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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

Identification Uncertainty in Inverse Material Model Parameter Determination: A Sensitivity‐Based Decision Process for Load Path Selection

This research proposes a sensitivity-based framework for selecting the optimal prescribed loading path for a biaxial cruciform specimen. Optimality here is determined by the direction and magnitude of the prescribed displacement that minimizes the influence of random noise on the material model parameter identification. Using simulated experimental data based on finite element simulation, in this work, we identify the material model parameters of a Ludwik hardening model and plane stress implementation of the Hill-48 yield criterion using finite element model updating (FEMU). Our analysis reveals that the identification (or estimator) uncertainty of model parameters depends on the displacement boundary conditions (i.e., loading sequence) and the ground-truth value of the individual parameters. Optimal experimental design (OED) criteria based on the Fisher information matrix were investigated to mitigate indecision in the choice of optimal load path when the identification uncertainty of different material model parameters optimized at different load paths. The determinant of the Fisher information matrix was chosen here as the more useful metric due to its ability to capture uncertainty of the most influential material model parameters. The proposed framework demonstrates potential for real-time automated load step selection using scalar criteria derived prior to mechanical loading. The framework can be generalized to other geometries, boundary conditions and material models, allowing this procedure to be utilized for different experimental configurations and materials.

Fayad, Samuel S. [University of Illinois at Urbana↗

One System, Many Models: Designing a Surrogate Model for Sulfur Thermal Energy Storage: Preprint

Industrial process heating (IPH) relies primarily on thermal energy generated by fossil fuel combustion to produce, treat, and alter manufactured goods. Thermal energy storage (TES) helps reduce the carbon footprint of IPH systems by facilitating the utilization of renewable and waste heat sources. A promising new TES technology uses elemental sulfur as the heat-storage medium. The design of sulfur TES systems can be evaluated with the aid of computational fluid dynamics (CFD). However, the computational cost of such CFD efforts is prohibitive to comprehensive optimizations over design parameters. To reduce this computational cost, machine learning (ML) models can be developed to act as surrogates for CFD. In this paper, we describe the process of building and evaluating surrogate ML models for facilitating optimization of sulfur TES systems for IPH. To enforce the thermodynamic relationship between the two modeled quantities, we develop a hybrid model for sulfur temperature using both direct predictions of temperature and calculations of temperature from predictions of the heat transfer coefficient. The hybrid model enforces this constraint at the expense of the slightly reduced accuracy compared to two disjoint models. The overall high accuracy observed in our model evaluation demonstrates the usefulness of such surrogate modeling for studying TES systems. This work contributes to the field of TES surrogate modeling by offering a novel accurate hybrid approach to predicting simultaneously the heat transfer coefficient and temperature of the heat storage medium.

computational fluid dynamics↗

ERL-Based Compact X-Ray FEL

We propose to develop an energy-recovery-linac (ERL)-based X-ray free-electron laser (XFEL). Taking advantage of the demonstrated high-efficiency energy recovery of the beam power in the ERL, the proposed concept offers the following benefits: i) recirculating the electron beam through high-gradient superconducting RF (SRF) cavities shortens the linac, ii) energy recovery in the SRF linac saves the klystron power and reduces the beam dump power, iii) the high average beam power produces a high average photon brightness. In addition, such a concept has the capability of delivering optimized high-brightness CW X-ray FEL performance at different energies with simultaneous multipole sources. In this paper, we will present the preliminary results on the study of feasibility, optics design and parameter optimization of such a device.

Lin, Fanglei↗

ERL-BASED COMPACT X-RAY FEL

We propose to develop an energy-recovery-linac (ERL)- based X-ray free-electron laser (XFEL). Taking advantage of the demonstrated high-efficiency energy recovery of the beam power in the ERL, the proposed concept offers the following benefits: i) recirculating the electron beam through high-gradient superconducting RF (SRF) cavities shortens the linac, ii) energy recovery in the SRF linac saves the klystron power and reduces the beam dump power, iii) the high average beam power produces a high average photon brightness. In addition, such a concept has the capability of delivering optimized high-brightness CW X-ray FEL performance at different energies with simultaneous multipole sources. In this paper, we will present the preliminary results on the study of feasibility, optics design and parameter optimization of such a device.

