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Results for “robust design”

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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Physics-based modeling and information-theoretic sensor and settings selection for tool wear detection in precision machining

Precision machining of metals is an energy intensive process with applications and impacts across the manufacturing industry. The energy efficiency, product yield, and maintenance of the precision machine require a digital twin that can assist with prognostics and health management. In this report a physics-based model is developed and validated against face milling data, and then used for the timely and precise inference of machining faults that cannot be measured directly. Computer numerical control (CNC) measurements of power and force are used through this physics-based machining model to predict deviations of the outputs of power consumption and cutting forces during normal operation. A model-based fault detection and isolation methodology is applied to determine the optimal (traditional and available) sensor suite and the test settings (admissible input values) that improve the inference of tool wear in face milling. The optimal sensor suite and input test settings are obtained by solving a mixed integer non-linear program that optimizes information-theoretic metrics relevant to the detection and isolation of tool wear from steady-state or transient machining measurements. Dynamic time warping and k—NN classification are then used to validate the robustness of the optimal design for fault detection test design, including the optimal sensor suite.

42 ENGINEERING↗
DOE OSTI2023

Design and performance of the Fermilab Constant Fraction Discriminator ASIC

Here, we present the design and performance characterization results of the novel Fermilab Constant Fraction Discriminator ASIC (FCFD) developed to readout low gain avalanche detector (LGAD) signals by directly using a constant fraction discriminator (CFD) to measure signal arrival time. Silicon detectors with time resolutions less than 30ps will play a critical role in future collider experiments, and LGADs have been demonstrated to provide the required time resolution and radiation tolerance for many such applications. The FCFD has a specially designed discriminator that is robust against amplitude variations of the signal from the LGAD that normally requires an additional correction step when using a traditional leading edge discriminator. The application of the CFD directly in the ASIC promises to be more reliable and reduces the complication of evolving time-walk corrections throughout the operational lifetime of the detector system. We will present a summary of the measured performance of the FCFD for input signals generated by internal charge injection, LGAD signals from an infrared laser, and LGAD signals from minimum-ionizing particles. The mean time response for LGAD signals with charge ranging between 5 and 26 fC has been measured to vary no more than 10ps, orders of magnitude more stable than an uncorrected leading edge discriminator based measurement, and effectively removes the need for any additional time-walk correction. The measured contribution to the time resolution from the FCFD ASIC is found to be 10ps for signals with charge above 20fC.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Towards standardized nuclear reactors: Seismic isolation and the cost impact of the earthquake load case

We report nuclear energy has a key role to play in global decarbonization. Impediments to the widespread deployment of reactors are their projected high capital cost and levelized cost of energy, and time required to analyze, design, license, construct, and commission them. The earthquake load case is a key cost driver for a new build nuclear plant, because near-surface soils and seismic hazard are different at each site, requiring site-specific analysis, design, engineering, qualification, licensing, and regulatory review, essentially making every design First-of-a-Kind (FoaK). To enable deployment at the scale needed for deep decarbonization, the cost and time impact of the seismic load case must be significantly mitigated, and plants must be standardized. Seismic base isolation has been proven to considerably reduce the earthquake response of structures and equipment but has yet to be applied to a nuclear power plant in the United States, in part because the financial impacts, positive or negative, are not known. Because there are no recent non-proprietary data to characterize the influence of the seismic load case on capital cost, it is difficult to confidently quantify the financial benefits of seismic isolation. Scheme-level designs of two fundamentally different advanced reactor buildings were developed to assemble cost data on the influence of the seismic load case. Both buildings were equipped with three bespoke pieces of safety-related equipment and analyzed for incremented levels of earthquake shaking to quantify the seismic penalty on equipment, in terms of vessel weights and horizontal accelerations. Using analysis results, a questionnaire was developed and transmitted to nuclear utilities, reactor developers, engineers, and equipment suppliers to collect cost data on engineering and fabrication costs for these unique pieces of safety-class equipment. Synthesis of the cost data showed that the seismic load case significantly affects the capital cost (sum of engineering and fabrication cost) of safety-class equipment, with engineering costs being comparable to fabrication costs. Standardization of safety-class equipment is made possible by seismic isolation, that is, equipment designed for minimal seismic robustness can resist earthquake shaking at a site of much higher seismic hazard. The average reduction in the capital cost of the safety-related equipment, enabled by seismic isolation, is a factor of two for FoaK equipment and a factor of five for standardized equipment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Sensitivity analysis, surrogate modeling, and optimization of pebble-bed reactors considering normal and accident conditions

