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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Surface smoothing for laser powder-bed Ti-6Al-4V by a transient liquid phase

Surface roughness is the primary driver of fatigue for additively manufactured metals. To address surface roughness, this work introduces a new method to smooth features beyond line-of-sight without material removal. The method applies a coating that triggers local surface remelting by activating a eutectic reaction during heat treatment. The associated liquid phase then wets and isothermally solidifies into a smoother surface. For Ti-6Al-4V fabricated with laser powder bed fusion, samples with and without TLP smoothing (using a Cu coating) were characterized with a suite of techniques, including mechanical testing, electron backscatter diffraction, synchrotron X-ray tomography, and fractography. TLP smoothing reduced surface roughness by 80% and amplified compressive residual stress at the surface by about 50%. With statistically equivalent virtual microstructures, crystal plasticity scrutinized the roles of phases, porosity, and surface roughness. Although the tensile strain-to-failure was reduced to 1% strain, the TLP smoothing process increased high-cycle fatigue strength by about 20% compared to control samples, pointing to future opportunities to optimize the new process through various coating compositions and heat treatment schedules. Overall, this work establishes a new paradigm for treating surfaces of materials for smoothness and compressive residual stress.

Additive manufacturing↗
DOE OSTI2022

From Protection and Prevention to Research and Discovery: Eligibility Assessment of the Health Research Laboratory (TA-43) and Historic Documentation for TA-43-0001 - Volume 1

The U.S. Department of Energy National Nuclear Security Administration Los Alamos Field Office (NA-LA) requests the New Mexico State Historic Preservation Officer (SHPO) to concur with the National Register of Historic Places (NRHP)–eligibility determinations detailed in this report for the Health Research Laboratory (HRL) complex in Technical Area 43 (TA-43) at the Los Alamos National Laboratory (LANL). As part of the LANL Footprint Reduction Program’s Decommissioning and Demolition (D&D) process, all facilities of the HRL complex are scheduled for characterization and future demolition.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Hydrogen from Carbonaceous Waste Material - Hydrogen Fuel Cells Prize Phase 2 Voucher: Cooperative Research and Development (Final Report)

NLR conducted a conceptual design study for scaling up biomass conversion technology from Green Fortress Engineering (GFE). GFE has proprietary technology where cellulosic biomass is thermally converted to a tar-free syngas. A ceramic membrane separation unit (MSU) previously developed with NLR can extract high-purity hydrogen from the syngas. The energy content of the retentate stream is sufficient to power the process with a gas-powered genset. Design details including mass and energy balances, process and instrumentation diagrams (P&ID), and major equipment schedules were delivered.

08 HYDROGEN↗
DOE OSTI2020

Current Status of the Synroc Waste Treatment Facility - 20263

Construction of the Synroc Waste Treatment Facility is well underway at ANSTO. This plant has been designed to treat intermediate level liquid waste arising from the production of Mo-99 within the newly constructed ANSTO Nuclear Medicine (ANM) precinct [1]. The facility utilises ANSTO Synroc technology that has been tailored to the chemical, physical, and radiological properties of the waste. The result is a highly durable wasteform with a significant reduction in the final volume of the treated waste. This paper presents the construction status of the Synroc Waste Treatment Facility and the status of the associated technology maturation plan. Construction of the building is scheduled for completion in late 2020 followed by process installation and commissioning. A key component of the technology maturation plan has been the construction of an Inactive Engineering Demonstrator [2]. This has aided in the mitigation of risks with respect to technology selection, process integration, and process nuclearisation. Furthermore, the demonstration facility has provided an environment for the design and development of the instrumentation and control philosophy resulting in a seamlessly integrated plant control system. Successful demonstration of the technology by the inactive engineering demonstrator has significantly reduced the associated risks. Details of the Synroc Waste Treatment Facility project progress will also be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Automated pipeline framework for processing of large-scale building energy time series data

