Results for “Complex industrial process” — Page 30

DOE OSTI2026

Accelerating laser ray tracing in high fidelity physics simulations of laser melting using squeeze U-net

Laser melting is a core component of the ongoing industrial revolution, dubbed Industry 4.0, as lasers facilitate fast and precise melting and fusion in advanced manufacturing. There is a strong need to optimize the laser process using simulations. However, this has proven challenging as high fidelity simulations are needed for predictive modeling and this is currently prohibitively expensive even when run on hundreds of processors on high performance computers. The challenge is capturing complex physics of laser material interaction, fluid dynamics, thermal physics and material phase transformations at various length and time scales. To close this technological gap, we modified a squeeze U-net to accelerate the laser ray tracing component of such high fidelity models by ~4x–40x while preserving the core physics principle of conservation of energy with 97% accuracy. This approach enables the accurate modeling of global laser energy absorption as a function of local surface temperatures and complex surface topologies, which govern the reflection directions and energy losses of laser rays upon interacting with the material surface.

Computer science↗

DOE OSTI2018

Characterization and mechanical properties of cladded stainless steel 316L with nuclear applications fabricated using electron beam melting

The ability to fabricate or join components of 316 L austenitic stainless steel using additive manufacturing (AM) processes such as laser and electron beam melting (EBM®) offers several advantages including enhanced part complexity, narrow or absent heat affected zones, increased part precision, avoidance of filler materials (such as traditional welds), and the ability to create metallurgically sound bonds. These attributes can contribute to improved mechanical properties of the fabricated components and component repair in nuclear, aerospace, and chemical industries. In the present work, we report that austenitic 316 L stainless steel additively manufactured by EBM exhibits a 76% increase in the yield strength and a corresponding increase of 29% in the ultimate tensile strength in contrast to the wrought substrate and commercial forged 316 L stainless steel. The EBM clad 316 L stainless steel elongation was 36%. The wrought substrate equiaxed grain size was ~30 μm in contrast to elongated, columnar grains ~0.1 mm wide and >1 mm in length for the EBM cladding. Transmission Electron Microscopy (TEM) analysis revealed that these columnar grains, which exhibited very straight, and presumably special grain boundaries having a very high (100) texture, contained a variety of sub-grain microstructures consisting of low-angle sub-grain boundaries containing dislocation tangles and stacking-fault arrays, and homogeneously distributed Cr 23 C 6 carbide precipitates, with no preferential carbide precipitation on either the straight, special columnar grain boundaries, or the very low-angle sub-grain boundaries. This observation and the formation of hierarchical microstructures which produce high strength and possibly corrosion resistance as a consequence of the absence of grain boundary carbide precipitation, illustrate the prospects for AM as a novel concept for achieving grain boundary engineering to promote high-strength and corrosion resistant alloys for high-temperature, corrosive environments, including elevated temperature nuclear reactor applications.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Bioadsorption of rare earth elements through cell surface display of lanthanide binding tags

In this study, with the increasing demand for rare earth elements (REEs) in many emerging clean energy technologies, there is an urgent need for the development of new approaches for efficient REE extraction and recovery. As a step toward this goal, we genetically engineered the aerobic bacterium Caulobacter crescentus for REE adsorption through high-density cell surface display of lanthanide binding tags (LBTs) on its S-layer. The LBT-displayed strains exhibited enhanced adsorption of REEs compared to cells lacking LBT, high specificity for REEs, and an adsorption preference for REEs with small atomic radii. Adsorbed Tb 3+ could be effectively recovered using citrate, consistent with thermodynamic speciation calculations that predicted strong complexation of Tb 3+ by citrate. No reduction in Tb 3+ adsorption capacity was observed following citrate elution, enabling consecutive adsorption/desorption cycles. The LBT-displayed strain was effective for extracting REEs from the acid leachate of core samples collected at a prospective rare earth mine. Our collective results demonstrate a rapid, efficient, and reversible process for REE adsorption with potential industrial application for REE enrichment and separation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

