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DOE OSTI2022

Tools Assessing Performance (FY2022 Quarter 4 Report)

We were finally successful in acquiring TTU’s 200-meter tower data for the duration of the Isolated Building Wake Experiment (IBWE). This data will provide an independent measurement of the undisturbed wind profile including heights far above those that are typical of meteorological sensor networks. These measurements will characterize the mean and turbulence throughout the atmospheric surface layer, which will be particularly useful for validation of highfidelity computational fluid dynamics models. This dataset can be shared freely among the TAP team but not outside of it as TTU sells this data to the wind power industry. The journal article overview has been submitted to LANL’s publication review and will be submitted to the Journal of Wind Engineering and Industrial Aerodynamics once the review is complete. We are nearing completion on another two articles. The first discusses analyses of the evolution of the measurements of mean wind speed along the centerline of the building as a function of atmospheric stability. Rather than using individual time steps, all of the wind speed measurements are normalized using the upwind measurement at 2 building heights (H) and filtered by wind direction and atmospheric stability. The second discusses the development of the diffusive wake model and uses the averaged profiles from the first article to validate the behavior of the model. The portion of the section below on the diffusive wake model discussing comparisons with the averaged profiles, will be included in the validation section of this paper.

17 WIND ENERGY↗

DOE OSTI2021

Trace explosive residue detection of HMX and RDX in post-detonation dust from an open-air environment

Explosives are often used in industry, geology, mining, and other applications, but it is not always clear what remains after a detonation or the fate and transport of any residual material. The goal of this study was to determine to what extent intact molecules of high explosive (HE) compounds are detectable and quantifiable from post-detonation dust and particulates in a field experiment with varied topography. We focused on HMX (1,3,5,7-Tetranitro-1,3,5,7-tetrazocane), which is less studied in field detonation literature, as the primary explosive material and RDX (1,3,5-Trinitroperhydro-1,3,5-triazine) as the secondary material. The experiment was conducted at Site 300, Lawrence Livermore National Laboratory’s Experimental Test Site, in California, USA. Two 20.4 kg and one 40.8 kg above ground explosions (primarily comprised of LX-14, an HMX-based polymer-bonded high explosive) were detonated on an open-air firing area on separate days. The complex terrain of the firing area (e.g., buildings, berm, low-height obstacles) was advantageous to study HE deposition in relation to plume dynamics. Three types of samples were collected up to 100 m away from each shot: surface swipes of aluminum plates, surface swipes of fixed objects, and filters from air samples. We used atmospheric flow tube-mass spectrometry (AFT-MS) to quantify picogram levels of molecular residue of HE material in the post-detonation dust. An aliquot of sample extract in methanol (e.g., 1 µL of 0.5 mL) was placed onto a resistive material and then thermally desorbed into the AFT-MS. We successfully detected and quantified both HMX and RDX in many of the samples. Based on mass (pg) detected and solution dilution, we back-calculated the mass collected on the swipe or filter (ng per sample). The aerial distribution of molecular residue was consistent with the path of the plume, which was strongly determined by wind speed and direction at the time of each shot. The quantity of material detected appeared to correlate more with distance from the shot and the wind conditions than with shot size. This study demonstrates that the picogram detection levels of AFT-MS are well-suited for quantification of analytes (e.g., HMX and RDX) in environmental samples.

atmospheric flow tube-mass spectrometry (AFT-MS), ↗

NASA NTRS2003

Optimal Inflatable Space Towers with 3 - 100 km Height

Theory and computations are provided for building inflatable space towers up to one hundred kilometers in height. These towers can be used for tourism, scientific observation of space, observation of the Earth's surface, weather and upper atmosphere, and for radio, television, and communication transmissions. These towers can also be used to launch space ships and Earth satellites. These projects are not expensive and do not require rockets. They require thin strong films composed from artificial fibers and fabricated by current industry. The towers can be built using present technology. The towers can be used (for tourism, communication, etc.) during the construction process and provide self-financing for further construction. The tower design does not require work at high altitudes; all construction can be done at the Earth's surface. The transport system for a tower consists of a small engine (used only for friction compensation) located at the Earth's surface. The tower is separated into sections and has special protection mechanisms in case of damage. Problems involving security, control, repair, and stability of the proposed towers are addressed in other publications. The author is prepared to discuss these and other problems with serious organizations desiring to research and develop these projects.

