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Cost-Benefit Assessment of Additive Manufacturing for Injection Molds

This report presents an additive-manufacturing (AM) technology, where AM Cyclic Olefin Resin (COR) molds would be used for injection molding. The National Laboratory of the Rockies (NLR) team has focused on the costs and economics of this developing technology. This report presents a cost-benefit analysis of using the polySpectra AM COR molds made of COR, at the start of the project (Present') and the potential lifetime, cost-effectiveness, and performance by the end of the project period (Period 3'). The analysis of the AM COR molds is compared to traditional Computer Numerical Control (CNC) machined aluminum molds across the time periods. A cost-benefit model framework has been developed to evaluate AM COR molds. This model accounts for mold delivery to customers, current and future levels of technology readiness, the type of material injected, and various business cases. AM COR molds offer a major advantage in lead time, reducing production setup from weeks or months (with CNC machining) to as little as two to five days. This enables faster prototyping, quicker design cycles, and accelerated time-to-market, critical in industries like electronics, aerospace, medical devices, and automotive. Even modest improvements in the durability of polySpectra AM COR molds show the potential for these molds to complement traditional tooling. With further development, AM COR mold technology could provide significant time and cost savings while supporting increased domestic manufacturing capacity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Advanced Energy Manufacturing and Recycling Grant Readiness Technical Assistance Program [Slides]

The U.S. Department of Energy's Office of Manufacturing and Energy Supply Chains (MESC) has launched a new technical assistance program, administered by NREL, in support of prospective applicants to the Advanced Energy Manufacturing and Recycling Grant Program. The competitive technical assistance program will help small- and medium-sized manufacturers understand the requirements of the Advanced Energy Manufacturing and Recycling Grant Program and prepare for future applications. Such applications must propose a project to build, retrofit, or expand facilities in coal communities for producing or recycling goods used to support clean energy supply chains. This presentation is for an informational webinar on Wednesday, April 26, 2023.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

PNNL 2017 Richland Campus Master Plan

Based in Richland, Washington, Pacific Northwest National Laboratory (PNNL) is one of 10 United States (U.S.) Department of Energy (DOE) Office of Science (SC) national laboratories. PNNL is DOE’s premier chemistry, earth sciences and data analytics Laboratory, delivering vital mission impacts in energy resiliency and national security. PNNL has 19 core capabilities, each a powerful combination of world-class staff, state-of-the-art equipment, and mission ready facilities. These capabilities represent a collective set of skills and a body of world-leading scientific and engineering work that provides exceptional value and mission delivery to DOE, the National Nuclear Security Administration (NNSA), the U.S. Department of Homeland Security (DHS), and the missions of other federal agencies and industry through strategic partnership projects. Operated by Battelle Memorial Institute (Battelle), PNNL has more than: 2.3 million gross square feet and 4,400 staff members. PNNL is implementing a rolling 10-year campus strategy (initiated in FY 2013) designed to deliver the foundation for the multidisciplinary science and engineering expertise, equipment, instrumentation, facilities, and infrastructure required to continue providing exceptional value and mission delivery. PNNL’s annual ten-year plan is published with SC’s Ten-Year Plans for the Science National Laboratories. The most recent publication is available at: https://science.energy.gov/lp/laboratory-planning-process/. This edition of the PNNL Richland Campus Master Plan (CMP) is an update to the 2012 CMP.

99 GENERAL AND MISCELLANEOUS↗

A new multi-mission data system for space flight support through the 1990's

The Space Flight Operations Center (SFOC) is described with attention given to historical and technical aspects. The SFOC is designed to support each new JPL mission with all of its mission-unique processing as a ready adaptation of some set of baseline capabilities. Another goal of the SFOC is to allow the migration of current older JPL missions from their current systems that use aging and costly hardware and software to newer systems with similar functionality. Upon its completion, the planned support includes both downlink and uplink processing for a projected six mission set.

Gainsborough, A. J.↗

"ATLAS" Advanced Technology Life-cycle Analysis System

Making good decisions concerning research and development portfolios-and concerning the best systems concepts to pursue - as early as possible in the life cycle of advanced technologies is a key goal of R&D management This goal depends upon the effective integration of information from a wide variety of sources as well as focused, high-level analyses intended to inform such decisions Life-cycle Analysis System (ATLAS) methodology and tool kit. ATLAS encompasses a wide range of methods and tools. A key foundation for ATLAS is the NASA-created Technology Readiness. The toolkit is largely spreadsheet based (as of August 2003). This product is being funded by the Human and Robotics The presentation provides a summary of the Advanced Technology Level (TRL) systems Technology Program Office, Office of Exploration Systems, NASA Headquarters, Washington D.C. and is being integrated by Dan O Neil of the Advanced Projects Office, NASA/MSFC, Huntsville, AL

Lollar, Louis F.↗

Holodeck: Telepresence Dome Visualization System Simulations

This paper explores the simulation and consideration of different image-projection strategies for the Holodeck, a dome that will be used for highly immersive telepresence operations in future endeavors of the National Aeronautics and Space Administration (NASA). Its visualization system will include a full 360 degree projection onto the dome's interior walls in order to display video streams from both simulations and recorded video. Because humans innately trust their vision to precisely report their surroundings, the Holodeck's visualization system is crucial to its realism. This system will be rigged with an integrated hardware and software infrastructure-namely, a system of projectors that will relay with a Graphics Processing Unit (GPU) and computer to both project images onto the dome and correct warping in those projections in real-time. Using both Computer-Aided Design (CAD) and ray-tracing software, virtual models of various dome/projector geometries were created and simulated via tracking and analysis of virtual light sources, leading to the selection of two possible configurations for installation. Research into image warping and the generation of dome-ready video content was also conducted, including generation of fisheye images, distortion correction, and the generation of a reliable content-generation pipeline.