This research provides a valuable tool that streamlines the optimization process while significantly increasing its accuracy. This study creates a robust framework for reactor design optimization by incorporating comprehensive modeling using the Comprehensive Reactor Analysis Bundle, or BlueCRAB, within the Multiphysics Object-Oriented Simulation Environment (MOOSE). BlueCRAB is the United States Nuclear Regulatory Commission's code suite for non-light water reactor analysis and includes the Griffin, Pronghorn, and Bison applications. This not only improves the efficiency of the optimization process but also enhances the reliability of the results. Such a tool is essential for advancing the state-of-the-art in pebble-bed reactor technology and is critical for achieving the goals of Generation IV reactors, which aim for safe, sustainable, and economically viable nuclear energy solutions. This work presents and applies this workflow on pebble-bed reactors while considering both normal and off-normal conditions. A representative gas-cooled pebble-bed reactor at equilibrium core conditions serves as the nominal design specification for normal operation and is based on previous research. The depressurized loss-of-forced-cooling accident is deployed for off-normal conditions in this work. After defining design-related parameters and quantities of interest regarding reactor safety and performance, this multiphysics model is sampled using the MOOSE stochastic tools module. The result is a comprehensive dataset of configurations, enabling sensitivity analysis and the generation of surrogate models. Subsequently, the dataset and surrogate models are employed in two optimization studies aimed at maximizing fuel utilization and economic profit while adhering to safety and operational constraints. Performing the optimization process with fuel utilization as the metric leads to an improvement of approximately 10%, compared to engineering-judgment-based nominal conditions. The optimization on economic profit leads to an estimated increase of ~300 million USD over the lifetime of the reactor.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Dara: Automated Multiple-Hypothesis Phase Identification and Refinement from Powder X-ray Diffraction

Powder X-ray diffraction (XRD) is a foundational technique for characterizing crystalline materials. However, the reliable interpretation of XRD patterns, particularly in multiphase systems, remains a manual and expertise-demanding task. As a characterization method that only provides structural information, multiple reference phases can often be fit to a single pattern, leading to potential misinterpretation when alternative solutions are overlooked. To ease humans’ efforts and address the challenge, we introduce Dara (data-driven automated Rietveld analysis), a framework designed to automate the robust identification and refinement of multiple phases from powder XRD data. Dara performs an exhaustive tree search over all plausible phase combinations within a given chemical space and validates each hypothesis using the BGMN Rietveld refinement routine. Key features include structural database filtering, automatic clustering of isostructural phases during tree expansion, and peak-matching-based scoring to identify promising phases for refinement. When ambiguity exists, Dara generates multiple hypothesis which can then be decided between by human experts or with further characterization tools. By enhancing the reliability and accuracy of phase identification, Dara enables scalable analysis of realistic complex XRD patterns and provides a foundation for integration into multimodal characterization workflows, moving toward fully self-driving materials discovery.

Biological databases↗
DOE OSTI2025

Uncovering the True Active Sites in Ni–N–C Catalysts for CO 2 Electroreduction

Understanding and designing active sites in single-atom catalysts (SACs) requires going beyond static models to capture their dynamic evolution under realistic electrochemical conditions. Here, in this work, we develop an integrated theoretical framework that accounts for operational conditions, by combining grand canonical density functional theory (GC-DFT) with machine-learning-accelerated sampling, to uncover structure–activity–stability relationships in Ni–N–C SACs for the CO 2 reduction reaction (CO 2 RR). A library of NiN x C 4–x (x = 0–4) motifs─representing coordination defects likely formed during high-temperature synthesis─was systematically evaluated. Under working conditions, these sites were found to undergo hydrogenation, and NiN 3 C 1_ H 1 was identified as the most probable active site. At reducing potentials, hydrogen adsorbs spontaneously at C–Ni bridge sites rather than Ni top sites, while subsurface hydrogen facilitates bent CO 2 adsorption crucial for activation. High CO 2 RR selectivity toward CO arises from site separation: Ni centers drive CO2RR, while the hydrogen evolution reaction (HER) occurs at the C–Ni bridge or N sites and from thermodynamic suppression of HER at moderate hydrogen coverage. At more negative potentials, a shift in the CO 2 RR rate-determining process (RDP) and Ni out-of-surface displacement induced by coadsorption of H and H 2 O jointly reduce activity and selectivity. Thus, both the high CO2RR selectivity of Ni–N–C catalysts and its reversal with more negative potentials can be rationalized by accounting for hydrogenated surfaces. This highlights the necessity of modeling realistic; in situ conditions. This framework provides generalizable insights into the dynamic behavior of active sites in SACs, offering guidance for the rational design of active and robust catalysts for a wide range of electrochemical reactions.

