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DOE OSTI2020

A State-Space Model of an Inverter-Based Microgrid for Multivariable Feedback Control Analysis and Design

In this work, a synchronous model for grid-connected and islanded microgrids is presented. The grid-connected model is based on the premise that the reference frame is synchronized with the AC bus. The quadrature component of the AC bus voltage can be cancelled, which allows to express output power as a linear equation for nominal values in the AC bus amplitude voltage. The model for the islanded microgrid is developed by integrating all the inverter dynamics using a state-space model for the load currents. This model is presented in a comprehensive way such that it could be scalable to any number of inverter-based generators using inductor–capacitor–inductor (LCL) output filters. The use of these models allows designers to assess microgrid stability and robustness using modern control methods such as eigenvalue analysis and singular value diagrams. Both models were tested and validated in an experimental setup to demonstrate their accuracy in describing microgrid dynamics. In addition, three scenarios are presented: non-controlled model, Linear-Quadratic Integrator (LQI) power control, and Power-Voltage (PQ/Vdq) droop–boost controller. Experimental results demonstrate the effectiveness of the control strategies and the accuracy of the models to describe microgrid dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Selected Uses of TSUNAMI in Critical Experiment Design and Analysis

Validation in criticality safety is performed by comparing the results of critical experiments with the calculated results from models of the experiments using the computational method to be validated. Laboratory critical experiments are controlled systems that achieve a k eff of approximately 1 and enable investigation of the parameters at which such a critical condition is achieved. For the critical experiments used in a validation to capture the biases of the materials and neutron energy spectra of interest, those materials must be included in the experiment such that they influence k eff or another observable parameter with statistical significance. This paper discusses the use of sensitivity uncertainty (S/U) methods to develop critical experiments for various purposes. S/U techniques are useful for understanding the underlying components of nuclear data which affect the k eff or another parameter of a given configuration. S/U calculations are most commonly used to compare existing experiments to applications of interest; however, S/U techniques can also be used to identify, optimize, or assess features of proposed experiments so that they can better test specific portions of nuclear data or match an application of interest. The S/U techniques discussed here are from the TSUNAMI code system. The two primary codes discussed in this work are TSUNAMI-3D, which implements the KENO criticality code to calculate the sensitivity of k eff to nuclear data, and TSAR, which calculates the sensitivity of a reactivity difference between two configurations based on their TSUNAMI-3D generated sensitivity profiles. The methods used in these tools are discussed in more detail in the SCALE manual. This paper is one of a series on the development and use of TSUNAMI tools. The other papers address development of TSUNAMI methods and a review of TSUNAMI applications.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Modeling and Design of the Triton OWC System (Final Report)

Two versions of the Triton Oscillating Water Column type device will be modeled in WEC Sim. First, a model of a wave-tank scale device which can be tuned and validated against tank test data. Second, a model of the deployment-scale device will be constructed following the method of the tank-scale device to ensure that relevant physics are captured. In the latter case, the geometry, PTO architecture, and other design details are not yet finalized, so the model will serve as a platform for design iteration as time and budget allows. A subset of this iteration will be automated using existing WEC-Sim capabilities. A primary focus of this work will be familiarizing Triton personnel with the WEC-Sim workflow and model details so that the model of the deployment device can continue to be enhanced after project end.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

Utilization of Additive Manufacturing for the Rapid Prototyping of C-Band Radiofrequency Loads

Additive manufacturing is a versatile technique that shows promise in providing quick and dynamic manufacturing for complex engineering problems. Research has been ongoing into the use of additive manufacturing for potential applications in radiofrequency (RF) component technologies. Here, we present a method for developing an effective prototype load produced from 316L stainless steel on a direct metal laser sintering machine. The model was tested using simulation software to verify the validity of the design. The load structure was manufactured by an online digital manufacturing company, showing the viability of using easily accessible tools to manufacture RF structures. The produced load was able to produce an S11 value of −22.8 dB at a C-band frequency of 5.712 GHz while under a vacuum. In a high-power test, the load was able to terminate a peak power of 8.1 MW. The discussion includes future applications of the present method and how it will help to improve the implementation of future accelerator concepts.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Smart culture medium optimization for recombinant protein production: Experimental, modeling, and AI/ML-driven strategies

