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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 55 records · Page 3

Development of city buildings dataset for urban building energy modeling

Urban building energy modeling (UBEM) is becoming a proven tool to support energy efficiency programs for buildings in cities. Development of a city-scale dataset of the existing building stock is a critical step of UBEM to automatically generate energy models of urban buildings and simulate their performance. This study introduces data needs, data standards, and data sources to develop city building datasets for UBEM. First, a literature review of data needs for UBEM was conducted. Then, the capabilities of the current data standards for city building datasets were reviewed. Moreover, the existing public data sources from several pioneer cites were studied to evaluate whether they are adequate to support UBEM. The results show that most cities have adequate public data to support UBEM; however, the data are represented in different formats without standardization, and there is a lack of common keys to make the data mapping easier. Finally, a case study is presented to integrate the diverse data sources from multiple city departments of San Francisco. The data mapping process is introduced and discussed. It is recommended to use the unique building identifiers as the common keys in the data sources to simplify the data mapping process. Furthermore, the integration methods and workflow are applied to other U.S. cities for developing the city-scale datasets of their existing building stock, including San Jose, Los Angeles, and Boston.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Deformation Behavior and Microstructure Evolution of Powder Metallurgy Ti6Al4V Alloy During Hot Compression

In order to determine appropriate workability parameters for cross-wedge rolling products of powder metallurgy (PM) Ti6Al4V alloys, thermal compression experiments were carried out within the temperature range of 850-1050 °C, the strain rate range of 0.1-10 s{sup −1}, and with a height decrease of 60%. The compression deformation behavior was investigated. A strain-compensated constitutive model was established based on the flow stress curves corrected by the friction, which can predict the flow behaviors under the entirety of the experimental deformation conditions. Moreover, the processing map was developed, and stable and unstable deformation regimes were established. The microstructure analysis illustrated that globularization and dynamic recrystallization were the main deformation mechanisms. The porosity of the compressed samples was greatly reduced and influenced by the temperature and strain rate. Considering the material flow stress, hot processing map, microstructure and porosity, the appropriate hot deformation parameters for PM Ti6Al4V alloy preforms are suggested.

36 MATERIALS SCIENCE↗

Spatial and Temporal Interpolation Analysis Process of Shock Loading

The following document serves to describe the current process that is utilized by W-13 analysts to approximate the pressure-time boundary condition seen by a test object from shock tube loading. The intent of this report is to capture the current capability and to encourage continued growth and development. Information on the required input variables, mapping process, and generated output information is covered in the following sections. Throughout the document, gaps and weaknesses of the mapping process are noted to encourage future development efforts.

42 ENGINEERING↗

Effect of Mn addition on deformation behaviour of 23% Cr low nickel duplex stainless steel

Highlights: • Increasing Mn content obviously affects dynamic softening behaviour of flow curves. • More complete austenite DRX occurred with middle Mn addition of 10.3% at 1 s{sup −1}. • The constitutive equations for different Mn addition alloys are developed. • The values of activation energy and Z parameter are lowest with middle Mn addition. • Different Mn addition processing maps with increasing strain were established. - Abstract: Isothermal compression testing of 23% Cr low nickel duplex stainless steels, with different Mn concentrations, was investigated in the temperature range of 1173–1423 K, the strain rate range of 0.01–10 s{sup −1} and with a height reduction of 70%. Increasing the Mn content from 6.3 to 14.1% affected the deformation dynamic softening behaviour of flow curves at lower temperature and higher strain rate. It was also observed that increasing the deformation stain rate contributed to flow softening, and was caused by dynamic recrystallization (DRX) as a function of Mn addition. Deformation microstructure analysis demonstrated that more complete austenite phase DRX occurred with 10.3% Mn addition than that with 6.3% Mn addition at 1 s{sup −1}, but an excessive Mn content of 14.1% was unfavourable due to the increase of austenite fraction and stacking fault energy enhancement. Increasing the strain rate to 10 s{sup −1} promoted austenite phase DRX at 1323 K with the Mn addition under large strain. Meanwhile, the ferrite phase DRX occurred at 1173 K/1–10 s{sup −1} with 6.3% Mn, and was weakened with higher Mn addition. Compared to the 6.3% and 14.1% Mn, continuous DRX occurred at 1323 K/1 s{sup −1} with 10.3% Mn, due to the larger fraction of high angle misorientations. The values for the activation energy and Zener–Hollomon parameter decreased with Mn addition from 6.3 to 10.3%, and then increased with a higher Mn addition of 14.1%, indicating that a proper content of Mn addition can reduce the thermal deformation resistance and promote DRX. The constitutive equations for different Mn addition alloys were developed using a hyperbolic sine equation. Processing maps with different Mn addition for the strains of 0.3, 0.6 and 1.2 were established. The 10.3% Mn content sample corresponded to the lowest instability region, implying that the workability was improved with the middle Mn addition.