WE-B-BRC-00: Concepts in Risk-Based Assessment

Prospective quality management techniques, long used by engineering and industry, have become a growing aspect of efforts to improve quality management and safety in healthcare. These techniques are of particular interest to medical physics as scope and complexity of clinical practice continue to grow, thus making the prescriptive methods we have used harder to apply and potentially less effective for our interconnected and highly complex healthcare enterprise, especially in imaging and radiation oncology. An essential part of most prospective methods is the need to assess the various risks associated with problems, failures, errors, and design flaws in our systems. We therefore begin with an overview of risk assessment methodologies used in healthcare and industry and discuss their strengths and weaknesses. The rationale for use of process mapping, failure modes and effects analysis (FMEA) and fault tree analysis (FTA) by TG-100 will be described, as well as suggestions for the way forward. This is followed by discussion of radiation oncology specific risk assessment strategies and issues, including the TG-100 effort to evaluate IMRT and other ways to think about risk in the context of radiotherapy. Incident learning systems, local as well as the ASTRO/AAPM ROILS system, can also be useful in the risk assessment process. Finally, risk in the context of medical imaging will be discussed. Radiation (and other) safety considerations, as well as lack of quality and certainty all contribute to the potential risks associated with suboptimal imaging. The goal of this session is to summarize a wide variety of risk analysis methods and issues to give the medical physicist access to tools which can better define risks (and their importance) which we work to mitigate with both prescriptive and prospective risk-based quality management methods. Learning Objectives: Description of risk assessment methodologies used in healthcare and industry Discussion of radiation oncology-specific risk assessment strategies and issues Evaluation of risk in the context of medical imaging and image quality E. Samei: Research grants from Siemens and GE.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

WE-B-BRC-01: Current Methodologies in Risk Assessment

Prospective quality management techniques, long used by engineering and industry, have become a growing aspect of efforts to improve quality management and safety in healthcare. These techniques are of particular interest to medical physics as scope and complexity of clinical practice continue to grow, thus making the prescriptive methods we have used harder to apply and potentially less effective for our interconnected and highly complex healthcare enterprise, especially in imaging and radiation oncology. An essential part of most prospective methods is the need to assess the various risks associated with problems, failures, errors, and design flaws in our systems. We therefore begin with an overview of risk assessment methodologies used in healthcare and industry and discuss their strengths and weaknesses. The rationale for use of process mapping, failure modes and effects analysis (FMEA) and fault tree analysis (FTA) by TG-100 will be described, as well as suggestions for the way forward. This is followed by discussion of radiation oncology specific risk assessment strategies and issues, including the TG-100 effort to evaluate IMRT and other ways to think about risk in the context of radiotherapy. Incident learning systems, local as well as the ASTRO/AAPM ROILS system, can also be useful in the risk assessment process. Finally, risk in the context of medical imaging will be discussed. Radiation (and other) safety considerations, as well as lack of quality and certainty all contribute to the potential risks associated with suboptimal imaging. The goal of this session is to summarize a wide variety of risk analysis methods and issues to give the medical physicist access to tools which can better define risks (and their importance) which we work to mitigate with both prescriptive and prospective risk-based quality management methods. Learning Objectives: Description of risk assessment methodologies used in healthcare and industry Discussion of radiation oncology-specific risk assessment strategies and issues Evaluation of risk in the context of medical imaging and image quality E. Samei: Research grants from Siemens and GE.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

