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At least 73 records · Page 4

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DOE OSTI2023

Uncertainty Quantification of Metal Additive Manufacturing Processing Conditions Through the use of Exascale Computing

Metal additive manufacturing (AM) is a disruptive manufacturing technology that opens the design space for parts outside those possible from traditional manufacturing methods. In order to accelerate industry and R&D needs to certify AM parts, the Exascale Additive Manufacturing project (ExaAM) has developed a suite of exascale-ready computational tools to model the process-to-structure-to-properties (PSP) relationship for additively manufactured metal components. One such tool is an uncertainty quantification (UQ) pipeline to quantify the effect that uncertainty in processing conditions has on local mechanical responses. We present an overview of this pipeline and its required simulation and workflow codes. Using the Oak Ridge National Laboratory’s (ORNL) exascale computer, Frontier, we utilize this pipeline to cross multiple length and time scales to predict the local mechanical response of a location within a complex AM bridge part, AMB2018-01 produced by the National Institute of Standards and Technology (NIST) as part of their 2018 AM-Bench test series. Our results are then compared to experimental mechanical tests of parts from the NIST build to quantify the error in the ExaAM UQ workflow.

Carson, Robert↗

DOE OSTI2024

USPAS Digital Low-Level RF firmware and software suite (uspas_llrf) v1.0

The USPAS Digital Low-Level RF firmware and software suite was originally developed for the USPAS 2023 LLRF course, for demonstrating the close loop RF control on the BerkeleyLab Marble FPGA carrier and Zest digitizer platform in controlling the RF field for various accelerators. The suite features Register-transfer level (RTL) designs for the board-support layer, digital signal processing and verification test benches, system-on-chip architecture, and Experimental Physics and Industrial Control System (EPICS) support, utilizing a open-source tool chain.

Du, Qiang↗

DOE OSTI2020

Development of Ionic Liquid-Additized, GF-5/6 Compatible Low-Viscosity Oils for Automotive Engine and Rear Axle Lubrication for 4% Improved Fuel Economy

This joint project among ORNL, GM, and DRO successfully developed ionic liquid-additized low viscosity lubricants, SAE 0W-12 and 70W-80, for both IC engine and rear axle lubrication, respectively, and demonstrated combined vehicle fuel economy improvement (FEI). Phosphonium-alkylphosphate ILs have been found to be the most effective among the candidates in protecting surface damage from both sliding wear and rolling contact fatigue, and optimal IL concentrations have been determined. The IL’s impact on three-way catalyst seems to be significantly less adverse than the conventional ZDDP. Oil formulations were optimized for both energy efficiency and wear protection. Tribological bench testing of the IL-additized low-viscosity oils showed at least 40% lower boundary friction, more than 60% lower elastohydrodynamic friction, and greater than 50% less wear compared with commercial baselines. IL-additized lubricants have demonstrated FEI by 9.9% in engine dynamometer tests under extreme conditions and 6.9% increased power output in gear rig tests. Prototype IL-additized engine oil and rear axle fluid exhibited combined FEI of 1.39% and 3.24% benchmarked against the state-of-the-art baselines in vehicle testing of fresh oils under the Federal Test Procedure (FTP) city cycle and Highway Fuel Economy Driving Schedule (HWFET), respectively. Used oil analysis suggested that the IL-additized low-viscosity oils produced less wear than the commercial baselines. The gained fundamental understanding and demonstrated FEI in this work pave the way for future development and implementation of the ionic liquid technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Tribological Evaluation of Candidate Coatings

This SPP project with Novus was to investigate tribological properties of candidate ceramic composites. Systematic tribological bench tests and surface characterization were performed to determine composition-property relationships of several Zr-Ti-B based ceramic composites of different compositions. The lowest friction coefficient was measured with Ti0.6Zr0.4B2 composition tested in the hydraulic oil. Surface characterization suggests a formation of ZDDP tribofilm in the worn region when tested with a hydraulic oil. In all experiments, the ceramic composites did not have measurable wear, but caused material loss of the steel countersurface.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Lessons Learned: Summary of Insights From the HERO WEC and Waves to Water Deployments Between 2022 and 2024