Bolonkin, Alexander↗

DOE OSTI2026

Deposition Height Prediction in Directed Energy Deposition

Using 316L stainless steel as a model material, reduced-order models are developed to predict capture efficiency, deposition height, and site-specific hardness in directed energy deposition. Capture efficiency is predicted over a 15 to 55 pct range using a dimensionless number derived from processing conditions and thermophysical properties. Deposition height is predicted over a 0.3 to 1.3 mm range without in situ sensing or prior training data, using two models based on the same mass and energy-balance principles. Predictions are compared with machine learning approaches. A quantitative relationship links deposition height, primary dendrite arm spacing (PDAS), and hardness: heights of 0.3 to 1.1 mm correspond to PDAS values of 2.7 to 5.1 µm and Vickers hardness (HV) of 160 to 219. Thinner layers cool more rapidly, producing finer microstructures and higher hardness. Samples fabricated with in situ variations in deposition height exhibited up to 55 HV differences between thick and thin regions, demonstrating that local control of deposition height enables predictive, site-specific hardness within a single build. These results establish deposition height prediction as a pathway for a priori process design and property control in directed energy deposition for 316L stainless steel.

Kunkel, William [Univ. of Wisconsin, Madison, WI (↗

DOE OSTI2025

Urban morphology from a landscape perspective: How building morphology distribution land models (BMDLM) emulate pattern and process

Urban form (e.g., building morphology such as height or footprint) can be used to predict environmental footprints, such as energy/water consumption and carbon emissions. Although progress has been made in predicting building characteristics to fill gaps in observation or derive 3-D representations, the relationships between morphology and other variables such as land use and population are poorly understood. Understanding these relationships may enable projections for how cities will evolve with landscapes in the future. A suite of random forest models, the Building Morphology Distribution Land Models (BMDLM), was developed to determine how well building morphology for two distinct statistical measures (central tendency and frequency) can be predicted using land use (e.g., zoning) and population at different resolutions. Clark County, Nevada and Los Angeles County, California are explored as case studies. Generally, 1-km models outperformed 30-m models. Frequency distribution models had the best performance, especially in LA County. Frequency models significantly outperformed spatial autocorrelative models using inverse distance weighting (IDW). BMDLM offers a new take on modeling urban form in which generalized landscape patterns are characterized to understand the influence of population and zoning on urban development, as described by urban scaling theory.

Sturtevant, Jillian [Baylor Univ., Waco, TX (Unite↗

DOE OSTI2020

Nonlinear dynamic analysis of solution multiplicity of buoyancy ventilation in a typical underground structure

Buoyancy ventilation is widely used in underground buildings, such as underground hydropower stations. Multiple solutions of buoyancy ventilation may exist in those underground structures. In this study, we developed a transient model comprising an ordinary differential equation system to describe buoyancy ventilation patterns in typical two-zone underground structures. Additionally, the accuracy of the model was validated. Nonlinear dynamical analysis was conducted to study multiple steady-state airflow. According to mathematical derivation, the configuration of one local heat source at the bottom corner introduces two stable solutions. The criterion to determine the stability and existence of solutions for more general scenarios was developed. Using this criterion, we obtained the multiple steady states of any two-zone underground buildings for different stack height ratios and the strength ratios of the heat sources. Furthermore, this criterion can be adopted for the design of buoyancy ventilation or natural smoke ventilation systems. Designers can change the height ratio of the stack or the heat ratio of two zones to induce the desired ventilation patterns. Finally, a case study was conducted with field measurements to demonstrate the use of the nonlinear dynamical analysis method to investigate the multiple steady states of buoyancy ventilation. Through the case study, we validated that the proposed criterion could produce the same result as the nonlinear dynamical analysis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Toolpath considerations for DED: Arc and laser welding

Directed energy deposition (DED) is a form of additive manufacturing that uses localized melted metal, similar to traditional arc welding, to construct an object. In comparison to polymer systems, metal systems can exert additional control over the build process through manipulation of the pool of melted metal, called the “melt pool.” This is especially important to maintain appropriate layer heights and create high quality builds. Additionally, metal systems allow site-specific control of the printed part, which enables advanced construction techniques that would otherwise not be possible. However, both of these types of control require support from the slicing software and, potentially, sensor feedback. This chapter will discuss these control processes and their basic implementation in a slicing program. The processes described here lay the foundation for more advanced solutions, particularly sensor feedback, that will be discussed later.

Borish, Michael↗

DOE OSTI2020

Chicago microclimate and building energy use data

These data comprise three elements: - High resolution, 90 m simulated weather data for 1 year at 15 min. intervals (with known gaps toward the end of each month). These files are in .csv format. - A mapping of individual buildings with individual IDs, their latitude/longitude location, and height. (Excel file) - Energy simulation output of these individual buildings, at 15 min. intervals for a whole year. (.json and other files)

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Chicago microclimate and building energy use data

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1980

Solar energy facility at North Hampton Recreation Center, Dallas, Texas

The solar energy facility located at the North Hampton Park Recreation and Health Center, Dallas, Texas is presented. The solar energy system is installed in a single story (two heights), 16,000 sq ft building enclosing a gymnasium, locker area, and health care clinic surrounded by a recreational area and athletic field. The solar energy system is designed to provide 80 percent of the annual space heating, 48 percent of the annual space cooling, and 90 percent of the domestic hot water requirements. The system's operation modes and performance data acquisition system are described. The system's performance during the months of June, July, August, September, and October of 1979 are presented and show a negative savings of energy. Experience to date indicates however that the system concept has promise of acceptable performance. It is concluded that if proper control and sequencing components was maintained, then the system performance would improve to an acceptable level.