36 MATERIALS SCIENCE↗

Hot Deformation Behavior of the 20 vol.% TiC/Cu-Al{sub 2}O{sub 3} Composites

Hot deformation behavior of the 20 vol.% TiC/Cu-Al{sub 2}O{sub 3} composite was studied using the Gleeble-1500D thermo-mechanical simulator with various strain rates at different deformation temperatures. The softening mechanism due to dynamic recrystallization was a feature of the high-temperature true stress–strain curves. The peak stress increased at the lower deformation temperature and the higher strain rate. Microstructure evolution was explored. Thermal deformation activation energy was calculated as 218.9 kJ/mol, and the constitutive equation was established. The processing map was constructed to obtain optimal processing domain of 700-850 °C and 0.001-0.04 s{sup −1} for hot working.

36 MATERIALS SCIENCE↗

Spectral analysis and temperature measurement during flash sintering under AC electric field

In-situ diffraction experiments were used to study the change in peak profiles of 8YSZ during conventional sintering and flash sintering under AC electric field. Using calibration from a conventionally heated standard, the lattice expansion of 8YSZ under flash conditions was correlated to actual specimen temperature, indicating temperature comparable to that required for conventional sintering. At higher current densities, a temperature rise greater than 2000 °C was reached, which resulted in abnormal grain growth and temperature instability. Microstructural analysis demonstrated that finer grain size can be achieved by limiting the current in order to avoid high specimen temperatures. Experiments varying the thickness of the green compact resulted in higher heat loss due to thermal conduction and corresponding reduction in final density. A replacement to the blackbody radiation model was successfully used to fit the data and explain all effects based on Joule heating as well as provide a flash sintering processing map incorporating furnace temperature, power dissipation, and sample geometry.

36 MATERIALS SCIENCE↗

New Tank Mapping Method Improves Waste Removal Process

Waste Tank Mapping Overview • Camera inspections are performed within available tank top risers and used to create waste tank maps – Several camera inspections are performed during waste removal transfers to verify the elevation of the visible salt/sludge mounds against the known elevation of the liquid surface • Tank mappings are used to evaluate the volume and distribution of saltcake or sludge that is present within the waste tank – Allows for refined operating strategies and process safety controls • New tank mapping process creates a standardized approach for accurately defining waste distribution within a waste tank while minimizing the required camera inspection footage – First utilized during the 2023 Tank 22 Sludge Removal Campaign

Mini, Melany [Savannah River Mission Completion (S↗

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗

Stakeholder Analysis Report Subtask 3.3 – CarbonSAFE Illinois East Sub-Basin Topical Report 8

Effective stakeholder engagement has been proven to be a critical component in the success of numerous CCS activities and is essential if the technology is to be widely developed in the future. This report contains a stakeholder assessment and highlights some engagement activities conducted during the CarbonSAFE Illinois East Sub-Basin Prefeasibility study. This report is intended to lay the groundwork and provide recommendations for the Wabash CarbonSAFE Feasibility project, currently underway in conjunction with the Wabash Valley Resources ammonia plant retrofit taking place at the former Terre Haute US DOE integrated gasification combined cycle plant. The analysis sets the stage for identifying and understanding the concerns of key stakeholders, describes actions currently underway, highlights perceptions of potential benefits and risks of project activities, and provides recommendations for short- and long-term forms of engagement. This study used social site characterization methods to better understand local and regional stakeholder positions and needs. The stakeholder engagement strategy will emphasize engagement with stakeholders that enable project development and those that are impacted by the project. The stakeholder analysis process can be broken down into the four basic steps of: identifying, analyzing, mapping, and prioritizing. Various stakeholders were identified by literature search, and additionally by a group of approximately twenty Indiana University SPEA master’s students via a stakeholder workshop. The stakeholder analysis and mapping process is used to help prioritize stakeholder engagement strategies; engagement strategies must be developed with particular stakeholder concerns in mind and messages tailored to those stakeholders’ needs. The stakeholder map with engagement strategy developed for this analysis suggests state government, industry, federal government, and state education are predicted to have the highest interest and influence and should be a priority focus in engagement. Local media, local landowners, local government, and utilities are predicted to have high influence but low interest and may also be a high priority group to engage. Environmental and economic impacts of activities that are considered to be important by stakeholders in the present day (key) or activities that have taken place in the past (legacy) can impact stakeholder perspectives and need to be considered when creating a stakeholder engagement strategy. The issue of environmental clean-up was identified in both the social media analysis and also through USEPA Environmental Justice analysis tools. Thus, it is clear this will be an important factor for consideration in any stakeholder engagement conducted in and around Terre Haute. Furthermore, stakeholder engagement education materials will need to emphasize that carbon dioxide is not a hazardous material, as well as address FAQs regarding CCS. In addition, recommendations for consideration when developing the stakeholder engagement strategy for projects in the Illinois East Sub-Basin in general and related to the Wabash CarbonSAFE project specifically include: drawing clear lines of responsibility between Wabash Valley Resources and ISGS-led Wabash CarbonSAFE that allow the projects to manage integration and messaging; the need for ISGS and other partners to maintain objectivity and remain trusted sources of information; monitoring of social media and continuing to engage with key stakeholder groups; and providing support for key stakeholders to become sources of project information and project champions.