Recombinant protein production (RPP) is central to biotechnology, where recombinant proteins are used as either end products or catalysts in the synthesis of chemicals, fuels, and materials. Among the major cost drivers, culture medium plays a pivotal role in determining protein yield and quality. This review presents a comprehensive perspective on the critical stages of “smart” culture medium optimization: planning, screening, modeling, optimization, and validation. In the planning stage, we examine the nutritional and energetic roles of medium components, including carbon, nitrogen, amino acids, salts, and trace metals, and their impacts on culture parameters such as pH, oxidative state, and osmolality. We highlight the variability in trace metal content due to water sources, culture vessels, and raw materials, which can substantially influence RPP. The screening stage covers Design of Experiments (DoE) approaches, assessing their theoretical basis, implementation, and limitations. For modeling, we describe methods that integrate experimental data to develop predictive models for smart medium formulation. Model-based optimization strategies can then be employed to select optimal media compositions for a given application. The validation stage aims to evaluate model predictions and provide feedback for model training and refinement. Finally, we survey mechanistic and artificial intelligence/machine learning (AI/ML)-driven models as integrated, transformational tools for predictive modeling of bioprocess conditions, nutrient availability, cellular metabolism, and protein quality, with the goal of optimizing culture media to enhance protein yields while reducing costs and environmental impact. We conclude by addressing the challenges of translating laboratory-scale medium optimization to industrial-scale settings and exploring future AI/ML-driven approaches that may overcome current bottlenecks and accelerate medium design for RPP. Overall, this review provides a unified framework for advancing smart medium design in RPP.

Artificial Intelligence/Machine Learning (AI/ML)↗

DOE OSTI2025

Electromagnetic Modeling of Lattice Structures in Additively Manufactured Electric Machines

Recent advancements in metal additive manufacturing (AM) show great potential to revolutionize the design and manufacturing of electromagnetic components used in the field of electrical engineering. Lattice structures directly printed by AM processes typically offer better structural performance with reduced weight, such as high stiffness, surface area, elongation, energy absorption, and porosity, than the solid counterpart. This paper aims to study the electromagnetic modeling of lattice structures used in additively manufactured magnetic cores or windings for electric machines. Three dimensional (3D) electromagnetic finite element (FE) analysis with high performance computing (HPC) shows the highest fidelity in predicting the electromagnetic performance of designs with lattice structures by preserving complex geometry details. FE-based homogenization methods have also been explored to potentially speed up concept design. A case study based on an additively manufactured axial-flux permanent magnet machine with a Hilbert pattern stator validates the discussed electromagnetic modeling approaches.

Chung, Shi-Uk [ANSYS, Inc.]↗

DOE OSTI2025

Experimental Investigation of Vapor Formation in Liquid CO2 Flow Through a Converging-Diverging Nozzle

Carbon dioxide is an attractive working fluid for many cycles, including for pumped thermal energy storage (PTES). A challenge with some proposed sCO2 PTES cycles is the operation of sCO2 machinery outside the typical bounds of experience, with local phase change from the liquid state being particularly unknown. Presently, there is insufficient data in the literature regarding multiphase CO2 to adequately design a multiphase-tolerant turbine, so generation of foundational data is required. This experimental study investigates the flow characteristics of sub-sonic liquid CO2 undergoing expansion and phase change in a converging-diverging nozzle. The nozzle is instrumented to measure static pressure, unsteady pressure, temperature, and density. The static pressure transducers are located at 27 axial locations to accurately characterize the pressure profile in the nozzle. High-accuracy RTDs are located at the entrance and exit of the nozzle, and three dynamic pressure transducers are strategically located to capture any unsteady phenomena. During testing, values of mass flow and nozzle inlet pressure are swept to vary the pressure drop and fluid properties. The measured total pressure drop in the nozzle is compared to a homogenous model and the Lockhart-Martinelli correlation method, with the latter predicting loss quite closely. The resulting data set is valuable for validating multiphase numerical models in a simple geometry before implementation of these models in turbomachinery design.