Lin, Fanglei↗

Design of High Efficient Mid-Wavelength Infrared Polarizer on ORMOCHALC Polymer

While an organically modified chalcogenide (ORMOCHALC) can be used to fabricate a polymeric mid-wavelength infrared (MWIR) polarizer with competitive extinction ratio compared to the commercial wire-grid polarizers, which are composed of fragile inorganic materials, there is still a knowledge gap regarding the systematic design process to obtain high transmission efficiency and extinction ratio. As such, a computational parameter study for design optimization is conducted with the geometric parameters of the bilayer grating ORMOCHALC polarizer. The computational study shows that the Fabry–Pérot cavity is the primary mechanism that determines the transmission behaviors and the extinction ratio. A bilayer grating design, guided by the parameter study, is realized through the thermal nanoimprint and metal deposition processes. The extinction ratios measured with the Fourier-transform infrared are 245, 304, and 351 at the wavelength of 3, 4, and 5 μm, respectively. Compared to the state-of-the-art of the polymeric MWIR linear polarizers, the extinction ratio is improved by 1.4 times, and the transmission efficiency is increased by 2.5 times. Theoretical analysis with the multiple-layer model based on the transfer matrix method predicts a matched transmission behavior with the experiment and a full-wave electromagnetic simulation.

42 ENGINEERING↗

Inverse design for waveguide dispersion with a differentiable mode solver

Inverse design of optical components based on adjoint sensitivity analysis has the potential to address the most challenging photonic engineering problems. However, existing inverse design tools based on finite-difference-time-domain (FDTD) models are poorly suited for optimizing waveguide modes for adiabatic transformation or perturbative coupling, which lies at the heart of many important photonic devices. Among these, dispersion engineering of optical waveguides is especially challenging in ultrafast and nonlinear optical applications involving broad optical bandwidths and frequency-dependent anisotropic dielectric material response. In this work, we develop gradient back-propagation through a general-purpose electromagnetic eigenmode solver and use it to demonstrate waveguide dispersion optimization for second harmonic generation with maximized phase-matching bandwidth. This optimization of three design parameters converges in eight steps, reducing the computational cost of optimization by ∼100x compared to exhaustive search and identifying new designs for broadband optical frequency doubling of laser sources in the 1.3–1.4 µm wavelength range. Furthermore, we demonstrate that the computational cost of gradient back-propagation is independent of the number of parameters, as required for optimization of complex geometries. This technique enables practical inverse design for a broad range of previously intractable photonic devices.

Gray, Dodd (ORCID:000000030469599X)↗

Test cavity and Iris-to-Coax transition for tuning and high-power verification of SNS DTL iris couplers

The Spallation Neutron Source (SNS) Drift Tube Linac (DTL) employs iris couplers to efficiently deliver RF power into the accelerating structure. To support the development, tuning, and high‑power conditioning of these couplers prior to installation in the actual DTLs, a dedicated test cavity and an iris‑to‑coaxial transition structure have been designed. This work presents the electromagnetic design, simulation, and optimization of the test setup, enabling precise characterization of the iris coupler’s performance. The transition structure allows for tuning of the iris opening dimensions without requiring a waveguide taper or full‑size waveguide transitions, while maintaining impedance matching between the coaxial feed and the iris geometry to minimize reflection and power loss. During low‑power tests, the iris opening di-mensions can be evaluated using the iris‑to‑coax transi-tion attached to the test cavity. For high‑power condi-tioning, full‑size waveguides with ceramic vacuum win-dows are connected to the test cavity to replicate opera-tional conditions. Key design parameters were optimized using computer-aided simulation, and sensitivity studies were conducted to assess the impact of mechanical toler-ances on RF performance. The resulting test platform provides a reliable and efficient means for tuning and validating iris couplers, contributing to improved opera-tional stability in the SNS DTL.

Lee, Sung-Woo [ORNL] (ORCID:000000030915835X)↗

Calibrating hypersonic turbulence flow models with the HIFiRE-1 experiment using data-driven machine-learned models.