In 2020, a team from the National Renewable Energy Laboratory (NREL) partnered with the East Carolina University Coastal Studies Institute to develop a small, modular, wave-powered point absorber desalination prototype. That prototype, known as the hydraulic and electric reverse osmosis wave energy converter (HERO WEC), was intended to de-risk the installation activities planned for the Waves to Water Prize sponsored by the Water Power Technologies Office. The NREL team was given approximately 18 months to design, build, bench test, and deploy the HERO WEC prototype. Since the initial HERO WEC development, it has been used for two in-lab test programs and three ocean deployments. The first in-lab test program focused on ensuring that the overall operation of the device occurred as expected and on validating the operation of safety systems such as pressure relief valves or electrical breakers for load mitigation. The second in-lab test program was the first time the NREL team leveraged NREL’s large-amplitude motion platform to characterize the performance of the HERO WEC. Of the three in-water deployments, the first deployment was effectively an installation and recovery practice with no meaningful wave activity during the time that it was installed. The second deployment was a 2-week effort that enabled both the electric and hydraulic configurations of the device to be in the water for approximately 5 days each. This deployment was also the first time that the team had the opportunity to perform a drivetrain swap on the Coastal Studies Institute research vessel. The third deployment had to be split into two separate installations due to minor damage incurred from the WEC spinning during the initial installation. This report summarizes the deployments, the challenges encountered with each deployment, and the lessons learned for future work.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than non-detonating engines. To understand the high-speed heat transfer dynamics inside an RDE, a novel, high-frequency heat flux gage is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Sensor bench testing is performed using a hot plate as a heat source, and the sensor response is compared to a finite-element analysis (FEA) model. The sensor response is then tested inside a water-cooled RDE and the wall heat flux is compared to calorimetry data.

rotating detonation engines↗

DOE OSTI2026

A Dedicated Muon EDM Experiment in the `g-2 Storage Ring

Spin precession experiments offer exciting motivations to search for new physics. We propose here an idea of using a modified version of the Muon g-2 storage ring for a potential new scientific program to search for a non-zero muon electric dipole moment (EDM). Using both electric and magnetic dipole fields to produce a "frozen spin" condition for the MDM (all the while enhancing the EDM spin precession), the storage ring would operate at a lower central muon momentum than for the present Muon g-2 measurement. The incident proton beam on target for the muon production can be obtained from the PIP-II high intensity proton beam. Preliminary calculations and simulation results of muon production at 800 MeV PoT, along with the determination of the closed orbit inside the hybrid 'g-2' storage ring configuration, shall be presented. Possibilities of using the 'g-2' storage ring as a test bench to demonstrate the freezing of the MDM spin precession shall be discussed. The operational range of the muon's momentum and energy, and their respective window of electric and magnetic field values to establish the frozen spin condition, shall be presented. We shall also briefly discuss the physics prospects and improvements in muon EDM bounds upon using Fermilab's PIP-II beam.

Narayanan, Aakaash [Fermilab] (ORCID:0000000157944↗

DOE OSTI2026

A Dedicated Muon EDM Experiment in the `g-2 Storage Ring

Narayanan, Aakaash [Fermilab] (ORCID:0000000157944↗

DOE OSTI2022

Forward silicon vertex/tracking detector design and R$\&$D for the future Electron-Ion Collider

The proposed high-luminosity high-energy Electron-Ion Collider (EIC) will provide a clean environment to precisely study several fundamental questions in the fields of high-energy and nuclear physics . A low material budget and high granularity silicon vertex/tracking detector is critical to carry out a series of hadron and jet measurements at the future EIC especially for the heavy flavor product reconstruction or tagging. The conceptual design of a proposed forward silicon tracking detector with the pseudorapidity coverage from 1.2 to 3.5 has been developed in integration with different magnet options and the other EIC detector sub-systems. The tracking performance of this detector enables precise heavy flavor hadron and jet measurements in the hadron beam going direction. The detector R&D for the proposed silicon technology candidates: Low Gain Avalanche Diode (LGAD) and radiation hard depleted Monolithic Active Pixel Sensor (MALTA), which can provide good spatial and timing resolutions, is underway. Bench test results of the LGAD and MALTA prototype sensors will be discussed.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Novel Ultrafast Lu2O3:Yb Ceramics for Future HEP Applications