25 ENERGY STORAGE↗
DOE OSTI2021

Directing reaction pathways via in situ control of active site geometries in PdAu single-atom alloy catalysts

Abstract The atomic scale structure of the active sites in heterogeneous catalysts is central to their reactivity and selectivity. Therefore, understanding active site stability and evolution under different reaction conditions is key to the design of efficient and robust catalysts. Herein we describe theoretical calculations which predict that carbon monoxide can be used to stabilize different active site geometries in bimetallic alloys and then demonstrate experimentally that the same PdAu bimetallic catalyst can be transitioned between a single-atom alloy and a Pd cluster phase. Each state of the catalyst exhibits distinct selectivity for the dehydrogenation of ethanol reaction with the single-atom alloy phase exhibiting high selectivity to acetaldehyde and hydrogen versus a range of products from Pd clusters. First-principles based Monte Carlo calculations explain the origin of this active site ensemble size tuning effect, and this work serves as a demonstration of what should be a general phenomenon that enables in situ control over catalyst selectivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Machine learning for endoleak detection after endovascular aortic repair

Diagnosis of endoleak following endovascular aortic repair (EVAR) relies on manual review of multi-slice CT angiography (CTA) by physicians which is a tedious and time-consuming process that is susceptible to error. We evaluate the use of a deep neural network for the detection of endoleak on CTA for post-EVAR patients using a novel data efficient training approach. 50 CTAs and 20 CTAs with and without endoleak respectively were identified based on gold standard interpretation by a cardiovascular subspecialty radiologist. The Endoleak Augmentor, a custom designed augmentation method, provided robust training for the machine learning (ML) model. Predicted segmentation maps underwent post-processing to determine the presence of endoleak. The model was tested against 3 blinded general radiologists and 1 blinded subspecialist using a held-out subset (10 positive endoleak CTAs, 10 control CTAs). Model accuracy, precision and recall for endoleak diagnosis were 95%, 90% and 100% relative to reference subspecialist interpretation (AUC = 0.99). Accuracy, precision and recall was 70/70/70% for generalist1, 50/50/90% for generalist2, and 90/83/100% for generalist3. The blinded subspecialist had concordant interpretations for all test cases compared with the reference. In conclusion, our ML-based approach has similar performance for endoleak diagnosis relative to subspecialists and superior performance compared with generalists.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Exploring the mobility of Cu in bimetallic nanocrystals to promote atomic-scale transformations under a reactive gas environment

Bimetallic nanocrystals (NCs) often show improved catalytic activities compared to their monometallic counterparts, but to optimize the performance it is crucial to understand how they behave under actual reaction conditions, i.e. in gas environments. Here, in this study, we use powder X-ray diffraction (PXRD), total scattering (TS) with pair distribution function (PDF) analysis and in situ high-resolution transmission electron microscopy (HR-TEM) to provide new insights into the atomic-scale behaviour of NC catalysts under a reactive gas environment. By investigating Au, Cu, Pd, PdCu, AuPd and AuCu NCs, we observe that the properties of bimetallic NCs differ significantly from their monometallic counterparts. While metal oxide phases formed for monometallic Pd and Cu under O 2 -exposure, bimetallic PdCu and AuCu NCs showed loss of metallic Cu in the crystalline phases after exposure to O 2 . However, upon introducing the bimetallic NCs to a reducing atmosphere, the Cu was found to reappear and reincorporate into a crystalline phase, forming the initial bimetallic structures. By combining TS, PDF analysis and in situ HR-TEM, we saw that Cu segregates to the NC surfaces or forms small CuO domains under O 2 -exposure. Our results thus indicate that the Cu mobility promotes segregation and formation of CuO along with the formation of a monometallic phase, which ultimately changes the resulting active surface sites of the nanocatalyst. Understanding the dynamical structure–property relations of nanocatalysts is key to enable rational design of efficient and robust catalysts for controlled catalytic reactions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Rare‐Earth Reduction in High‐Speed PM‐Assisted Synchronous Reluctance Motors Using Hybrid Magnet Strategies and Design Optimisation for 800 V EVs