In this paper we study the efficacy of combining machine-learning methods with projection-based model reduction techniques for creating data-driven surrogate models of computationally expensive, high-fidelity physics models. Such surrogate models are essential for many-query applications e.g., engineering design optimization and parameter estimation, where it is necessary to invoke the high-fidelity model sequentially, many times. Surrogate models are usually constructed for individual scalar quantities. However there are scenarios where a spatially varying field needs to be modeled as a function of the model’s input parameters. Here we develop a method to do so, using projections to represent spatial variability while a machine-learned model captures the dependence of the model’s response on the inputs. The method is demonstrated on modeling the heat flux and pressure on the surface of the HIFiRE-1 geometry in a Mach 7.16 turbulent flow. The surrogate model is then used to perform Bayesian estimation of freestream conditions and parameters of the SST (Shear Stress Transport) turbulence model embedded in the high-fidelity (Reynolds-Averaged Navier–Stokes) flow simulator, using shock-tunnel data. The paper provides the first-ever Bayesian calibration of a turbulence model for complex hypersonic turbulent flows. We find that the primary issues in estimating the SST model parameters are the limited information content of the heat flux and pressure measurements and the large model-form error encountered in a certain part of the flow.

42 ENGINEERING↗

Comparative Study on the Photoelectrochemical Hydrogen Production from the Layout Optimization in a Unit Cell

Solar-driven water splitting is achieved by connecting photovoltaics with electrolysis. Recently, integrated approaches of the two configurations for photoelectrochemical reactions have shown great potential in a combined unit, but strategies to address further material and cell development face significant scientific challenges. Here, in this work, we present an experimental demonstration of photoelectrochemical (PEC) unit-cells with efficient separate dual compartments for oxygen evolution and hydrogen evolution reactions. The design and fabrication of cell architectures with various degrees of integration are investigated efficient and sustainable PEC processes. The effect of the nanostructured silicon (Si) photoelectrodes, including the adoption of layer architectures, surface protection layer deposition, and membrane electrode assembly is further studied to optimize the design parameters of the PEC unit-cells. This developed PEC cell with the Si photocathode achieved a photocurrent density of -4.8 mA cm –2 at -2.0 V cell and -2.87 mA cm –2 at -1.6 V cell . It clearly provides a critical milestone for unbiased solar water splitting. Practical solar to hydrogen (STH) can be directly estimated in investigating PEC performance in this unit-cell as assembled with a solar cell. It is a significantly meaningful step forward in practical solar fuel production.

08 HYDROGEN↗

Controlling Mass Transport in Direct Carbon Dioxide Zero-Gap Electrolyzers via Cell Compression

The development of high-performance CO 2 electrolyzers is crucial for accelerating the sustainable production of fuels and chemicals integrated with renewable energy sources. Here, we introduce a methodology to actively control mass transport inside a realistic zero-gap membrane electrode assembly of a CO 2 electrolyzer by varying the gasket thickness, which consequently changes the cell compression. This allows control over the thickness and porosity of the gas diffusion electrodes, influencing the overall electrolyzer performance, as demonstrated using Ag-deposited electrodes. At low operating voltages (<2.9 V), both high- and low-compression electrolyzers exhibit similar faradaic efficiencies and partial current densities for CO formation. However, at high voltages, the low-compression electrolyzer with high electrode porosity demonstrates superior CO selectivity and activity with suppressed H 2 formation. These experimental results are validated by the computational membrane electrode assembly (MEA) model developed by using the measured in situ electrode thicknesses and electrode porosities. Additionally, liquid electrolyte saturation at the catalyst layer is found to play a dominant role in determining the mass transport, resulting in a decreased electrolyzer performance with low electrode porosity. Finally, the systematic investigation in this study improves the understanding of the transport dynamics in MEA-based devices and provides insights into optimizing device design parameters for industry-relevant CO 2 electrolysis.

30 DIRECT ENERGY CONVERSION↗

Final cooling with thick wedges for a muon collider

In the final cooling stages for a muon collider, the transverse emittances are reduced while the longitudinal emittance is allowed to increase. In previous studies, Final 4-D cooling used absorbers within very high field solenoids to cool low-momentum muons. Simulations of the systems did not reach the desired cooling design goals. In this study, we develop and optimize a different conceptual design for the final 4D cooling channel, which is based on using dense wedge absorbers. We used G4Beamline to simulate the channel and Python to generate and analyze particle distributions. We optimized the design parameters of the cooling channel and produced conceptual designs (corresponding to possible starting points for the input beam) which achieve transverse cooling in both x and y by a factor of ~3.5. These channels achieve a lower transverse and longitudinal emittance than the best design previously published.

