emphasis on techniques dealing with shape optimization of the boundaries of two and three dimensional bodies. Attention is focused on the special problems of structural shape optimization which are due to a finite element model which must change during the optimization process. These problems include the requirement for sophisticated automated mesh generation techniques and careful choice of design variables. They also include special problems in obtaining sufficiently accurate sensitivity derivatives.

Haftka, R. T.↗

DOE OSTI2025

Fuel performance analysis of fully-resolved TRISO compact

The TRi-structural ISOtropic (TRISO) fuel multilayered coating structure offers multiple barriers to fission product release, enhancing safety and performance. The heterogeneous nature of TRISO fuel compacts, comprising thousands of randomly distributed coated fuel particles embedded in a graphite matrix, creates intricate stress fields and thermal gradients that cannot be accurately modeled using simplified one-dimensional or homogenized approaches. Consequently, three-dimensional modeling enables the prediction of fuel compact dimensional changes, internal pressure buildup, and fission product transport pathways under diverse irradiation and thermal conditions. This capability facilitates detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating failures, which directly impact fuel performance and safety margins. This capability is particularly critical for advanced reactors, such as high-temperature gas-cooled reactors and other Generation IV reactor designs where TRISO fuel operates at elevated temperatures and burn-up levels. This work introduces a novel method to generate an optimized packing of TRISO compacts and a complete 3D mesh with random distribution of TRISO particles, which are discretized into each coating component layer.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1995

Aerodynamic shape optimization of wing and wing-body configurations using control theory

This paper describes the implementation of optimization techniques based on control theory for wing and wing-body design. In previous studies it was shown that control theory could be used to devise an effective optimization procedure for airfoils and wings in which the shape and the surrounding body-fitted mesh are both generated analytically, and the control is the mapping function. Recently, the method has been implemented for both potential flows and flows governed by the Euler equations using an alternative formulation which employs numerically generated grids, so that it can more easily be extended to treat general configurations. Here results are presented both for the optimization of a swept wing using an analytic mapping, and for the optimization of wing and wing-body configurations using a general mesh.

Reuther, James↗

NASA NTRS2004

On the Use of Parmetric-CAD Systems and Cartesian Methods for Aerodynamic Design

Automated, high-fidelity tools for aerodynamic design face critical issues in attempting to optimize real-life geometry arid in permitting radical design changes. Success in these areas promises not only significantly shorter design- cycle times, but also superior and unconventional designs. To address these issues, we investigate the use of a parmetric-CAD system in conjunction with an embedded-boundary Cartesian method. Our goal is to combine the modeling capabilities of feature-based CAD with the robustness and flexibility of component-based Cartesian volume-mesh generation for complex geometry problems. We present the development of an automated optimization frame-work with a focus on the deployment of such a CAD-based design approach in a heterogeneous parallel computing environment.

Nemec, Marian↗

DOE OSTI2024

Optimization of the Second Target Station cold source moderators using an automated workflow

The Second Target Station (STS) at the US Department of Energy’s Oak Ridge National Laboratory is designed to become the world’s highest peak-brightness spallation source of cold neutrons. Successful completion of the STS, which is currently in the preliminary design phase, will provide transformative new capabilities to examine novel materials for future technologies. At STS, neutrons will be generated by spallation reactions in a solid tungsten target. They will be moderated and thermalized in two cold (20 K) para-hydrogen moderators. Careful optimization of these moderators is essential to the project’s success. To find optimal moderator designs, an advanced optimization workflow integrates high-fidelity neutronics calculations using the Monte Carlo N-Particle (MCNP) transport code MCNP6.2 with state-of-the-art optimization algorithms in the Dakota optimization toolkit. For each design iteration, a parametrized solid CAD geometry is generated in Creo and automatically converted into an unstructured mesh geometry by Attila 4MC for the neutronics calculation with MCNP. Iterations repeat until optimal designs are found. Herein this paper presents the results of a sensitivity and optimization study for the cylindrical and tube moderators. Both moderators can be optimized for maximum peak brightness, maximum time-integrated brightness, or any combination between these extremes. Maximum peak brightness is achieved by using smaller optimal dimensions of the moderators, whereas maximum time-integrated brightness is achieved by using larger dimensions. A Pareto front details the designs that optimally balance both brightness metrics. The Pareto front can be found in only 40–110 iterations with 4–5 design parameters when using the efficient global and Pareto-set optimization algorithms in Dakota. Additionally, important engineering constraints can be taken into account, such as the coupling between the cylindrical moderator radius and aluminum vessel wall thicknesses required to ensure structural integrity of the vessels. This interaction has a significant impact on the resulting optimal designs. Our new, highly efficient, fully automated optimization workflow will be used to optimize additional STS components in the future and can be adopted for design and optimization studies at other experimental neutron and accelerator facilities.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