25 ENERGY STORAGE↗

DOE OSTI2024

Photovoltaic inverter-based quantification of snow conditions and power loss

Snow is a significant challenge for photovoltaic (PV) systems at northern latitudes, where the pace of deployment is rapid but snow-related power losses can exceed 30% of annual production. Accurate snow-related power loss estimation methods for utility-scale sites can support snow mitigation strategies, inform resource planning and validate predictive snow-loss models. This study builds on our previous work on inverter-based detection of snow, and its implications for utility-scale power production, by validating the accuracy of our snow-loss method across different PV sites and system designs and highlighting its value in bringing greater visibility to PV plant operations in winter. Our estimation method is both novel and scalable, requiring only standard monitoring data to correlate snow-related losses with meteorological data. As demonstrated here, our validation method involved three main steps: 1) estimation of performance losses for multiple systems by comparing measured inverter data to modeled data; 2) application of a detection framework to identify which performance losses are snow-related; and 3) comparison of snow-related losses among three utility-scale sites differing in tilt angle. Results show that utility-scale systems at higher tilt angles consistently shed snow more quickly/completely than their lower-tilt counterparts. Further, monthly and seasonal snow losses are inversely and non-linearly correlated with tilt angle when normalized for cumulative snowfall. These results are consistent with the findings of previous studies and support the broad applicability of this method to fixed-tilt utility-scale PV systems around the world that routinely experience snow-related performance losses.

Cooper, Emma C. (ORCID:0000000190554098)↗

DOE OSTI2020

BISON High Burnup Structure Modeling Capabilities Validated with a Selection of the Halden IFA-650 Rods

The U.S. Department of Energy (DOE)’s Nuclear Energy Advanced Modeling and Simulation (NEAMS)program aims to develop predictive capabilities using computational methods for the analysis and design of advanced reactor and fuel cycle systems. This program has been supporting the development of BISON, a high-fidelity and high-resolution fuel performance tool at the engineering scale. This document continues analysis and refinement of capabilities added to BISON early this calendar year in regards to the incorporation of capabilities applicable to extended burnups in response to industry interest. Details are provided on high burnup thermal conductivity models, a refitting of the high-burnup structure (HBS) porosity formation model to include additional data, the coupling of the HBS volume fraction model to thermal conductivity and fine fragmentation models, and validation activities. The IFA-650.4 and IFA-650.9 loss of coolant accident (LOCA) analyses are revisited with the latest developments in this report. A new validation case, IFA-650.14 has also been added to the BISON test suite.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Computation of Direct Sensitivities of Spatial Multibody Systems With Joint Friction

Abstract Friction exists in most mechanical systems and may have a major influence on the dynamic performance of the system. The incorporation of friction in dynamic systems has been a subject of active research for several years owing to its high nonlinearity and its dependence on several parameters. Consequently, optimization of dynamic systems with friction becomes a challenging task. Gradient-based optimization of dynamical systems is a prominent technique for optimal design and requires the computation of model sensitivities with respect to the design parameters. The novel contribution of this paper is the derivation of the analytical methodology for the computation of direct sensitivities for smooth multibody systems with joint friction using the Lagrangian index-1 formulation. System dynamics have been computed using two different friction models; the Brown and McPhee, and the Gonthier et al. model. The methodology proposed to obtain model sensitivities has also been validated using the complex finite difference method. A case study has been conducted on a spatial multibody system to observe the effect of friction on the dynamics and model sensitivities, compare sensitivities with respect to different parameters and demonstrate the numerical and validation aspects. Since design parameters can have very different magnitudes and units, the sensitivities have been scaled with the parameters for comparison. Finally, a discussion has been presented on the interpretation of the case study results. Due to the incorporation of joint friction, ‘jumps’ or discontinuities are observed in the model sensitivities akin to those observed for hybrid dynamical systems.