43 PARTICLE ACCELERATORS↗

A Self Consistent 2D Simulation of Coherent Synchrotron Radiation Effects on Beam Dynamics

An increasing interest in high quality and high current electron beams necessitates a thorough understanding and prediction of coherent synchrotron radiation effects. The self-interaction of charged particles in a beam undergoing synchrotron motion is a physically significant process that is all too often computationally intensive with very little analytical results to rely on for the general case. The coherent spectrum of this interaction is of utmost importance to the design of free electron lasers (FELs) and an accurate assessment is imperative for their design. This work presents a novel implementation to the numerical simulation of charged particle beams. The simulation is a self-consistent approach including the self-fields generated by the beam of which coherent synchrotron radiation effects are of primary interest. A particle-in-cell model is used where a planar beam sampled by point particles is deposited on an encompassing grid at each timestep. The electromagnetic fields are calculated on the grid using the retarded potentials according to causality. The electromagnetic forces from the fields are interpolated on each particle which in turn advance in time. The simulation is benchmarked against well-established results for coherent synchrotron radiation effects. In addition, studies are provided that show the convergence of simulation results for increasing resolution. A study into the transverse beam size effects on beam dynamics is performed as well as a proof of concept where the simulation is used by a genetic algorithm to optimize the design parameters of a beam lattice. The results of these studies in tandem verify the efficacy of the simulation for its practical use in accelerator design or the study of synchrotron radiation effects

Duffin, Dallan [Old Dominion Univ., Norfolk, VA (U↗

Deployable Wind-Hybrid Power Systems for Defense and Disaster Response Applications

This report presents an analysis of the performance of deployable energy systems comprised of wind energy systems integrated with diesel generators, photovoltaic systems, and battery storage to meet the load requirements of a representative U.S. Army forward operating base. The analysis is conducted using HOMER, a microgrid analysis software that can search through a wide range of parameters to design and optimize microgrid power systems. The search parameters include the system architecture, the wind and solar resources, and the availability of diesel fuel. The results of the analysis measure the relative performance of the different systems and environments in terms of the overall transportation cost to deploy the system and the ability to provide resilience in terms of meeting mission critical loads.

02 PETROLEUM↗

Application of Advanced Materials Processing to Enable Direct Production of Fast Reactor Fuel Alloys

Argonne National Laboratory (the Contractor), located in Lemont, IL, and Oklo, Inc. (the Participant), headquartered in Sunnyvale, CA, entered into a Cooperative Research and Development Agreement (CRADA) to integrate advanced electrorefining co-deposition and molten-salt monitoring technologies to produce a uranium-transuranic (U/TRU) alloy within a controlled composition range that can be used as fast reactor fuel for Oklo, Inc.’s advanced reactor technology. Argonne performed the integration of electrorefining and process monitoring technologies, determined operating parameters for producing U/TRU alloys, and developed optimized design and operating parameters for co-deposition of U/TRU alloys. Oklo, Inc. worked with Argonne and the Nuclear Regulatory Commission (NRC) to provide the necessary process documentation to begin implementing pyroprocessing technology in the fast reactor fuel production process. Outcomes of this project included a pilot-scale co-deposition cathode design and technical basis for the operation of the co-deposition electrorefiner to produce U/TRU alloys with controlled composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Optimization of the moderators in the STS preliminary design

