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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Solid State Lighting Program (Falcon)

Over the past two years, KLA-Tencor and partners successfully developed and deployed software and hardware tools that increase product yield for High Brightness LED (HBLED) manufacturing and reduce product development and factory ramp times. This report summarizes our development effort and details of how the results of the Solid State Light Program (Falcon) have started to help HBLED manufacturers optimize process control by enabling them to flag and correct identified killer defect conditions at any point of origin in the process manufacturing flow. This constitutes a quantum leap in yield management over current practice. Current practice consists of die dispositioning which is just rejection of bad die at end of process based upon probe tests, loosely assisted by optical in-line monitoring for gross process deficiencies. For the first time, and as a result of our Solid State Lighting Program, our LED manufacturing partners have obtained the software and hardware tools that optimize individual process steps to control killer defects at the point in the processes where they originate. Products developed during our two year program enable optimized inspection strategies for many product lines to minimize cost and maximize yield. The Solid State Lighting Program was structured in three phases: i) the development of advanced imaging modes that achieve clear separation between LED defect types, improves signal to noise and scan rates, and minimizes nuisance defects for both front end and back end inspection tools, ii) the creation of defect source analysis (DSA) software that connect the defect maps from back-end and front-end HBLED manufacturing tools to permit the automatic overlay and traceability of defects between tools and process steps, suppress nuisance defects, and identify the origin of killer defects with process step and conditions, and iii) working with partners (Philips Lumileds) on product wafers, obtain a detailed statistical correlation of automated defect and DSA map overlay to failed die identified using end product probe test results. Results from our two year effort have led to “automated end-to-end defect detection” with full defect traceability and the ability to unambiguously correlate device killer defects to optically detected features and their point of origin within the process. Success of the program can be measured by yield improvements at our partner’s facilities and new product orders.

Meeks, Steven↗
DOE OSTI2022

MPC4CLR (Model-Predictive-Control-for-Critical-Load-Restoration-in-Power-Distribution-Systems) [SWR-22-24]

Model predictive control (MPC) is a system or process control technique for making decisions under uncertainty via rolling look-ahead optimizations at each control step where only the current step decisions are applied, and the rest are discarded. In this work, we developed an MPC for a critical load restoration (CLR) in power distribution systems to recover system service (electricity delivery) following an extreme event-triggered substation outage. The method considers the problem of controlling distributed energy resources (DERs) of the distribution system with the objective of achieving maximum load pick up while satisfying distribution network flow and voltage constraints. A linearized optimal power flow (OPF) model is employed to represent the physics of the network. The problem formulation is augmented with a ramping (up) reserve product for the DERs to ensure improved and upward monotonic load restoration as time evolves. Simulation analysis and performance tests are performed using a modified IEEE 13-bus test feeder integrated with wind, solar, microturbine, and energy storage battery. The software is developed using various software packages in Julia and Python. The MPC model is implemented using the JuMP optimization language in Julia while the data analytics including renewable generation and load demand forecasts, running the MPC simulation and visualizations is performed in Python.

Eseye, Abinet Tesfaye↗
DOE OSTI2025

Dynamic Model of a supercritical CO2 10MW Recompression Closed Brayton Cycle

This model of the 10MW recompression closed Brayton cycle (RCBC) was developed in conjunction with the DOE’s Supercritical Transformational Electric Power (STEP) project. A high-fidelity dynamic model was used extensively to study the dynamic characteristics of the cycle and develop the process control architecture and strategies for start-up and shutdown procedures. This version of the model has been simplified from the original version to be more accessible for a variety of applications and research. The controllers developed for the original model have been maintained for this version and tuned to give a similar performance to the original model. This model can be used to perform similar studies as those performed in Liese et al (2020). The overall cycle performance will not be identical but will perform similarly.