Commercial buildings account for one third of the total electricity consumption in the United States and a significant amount of this energy is wasted. Therefore, there is a need for “virtual” energy audits, to identify energy inefficiencies and their associated savings opportunities using methods that can be non-intrusive and automated for application to large populations of buildings. Here we demonstrate virtual energy audits applied to large populations of buildings’ time-series smart-meter data using a systematic approach and a fully automated Building Energy Analytics (BEA) Pipeline that unifies, cleans, stores and analyzes building energy datasets in a non-relational data warehouse for efficient insights and results. This BEA pipeline is based on a custom compute job scheduler for a high performance computing cluster to enable parallel processing of Slurm jobs. Within the analytics pipeline, we introduced a data qualification tool that enhances data quality by fixing common errors, while also detecting abnormalities in a building’s daily operation using hierarchical clustering. We analyze the HVAC scheduling of a population of 816 buildings, using this analytics pipeline, as part of a cross-sectional study. With our approach, this sample of 816 buildings is improved in data quality and is efficiently analyzed in 34 minutes, which is 85 times faster than the time taken by a sequential processing. The analytical results for the HVAC operational hours of these buildings show that among 10 building use types, food sales buildings with 17.75 hours of daily HVAC cooling operation are decent targets for HVAC savings. Overall, this analytics pipeline enables the identification of statistically significant results from population based studies of large numbers of building energy time-series datasets with robust results. These types of BEA studies can explore numerous factors impacting building energy efficiency and virtual building energy audits. This approach enables a new generation of data-driven buildings energy analysis at scale.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Hydrodynamic Test Requirements Process Improvements

Hydrodynamic testing at Los Alamos National Laboratory would benefit from a process improvement for the requirements process. Cameo was used as a digital solution for requirements management to allow Lead Engineers to track requirements more effectively. This was identified as a process improvement throughout this Capstone project. This report includes a project proposal, business case, literature review, methodology, project plan, data analysis, decision-making report, financial analysis report, discussion, and conclusion. Initially, this project focused on figuring out a solution for the hydrotest requirement process improvements. The scope narrowed to focus on the use of Cameo for requirement capture and management. During this Capstone, four tests had digital models produced for requirements management in Cameo. The initial model was the baseline, with core requirements used across the tests. Commonalities in tests were used and the core requirements allowed for process efficiencies. In the data analysis, it was seen that overall, the implementation of using Cameo for requirements resulted in a decreasing trend for both schedule and normalized cost. Tests have different complexity levels which is also a factor in how long the requirements process will take. Additional data is needed to continue analyzing process improvements. Through decisionmaking and financial analysis, the recommendation was to use Cameo for requirements process improvement. Multiple experts provided feedback for requirements that were then captured within models. Numerous tangible and intangible benefits were identified with this process improvement. For return on investment, the metric of success was schedule reduction, which was overall seen. Four tests were analyzed, so future analysis will be needed. There is also not a great financial risk because the main cost would be purchasing more licenses. Individuals must generate requirements whether using this software or not. Overall, training is needed to help improve the skillsets of Lead Engineers but is already being supported on a regular frequency. A desktop guide was started associated with explaining the process, however, it is a work in progress. The team plans on adding additional information in the digital models to help status when requirements are met using verification methods and artifacts. From working on this project an improved understanding of Cameo and requirements was the result. There are future opportunities to extend the usage for requirements management and progress will continue after this project.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Inferring the Dynamics of the State Evolution During Quantum Annealing

To solve an optimization problem using a commercial quantum annealer, one has to represent the problem of interest as an Ising or a quadratic unconstrained binary optimization (QUBO) problem and submit its coefficients to the annealer, which then returns a user-specified number of low-energy solutions. It would be useful to know what happens in the quantum processor during the anneal process so that one could design better algorithms or suggest improvements to the hardware. However, existing quantum annealers are not able to directly extract such information from the processor. Hence, in this work we propose to use advanced features of D-Wave 2000Q to indirectly infer information about the dynamics of the state evolution during the anneal process. Specifically, D-Wave 2000Q allows the user to customize the anneal schedule, that is, the schedule with which the anneal fraction is changed from the start to the end of the anneal. Furthermore, using this feature, we design a set of modified anneal schedules whose outputs can be used to generate information about the states of the system at user-defined time points during a standard anneal. With this process, called "slicing", we obtain approximate distributions of lowest-energy anneal solutions as the anneal time evolves. We use our technique to obtain a variety of insights into the annealer, such as the state evolution during annealing, when individual bits in an evolving solution flip during the anneal process and when they stabilize, and we introduce a technique to estimate the freeze-out point of both the system as well as of individual qubits.