This report details the results for an optimization of the dimensions of the moderators in the preliminary design of the Spallation Neutron Source Second Target Station (STS). This study uses the optimization algorithms of Dakota and an unstructured mesh model for the moderators in MCNP. More details on the unstructured mesh model and the automated mesh generation can be found in [3]. Parallel to this effort, the same moderator geometries have been optimized using a constructive solid geometry (CSG) MCNP model. More details on this model and its results can be found in [4]. Three optimal designs are selected for each moderator: one that is optimized for maximum peak brightness, one for maximum time-integrated brightness, and one for a combination of peak and time-integrated brightness. The backbone of the optimization work flow is provided by Dakota. For each set of design parameters requested by Dakota, a new solid geometry is automatically built in Creo and SpaceClaim, and subsequently exported to Attila4MC to generate an unstructured mesh geometry for MCNP. After the MCNP calculation is finished, the objective function (e.g., brightness metric) is returned to Dakota. After the new design has been evaluated, a result-file is written, and Dakota proposes the next set of design parameters to be evaluated. The loop continues until a specified convergence criterion has been met. The design parameters of the cylindrical (upper) moderator include the hydrogen radius, the premoderator thickness (top, bottom, radial), the beryllium radius and the horizontal position of the moderator. The crucial design choice is the hydrogen radius. A radius of 62 mm is shown to provide the maximum time-integrated brightness. The maximum peak brightness occurs with a radius of 40 mm. A combined (middle) design, which balances peak and time-integrated brightnesses, is obtained with a hydrogen radius of 50 mm. The premoderator thicknesses and the beryllium radius are slightly larger in the design optimized for time-integrated brightness than in the design optimized for peak brightness. The sensitivity to these two parameters is relatively small close to the optimal configurations. The hydrogen vessel and vacuum vessel wall thicknesses are dependent on the radius of the liquid hydrogen due to structural integrity requirements. The increased wall thicknesses for larger vessels significantly penalize the time-integrated brightness, with the maximum obtainable value reduced by more than 10% relative to earlier studies which used fixed vessel wall thicknesses. The impact of the variable wall thicknesses is much less for the peak brightness and combined brightness designs. The design parameters of the tube (lower) moderator selected for the optimization are the tube length, the annular premoderator thickness, the beryllium radius and the horizontal position of the moderator. The tube length is the crucial parameter and is chosen large (210 mm) and small (125 mm) in the designs optimized for time-integrated and peak brightness respectively. A combined optimal design has a tube length of 170 mm. The premoderator thickness and the beryllium radius are chosen larger in the design optimized for time-integrated brightness.

42 ENGINEERING↗

Multi-Objective Optimization of Uranium Target Assembly–3: A Comparison of Genetic and Traditional Methods

Commonly produced as a byproduct of uranium fission, 99 Mo is a key medical isotope that is in high demand in the United States. An international goal is to switch from medical isotope production technologies that require highly enriched uranium to medical isotope production technologies that require only low-enriched uranium. Niowave Inc. is contributing to this goal by developing an accelerator-driven subcritical assembly called the Uranium Target Assembly (UTA). This work compares the performance of Dakota’s Multi-Objective Genetic Algorithm (MOGA) against traditional sensitivity analysis in the neutronic optimization of the UTA-3 system. The design objectives are k-eigenvalue (k eff ) and natural uranium fission power, which are directly correlated with the amount of 99 Mo produced. Dakota:MOGA did not perform as well as human engineering ingenuity in optimization studies with high numbers of input parameters, such as fuel rod type selection and fuel rod placement. However, Dakota:MOGA did outperform traditional sensitivity analysis in optimization studies with fewer than 20 parameters and revealed the degree to which each parameter influences the optimal design space for k eff and natural uranium fission power (to a lesser extent). As the design model became more complex in the final stage of design, the computational resources required to calculate the design objective values in the Monte Carlo N-Particle transport code from selected input parameter combinations limited Dakota:MOGA’s performance, and, unfortunately, human intervention was required to discern the optimal design space. In conclusion, future work will attempt to reduce computational resource constraints by incorporating areduced-order neutronics model into the optimization cycle.

Accelerator-driven systems↗

Inertial Confinement Fusion Design Search Using Bayesian Optimization

Inertial confinement fusion (ICF) experiments rely on complex multi-physics simulation codes such as the Lawrence Livermore National Laboratory-developed HYDRA to guide design work. However, these simulations have several dozen tunable parameters and can be computationally expensive. This makes searching the parameter space challenging and time-consuming. Recently developed automated tools utilize Bayesian optimization to search these high-dimensional parameter spaces for optimal designs. The optimization tools run 2D integrated simulations in HYDRA to converge on a design that produces specified scalar or vector outputs. In this paper, we apply the Bayesian optimization tools to two common tuning scenarios. First, we tune simulation inputs to match measurements of a well-characterized experiment at the National Ignition Facility. This type of tuning is commonly performed to compensate for the use of simplified simulation settings (e.g. reduced resolution) or to account for missing physics in the simulations. Second, we search for an ICF simulation design that has a particular radiation drive profile. These optimizations replicate the kinds of tuning researchers routinely perform, but do so with significantly reduced manual effort. This approach demonstrates a powerful and efficient pathway toward autonomous, high-fidelity design optimization for future ICF experiments.

Bayesian optimization↗