Source record↗

NASA NTRS1993

Topographic mapping using a monopulse SAR system

Terrain height variations in mountainous areas cause two problems in the radiometric correction of SAR images: the first being that the wrong elevation angle may be used in correcting for the radiometric variation of the antenna pattern; the second that the local incidence angle used in correcting the projection of the pixel area from slant range to ground range coordinates may vary from that given by the flat earth assumption. We propose a novel design of a SAR system which exploits the monopulse principle to determine the elevation angle and thus the height at the different parts of the image. The key element of such a phase monopulse system is an antenna, which can be divided into a lower and upper half in elevation using a monopulse comparator. In addition to the usual sum pattern, the elevation difference pattern can be generated by a -pi phase shift on one half of the antenna. From the ratios of images radiometrically modulated by the difference and sum antenna pattern in cross-track direction, we can derive the appropriate elevation angle at any point in the image. Together with the slant range we can calculate the height of the platform above this point using information on the antenna pointing and the platform attitude. This operation, repeated at many locations throughout the image, allows us to build up a topographic map of the height of the aircraft above each location. Inversion of this map, using the precisely determined aircraft altitude and the accurate flight path, leads to the actual topography of the imaged surface. The precise elevation of one point in the image could also be used to convert the height map to a topographic map. In this paper, we present design considerations for a corresponding airborne SAR system in X-Band and give estimates of the error due to system noise and azimuth ambiguities as well as the expected performance and precision in topographic mapping.

Zink, M.↗

DOE OSTI2020

Real-Time Defect Correction in Large-Scale Polymer Additive Manufacturing via Thermal Imaging and Laser Profilometer

Defects can result in a failed part and are costly in terms of time and material. This cost is even greater in the context of large-scale additive manufacturing where the objects can be very large. As a result, a great deal of research has focused on defect identification and mitigation. To address defects during object construction, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated an in-situ control system comprised of two sensors: a thermal camera and laser profilometer. This control system adjusted material flow and build speed to mitigate three types of defects: low layer times, underfill, and overfill. Several test objects were constructed. The control system was found to adjust build parameters to handle low layer times of approximately 15 seconds and height deviations from -100% underfill (the absence of a layer) to 50% overfill. Within two layers, height deviations could be returned to within 10% of the expected layer height. Further, preliminary results suggest the system can compensate for uneven build surfaces.

Borish, Michael↗

DOE OSTI2021

Utility-scale Building Type Assignment Using Smart Meter Data

United States building energy use accounted for 40% of total energy use, 74% of peak demand, and $412 billion in 2019. Building energy modeling allows researchers to simulate building physics, gain insights into possible energy/demand saving opportunities, and assess cost-effective resilience amidst climate change. Many building features needed to create building energy models are readily available such as 2D footprints and LiDAR (height). A critical feature that is not generally obtainable is the building type. In partnership with a utility, a years worth of real-world, 15-minute electrical use data has been examined. The smart meter data is compared to 97 different prototype building energy models to assign building type. Real-world considerations including data preparation, quality assurance, and handling of missing values for advanced metering infrastructure data are addressed. Euclidean distance for pattern-matching of energy use, dynamic time warping, and time-window statistics with machine learning are compared for determining building type from measured electricity use.

Bass, Brett↗

DOE OSTI2023

Pressure-based process monitoring of direct-ink write material extrusion additive manufacturing

As additive manufacturing (AM) has become a reliable method for creating complex and unique hardware rapidly, the quality assurance of printed parts remains a priority. In situ process monitoring offers an approach for performing quality control while simultaneously minimizing post-production inspection. For extrusion printing processes, direct linkages between extrusion pressure fluctuations and print defects can be established by integrating pressure sensors onto the print head. In this work, the sensitivity of process monitoring is tested using engineered spherical defects. Pressure and force sensors located near an ink reservoir and just before the nozzle are shown to assist in identification of air bubbles, changes in height between the print head and build surface, clogs, and particle aggregates with a detection threshold of 60–70% of the nozzle diameter. Visual evidence of printed bead distortion is quantified using optical image analysis and correlated to pressure measurements. Importantly, this methodology provides an ability to monitor the quality of AM parts produced by extrusion printing methods and can be accomplished using commonly available pressure-sensing equipment.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Support Vector Machines for Classification of Direct Energy Deposition Standoff Distance for Improved Process Control