Controls,Power Cycles,Process Systems Engineering,↗
DOE OSTI2014

Nuclear Security: Quantifying Late Detection in MC&A

The objectives of this presentation are to understand the concept of late detection; review the statistics used in MC&A; specify the Pd and timelines for Pd for MC&A elements for item inventories; review elements of process control as they relate to bulk processes; and specify the timelines and detection thresholds for Pd for MC&A elements for bulk or Processing Operations.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2019

Chemical Kinetic Effects on Detonation Wave Generation in a Semi-Bounded Channel

The coupled effects of mixing and ignition are investigated in a semi-bounded channel that emulates a rotating detonation engine geometry. In previous studies, a robust mechanism of self-excited detonation wave generation was discovered with O 2 /CH 4 reactants in this experiment. The behavior requires symbiosis between the chemical kinetics of the reactant mixture and the dynamics of the reactant injection process. The reactant jet dynamics are controlled principally by the geometry of the system and the pressure differences across the injector. The chemical kinetics are modified by changing the reactant composition to investigate how the combustion behavior changes when the kinetics become the rate-controlling process. Ignition delay timescales are increased by introducing an inert gas, N 2 , to the oxidizer flow; conversely, ignition delay time-scales are decreased by replacing natural gas fuel with hydrogen, H 2 . The effects of the oxidizer modifications to the chemical kinetics for each fuel are studied independently to characterize the amplification process associated with the self-excited instability, and apply this understanding to the sustainability of detonations in a comparable RDE environment.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

Magnetotactic Bacteria as Potential Sources of Bioproducts

Magnetotactic bacteria (MTB) produce intracellular organelles called magnetosomes which are magnetic nanoparticles composed of magnetite (Fe3O4) or greigite (Fe3S4) enveloped by a lipid bilayer. The synthesis of a magnetosome is through a genetically controlled process in which the bacterium has control over the composition, direction of crystal growth, and the size and shape of the mineral crystal. As a result of this control, magnetosomes have narrow and uniform size ranges, relatively specific magnetic and crystalline properties, and an enveloping biological membrane. These features are not observed in magnetic particles produced abiotically and thus magnetosomes are of great interest in biotechnology. Most currently described MTB have been isolated from saline or brackish environments and the availability of their genomes has contributed to a better understanding and culturing of these fastidious microorganisms. Moreover, genome sequences have allowed researchers to study genes related to magnetosome production for the synthesis of magnetic particles for use in future commercial and medical applications. Here, we review the current information on the biology of MTB and apply, for the first time, a genome mining strategy on these microorganisms to search for secondary metabolite synthesis genes. More specifically, we discovered that the genome of the cultured MTB Magnetovibrio blakemorei, among other MTB, contains several metabolic pathways for the synthesis of secondary metabolites and other compounds, thereby raising the possibility of the co-production of new bioactive molecules along with magnetosomes by this species.

magnetosomes↗
DOE OSTI2026

A Compact Cryogenic Environment for In Situ Neutron Diffraction Under Mechanical Loading

Understanding the deformation mechanisms of materials at cryogenic temperatures is crucial for cryogenic engineering applications. In situ neutron diffraction is a powerful technique for probing such mechanisms under cryogenic conditions. In this study, we present the development of a compact cryogenic environment (CCE) designed to facil-itate in situ neutron diffraction experiments under mechanical loading at tempera-tures as low as 77 K. The CCE features a polystyrene foam cryogenic chamber, alumi-num blocks serving as neutron-transparent cold sinks, a liquid nitrogen dosing system for cryogen delivery, a nitrogen gas flow control system for thermal management, a process controller for temperature control, and a pair of thermally isolated grip adapt-ers for mechanical testing. The CCE achieves reliable temperature control with mini-mal neutron attenuation. Utilizing this setup, we conducted three in situ neutron dif-fraction tensile tests on a 316L stainless steel at 77 , 173 , and 298 K, respectively. The results highlight the pronounced effects of cryogenic temperatures on the material's deformation mechanisms, underscoring both the significance of cryogenic deformation studies and the effectiveness of the CCE.

