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DOE OSTI2022

DED Additively Manufactured HEAs Optimized via Parametric Study of Functionally Graded Materials

Complex concentrated alloys (CCAs) are a system of alloys composition of nearly equiatomic elements, creating a state of high configurational entropy in the material. These alloys are of interest for various industrial applications due to their high strength and hardness, wide operational temperature range, creep and diffusion resistance, and radiation resistance. In the current work CoCrFeNi-base CCAs are synthesize by combining three commonly industrial alloys: IN718, SS316L, and 70Co30Cr (commercially known as Stellite 21), in-situ utilizing directed energy deposition (DED) additive manufacturing (AM). One bulk specimen is fabricated with a 1:1:1 ratio of IN718, SS316L, and 70Co30Cr where IN718 is a source of nickel and chrome, SS316 is a source of iron and chrome, and 70Co30Cr is a source of cobalt and supplemental chrome. Additionally, a functionally graded material (FGM) of the identified CCA system from SS316 was fabricated with 10 layers, where the initial five layers are the base material of SS316L and graded by steps of 20% to transition to the CCA system. Overall build quality, microstructure, compositional distribution, phases analysis, and microhardness were studied by laser optical microscopy, scanning election microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction analysis (XRD), and Vickers microhardness techniques. Overall build quality showed a successful bulk build with acceptable density, however unmelted particles are observed in the as-built alloy. Compositional results show that the system meets the Boltzmann’s hypothesis definition of an HEA, and that an FCC CCA was produced with increased hardness, small grain size, and superior hardness properties to the SS316L substrate. While initial XRD results show predominately FCC structure, EDS analysis of interdendritic regions show the existence of Laves phases in the material. The fabrication of an FGM CCA allowed for potential screening of additional alloy mixes which may be of interest to explore in future research, and the resulting composition is compared to predicted values. This novel method of CCA fabrication results in substantial cost savings of these CCA systems over traditional methods.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A System of Agents for Supporting Optimization and Control of a Connected Community

The residential sector consumes a significant portion of the electricity sold in the United States. Above 60% of the energy used in the sector is used to operate heating, ventilation, and air conditioning (HVAC) systems and water heating (WH) systems. With the increase of intelligence in the grid and the new decision and control options enabled by the Internet of Things; control of these devices can be used to support the grid. Therefore, this article presents a scalable multiagent system for optimizing HVAC and WH systems while maintaining comfort. It allows a utility to orchestrate the shifting of energy from critical periods without direct control, but instead by using a price signal. The architecture, optimization formulation, implementation strategy and results from an implementation project are discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

2020 High Energy Physics Network Requirements Review (Final Report)

The Energy Sciences Network (ESnet) is the high-performance network user facility for the US Department of Energy (DOE) Office of Science (SC) and delivers highly reliable data transport capabilities optimized for the requirements of data-intensive science. In essence, ESnet is the circulatory system that enables the DOE science mission by connecting all of its laboratories and facilities in the United States and abroad. ESnet is funded and stewarded by the Advanced Scientific Computing Research (ASCR) program and managed and operated by the Scientific Networking Division at Lawrence Berkeley National Laboratory (LBNL). ESnet is widely regarded as a global leader in the research and education networking community. Throughout 2020,ESnet and the Office of High Energy Physics (HEP) of the DOE SC organized an ESnet requirements review of HEP-supported activities. Preparation for this event included identification of key stakeholders: program and facility management, research groups, technology providers, and a number of external observers. These individuals were asked to prepare formal case study documents about their relationship to the HEP program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward. A series of pre-planning meetings better prepared case study authors for this task, along with guidance on how the review would proceed in a virtual fashion. ESnet and ASCR use requirements reviews to discuss and analyze current and planned science use cases and anticipated data output of a particular program, user facility, or project to inform ESnet’s strategic planning, including network operations, capacity upgrades, and other service investments. A requirements review comprehensively surveys major science stakeholders’ plans and processes in order to investigate data management requirements over the next 5–10 years.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗

DOE OSTI2025

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

42 ENGINEERING↗

DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2015

Alternative to Nitric Acid Passivation

The Ground Systems Development and Operations (GSDO) Program at NASA John F. Kennedy Space Center (KSC), Florida, has the primary objective of modernizing and transforming the launch and range complex at KSC to benefit current and future NASA programs along with other emerging users. Described as the launch support and infrastructure modernization program in the NASA Authorization Act of 2010, the GSDO Program will develop and implement shared infrastructure and process improvements to provide more flexible, affordable, and responsive capabilities to a multi-user community. In support of NASA and the GSDO Program, the objective of this project is to qualify citric acid as an environmentally-preferable alternative to nitric acid for passivation of stainless steel alloys. This project is a direct follow-on to United Space Alliance (USA) work at KSC to optimize the parameters for the use of citric acid and verify effectiveness. This project will build off of the USA study to further evaluate citric acids effectiveness and suitability for corrosion protection of a number of stainless steels alloys used by NASA, the Department of Defense (DoD), and the European Space Agency (ESA).

stainless steel↗

NASA NTRS2022

Environmental Testing of the OVEN System for Lunar Water Extraction and Prospecting

Introduction: The presence of water ice in permanently shadowed regions on the lunar surface [1] may enable a sustained human presence on the Moon with minimal need for consumables. However, in order to develop a long term utilization plan that includes the usage of in-situ water we must first understand the abundance, stratigraphy and distribution of this re-source. Multiple space agencies currently have plans for lunar water prospecting missions. The Optimized Volatile Extraction Node (OVEN) was designed for water prospecting missions that require samples to be weighed, sealed, and heated as the means of determining water concentration. This method of water quantification necessitates a fair amount of automation, so a rigorous environmental test program was performed in order to build confidence in the performance of the OVEN design. The work presented here describes the OVEN environmental test program as well as ongoing efforts to improve on the design. Vibration: The OVEN participated in two rounds of random vibration tests. The first test was a stand-alone test performed at the Energy Systems Test Area of the Johnson Space Center. The second test was an integrated test with the mobile platform developed for the Resource Prospector project. The OVEN survived both tests without damage, but the tests did provide valuable lessons learned with regards to specific operations. Thermal Vacuum: The OVEN was successfully demonstrated at a temperature range of -50 to 75 C in a thermal vacuum chamber. The need to heat motor gearboxes at lower temperatures was predetermined so this test program was completed by implementing a method of gearbox heating that used the existing circuitry within the motors. Dust: A custom dynamometer was built in order to determine the torque required to move the various mechanisms within the OVEN at a range of temperatures. The OVEN system was coated with lunar dust simulant in order to determine mechanism torques under a worst-case operating condition. Sublimation: Sublimation losses within the OVEN were quantified through a series of test configurations, including an integrated test in a thermal vacuum chamber at Glenn Research Center [2]. Current Work: The OVEN subsystem is currently not a component of any existing prospecting missions, but work continues that will take the lessons learned from previous environmental tests and improve on the design in order to be considered for future prospecting opportunities. References: [1] Colaprete, A., Schultz, P., Heldmann, J., Wooden, D., Shirley, M., Ennico, K., ... & Sollitt, L. (2010). Detection of water in the LCROSS ejecta plume. science, 330(6003), 463-468. [2] Kleinhenz, J., Smith, J., Roush, T., Colaprete, A., Zacny, K., Paulsen, G., ... & Paz, A. (2018). Volatiles Loss from water bearing regolith simulant at Lunar Environments. In Earth and Space 2018: Engineering for Extreme Environments (pp. 454-466). Reston, VA: American Society of Civil Engineers.

A Paz↗

DOE OSTI2023

Biological and Environmental Research Network Requirements Review (Final Report)

The Energy Sciences Network (ESnet) is the high-performance network user facility for the US Department of Energy (DOE) Office of Science (SC) and delivers highly reliable data transport capabilities optimized for the requirements of data-intensive science. In essence, ESnet is the circulatory system that enables the DOE science mission by connecting all its laboratories and facilities in the US and abroad. ESnet is funded and stewarded by the Advanced Scientific Computing Research (ASCR) program and managed and operated by the Scientific Networking Division at Lawrence Berkeley National Laboratory (LBNL). ESnet is widely regarded as a global leader in the research and education (R&E) networking community. Between August 2022 and April 2023, ESnet and the Office of Biological and Environmental Research (BER) of the DOE SC organized an ESnet requirements review of BER-supported activities. Preparation for these events included identification of key stakeholders: program and facility management, research groups, and technology providers. Each stakeholder group was asked to prepare formal case study documents about its relationship to the BER ESS program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward. A series of pre-planning meetings better prepared case study authors for this task, along with guidance on how the review would proceed in a virtual fashion.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