01 COAL, LIGNITE, AND PEAT↗

A High-Throughput Method to Define Additive Manufacturing Process Parameters: Application to Haynes 282

This paper demonstrates how an analytical and experimental method can be used to rapidly define the 45 additive manufacturing settings for a new alloy where the process parameters were previously unknown. A nickel-based superalloy, Haynes 282, was chosen for the analysis. An experimental matrix of focused processing parameters was predicted with a dimensionless number and 100 samples were printed using the Selective Laser Melting technique. High-throughput measurements validated the predicted process conditions needed to achieve desired density and hardness. The whole process was completed in 16 hours. The new technique was confirmed with analytical processing maps adopted by the metal additive manufacturing community. With the predicted set of process parameters, microstructural characterizations and tensile testing were used to confirm the predictions. The resultant as-fabricated microstructures have refined length scales of both microsegregation and secondary phase distributions. As a result, the mechanical properties were comparable within the predicted processing window and exhibited high strength and high ductility.

Laser Material Processing↗

CryoTEN: efficiently enhancing cryo-EM density maps using transformers

Abstract Motivation Cryogenic electron microscopy (cryo-EM) is a core experimental technique used to determine the structure of macromolecules such as proteins. However, the effectiveness of cryo-EM is often hindered by the noise and missing density values in cryo-EM density maps caused by experimental conditions such as low contrast and conformational heterogeneity. Although various global and local map-sharpening techniques are widely employed to improve cryo-EM density maps, it is still challenging to efficiently improve their quality for building better protein structures from them. Results In this study, we introduce CryoTEN—a 3D UNETR++ style transformer to improve cryo-EM maps effectively. CryoTEN is trained using a diverse set of 1295 cryo-EM maps as inputs and their corresponding simulated maps generated from known protein structures as targets. An independent test set containing 150 maps is used to evaluate CryoTEN, and the results demonstrate that it can robustly enhance the quality of cryo-EM density maps. In addition, automatic de novo protein structure modeling shows that protein structures built from the density maps processed by CryoTEN have substantially better quality than those built from the original maps. Compared to the existing state-of-the-art deep learning methods for enhancing cryo-EM density maps, CryoTEN ranks second in improving the quality of density maps, while running >10 times faster and requiring much less GPU memory than them. Availability and implementation The source code and data are freely available at https://github.com/jianlin-cheng/cryoten.

Biochemistry & Molecular Biology↗

Rapid Solidification Effects in Additively Manufactured Si and SiGe Compositions

SiGe alloys have a proven track record as robust high-temperature thermoelectric materials, powering NASA missions like SNAP-10A, LES-9, and Voyager 1 and 2. Enhancing thermoelectric efficiency hinges on minimizing thermal conductivity while preserving electrical conductivity. Rapid solidification via LPBF can generate microstructural features such as subgrain cellular boundaries and twinning, which may help reduce thermal conductivity while preserving semiconducting behavior. Here, this study investigates the potential of laser powder bed fusion (LPBF) additive manufacturing to fabricate nanostructured Si and SiGe thermoelectric materials. High cooling rates (10 5 to 10 7 K/s) rates inherent to the LPBF process are conducive to forming such nanostructures. Moreover, this fabrication technique could also be suitable for fabricating complex geometries needed to achieve improved device level performance. Process mapping of commercial Si powder with irregular morphology was first performed to understand the LPBF processing behavior of this semiconductor material. Subsequent studies included in-house synthesized B-doped (p-type) Si7 8 Ge 22 spherical powder that was produced via ultrasonic atomization. Scan strategies involved multiple laser exposures to mitigate solidification cracking: a high density of >98% was achieved, but solidification cracking could not be fully eliminated. Subsequently, a high electrical resistivity (i.e., low conductivity) was observed, but the measured Seebeck coefficient, ∼230 μV/K @ 500 °C, proved that good semiconductor material was being fabricated. A subgrain cellular structure (5–10 μm) was observed as defined by Ge segregation to the intercellular boundaries. The remelting strategies helped lower the cooling rates in processing SiGe, but this still resulted in high residual stresses, which induced a remarkably high density of twins (78–95%) to accommodate the deformation. This unique grain structure offers an avenue for phonon scattering and potential improvements in thermoelectric performance.