WE-B-BRC-02: Risk Analysis and Incident Learning

Prospective quality management techniques, long used by engineering and industry, have become a growing aspect of efforts to improve quality management and safety in healthcare. These techniques are of particular interest to medical physics as scope and complexity of clinical practice continue to grow, thus making the prescriptive methods we have used harder to apply and potentially less effective for our interconnected and highly complex healthcare enterprise, especially in imaging and radiation oncology. An essential part of most prospective methods is the need to assess the various risks associated with problems, failures, errors, and design flaws in our systems. We therefore begin with an overview of risk assessment methodologies used in healthcare and industry and discuss their strengths and weaknesses. The rationale for use of process mapping, failure modes and effects analysis (FMEA) and fault tree analysis (FTA) by TG-100 will be described, as well as suggestions for the way forward. This is followed by discussion of radiation oncology specific risk assessment strategies and issues, including the TG-100 effort to evaluate IMRT and other ways to think about risk in the context of radiotherapy. Incident learning systems, local as well as the ASTRO/AAPM ROILS system, can also be useful in the risk assessment process. Finally, risk in the context of medical imaging will be discussed. Radiation (and other) safety considerations, as well as lack of quality and certainty all contribute to the potential risks associated with suboptimal imaging. The goal of this session is to summarize a wide variety of risk analysis methods and issues to give the medical physicist access to tools which can better define risks (and their importance) which we work to mitigate with both prescriptive and prospective risk-based quality management methods. Learning Objectives: Description of risk assessment methodologies used in healthcare and industry Discussion of radiation oncology-specific risk assessment strategies and issues Evaluation of risk in the context of medical imaging and image quality E. Samei: Research grants from Siemens and GE.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

WE-B-BRC-03: Risk in the Context of Medical Imaging

Prospective quality management techniques, long used by engineering and industry, have become a growing aspect of efforts to improve quality management and safety in healthcare. These techniques are of particular interest to medical physics as scope and complexity of clinical practice continue to grow, thus making the prescriptive methods we have used harder to apply and potentially less effective for our interconnected and highly complex healthcare enterprise, especially in imaging and radiation oncology. An essential part of most prospective methods is the need to assess the various risks associated with problems, failures, errors, and design flaws in our systems. We therefore begin with an overview of risk assessment methodologies used in healthcare and industry and discuss their strengths and weaknesses. The rationale for use of process mapping, failure modes and effects analysis (FMEA) and fault tree analysis (FTA) by TG-100 will be described, as well as suggestions for the way forward. This is followed by discussion of radiation oncology specific risk assessment strategies and issues, including the TG-100 effort to evaluate IMRT and other ways to think about risk in the context of radiotherapy. Incident learning systems, local as well as the ASTRO/AAPM ROILS system, can also be useful in the risk assessment process. Finally, risk in the context of medical imaging will be discussed. Radiation (and other) safety considerations, as well as lack of quality and certainty all contribute to the potential risks associated with suboptimal imaging. The goal of this session is to summarize a wide variety of risk analysis methods and issues to give the medical physicist access to tools which can better define risks (and their importance) which we work to mitigate with both prescriptive and prospective risk-based quality management methods. Learning Objectives: Description of risk assessment methodologies used in healthcare and industry Discussion of radiation oncology-specific risk assessment strategies and issues Evaluation of risk in the context of medical imaging and image quality E. Samei: Research grants from Siemens and GE.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2023

High‐Throughput Computational Guided Development of Refractory Complex Concentrated Alloys‐based Composite

ULTIMATE is a leading-edge DOE program to develop ultrahigh temperature materials for gas turbine use in the aviation and power generation industries. This team, headquartered at West Virginia University and including collaborators from the National Energy Technology Laboratory and Advanced Manufacturing LLC, has developed a new class of ultra-high temperature Refractory Complex Concentrated Alloys-based Composites (RCCC) for high temperature applications such as combustion turbines used in the aerospace and energy industries. The RCCC consist of Refractory Complex Concentrated Alloys (RCCA) mixed with particles of Refractory High Entropy Carbides, to increase RCCA strength to withstand extreme conditions. These new materials optimize the balance among strength, creep (deformation), density, and stability at 1300 °C (2372 °F), while maintaining ductility once the alloy cools to room temperature. The research team has developed advanced manufacturing processes using the pulsed electric current and laser 3D printing to produce test coupons of these materials.