42 ENGINEERING↗
DOE OSTI2022

Operational Probabilistic Tools for Solar Uncertainty (OPTSUN) (Final Project Report for DOE Solar Forecasting II Project)

Increasing levels of solar PV can challenge system operations and may require novel methods to operate the power system reliably and efficiently. Power system operating plans generally use deterministic forecasts, in which the variable energy resources are represented by the expected value for each interval of the decision horizon. Probabilistic forecasts are relatively new but have the potential to address the shortfalls of deterministic forecasts. However, understanding how best to use such forecasts is still a key gap in industry and was the focus of this project. The project had three workstreams. In a forecasting workstream, improvements were made to baseline probabilistic forecasts using a number of new approaches such as machine learning methods and improved input data. In a design workstream, advanced simulation tools used these forecasts to investigate newly proposed reserve determination methods. Lastly, in a demonstration workstream a scheduling management platform (SMP) was developed to leverage probabilistic forecasts in a modular and customizable manner. In order to study the benefits that could be accrued, the project team collaborated with three utility partners (Duke Energy, Southern Company and Hawaiian Electric) to deliver improved probabilistic forecasts for each region and to model each region in case studies using advanced production cost modeling tools. Different methods to determine operating reserve requirements from probabilistic forecasts were developed, simulated, and tested across each region. The benefits of using these newly proposed methods varied by utility, but, in general, using probabilistic forecasts as well as historical data to set the reserve requirements seems to improve reliability related results, with less risk of reserve or supply shortfalls. The cost implications were not always straightforward; in some cases the new methods could show a reduction in expected operating costs, but often the increase in reserves associated with better risk mitigation using probabilistic forecasts could result in an increase in operating costs in the simulations. The SMP tool was developed to process probabilistic forecasts from their initial receipt through to scheduling decisions. This open-source tool consists of several modules for scenario development, reserve requirements calculation, and visualization. The SMP tool was demonstrated to a wide range of operators and stakeholders at all three utilities and further improved based on their feedback. The tool will be available on www.epri.com/optsun. The proposed probabilistic information-based reserve determination approaches have the potential to be implemented by different regions to ensure an economic and reliable power system operation on power systems integrating increasing levels of variable renewable resources. The innovative yet practical methods developed in this project demonstrated tangible benefits from using probabilistic forecasts beyond just study-based assessments to include three unique balancing areas. The demonstrated benefits across the multiple utility environments, are expected to provide system operators in all regions the confidence required and a platform to adopt the new forecasting and operating methods.

14 SOLAR ENERGY↗
DOE OSTI2022

Multiscale simulation of integrated energy system and electricity market interactions

Accelerating the deep decarbonization of the world's electric grids requires the coordination of complex energy systems and infrastructures across timescales from seconds to decades. Here, we present a new multiscale simulation framework that integrates process- and grid-centric modeling paradigms to better design, operate, and control integrated energy systems (IESs), which combine multiple technologies, in wholesale energy markets. Traditionally, IESs are analyzed with a process-centric paradigm such as levelized cost of electricity (LCOE) or annualized net revenue, ignoring important interactions with electricity markets. This framework explicitly models the complex interactions between an IES's bidding, scheduling, and control decisions and the energy market's clearing and settlement processes, while incorporating operational uncertainties. Through two case studies, we show the importance of understanding and quantifying complex resource-grid interactions. In case study 1, we demonstrate that optimized bidding from one resource shifts the profit distribution for all energy systems in the market. This result suggests new and more flexible IES technologies can disrupt the economics of all market participants, possibly leading to accelerated retirements of less flexible resources. Interestingly, the optimized bidding has little impact on grid-level aggregate statistics, such as total generation costs and renewable penetration rate. While aggregate modeling strategies may remain valid under some IES adoption scenarios for analysis focused on regional outcomes, direct comparisons of IES technologies at specific locations without considering these interactions may lead to misleading or incorrect conclusions. In case study 2, we consider the design and flexible operation of IESs that hybridize conventional generators with energy storage. Through a sensitivity analysis, we find that as the size of the storage system increases, the total number of start-ups for coal- and natural gas-based IESs reduced by 25% and 33.6%, and the total thermal generator ramping (i.e., mileage) reduced by 86.5% and 62.5%, respectively. This shows the primary benefit of storage may not be reduced operational costs (which do not change significantly) but fewer start-ups and less ramping, which may greatly simplify the design, operation, and control of carbon capture systems. The new modeling and optimization capabilities from this work enable the coupling of rigorous, dynamic process models with grid-level production cost models to quantitatively identify the nuanced interdependencies across these vast timescales that must be addressed to realize clean, safe, and secure energy production. Moreover, the proposed general multiscale simulation framework is applicable to all IES technologies and can be easily extended to consider other energy carriers (e.g., hydrogen, ammonia) and energy infrastructures (e.g., natural gas pipelines).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Automated Assembly Progress Monitoring in Modular Construction Factories Using Computer Vision-Based Instance Segmentation