Engineering↗

DOE OSTI2025

Evaluation of Seismic Artificial Intelligence with Uncertainty

Artificial intelligence has transformed the seismic community with deep learning models (DLMs) that are trained to complete specific tasks within workflows. However, there is still a lack of robust evaluation frameworks for evaluating and comparing DLMs. Here, we address this gap by designing an evaluation framework that jointly incorporates two crucial aspects: performance uncertainty and learning efficiency. To target these aspects, we meticulously construct the training, validation, and test splits using a clustering method tailored to seismic data and enact an expansive training design to segregate performance uncertainty arising from stochastic training processes and random data sampling. The framework’s ability to guard against misleading declarations of model superiority is demonstrated through the evaluation of PhaseNet (Zhu and Beroza, 2018), a popular seismic phase picking DLM, under three training approaches. Our framework helps practitioners choose the best model for their problem and set performance expectations by explicitly analyzing model performance with uncertainty at varying budgets of training data.

58 GEOSCIENCES↗

DOE OSTI2023

A helical actuator driven by biased SMA: design, model, and experiment

A helical actuator driven by biased shape memory alloy (SMA) patterns embedded into a soft composite ribbon base is presented in this work. Instead of common U-shape SMA wires, a single SMA wire is woven into planar patterns, which enable helical deformation of the composite ribbon from an initially flat geometry. An analytical static model is established for accurate and rapid prediction of the helical reconfiguration arising from the shape memory effect of woven SMA patterns, followed by validation of the static model using the finite element method (FEM). The finite element results are compared with the analytical solutions given by this static model, which show a high agreement. Parametric study of the influences of eight independent design variables on the dependent helical parameters, such as combined curvatures, pitches, and helical angles, is completed. It is found that the helically deformed geometry is mainly dominated by diameters, biased positions, inclined angles, and numbers of skewed segments of the SMA wire. Fabrication and in-situ experimental test of a prototype of such helical actuators qualitatively demonstrate its dramatic three-dimensional (3D) spiral reconfiguration from a two-dimensional (2D) flat ribbon. In conclusion, such SMA patterns will allow more diverse designs of soft actuators for a wider range of robotic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Designing an Optimal Sensor Network via Minimizing Information Loss

Optimal experimental design is a classic topic in statistics, with many well-studied problems, applications, and solutions. The design problem we study is the placement of sensors to monitor spatiotemporal processes, explicitly accounting for the temporal dimension in our modeling and optimization. We observe that recent advancements in computational sciences often yield large datasets based on physics-based simulations, which are rarely leveraged in experimental design. We introduce a novel model-based sensor placement criterion, along with a highly-efficient optimization algorithm, which integrates physics-based simulations and Bayesian experimental design principles to identify sensor networks that “minimize information loss” from simulated data. Our technique relies on sparse variational inference and (separable) Gauss-Markov priors, and thus may adapt many techniques from Bayesian experimental design. We validate our method through a case study monitoring air temperature in Phoenix, Arizona, using state-of-the-art physics-based simulations. Our results show our framework to be superior to random or quasi-random sampling, particularly with a limited number of sensors. We conclude by discussing practical considerations and implications of our framework, including more complex modeling tools and real-world deployments.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Uncertainty Propagation from Experiment Measurements to Modeling Approaches: A Case for SMR Steam Entrainment Testing

To license new and advanced reactor designs, regulators must be convinced that their unique safety cases—relative to existing large scale reactors—have been adequately addressed by the designed reactor protection systems. In water cooled small modular reactors (SMRs), droplet entrainment in steam flow has significant implications on the progression of accident scenarios due to its compact design features, which requires representative test data applicable to SMR designs. Computer code, modeling and simulation (M&S) tools and models require adequate verification, assessment, and qualification. This includes M&S results validation against scaled empirical data within allowable uncertainty bands to gain regulatory approvals during the various stages of reactor system design, demonstration, and commercialization. However, measurement uncertainty within the empirical datasets and test data applicability ranges requires careful consideration of M&S inputs (i.e., boundary conditions, and initial conditions), and verification and validation efforts. This study focuses on uncertainty quantification in designing scaled test facilities for SMR applications with appropriate measurements and a standard data-reduction method to estimate thermal hydraulics characteristics parameters that incorporate physics phenomena of interest. In addition, this study supports the evaluation model development and assessment process using M&S that interfaces with advanced computing tools and digital twin capabilities. This will allow synchronization between experiment and modeling approaches for droplet entrainment testing and analysis, improving diagnostics, prognostics, and decision-making to accelerate regulatory approval.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