Yu, Dunji [ORNL] (ORCID:0000000189467851)↗
NASA NTRS1986

Software development to support sensor control of robot arc welding

The development of software for a Digital Equipment Corporation MINC-23 Laboratory Computer to provide functions of a workcell host computer for Space Shuttle Main Engine (SSME) robotic welding is documented. Routines were written to transfer robot programs between the MINC and an Advanced Robotic Cyro 750 welding robot. Other routines provide advanced program editing features while additional software allows communicatin with a remote computer aided design system. Access to special robot functions were provided to allow advanced control of weld seam tracking and process control for future development programs.

Silas, F. R., Jr.↗
NASA NTRS1991

Software life cycle methodologies and environments

Products of this project will significantly improve the quality and productivity of Space Station Freedom Program software processes by: improving software reliability and safety; and broadening the range of problems that can be solved with computational solutions. Projects brings in Computer Aided Software Engineering (CASE) technology for: Environments such as Engineering Script Language/Parts Composition System (ESL/PCS) application generator, Intelligent User Interface for cost avoidance in setting up operational computer runs, Framework programmable platform for defining process and software development work flow control, Process for bringing CASE technology into an organization's culture, and CLIPS/CLIPS Ada language for developing expert systems; and methodologies such as Method for developing fault tolerant, distributed systems and a method for developing systems for common sense reasoning and for solving expert systems problems when only approximate truths are known.

Fridge, Ernest↗
NASA NTRS1999

Real-time Adaptive Control Using Neural Generalized Predictive Control

The objective of this paper is to demonstrate the feasibility of a Nonlinear Generalized Predictive Control algorithm by showing real-time adaptive control on a plant with relatively fast time-constants. Generalized Predictive Control has classically been used in process control where linear control laws were formulated for plants with relatively slow time-constants. The plant of interest for this paper is a magnetic levitation device that is nonlinear and open-loop unstable. In this application, the reference model of the plant is a neural network that has an embedded nominal linear model in the network weights. The control based on the linear model provides initial stability at the beginning of network training. In using a neural network the control laws are nonlinear and online adaptation of the model is possible to capture unmodeled or time-varying dynamics. Newton-Raphson is the minimization algorithm. Newton-Raphson requires the calculation of the Hessian, but even with this computational expense the low iteration rate make this a viable algorithm for real-time control.

Haley, Pam↗
NASA NTRS2005

Some Improvements in H-PDLCs

Some improvements have been made in the formulation of holographically formed polymer-dispersed liquid crystals (H-PDLCs) and in the fabrication of devices made from these materials, with resulting improvements in performance. H-PDLCs are essentially volume Bragg gratings. Devices made from H-PDLCs function as electrically switchable reflective filters. Heretofore, it has been necessary to apply undesirably high drive voltages in order to switch H-PDLC devices. Many scientific papers on H-PDLCs and on the potential utility of H-PDLC devices for display and telecommunication applications have been published. However, until now, little has been published about improving quality control in synthesis of H-PDLCs and fabrication of H-PDLC devices to minimize (1) spatial nonuniformities within individual devices, (2) nonuniformities among nominally identical devices, and (3) variations in performance among nominally identical devices. The improvements reported here are results of a research effort directed partly toward solving these quality-control problems and partly toward reducing switching voltages. The quality-control improvements include incorporation of a number of process controls to create a relatively robust process, such that the H-PDLC devices fabricated in this process are more nearly uniform than were those fabricated in a prior laboratory-type process. The improved process includes ultrasonic mixing, ultrasonic cleaning, the use of a micro dispensing technique, and the use of a bubble press.