ARIES Network Requirements Review

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

NASA NTRS2011

Building a Shared Definitional Model of Long Duration Human Spaceflight

In 1956, on the eve of human space travel Strughold first proposed a simple classification of the present and future stages of manned flight that identified key factors, risks and developmental stages for the evolutionary journey ahead. As we look to optimize the potential of the ISS as a gateway to new destinations, we need a current shared working definitional model of long duration human space flight to help guide our path. Initial search of formal and grey literature augmented by liaison with subject matter experts. Search strategy focused on both the use of term long duration mission and long duration spaceflight, and also broader related current and historical definitions and classification models of spaceflight. The related sea and air travel literature was also subsequently explored with a view to identifying analogous models or classification systems. There are multiple different definitions and classification systems for spaceflight including phase and type of mission, craft and payload and related risk management models. However the frequently used concepts of long duration mission and long duration spaceflight are infrequently operationally defined by authors, and no commonly referenced classical or gold standard definition or model of these terms emerged from the search. The categorization (Cat) system for sailing was found to be of potential analogous utility, with its focus on understanding the need for crew and craft autonomy at various levels of potential adversity and inability to gain outside support or return to a safe location, due to factors of time, distance and location.

Orr, M.↗

DOE OSTI2022

Technoeconomics of Particle-based CSP Featuring Falling Particle Receivers with and without Active Heliostat Control

This report documents the results and conclusions of a recent project to understand the technoeconomics of utility-scale, particle-based concentrating solar power (CSP) facilities leveraging unique operational strategies. This project included two primary objectives. The first project objective was to build confidence in the modeling approaches applied to falling particle receivers (FPRs) including the effect s of wind. The second project objective was to create the necessary modeling capability to adequately predict and maximize the annual performance of utility-scale, particle-based CSP plants under anticipated conditions with and without active heliostat control. Results of an extensive model validation study provided the strongest evidence to date for the modeling strategies typically applied to FPRs, albeit at smaller receiver scales. This modeling strategy was then applied in a parametric study of candidate utility-scale FPRs, including both free-falling and multistage FPR concepts, to develop reduced order models for predicting the receiver thermal efficiency under anticipated environmental and operating conditions. Multistage FPRs were found to significantly improve receiver performance at utility-scales. These reduced order models were then leveraged in a sophisticated technoeconomic analysis to optimize utility-scale , particle-based CSP plants considering the potential of active heliostat control. In summary, active heliostat control did not show significant performance benefits to future utility-scale CSP systems though some benefit may still be realized in FPR designs with wide acceptance angles and/or with lower concentration ratios. Using the latest FPR technologies available, the levelized-cost of electricity was quantified for particle-based CSP facilities with nominal powers ranging from 5 MW e up to 100 MW e with many viable designs having costs < 0.06 $/kWh and local minimums occurring between ~25–35 MW e .

14 SOLAR ENERGY↗

DOE OSTI2022

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources: Preprint

Integration of a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problem requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (controllable DERs) including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperformed other benchmark controllers regarding computation time without compromising operational performance.

DER↗

DOE OSTI2022

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources

Integrating a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problems requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (controllable DERs), including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperforms other benchmark controllers regarding computation time without compromising operational performance.

DER↗

DOE OSTI2026

A Discrete Hankel Transform Approach to Nuclear Data Processing for Fusion Applications

This study introduces advancements to the numerical solutions employed in the processing of nuclear data for fusion applications. It leverages the convolution theorem and Fourier transform techniques to enhance computational efficiency and broaden applicability. Building upon a previously reported discrete Hankel transform approach for Doppler broadening, this work refines the solution of convolution integrals central to these applications. The methodology provides a general and unified framework for evaluating any convolution operation, regardless of whether the underlying problem involves temperature effects in nuclear reactions. The applicability to the nuclear data processing for fusion is demonstrated by deriving the convolution integrals for some of the fusion-related quantities. As before, the convolution operation utilizes a Gaussian-based kernel; however, the discrete Hankel transform of order $𝛼$ = $\frac{1}{2}$ is now applied to the forward Fourier transform of the nonkernel argument, rather than the inverse Fourier transform. This modification eliminates the need for the integration of the nonkernel, cross section–based function, which is a step that posed challenges for certain pointwise cross-section representations. It also removes the requirement for cross-section linearization. Optimized for graphics processing unit architectures, the approach significantly improves computational performance. These advancements are currently under evaluation as the foundation for the next-generation thermonuclear data file processing codes being developed at Lawrence Livermore National Laboratory.