A Mixed-Method Design Approach for Empirically Based Selection of Unbiased Data Annotators

Implicit bias embedded in the annotated data is by far the greatest impediment in the effectual use of supervised machine learning models in tasks involving race, ethics, and geopolitical polarization. For societal good and demonstrable positive impact on wider society, it is paramount to carefully select data annotators and rigorously validate the annotation process. Current approaches to selecting annotators are not sufficiently grounded in scientific principles and are limited at the policy-guidance level, thereby rendering them unusable for machine learning practitioners. This work proposes a new approach based on the mixed-methods design that is functional, adaptable, and simpler to implement in selecting unbiased annotators for any machine learning problem. By demonstrating it on a real-world geopolitical problem, we also identified and ranked key inane profile characteristics towards an empirically-based selection of unbiased data annotators.

Thakur, Gautam Malviya↗

DOE OSTI2022

CTF Validation and Verification: Version 4.3

Coolant-Boiling in Rod Arrays- Two Fluids (COBRA-TF) is a thermal/hydraulic (T/H) simulation code designed for light water reactor (LWR) analysis. It uses a two-fluid, three-field (i.e., fluid film, fluid drops, and vapor) modeling approach. Both subchannel and 3D Cartesian forms of nine conservation equations are available for LWR modeling. The code was originally developed by Pacific Northwest Laboratory in 1980 and has been used and modified by several institutions over the last several decades. COBRA-TF is also used at the Pennsylvania State University (PSU) by the Reactor Dynamics and Fuel Modeling Group (RDFMG) and has been improved, updated, and subsequently became the CTF. One part of the improvement process includes validating the methods in CTF. This document seeks to provide a certain level of certainty and confidence in the predictive capabilities of the code for the scenarios it was designed to model—rod bundle geometries with operating conditions that are representative of prototypical pressurized water reactor (PWR)s and boiling water reactor (BWR)s in both normal and accident conditions. This is done by modeling a variety of experiments that simulate these scenarios and then presenting a qualitative and quantitative analysis of the results that demonstrates the accuracy to which CTF is capable of capturing specific quantities of interest.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

CTF Validation and Verification: Version 4.4

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

CTF Validation and Verification (V.4.2)

Coolant-Boiling in Rod Arrays- Two Fluids (COBRA-TF) is a thermal/hydraulic (T/H) simulation code designed for Light Water Reactor (LWR) analysis. It uses a two-fluid, three-field (i.e. fluid film, fluid drops, and vapor) modeling approach. Both sub-channel and 3D Cartesian forms of nine conservation equations are available for LWR modeling. The code was originally developed by Pacific Northwest Laboratory in 1980 and has been used and modified by several institutions over the last several decades. COBRA-TF is also used at the Pennsylvania State University (PSU) by the Reactor Dynamics and Fuel Modeling Group (RDFMG) and has been improved, updated, and subsequently became the PSU RDFMG version of COBRA-TF (CTF). One part of the improvement process includes validating the methods in CTF. This document seeks to provide a certain level of certainty and confidence in the predictive capabilities of the code for the scenarios it was designed to model-rod bundle geometries with operating conditions that are representative of prototypical Pressurized Water Reactor (PWR)s and Boiling Water Reactor (BWR)s in both normal and accident conditions. This is done by modeling a variety of experiments that simulate these scenarios and then presenting a qualitative and quantitative analysis of the results that demonstrates the accuracy to which CTF is capable of capturing specific quantities of interest.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