A critical factor in the implementation of direct energy deposition is the ability to maintain the standoff distance between the nozzle and the build surface, as this influences powder capture efficiency and overall part quality. Due to process-related variations, layer height may vary, causing unintended variation in standoff distance and poor build quality. While prior work has utilized contact probing to qualify standoff distance during processing, in situ methods for qualification of standoff distance are of major interest. The present work seeks to understand efficacy of image-based methods for classifying standoff distance variation in real-time using support vector machines (SVMs). It was hypothesized that the size of the melt pool and the amount of spatter will have significant correlations with deviations in the standoff distance; thus, SVMs were used on a dataset that is comprised of morphological features of melt pool size and image entropy. The SVM model was used to classify melt pool images into categories according to standoff distance variation from nominal. K-folds cross validation was used to find the optimal hyperparameters for the SVM model. To understand the impact of the selected features on the classification performance and inference speed, multiple models were trained with differing numbers of included features. Results for classification score, inference time, and image preprocessing/feature extraction from these data are reported. The present results show that the SVM model was able to predict the standoff distance classification with an accuracy of 97 percent and a speed of 0.122 s per image, making it a viable solution for real-time control of standoff distance.

Klesmith, Zoe↗

NASA NTRS1990

Second Vapor-Level Sensor For Vapor Degreaser

Second vapor-level sensor installed at lower level in vapor degreaser makes possible to maintain top of vapor at that lower level. Evaporation reduced during idle periods. Provides substantial benefit, without major capital cost of building new vapor degreaser with greater freeboard height.

Painter, Nance M.↗

NASA NTRSDate not supplied

Liquid Droplet Printing

The center has recently invested in a new additive manufacturing technology known as liquid metal jetting or liquid droplet printing. The Additec ElemX machine’s process utilizes wire feedstock fed into a ceramic crucible, where it is melted and ejected by pulsed Lorentz force using an external coil. The team will start with material characterization of various commercially available aluminum alloys to establish process parameters, repeatability, mechanical properties, and microstructure. Future research will consider additional alloys and explore concepts that may potentially adapt the technology for relevance in zero or low gravity environments. The printer has a 12”x12”x4.7” build volume and 0.24mm minimum layer height, with surface finishes comparable to sand castings.

liquid droplet printing↗

NASA NTRS2012

A Volcanic Origin for Sinuous and Branching Channels on Mars: Evidence from Hawaiian Analogs

Observations of sinuous and branching channels on planets have long driven a debate about their origin, fluvial or volcanic processes. In some cases planetary conditions rule out fluvial activity (e.g. the Moon, Venus, Mercury). However, the geology of Mars leads to suggestions that liquid water existed on the surface in the past. As a result, some sinuous and branching channels on Mars are cited as evidence of fluvial erosion. Evidence for a fluvial history often focuses on channel morphologies that are unique from a typical lava channel, for instance, a lack of detectable flow margins and levees, islands and terraces. Although these features are typical, they are not necessarily diagnostic of a fluvial system. We conducted field studies in Hawaii to characterize similar features in lava flows to better define which characteristics might be diagnostic of fluvial or volcanic processes. Our martian example is a channel system that originates in the Ascraeus Mons SW rift zone from a fissure. The channel extends for approx.300 km to the SE/E. The proximal channel displays multiple branches, islands, terraces, and has no detectable levees or margins. We conducted field work on the 1859 and 1907 Mauna Loa flows, and the Pohue Bay flow. The 51-km-long 1859 Flow originates from a fissure and is an example of a paired a a and pahoehoe lava flow. We collected DGPS data across a 500 m long island. Here, the channel diverted around a pre-existing obstruction in the channel, building vertical walls up to 9 m in height above the current channel floor. The complicated emplacement history along this channel section, including an initial a a stage partially covered by pahoehoe overflows, resulted in an appearance of terraced channel walls, no levees and diffuse flow margins. The 1907 Mauna Loa flow extends > 20 km from the SW rift zone. The distal flow formed an a a channel. However the proximal flow field comprises a sheet that experienced drainage and sagging of the crust following the eruption. The lateral margins of the proximal sheet, past which all lava flowed to feed the extensive channel, currently display a thickness of < 20 cm. Were this area covered by a dust layer, as is the Tharsis region on Mars, the margins would be difficult to identify. The Pohue Bay flow forms a lava tube. Open roof sections experienced episodes of overflow and spill out. In several places the resultant surface flows appear to have moved as sheet flows that inundated the preexisting meter scale features. Here the flows developed pathways around topographic highs, and in so doing accreted lava onto those features. The results are small islands within the multiple branched channels that display steep, sometimes overhanging walls. None of these features alone proves that the martian channel networks are the result of volcanic processes, but analog studies such as these are the first step towards identifying which morphologies are truly diagnostic of fluvial and volcanic channels.

Bleacher, Jacob E.↗