Nuclear science and engineering↗

DOE OSTI2020

An Interior-Point Solver for Optimal Power Flow Problem Considering Distributed FACTS Devices

In this paper, we propose an AC optimal power flow (ACOPF) model considering distributed flexible AC transmission system (D-FACTS) devices, in which the reactance of D-FACTS equipped lines are introduced as decision variables. This is motivated by increasing interests in using D-FACTS devices to address system operational and cyber-security concerns. First, D-FACTS devices can be incorporated in real-time operations for economic benefits such as managing power congestions and reducing system losses. Second, D-FACTS devices can be utilized by moving target defense (MTD), an emerging concept against cyber-attacks, to prevent attackers from knowing true system configurations. Therefore, system operators can use the proposed ACOPF model to achieve economic benefits and provide the setpoints of D-FACTS devices for MTD at the same time. In addition, we rigorously derive the gradient and Hessian matrices of the objective function and constraints, which are further used to build an interior-point solver of the proposed ACOPF. Numerical results on the IEEE 118-bus transmission system show the validity of the proposed ACOPF model as well as the efficacy of the interior-point solver in minimizing system losses and generation costs.

Liu, Bo↗

DOE OSTI2023

Minimizing Ground Risk in Cellular-Connected Drone Corridors With mmWave Links

Unmanned Aircraft Systems (UASs) have been receiving significant interest and support from academia, industry, and regulatory bodies over the past decade due to their various use cases. To safely integrate UAS operations into the national airspace, particularly overpopulated regions, the risk posed to ground users, buildings, and vehicles due to unmanned aerial vehicle (UAV) flight should be minimized. This risk can be represented by a numerical metric, which we refer to in this article as the “ground risk.” Many UAS applications also depend on the presence of a reliable wireless communication link between the UAV and a control station for the transmission of UAV position, surveillance video, UAV payload commands, and other mission-related data. Such wireless communication requirements also need to be considered in the design of UAS operations. In this article, we consider both these aspects and study the design of nonintersecting trajectories for UAS operations to minimize ground risk, subject to constraints on the wireless signal strength and geometry of the trajectory, specified in terms of: 1) an enclosing cylinder within which the trajectory must lie and 2) an integrated angular change along the UAV's trajectory. The performance of a computationally expensive optimal algorithm is compared with that of a computationally faster heuristic approach within the dense urban environment of Manhattan, NY, USA. Performance evaluation using ray-tracing simulations shows that the heuristic approach performs close to the optimal algorithm at a reduced computation cost. In conclusion, this research can be utilized to make UAS operations safe and reliable and accelerate their adoption.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Scalable Predictive Control and Optimization for Grid Integration of Large-Scale Distributed Energy Resources

Integrating a large number of distributed energy resources (DERs) into the power grid needs a scalable power balancing method. We formulate the power balancing problem as a look-ahead optimization problem to be solved sequentially by a power distribution system aggregator based on a model predictive control (MPC) framework. Solving large-scale look-ahead control problems requires proper configuration of the control steps. In this paper, to solve large-scale control problems, we propose a variable time granularity where control time steps nearby the current control step have finer resolutions. The aggregator objective includes maximization of power production revenue and minimization of power purchasing expense, renewable power curtailment, and mileage costs for energy storage and electric vehicle (EV) charging stations while satisfying system capacity and operational constraints. The control problem is formulated as a mixed-integer linear program (MILP) and solved using the XpressMP solver. We perform simulations considering a copper plate representation of a large distribution network consisting of 2507 devices (control-lable DERs), including curtailable photovoltaics (PVs), energy storage batteries, EV charging stations, and buildings with heating, ventilation, and air conditioning units (HVACs). We show the effectiveness of the proposed approach in managing DERs interactively for maximum energy trading profit and local supply-demand power balancing. Finally, we demonstrate that the proposed method outperforms other benchmark controllers regarding computation time without compromising operational performance.

DER↗