Crawford, Gregory P.↗
NASA NTRS2019

Optically Enhanced Bonding Workstation for Robust Bonding

Process control is one of the methods recommended by the FAA to reduce risk in fabrication of structurally bonded composite joints for aircraft structure based on guidance provided in circular AC-107B for certification of structurally bonded joints. An Optically Enhanced Bonding Workstation is presented here that reduces the risk in bonded joint fabrication. Results will be presented demonstrating the benefits of process monitoring and its ability to reduce risk in performing pre-bond composite surface preparation steps. This supports reduction in the timeline to certification of bonded composite structures through development of a robust bonding process upstream of any part certification steps. Sanding surface preparation has been identified as a high risk process step that is known to impact bond performance. Control of sanding during surface preparation can be performed using portable surface analysis tools previously identified including included gloss, color, Fourier Transform Infrared spectroscopy (FTIR) and optically stimulated electron emissions (OSEE). Threshold limits for the surface analysis tool measurements were determined based on an example objective bonding system utilizing a common EA9394 paste adhesive measured using standard double cantilever beam fracture toughness testing. The patented Optically Enhanced Bonding Workstation (OEBW), was tailored to monitor and control the epoxy composite surface preparation step. Surface analysis tool threshold limits were incorporated into the OEBW to demonstrate improved composite bond performance through process control. The surface analysis tools investigated here can easily be incorporated into an automated system due to their applicability to rapidly quantify the composite sanded surface treatment and their portability.

Kutscha, Eileen O.↗
DOE OSTI2019

Inhibiting Brittle Intermetallic Layer in Magnesium/Aluminum Bimetallic Castings via In Situ Formation of Mg{sub 2}Si Phase

A quasi-continuous Mg{sub 2}Si layer is formed in situ at the magnesium/aluminum interface of bimetallic castings, by selecting a Si-containing aluminum alloy and overcasting process control. This effectively inhibits the formation of brittle intermetallic compounds (Al{sub 3}Mg{sub 2}, Al{sub 12}Mg{sub 17}) during the casting process, and the mechanisms are discussed based on phase diagram calculations and experimental validation. It is, thus, recommended to select Si-containing Al alloys as substrate for Mg/Al bimetallic castings.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Long-term single-column model intercomparison of diurnal cycle of precipitation over midlatitude and tropical land

General Circulation Models (GCMs) have for decades exhibited difficulties in modelling the diurnal cycle of precipitation (DCP). This issue can be related to inappropriate representation of the processes controlling sub-diurnal phenomena like convection. In this study, 11 single-column versions of GCMs are used to investigate the interactions between convection and environmental conditions, processes that control nocturnal convections, and the transition from shallow to deep convection on a diurnal time-scale. Long-term simulations are performed over two continental land sites: the Southern Great Plains (SGP) in the USA for 12 summer months from 2004 to 2015 and the Manacapuru site at the central Amazon (MAO) in Brazil for two full years from 2014 to 2015. The analysis is done on two regimes: afternoon convective regime and nocturnal precipitation regime. Most models produce afternoon precipitation too early, likely due to the missing transition of shallow-to-deep convection in these models. At SGP, the unified convection schemes better simulate the onset time of precipitation. At MAO, models produce the heating peak in a much lower level compared with observation, indicating too shallow convection in the models. For nocturnal precipitation, models that produce most of nocturnal precipitation all allow convection to be triggered above the boundary layer. This indicates the importance of model capability to detect elevated convection for simulating nocturnal precipitation. Sensitivity studies indicate that (a) nudging environmental variables towards observations has a minor impact on DCP, (b) unified treatment of shallow and deep convection and the capability to capture mid-level convection can help models better capture DCP, and (c) the interactions of the atmosphere with other components in the climate system (e.g. land) are also important for DCP simulations in coupled models. Finally, these results provide long-term statistical insights on which physical processes are essential in climate models to simulate DCP.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

The Application of Convolutional Neural Networks (CNNs) to Recognize Defects in 3D-Printed Parts