36 MATERIALS SCIENCE↗

NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗

DOE OSTI2024

Domestication of Algae for Increasing Biomass Productivity

Microalgae cultivation processes have been developed for the production of a variety of bioproducts, however currently only a few species are used in commercial applications. Their domestication, that is strain improvements, is still in its infancy, with major advances required, specifically to maximize biomass productivity a limiting factor in microalgae production. This requires a deep understanding of algal biology, in particular to develop superior strains without the need of genetic technologies that would require lengthy regulatory permits, and often limit consumer acceptance. Adaptive Laboratory Evolution techniques, alone or in conjunction with sexual recombination, can allow for rapid develop of improved strains and their industrial production. Light harvesting antenna reduction has been a major approach to achieve increased photon utilization efficiency by cultures operating under full sunlight conditions due to higher light saturation levels, allowing for higher productivities under outdoor conditions. Decades of research yielded some promising results under controlled conditions with a few specific mutant strains. However, these failed to achieve the anticipated higher productivities in actual algal mass cultures, in part due to the inability of single mutations to overcome photoinhibition, reactive oxygen species, and other pleiotropic impacts on the complex metabolic processes of photosynthesis. Higher productivity strains will require multiple genetic improvements. We report on recent Adaptive Laboratory Evolution with the green alga Scenedesmus obliquus resulting in higher biomass productivity in open pond cultivation. Coupling our approach with sexual recombination and genome sequencing provides a path to algal domestication suitable for large-scale, low-cost biomass production.

09 BIOMASS FUELS↗

NASA NTRS2008

Assessing Requirements Quality through Requirements Coverage

In model-based development, the development effort is centered around a formal description of the proposed software system the model. This model is derived from some high-level requirements describing the expected behavior of the software. For validation and verification purposes, this model can then be subjected to various types of analysis, for example, completeness and consistency analysis [6], model checking [3], theorem proving [1], and test-case generation [4, 7]. This development paradigm is making rapid inroads in certain industries, e.g., automotive, avionics, space applications, and medical technology. This shift towards model-based development naturally leads to changes in the verification and validation (V&V) process. The model validation problem determining that the model accurately captures the customer's high-level requirements has received little attention and the sufficiency of the validation activities has been largely determined through ad-hoc methods. Since the model serves as the central artifact, its correctness with respect to the users needs is absolutely crucial. In our investigation, we attempt to answer the following two questions with respect to validation (1) Are the requirements sufficiently defined for the system? and (2) How well does the model implement the behaviors specified by the requirements? The second question can be addressed using formal verification. Nevertheless, the size and complexity of many industrial systems make formal verification infeasible even if we have a formal model and formalized requirements. Thus, presently, there is no objective way of answering these two questions. To this end, we propose an approach based on testing that, when given a set of formal requirements, explores the relationship between requirements-based structural test-adequacy coverage and model-based structural test-adequacy coverage. The proposed technique uses requirements coverage metrics defined in [9] on formal high-level software requirements and existing model coverage metrics such as the Modified Condition and Decision Coverage (MC/DC) used when testing highly critical software in the avionics industry [8]. Our work is related to Chockler et al. [2], but we base our work on traditional testing techniques as opposed to verification techniques.

Rajan, Ajitha↗

DOE OSTI2025

Deciphering electrocatalysts with multimodal operando approaches

Here, the electrocatalytic processes of a copper catalyst during nitrate electroreduction are unveiled by correlated operando microscopy and spectroscopy. Catalysts are vital to the modern chemical industry, yet their development has largely relied on trial-and-error approaches. Optimizing catalysts requires a fundamental understanding of their structure–chemical property behaviour under operational conditions. However, operando characterization remains challenging, especially for reactions occurring in the complex and dynamic liquid environments of electrochemical systems. Over the past decade, the rapid development of in situ and operando environmental transmission electron microscopy (ETEM) and microelectromechanical system (MEMS)-based closed-cell holders, enabling environmental studies within the vacuum environment of transmission electron microscopy (TEM), has substantively advanced understanding of heterogeneous catalysis, notably for gas-phase reactions. In situ ETEM enables the direct observation of the catalyst evolution in terms of structure, morphology and chemical state at the nano-to-atomic scale, providing insights into their correlation with catalytic performance.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Systematic improvement of redox potential calculation of Fe(III)/Fe(II) complexes using a three-layer micro-solvation model