Modular construction has recently gained interest as a transformative construction method. In this method, a large portion of the construction is performed inside factories, where processes are fast-paced and interdependent; therefore, any deviation from the schedule can delay the production. Such deviations are frequent in modular factories due to the labor-intensive nature of the tasks. This propagation of delays can be mitigated by continuously monitoring each process; however, current manual monitoring methods are laborious, and recently proposed contact sensor-based methods are intrusive to the work. In addition, recent computer vision-based monitoring methods inside factories are limited to detection algorithms that fail to provide the pixel-level accuracy required for assembly progress monitoring in highly occluded factory scenes, and they require a large number of manual annotations. Therefore, this paper proposes a method to monitor the installation of subassemblies in modular construction factories using mask R-CNN instance segmentation and improves the data efficiency of the model using a copy-paste augmentation method. This method was validated on the CCTV videos captured from a modular construction factory in the US, resulting in a 9% mAP improvement in segmentation.

computer vision↗
DOE OSTI2022

Co-scheduling Ensembles of In Situ Workflows

Molecular dynamics (MD) simulations are widely used to study large-scale molecular systems. HPC systems are ideal platforms to run these studies, however, reaching the necessary simulation timescale to detect rare processes is challenging, even with modern supercomputers. To overcome the timescale limitation, the simulation of a long MD trajectory is replaced by multiple short-range simulations that are executed simultaneously in an ensemble of simulations. Analyses are usually co-scheduled with these simulations to efficiently process large volumes of data generated by the simulations at runtime, thanks to in situ techniques. Executing a workflow ensemble of simulations and their in situ analyses requires efficient co- scheduling strategies and sophisticated management of computational resources so that they are not slowing down each other. In this paper, we propose an efficient method to co-schedule simulations and in situ analyses such that the makespan of the workflow ensemble is minimized. We present a novel approach to allocate resources for a workflow ensemble under resource constraints by using a theoretical framework modeling the workflow ensemble’s execution. We evaluate the proposed approach using an accurate simulator based on the WRENCH simulation framework on various workflow ensemble configurations. Results demonstrate the significance of co-scheduling simulations and in situ analyses that couple data together to benefit from data locality, in which inefficient scheduling decisions can lead to slowdown in makespan up to a factor of 30.

Do, Tu Mai Anh↗
DOE OSTI2022

Small Hydropower Interconnections: Small Hydropower in the United States

Small hydropower projects, which we define as generators below 20 MW in capacity have been the predominant source of hydropower growth over the past decade and create the most cost-effective and environmentally permissible avenues for new hydropower installation in the United States (DOE 2016; Johnson et al. 2018). Small hydropower developers across the United States have found that interconnecting these projects with the grid can be challenging due to unexpected costs and schedule overruns. Understanding the interconnection challenges and improving the process may allow more small hydropower projects to be successful. Noting these challenges, the U.S. Department of Energy Water Power Technologies Office enlisted Pacific Northwest National Laboratory (PNNL) and Oak Ridge National Laboratory (ORNL) to investigate the small hydropower interconnection landscape across the United States. To begin to analyze the existing interconnection processes and challenges facing small hydropower, the state of small hydropower development in the U.S. must first be described to understand the characteristics of the industry. The first in a series, this paper presents the state of small hydropower projects in the U.S. to describe their type, location, and size based on data extracted from the HydroSource database (ORNL 2020). The following papers in the series will detail the variety of state interconnection processes to connect power generators with the grid (“Small Hydropower Interconnections: State Interconnection Processes”), analyze these interconnection processes (“Small Hydropower Interconnections: Analysis of Interconnection Processes”), and present best practices in interconnection processes (“Small Hydropower Interconnections: Best Practices”) that will help overcome barriers to future small hydropower development.