The trend towards electrifying transportation systems has stimulated research endeavours aimed at developing electric machines that are not only high speed and efficient but also low‐cost and compact. To support this transition, the US Department of Energy (DOE) has established ambitious targets of $7/kW cost and 12 kW/L power density for the electric drivetrains. This paper attempts to meet these targets by proposing high‐speed permanent magnet assisted synchronous reluctance machine (PMASynRM) topologies enabled by hybrid magnet strategies, combining rare‐earth (RE) magnets with low‐cost, RE‐free alternatives. Modified 2‐layer and 3‐layer U‐shaped rotor configurations, featuring structural reinforcements to withstand high mechanical stress at elevated speeds, are developed. A multi‐objective design optimisation framework is employed to optimise the rotor design, targeting reductions in RE magnet volume, magnet demagnetisation risk and torque ripple while achieving the desired electromagnetic performance. A comprehensive analysis of the optimised rotor designs, compared against a 16,000 rpm, 800 V baseline IPM motor, shows over 70% RE reduction, demagnetisation risk below 3.5% and torque ripple under 10%. Detailed analyses of performance trends across various magnet combinations and rotor configurations highlight the viability of hybrid magnet PMASynRM designs as cost‐effective, robust and energy‐efficient solutions for next‐generation EVs.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Non-autoregressive time-series methods for stable parametric reduced-order models

Advection-dominated dynamical systems, characterized by partial differential equations, are found in applications ranging from weather forecasting to engineering design where accuracy and robustness are crucial. There has been significant interest in the use of techniques borrowed from machine learning to reduce the computational expense and/or improve the accuracy of predictions for these systems. These rely on the identification of a basis that reduces the dimensionality of the problem and the subsequent use of time series and sequential learning methods to forecast the evolution of the reduced state. Often, however, machine-learned predictions after reduced-basis projection are plagued by issues of stability stemming from incomplete capture of multiscale processes as well as due to error growth for long forecast durations. To address these issues, we have developed a non-autoregressive time series approach for predicting linear reduced-basis time histories of forward models. In particular, we demonstrate that non-autoregressive counterparts of sequential learning methods such as long short-term memory (LSTM) considerably improve the stability of machine-learned reduced-order models. Further, we evaluate our approach on the inviscid shallow water equations and show that a non-autoregressive variant of the standard LSTM approach that is bidirectional in the principal component directions obtains the best accuracy for recreating the nonlinear dynamics of partial observations. Moreover-and critical for many applications of these surrogates-inference times are reduced by three orders of magnitude using our approach, compared with both the equation-based Galerkin projection method and the standard LSTM approach.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Detrimental effects and mitigation of the joint feature in double shell implosion simulations

Double shell capsules provide an attractive option in inertial confinement fusion experiments due to their potential for achieving a low-convergence, robust burn. However, these designs suffer from symmetry degradation and accompanying reduced fuel confinement due to the currently necessary joint between the two hemispheres of the outer shell. Here, the gap widens as a result of the excess ablation pressure produced by x rays that penetrate the joint during the drive phase, and this perturbation grows and imprints onto the inner shell during the collision. xRAGE Eulerian radiation-hydrodynamic simulations predict significant reductions in deuterium–tritium fusion yields compared to joint-less simulations when the depth of the outer joint is increased, whereas the performance is less sensitive to the depth of the inner gap. Here we examine the technique of plating the insides of the outer gap with a high-Z material to mitigate the impact of this feature. Gold-plating in quantities comparable to or exceeding the “missing” outer shell mass shows promise toward restoring both implosion symmetry and yield closer to the joint-less levels, and synthetic diagnostics suggest that high-energy x-ray radiographs can capture this shape retention of the inner and outer shells in experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Design options for achieving burning plasma and gain for next-generation laser direct-drive facilities