Cracks and pores are two common defects in metallic additive manufacturing (AM) parts. In this paper, deep learning-based image analysis is performed for defect (cracks and pores) classification/detection based on SEM images of metallic AM parts. Three different levels of complexities, namely, defect classification, defect detection and defect image segmentation, are successfully achieved using a simple CNN model, the YOLOv4 model and the Detectron2 object detection library, respectively. The tuned CNN model can classify any single defect as either a crack or pore at almost 100% accuracy. The other two models can identify more than 90% of the cracks and pores in the testing images. In addition to the application of static image analysis, defect detection is also successfully applied on a video which mimics the AM process control images. The trained Detectron2 model can identify almost all the pores and cracks that exist in the original video. This study lays a foundation for future in situ process monitoring of the 3D printing process.

36 MATERIALS SCIENCE↗
DOE OSTI2016

SU-F-P-33: Combining Research and Professional Practice in the Clinical Setting: A Medical Physicist Personal Experience

Purpose: To initiate a discussion on the current and evolving role of Medical Physicists based on author’s professional and research experience in patient safety and quality control. Methods: Several professionals of the departments of Medical Physics and Radiation Oncology, chiefly devoted to clinical tasks, began a research program on patient safety and quality control in a framework provided by the implementation of intraoperative radiotherapy (IORT). We performed studies on virtual simulation for IORT, in vivo dosimetry, failure mode and effect analysis (FMEA), statistical process control (SPC), and receiver operating characteristics of dosimetric equipment. This was done with the support of our research foundation and different grants while continuing with our departmental clinical routine involving about 1600 annual treatments with two linacs and different brachytherapy techniques. Results: We published 5 papers in international journals in the last two years. This author conducted a doctoral research which resulted in a dissertation in 2015. The extra time spent after treatments was essential to succeed. Funding and support achieved via our foundation played a crucial role; but this would have not been possible without punctual external mentoring and partnership. FMEA conclusions were able to be implemented only with staff commitment; however, conclusions concerning equipment cannot be easily communicated to manufacturers. These tasks required extra training in the appropriated methods. Conclusion: Research needed the support of a dedicated foundation, which would have been very difficult to obtain with the sole participation of our departments. FMEA and SPC results may need engagement of staff and manufacturers, respectively, hard to achieve without strong recommendations or even a regulatory framework. All these fields need evolution of Medical Physicists’ roles and additional training. Devotion to both clinical tasks and research could be unfeasible for Medical Physicists in the clinical setting without the appropriate rearrangement of their schedules and tasks. Supported by grants IPT-300000-2010-3 and PI11/01659. ERDF funds and Spanish Government.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Human Performance Measures for the Evaluation of Nuclear Power Plant Control Room Interfaces: A Systematic Review - 265

The purpose of this study was to review the literature related to measuring human performance in the design and evaluation of the human-system interface (HSI) of nuclear power plant (NPP) control rooms and synthesize lessons learned and future directions for research and practice in this field. The design and evaluation of digital or hybrid HSI requires comprehensive measurement of human performance to ensure quality and safety of the nuclear power process control. Human factors evaluation frameworks have been proposed to guide the measurement of human performance constructs. However, there are few guides for selecting appropriate measures for those constructs. A systematic review of empirical research literature was conducted. Studies were identified through academic publication databases and grey literature searches. Eligible studies were coded and information regarding human performance measures was extracted and analyzed. A total of 80 studies met the criteria. Human performance measures extracted from the reviewed studies included measures of: behavioral performance; workload; situation awareness; human-human or human-machine cooperation; other cognitive performance indicators; and system performance. Behavioral performance (speed and accuracy), workload, and situation awareness were the most frequently measured constructs with validated and domain-specific instruments. The results of the literature review provided an overview of the human performance constructs and their corresponding measures for NPP control room HSI evaluation. These results can be used as an initial guide to establish appropriate and comprehensive measurements of human performance for such evaluations. Future directions in measure development are also discussed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