13 HYDRO ENERGY↗
DOE OSTI2025

Floating Offshore Wind US Manufacturing and Commercialization (CRADA Final Report)

Create a detailed manufacturing, assembly, load-out, transportation, upending, turbine integration, and offshore transportation plan for a hypothetical project in one of the California lease areas off the central coast. Develop a detailed schedule and cost estimation for each step of the process and compare with conventional floating platform designs.

17 WIND ENERGY↗
DOE OSTI2020

RLScheduler: An Automated HPC Batch Job Scheduler Using Reinforcement Learning

Today’s high-performance computing (HPC) platforms are still dominated by batch jobs. Accordingly, effective batch job scheduling is crucial to obtain high system efficiency. Existing HPC batch job schedulers typically leverage heuristic priority functions to prioritize and schedule jobs. But, once configured and deployed by the experts, such priority functions can hardly adapt to the changes of job loads, optimization goals, or system settings, potentially leading to degraded system efficiency when changes occur. To address this fundamental issue, we present RLScheduler, an automated HPC batch job scheduler built on reinforcement learning. RLScheduler relies on minimal manual interventions or expert knowledge, but can learn high-quality scheduling policies via its own continuous ‘trial and error’. We introduce a new kernel-based neural network structure and trajectory filtering mechanism in RLScheduler to improve and stabilize the learning process. Through extensive evaluations, we confirm that RLScheduler can learn high-quality scheduling policies towards various workloads and various optimization goals with relatively low computation cost. Moreover, we show that the learned models perform stably even when applied to unseen workloads, making them practical for production use.

Zhang, Di↗
DOE OSTI2023

Conquering Data Chaos: Research Data Management with Kubernetes

Managing massive volumes of data and effectively making it accessible to researchers poses significant challenges and is a barrier to scientific discovery. In many cases, critical data is locked up in unwieldy file formats or one-off databases and is too large to effectively process on a single machine. This talk explores the role of Kubernetes, an open-source container orchestration platform, in addressing research data management challenges. I will discuss how we are using a set of publicly available open-source and home-grown tools in the National Renewable Energy Lab (NREL) Data, Analysis, and Visualization (DAV) group to help researchers overcome data-related bottlenecks. The talk will begin by providing an overview of the data challenges faced in research data management, including data storage, processing, and analysis. I will highlight Kubernetes' ability to handle large-scale data by leveraging containerization and distributed computing, including distributed storage. Kubernetes allows researchers to encapsulate data processing infrastructure and workflows into portable containers, enabling reproducibility and ease of deployment. Kubernetes can then schedule and manage the resource allocation of these containers to enable efficient utilization of limited computing resources, leading to more efficient data processing and analysis. I will discuss some limitations of traditional, siloed approaches to dealing with data and emphasize the need for solutions which foster collaboration. I will highlight how we are using Kubernetes at NREL to facilitate data sharing and cooperation among research teams. Kubernetes' flexible architecture enables the deployment of shared computing environments, such as Apache Superset, where researchers can seamlessly access and analyze shared datasets. Providing the ability to have one research team easily consume data generated by another, utilizing Kubernetes' as a central data platform, is one of the major wins we've encountered by adopting the platform. Finally, I will showcase real-world use cases from NREL where we have used Kubernetes to solve some persistent data challenges involving large volumes of sensor and monitoring data. I will discuss the challenges we encountered when creating our cluster and making it available as a production-ready resource. I will also discuss the specific suite of tools, including Postgres and Apache Druid for columnar and timeseries data, and Redpanda Kafka for streaming data we have deployed in our infrastructure, and the process that went into the selection of these tools.

collaborative environment↗
DOE OSTI2023

Process Usage of 3M Novec™ Fluids at LANL [Slides]

Overview: LANL is using several 3M Novec TM hydrofluoroether (HFE) fluids in production processes; Novec TM HFR fluids currently being used for LANL production processes are: HFE-71IPA, HFE-72DE, HFE-7100, and HFE-7500; With the exit of these fluids being sold commercially scheduled for 2025, LANL is researching what about these HFE fluids make them specifically effective for the processes they are used for in hopes of finding adequate replacement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