The development of next-generation laser technology opens up the potential to build a direct-drive inertial confinement fusion facility that is capable of reaching burning plasma or ignition conditions at moderate laser energies in the hundreds of kilojoules. The addition of bandwidth to the laser source and the use of focal-spot zooming are predicted to significantly increase the ablative drive pressure, while a larger number of beam-ports (∼100) will keep irradiation nonuniformities below an acceptable limit. This study outlines target design options for reaching burning plasma and ignition using laser direct-drive (LDD). It is shown that such designs are predicted to robustly reach ignition at a laser drive energy of 250 kJ. Two-dimensional (2D) simulations are used to investigate the scaling of target performance vs power imbalance, mispointing and imprint. The simulations confirm that 250 kJ is sufficient to maintain gain above unity when perturbed with the amount of power imbalance, mispointing and laser imprint achievable in current direct-drive experiments on OMEGA.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Logical gates embedding in artificial spin ice

The realization and study of arrays of interacting magnetic nanoislands, such as artificial spin ices, have reached mature levels of control that allow design and demonstration of exotic, collective behaviors not seen in natural materials. Advances in the direct manipulation of their local, binary moments also suggest a use as nanopatterned, interacting memory media, for computation within a magnetic memory. Recent experimental work has demonstrated the possibility of building logic gates from clusters of interacting magnetic domains, and yet the possibility of large scale integration of such gates can prove problematic even at the theoretical level. Here we introduce theoretically complete sets of logical gates, in principle realizable in an experiment, and we study the feasibility of their integration into tree-like circuits. By evaluating the fidelity control parameter between their collective behavior and their expected logic functionality we determine conditions for integration. Also, we test our numerical results against the presence of disorder in the couplings, showing that the design gate structure is robust to small coupling perturbations, and thus possibly to small imperfections in the fabrication of the islands.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

The construction of large-scale structure catalogs for the Dark Energy Spectroscopic Instrument

We present the technical details on how large-scale structure (LSS) catalogs are constructed from redshifts measured from spectra observed by the Dark Energy Spectroscopic Instrument (DESI). The LSS catalogs provide the information needed to determine the relative number density of DESI tracers as a function of redshift and celestial coordinates and, e.g., determine clustering statistics. We produce catalogs that are weighted subsamples of the observed data, each matched to a weighted `random' catalog that forms an unclustered sampling of the probability density that DESI could have observed those data at each location. Precise knowledge of the DESI observing history and associated hardware performance allows for a determination of the DESI footprint and the number of times DESI has covered it at sub-arcsecond level precision. This enables the completeness of any DESI sample to be modeled at this same resolution. The pipeline developed to create LSS catalogs has been designed to easily allow robustness tests and enable future improvements. We describe how it allows ongoing work improving the match between galaxy and random catalogs, such as including further information when assigning redshifts to randoms, accounting for fluctuations in target density, accounting for variation in the redshift success rate, and accommodating blinding schemes.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Longitudinal coherence and short-term wind speed prediction based on a nacelle-mounted Doppler lidar

The spatial structure of turbulence in atmospheric boundary layer flows is highly relevant to wind energy. In particular, wind turbine control strategies based on inflow preview measurements require knowledge of the longitudinal evolution of turbulent flow as it approaches the rotor. These upstream measurements are usually obtained with nacelle-mounted wind lidars. In contrast to traditional in situ anemometry, lidars collect measurements within a probe volume which varies in size depending on the technology of the commercial system being used. Here, we address two issues related to the use of wind lidar to measure the incoming flow to a wind turbine: (i) whether existing longitudinal coherence models can be used to predict flow at the rotor, based on measurements performed at a distance away from the rotor; and (ii) what effect probe-volume averaging has on the inflow predictions. These two questions are critical to the design and implementation of robust wind turbine control strategies. To address these questions, we perform field measurements and large-eddy simulations to determine which incoming flow structures can be readily predicted with existing coherence models, and which require additional corrections to account for lidar volumetric averaging effects. Results reveal that the wind turbine induction zone has a negligible impact on the longitudinal coherence and first-order turbulence quantities, such as the standard deviation of velocity fluctuations. However, the phase of the signal, from which advection time periods of the turbulent structures are derived, is affected by the rotor blockage effect.

17 WIND ENERGY↗