figure of merit↗

Managing Through Continuous Improvement: If it doesn’t challenge you, it won’t change you

The past 24 months has been one of non-stop continuous improvement – every month, every week, every day, and every hour. It has been filled with continuously re-examining and challenging business systems, work processes, and legacy culture. The journey was difficult, but well worth it. It began by examining the existing conditions in each organization and building the case for change. When we stepped back and looked at our processes, systems, tools, and performance objectively, we realized we were struggling with frequent organizational, resource, and schedule conflicts, work processes that were not well-defined or expert based, project delays were common, management methods were predominantly reactive, advanced planning was limited to the near-term, no integration in scheduling across organizations, limited to no performance metrics to measure and manage performance, and internal and external customers did not feel like we were meeting their quality and performance expectations. It was a wake-up call. Change began at the top with a change leadership with where a new vision, expectations, and commitment were established. Leaving no stone left unturned, every aspect of the business was challenged which opened up communication and exposed the gaps. This was done in a ‘safe’ environment allowing for honest and solution-oriented discussion and action. The leadership team committed to managing through continuous improvement. The organizational structure was realigned to better align scope, responsibilities, execution, and customer focus. Visibility and transparency became the norm as higher levels of leadership and supporting organizations were invited to be part of regular strategy meetings and partnership discussion, effectively opening up the dialogue. This required a tremendous amount of trust and faith in a short period of time. Health assessments were conducted on each organization with specific lines of inquiry. These self-assessments helped to identify better define the scope of the organization and where targeted improvements were needed. Frequent organizational reviews were implemented to answer three fundamental questions: 1) What is your organization paid to do (scope)?, 2) How does your organization, or you, demonstrate that you are doing the job effectively?, and 3) What are you doing to improve your performance? To answer the first question, leaders defined the scope of the organization. Leaders were required to provide a path forward, with specific actions, where performance was not at expected levels internally at first and then from the stakeholders. Where business processes were not clearly understood, process maps were developed to provide this clarity for both those performing the work and those utilizing the process – the customers. To help answer the second question, numerous automated or semi-automated real-time, dynamic performance metrics were developed and implement to help leaders gain the visibility and demonstrate performance in six areas of operational excellence: safety, security, quality, effectiveness, productivity, and sustainability. Analysis of the performance provided windows of transparency and trends of work performance, work delays, cycle times, utilization, and much more that revealed many areas of improvement that were either not visible or desired to be visible. At the same time, they provided real-time progress which generated initial performance improvements by just beginning to measure. To address the third question, where systems did not support effectiveness of an existing or new process, then systems and tools were developed and implemented to drive the right behaviors and reinforce the processes. Tools and metrics were one of the major catalysts for culture shift and change. Risk assessments were leveraged into continuous improvement strategies, plans, and schedules. Targeted initiatives were identified and performed. Change and improvement was not, and is not, without significant and common challenges including limited/fixed budgets, resource availability, data access, natural resistance to change, and numerous other reasons or excuses – we called them ‘off-ramps’ and began to close them one-by-one. The results and outputs were significant and impactful in each organization and across the business with increased productivity, efficiency, visibility, accountability, management, and performance. Stakeholder satisfaction also increased. Cost and time savings allowed to more continuous improvement efforts to be performed. The effort clearly provided clear and measurable return on investment and value. Efforts that once seemed impossible, not feasible, or not achievable were performed. Decades-long issues were solved. ‘Impossible things are simply those which so far have never been done’ said Elbert Hubbard. So what will the next year be for you and your organization? Are you satisfied with the ‘same ‘ol, same ‘ol?’ Will you fall into the complacency trap and believe that change is too difficult, too expensive, and not necessary (or any number of possible excuses) or will you make this year your year or continuous improvement (and every year thereafter…)? Remember – what you do today can improve all your tomorrows’ (Ralph Marston).