Electrochemical transformations of metal ions in aqueous media are challenging to model accurately due to the dynamic solvation structure surrounding ions at different charge states. Predictive modeling at the atomistic scale is essential for understanding these solvation architectures but is often computationally prohibitive. In this contribution, we present a simple, fast, and accurate three-layer micro-solvation model to evaluate the redox potential of metal ions in aqueous solutions. Our model, developed and validated for Fe 3+ /Fe 2+ redox potentials, combines the DFT-based geometry optimizations of the octahedral Fe complex with two layers of explicit water molecules to capture solute–solvent interactions and an implicit solvation model to account for bulk solvent effects. This approach yields accurate predictions for Fe 3+ /Fe 2+ redox potentials in water, achieving errors of 0.02 V with ωB97X-V, 0.01 V with ωB97X-D3, 0.04 V with ωB97M-V, and 0.02 V with B3LYP-D3 functionals. We further demonstrate the generality of our model by applying it to additional metal complexes, including the challenging Fe(CN) 6 3−/4− system, where our model successfully achieves close agreement with experimental values, with an error of 0.07 V and an average error of 0.21 V for all five systems. In summary, the presented simple solvation model has broad applicability and potential for enhancing computational efficiency in redox potential predictions across various chemical and industrial processes of metal ions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2015

Quantum cascade laser based monitoring of CF{sub 2} radical concentration as a diagnostic tool of dielectric etching plasma processes

Dielectric etching plasma processes for modern interlevel dielectrics become more and more complex by the introduction of new ultra low-k dielectrics. One challenge is the minimization of sidewall damage, while etching ultra low-k porous SiCOH by fluorocarbon plasmas. The optimization of this process requires a deeper understanding of the concentration of the CF{sub 2} radical, which acts as precursor in the polymerization of the etch sample surfaces. In an industrial dielectric etching plasma reactor, the CF{sub 2} radical was measured in situ using a continuous wave quantum cascade laser (cw-QCL) around 1106.2 cm{sup −1}. We measured Doppler-resolved ro-vibrational absorption lines and determined absolute densities using transitions in the ν{sub 3} fundamental band of CF{sub 2} with the aid of an improved simulation of the line strengths. We found that the CF{sub 2} radical concentration during the etching plasma process directly correlates to the layer structure of the etched wafer. Hence, this correlation can serve as a diagnostic tool of dielectric etching plasma processes. Applying QCL based absorption spectroscopy opens up the way for advanced process monitoring and etching controlling in semiconductor manufacturing.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Physical vapor deposition simulator by graphical processor unit ray casting

This paper presents fast, accurate software for modeling physical vapor deposition systems over irregular surfaces. The model is implemented using graphics processing unit (GPU) ray casting. Applied models are viewed as a cross section of the area of interest. Given evaporation rate, time, and angular profiles in a vacuum system, an iterative time-step approach for calculating deposition profiles is calculated in the GPU architecture following a ballistic modeling approach. Thin-film technologies for the electronics industry will require evaporations on complex surfaces. Depending on the nature of the surface, a uniform thin film across the topology is wanted for various device parameters. The ray casting method is tested against various profiles. The code is freely distributed on GitHub (see https://github.com/adam-r-thomas/PVDS).

Engineering↗

DOE OSTI2024

Advancing community-engaged research for offshore wind on the West Coast

The Biden Administration has called for 30 GW of offshore wind (OSW) to be implemented by 2030 and 15 GW of floating OSW by 2035. Because floating OSW is a novel technology for the West Coast, the United States, and the world, there is limited information about the implications of floating OSW for coastal communities. Floating OSW faces a complex regulatory landscape and a wide set of interested parties that stand to gain or lose based on the development process and outcomes. Key agencies are often siloed in their mission space, with little attention or resources for innovation in planning. Furthermore, many communities along the West Coast of the U.S. have experienced the boom-and-bust cycles of large, extractive industries that use coastal resources to benefit consumers in other locations, while leaving behind few long-lasting benefits at the local level. These siloes in government and civic society, and the lack of trust born out of past failures, make it difficult for communities, government agencies, scientists, and industry to plan for OSW based on community values and concerns. There is a need to develop projects that more equitably distribute benefits while safeguarding the ocean ecosystems upon which coastal populations depend.