Inorganic scintillators activated by charge transfer luminescence Yb3+ are considered promising ultrafast material to break the ps timing barrier for future high energy physics applications. Inorganic scintillators in ceramic form are potentially more cost-effective than crystals because of their lower fabrication temperature and no need for aftergrowth mechanical processing. This paper reports an investigation on Lu2O3:Yb and Lu2xY2(1−x)O3:Yb scintillating ceramic samples fabricated by Radiation Monitoring Devices Inc. All samples show X-ray excited luminescence peaked at 370 nm. Ultrafast decay time of 1.1 ns was observed by using a microchannel plate-photomultiplier tube-based test bench at Caltech. Considering its intrinsic high density (9.4 g/cm3), Lu2O3:Yb ceramics are promising for future time of fight application for high energy physics experiments.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Photovoltaic System Health-State Architecture for Data-Driven Failure Detection

The timely detection of photovoltaic (PV) system failures is important for maintaining optimal performance and lifetime reliability. A main challenge remains the lack of a unified health-state architecture for the uninterrupted monitoring and predictive performance of PV systems. To this end, existing failure detection models are strongly dependent on the availability and quality of site-specific historic data. The scope of this work is to address these fundamental challenges by presenting a health-state architecture for advanced PV system monitoring. The proposed architecture comprises of a machine learning model for PV performance modeling and accurate failure diagnosis. The predictive model is optimally trained on low amounts of on-site data using minimal features and coupled to functional routines for data quality verification, whereas the classifier is trained under an enhanced supervised learning regime. The results demonstrated high accuracies for the implemented predictive model, exhibiting normalized root mean square errors lower than 3.40% even when trained with low data shares. The classification results provided evidence that fault conditions can be detected with a sensitivity of 83.91% for synthetic power-loss events (power reduction of 5%) and of 97.99% for field-emulated failures in the test-bench PV system. Finally, this work provides insights on how to construct an accurate PV system with predictive and classification models for the timely detection of faults and uninterrupted monitoring of PV systems, regardless of historic data availability and quality. Such guidelines and insights on the development of accurate health-state architectures for PV plants can have positive implications in operation and maintenance and monitoring strategies, thus improving the system’s performance.

photovoltaics↗

DOE OSTI2022

Diagnostic development for parallel wave-number measurement of lower hybrid waves in EAST

An eight-channel magnetic probe diagnostic system has been designed and installed adjacent to the 4.6 GHz lower hybrid (LH) grill antenna in the low-field side of the EAST tokamak in order to study the n|| evolution of lower hybrid waves in the first pass from the launcher to the core plasma. The magnetic probes are separated by 6.6 mm, which allows measurement of the dominant parallel refractive index n|| up to n|| =5 for 4.6GHz LH waves. The magnetic probes are designed to be sensitive to the magnetic field component perpendicular to the background magnetic field with a slit on the casing that encloses the probe. The intermediate frequency (IF) stage, which consists of two mixing stages, down-coverts the frequency of the measured wave signals at 4.6 GHz to 20 MHz. A bench test demonstrates the phase stability of the magnetic probe diagnostic system. By evaluating the phase variation of the measured signals along the background magnetic field, the dominant n|| of the LH wave in the scrape-off layer (SOL) has been deduced during the 2019 experimental campaign. In the low density plasma, the measured dominant n|| of the lower hybrid waves is about 2.1, corresponding to the main peak 2.04 of the launched n|| spectrum. The n|| deduced by the least square linear fit method remains near this value in the low density plasma with a high spatial correlation magnitude of 0.9. With an eight-channel probe system a wave-number spectrum has also been deduced, which has a peak near to the measured dominant n||.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Modeling of H2 Dispersion at ARIES

Hydrogen is a versatile and clean energy carrier that can be produced from various renewable sources such as wind, solar, and hydropower and help decarbonize electricity grids, industry, and transportation. Using the Hydrogen Research Facility under Advanced Research on Integrated Energy Systems (ARIES) at the National Renewable Energy Laboratory's (NREL) Flatirons campus as a test bench, the study examines the feasibility, useability, and value of using computational fluid dynamics (CFD) techniques to model hydrogen dispersion. The ARIES facility was chosen because controlled hydrogen releases can be performed at a rate of 27 kg-H2/hr. Site-specific atmospheric and weather condition data such as wind speed and temperature were used as inputs to the model. The results show statistical distributions and ranges of hydrogen concentrations at locations throughout the domain. Wind conditions are found to significantly impact the release behavior, including the hydrogen cloud's direction and concentrations. At low wind speeds (below 1 mph), hydrogen forms a cloud and at higher wind speeds (> 2-4 mph) hydrogen plume stretches in the direction of wind momentum. From >100 simulations for ARIES site-specific conditions, statistical quantities combined with a clustering algorithm were used to propose sensor location at various elevations from ground.