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

Towards a Comparative Assessment of Data-Driven Process Models in Health Information Technology

Process mining for conformance analysis focuses on comparing a reference process model against a data-driven process model that is generated via log files from information technology systems. While this approach is helpful when there is an existing process model in an organization, it leaves the question of what to do in the absence of a complete reference process model unanswered. In this paper, we present a comparative assessment approach that combines process mining, process mapping for dimensionality reduction, and statistical analysis. Our goal is to find similarities and dissimilarities in data-driven process models among U.S. Veterans Health Administration (VHA) facilities to assess process conformance among different healthcare facilities, which can help assess the standardization of care. We illustrate our approach by applying it to two clinical radiology order process models generated by two similar facilities. Our results demonstrate statistical similarities in the standardization of care among those two facilities.

Klasky, Hilda↗

Comparative Assessment of Data-driven Process Models in Health Information Technology

Process mining for conformance analysis consists of comparing a reference process model against a data-driven process model generated via log files from information technology systems. However, in the absence of a complete reference process model, we found no suggested approaches in the literature to address the need for evaluating process conformance among different healthcare facilities to assess standardization of care. Our goal is to find similarities and dissimilarities in data-driven process models among US Veterans Health Administration (VHA) facilities that can be indicative of patient safety issues. Our hypothesis was that the analysis would not produce statistically significant differences in outcome. We present a unique implementation of conformance analysis in process mining that consists of combining process mining, process mapping and statistical metrics. We illustrate our approach by applying it to the analysis of two clinical radiology order process models generated from healthcare data provided by two similar facilities in the VHA. The comparative assessment showed that about 70% of the orders completed successfully and 30% were not completed due to policy and duplications. Our analysis found a good statistical correlation between both facilities, as the Spearman’s correlation coefficient between facilities for the frequency of cases per total hours was 0.87879, for the frequency of cases by state transition was 0.79702 and for the throughput time per state transition was 0.63582. Additional statistical analyses using the Mann-Whitney U test and the root mean square error both produced values that were not significant. The foregoing approach validated our hypothesis by demonstrating a good statistical correlation of data describing the flow of clinical radiology orders absent a credible reference model. Finding good agreement between both facilities was important in confirming that the clinical orders flow in a similar manner, suggesting standardization of care.

97 MATHEMATICS AND COMPUTING↗

Experimental Study on the Hot Deformation Characterization of Low-Carbon Nb-V-Ti Microalloyed Steel

X80 steel, as typical low-carbon Nb-V-Ti microalloyed steel, is getting more and more attention in oil and gas transmission pipeline manufacturing. In this paper, the hot deformation behavior of X80 steel has been investigated. Hot compression tests of the steel were conducted under different temperatures and strain rates. Based on the experimental data, the flow stress constitutive equations were established. It is found that the hot deformation activation energy of this steel is higher than C-Mn and low-carbon steel. Then, the kinetics model and grain size model of dynamic recrystallization were developed according to the flow curves and the optical microstructures. In addition, the processing maps were developed to analyze the workability of X80 steel at elevated temperature. The analysis results show that the optimum processing window is at the temperature of 1300-1473 K and the strain rate of 0.01-10 s{sup −1}. The microstructure observation indicates that the optimum processing parameters are applicable to the tested steel.

36 MATERIALS SCIENCE↗

Systematic analysis of melt pool dynamics in laser processing of mixed powder feedstocks

Functionally graded materials (FGMs) fabricated via additive manufacturing of blended powders offer the potential to spatially tailor properties for new technologies, such as fusion first-wall systems, turbine blades, and spacecraft. However, processing these materials is difficult due to the multiplicity of processing parameters to optimize, all of which must be changed as substrate material, powder feedstock compositions, and melt pool dynamics evolve. Here, this work systematically evaluates the qualitative and quantitative effects of these variables on the melt pool size, shape, composition, and particle distribution in an exemplar Ti-Ta system, and connects the experimental results to Marangoni flow behavior and phenomena observed in other systems. Increasing laser power linearly increases melt pool size and layer thickness, driving engineering considerations such as part/geometrical tolerances. Decreasing laser velocity changes the melt pool shape from lenticular to convex and reduces chemical homogeneity due to extreme thermal and compositional gradients between the melt pool center and boundaries. Thermophysical property differences between the powder feedstock and substrate material, as well as the directionality of the gradient, affect dilution and melt pool dynamics, which in turn affect the melt pool boundary characteristics, shape, and uniformity. Mixed powder feedstocks of intermediate compositions do not behave according to linear interpolations between single-material endpoints, instead building taller and wider melt pools. As such, it is recommended to quantify process maps for at least one intermediate composition in the FGM or multi-material system of interest to ensure optimized processing parameters, predictable melt pool sizes and shapes, and compositional and spatial precision.

Dissimilar↗