17 WIND ENERGY↗

DOE OSTI2018

Integrated pre-feasibility study for CO 2 geological storage in the Cascadia Basin, offshore Washington State, British Columbia

The Cascadia CarbonSAFE project conducted a pre-feasibility study to evaluate technical and nontechnical aspects of storing 50 million metric tons (MMT) of carbon dioxide in a safe, ocean basalt reservoir offshore Washington State and British Columbia. Sub-seafloor basalts are very common on Earth and enable geological mineralization as a long-term storage mechanism, permanently sequestering the carbon in solid rock form. This project evaluated the offshore storage complex, developed potential industrial source/transport scenarios, built an inventory of existing geophysical/geological data and environmental monitoring capabilities, conducted laboratory studies and reservoir modeling to determine storage capacity, and analyzed economic factors, regulatory requirements, and project management risks. Our team included researchers at Columbia University in New York, Pacific Northwest National Laboratory (PNNL) in Washington, University of Victoria in British Columbia, University of California at Santa Cruz, and GHG Underground in Maine, as well as collaborators at University of Iceland in Reykjavik and University of Washington in Saint Louis. In the study region, large emitters (>100,000 MT/year) generate a total of approximately 40 MMT annually from stationary sources, such as power plants, refineries, ammonia production, and mineral processing plants. Five potential industry source/transport scenarios were identified (three in U.SA S. and two in Canada) to potentially provide 50 MMT of carbon dioxide to the offshore reservoir. One scenario included net carbon-negative sources that would reduce atmospheric levels. The inventory of existing data illustrated that basalt properties in the region are potentially beneficial for long-term storage. Permeability is on the order of 0.1 to 1 Darcies within the uppermost 600 m of ocean crust and density-derived porosity reaches 10–20% in thin layers that provide act as flow channels and provide access to porous and permeable basalt. Fine-grained sediments overlying basalt provide a low-permeability barrier separating the storage reservoir from the overlying ocean. Subsurface monitoring of the storage complex benefits from a unique opportunity close proximity of to the nearby NEPTUNE cabled seafloor observatory, which actively transmits data to shore and could be used to monitor reservoir properties. Injection pressure changes, reservoir chemistry, seismicity, well head corrosion, and potential leakage monitoring would be feasible in real time. Using existing data and published models, the STOMP-CO 2 modeling code developed at PNNL was used to simulate carbon dioxide injection, storage, and mineralization in the reservoir. Preliminary simulations indicate that a 50 MMT carbon dioxide plume injected over a 20-year period remains well within the reservoir area, both laterally and vertically, for at least a 50-year period of post-injection monitoring. Laboratory studies on core samples from Cascadia measured dissolution rates in CO 2 –basalt–seawater mixtures and indicated large variability in rates with the potential for complete mineralization. Compared to published data, the dissolution rate measured in these samples is faster, decreasing the time until full conversion to carbonate minerals would occur. Adding geochemical reactivity in the STOMP-CO 2 model indicates that carbon dioxide would be fully converted to carbonate minerals in 135 years or less after injection ceases. The project assessed the viability and costs for the five scenarios using either dedicated offshore pipelines or shipping vessels. Carbon dioxide capture costs were not considered. Shipping incurred lower upfront CAPEX costs, and because most viable sources were located near the shore and waterways, shipping is preferred; no dedicated carbon dioxide pipelines exist in the region. The project also considered potential risks from mixed-use impacts on surrounding lands and ocean areas, such as active use by commercial and recreational fisherman, and other community considerations in planning for public engagement in the future. Other project risks were identified, including project management, permitting and compliance, and financing, as well as technical issues such as long-term instrumentation, plume migration, and model development. Geological concerns like reservoir permeability, seal, and induced seismicity held relatively low risk. The regulatory framework for offshore storage in the U.S. and Canada may be covered by general legal/regulatory programs, but is not yet fully defined. Existing programs appear to restrict the transportation of carbon dioxide across national boundaries (e.g., Canada to U.S.) and its sub-seabed disposal in some circumstances. Our assessment suggests that developing specific and separate pilot projects will help to advance the technical feasibility and regulatory requirements in each country, and lessons learned from such activities may be transferable elsewhere around the globe.

42 ENGINEERING↗

DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