dispersion↗

DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

rotating detonation engines↗

DOE OSTI2022

A High Power Prototype of a Harmonic Kicker Cavity

A harmonic kicker, a beam exchange device that can deflect the beam at an ultra-fast time scale (a few ns), has been developed in Jefferson Lab *, **. The high power prototype that can deliver more than a 100 kV kick at 7 kW was fabricated. The RF performance of cavity such as the harmonic resonant frequencies, kick profiles, it’s stability, and electric center is tested at bench. The cavity will eventually be tested with a beam at Upgraded Injector Test Facility (UITF) in Jefferson Lab. In this paper, we report some features of fabrication and bench test results. We also briefly describe our beam test plan in the future.

Park, Gunn↗

DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗

DOE OSTI2024

Theory, analysis, and testing of an angular resonator for wave energy generation

This article describes the theory, analysis, and initial bench-top testing of a minimally invasive, rotational resonator designed to produce small amounts of electrical energy for use in oceanic observation buoys. Here, this work details the systems of equations that govern such a resonator, its potential power production, and its predicted effects on the modified motion of the buoy. Finally, a bench-top test apparatus is designed and experimented upon to identify the system and verify the system of equations empirically.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Development of an ERT‐Based Framework for Bentonite Buffers Monitoring From Laboratory Tests: 1. Characterizing Thermal–Hydrological–Mechanical Processes

Abstract Bentonite clay is widely used in engineered barrier systems for the permanent disposal of high‐level radioactive waste due to its low permeability, high swelling capacity, and thermal stability. However, the complex thermal‐hydrological‐mechanical (THM) processes induced by heating from decaying radioactive waste and hydration from surrounding rock can lead to heterogeneous changes that are difficult to measure and predict. This study develops an Electrical Resistivity Tomography (ERT)‐based framework for monitoring THM processes, progressing from sample‐scale to bench‐scale tests, to inform field‐scale applications. Sample‐scale tests analyzed small bentonite samples under controlled variations in water content, temperature, and porosity to establish fundamental resistivity relationships. Bench‐scale tests involved larger bentonite columns subjected to heating (up to 200°C) and hydration under controlled pressure, simulating repository conditions. ERT measurements, complemented by X‐ray CT imaging, temperature monitoring, and tracing sensors, revealed coupled THM processes, such as hydration‐induced compression, swelling, and thermal gradients, leading to complex resistivity patterns. The results demonstrate the potential of ERT for capturing THM‐induced resistivity changes, though challenges remain in upscaling and quantitative analysis. This study evaluates laboratory test capabilities and proposes future improvements for understanding THM‐induced resistivity responses. A conceptual framework for ERT implementation in field‐scale monitoring is presented, synthesizing findings from both scales and exploring how ERT data can inform long‐term modeling and reduce prediction uncertainties. Overall, this ERT‐based framework offers a robust method for monitoring bentonite buffers, aiding in early issue detection and supporting the safe long‐term disposal of radioactive waste in geological repositories, while highlighting the need for future development. Plain Language Summary Bentonite clay is crucial in engineered barrier systems (EBS) for containing high‐level radioactive waste due to its ability to absorb water, swell, seal and remain stable under high temperatures. When bentonite absorbs water and heats up from radioactive decay, it experiences complex changes in its physical and mechanical properties. Understanding these changes is important for ensuring the long‐term safety and effectiveness of EBS. This study used Electrical Resistivity Tomography (ERT), a non‐invasive method that measures electrical conductivity to monitor these changes during laboratory experiments. The ERT data revealed significant variations in resistivity corresponding to changes in water content, temperature, and density, providing detailed spatial and temporal insights into the behavior of bentonite. These findings enhance our ability to predict the long‐term performance of bentonite barriers, ensuring the safe containment of radioactive waste. By improving our understanding of bentonite's behavior, this research supports the development of more reliable and effective barrier systems for radioactive waste disposal, protecting the environment and public health. Key Points ERT monitoring was employed to capture resistivity changes in bentonite during controlled heating and hydration experiments, providing insights into THM processes ERT data reveal significant resistivity changes correlated with water content, temperature, and mechanical effects, enhancing the understanding of THM dynamics in bentonite This study explores the potential of the framework for application in field‐scale EBS monitoring, emphasizing the need for integrating additional geophysical methods for comprehensive subsurface imaging

Chen, Hang↗