Hite, Nicolas↗

Foundational Low-Carbon Hydrogen Research

HydroGEN is a multi-lab consortium focused on early-stage R&D in H2 production, supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO). The consortium advances research and development (R&D) of innovative materials for advanced water splitting (AWS) technologies to enable clean, sustainable and low-cost ($1/kg H2) hydrogen production and fosters cross-cutting innovation using theory-guided applied materials R&D to advance all emerging water-splitting pathways for hydrogen production. HydroGEN is focused on low technology readiness level AWS technologies, including low- (alkaline exchanged membrane electrolysis) and high-temperature electrolysis (proton-conducting solid oxide electrolysis), photoelectrochecmical (PEC) and solar thermochemical (STCH) water splitting. This presentation will provide an overview of the HydroGEN EMN, its relationship to the H2NEW consortium, technical highlights of a few lab-led R&D projects, and the community appproach to benchmarking and protocol development for advanced water splitting technologies. Low-carbon hydrogen plays a vital role in the carbon dioxide utilization and decarbonization of several chemical and fuel industries.

advanced water splitting materials AEM↗

Technology Solutions Case Study: High-Performance Ducts in Hot-Dry Climates

Ducts in conditioned space (DCS) represent a high priority measure for moving the next generation of new homes to the Zero Net Energy performance level. Various strategies exist for incorporating ducts within the conditioned thermal envelope. To support this activity, in 2013 the Pacific Gas & Electric Company initiated a project with Davis Energy Group (lead for the Building America team, Alliance for Residential Building Innovation) to solicit builder involvement in California to participate in field demonstrations of various DCS strategies. Builders were given incentives and design support in exchange for providing site access for construction observation, diagnostic testing, and builder survey feedback. Information from the project was designed to feed into California's 2016 Title 24 process, but also to serve as an initial mechanism to engage builders in more high performance construction strategies. This Building America project complemented information collected in the California project with BEopt simulations of DCS performance in hot/dry climate regions.

ARBI↗

Technology readiness levels for advanced nuclear fuels and materials development

The Technology Readiness Level (TRL) process is used to quantitatively assess the maturity of a given technology. It was pioneered by the National Aeronautics and Space Administration (NASA) in the 1980s to develop and deploy new systems for space applications. The process was subsequently adopted by the Department of Defense (DoD) to develop and deploy new technology and systems for defense applications as well as the Department of Energy (DOE) to evaluate the maturity of new technologies in major construction projects. Advanced nuclear fuels and materials development is a critical technology needed for improving the performance and safety of current and advanced reactors, and ultimately closing the nuclear fuel cycle. Because deployment of new nuclear fuel forms requires a lengthy and expensive research, development, and demonstration program, applying the TRL concept to the advanced fuel development program is very useful as a management, communication and tracking tool. Furthermore, this article provides examples regarding the methods by which TRLs are currently used to assess the maturity of nuclear fuels and materials under development in the DOE Fuel Cycle Research and Development (FCRD) Program within the Advanced Fuels Campaign (AFC).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Virginia Offshore Wind Technology Advancement Project (VOWTAP) DOE EE0005985 Final Technical Report Rev 1a

The primary purpose of the VOWTAP was to advance the offshore wind industry in the United States (U.S.) by demonstrating innovative technologies and process solutions that would establish offshore wind as a cost-effective renewable energy resource. The VOWTAP Team proposed to design, construct, and operate a 12 megawatt (MW) offshore wind facility located approximately 27 statute miles (mi) (24 nautical miles [nm], 43 kilometers [km]) off the coast of Virginia. The proposed Project would consist of two Alstom Haliade™ 150-6 MW turbines mounted on inward battered guide structures (IBGS), a 34.5-kilovolt (kV) alternating current (AC) submarine cable interconnecting the WTGs (inter-array cable), a 34.5-kV AC submarine transmission cable (export cable), and a 34.5 kV underground cable (onshore interconnection cable) that would connect the Project with existing Dominion infrastructure located in Virginia Beach, Virginia (Figure 1). Interconnection with the existing Dominion infrastructure would also require an onshore switch cabinet, a fiber optic cable, and new interconnection station to be located entirely within the boundaries of the Camp Pendleton State Military Reservation (Camp Pendleton). The VOWTAP balanced technology innovation with commercial readiness such that turbine operations were anticipated to commence by 2018. Dominion, as the leaseholder of the Virginia Wind Energy Area (WEA), anticipated leveraging lessons learned through the VOWTAP, and applying them to future commercial-scale offshore wind development.

17 WIND ENERGY↗

A Data Science and Machine Learning Platform Supporting Large Particle Accelerator Control and Diagnostics Applications Final Report: SBIR Initial Phase II DE-SC0022583

The Machine Learning Data Platform (MLDP) is a product providing full-stack support for data science, Machine Learning, and Artificial Intelligence (ML/AI) applications at particle accelerator and large experimental physics facilities. It supports ML/AI applications from front-end, high-speed acquisition of heterogeneous, time-series data, through data archiving and management, to back-end analysis. The MLDP embodies a “data-science ready” platform for data analysis and ML/AI applications in diagnosis, modelling, control, and optimization of these facilities. It provides data scientists and applications a consistent, datacentric interface to archive data standardizing implementation and deployment of ML/AI algorithms to different operations configurations within the same facility, or between facilities. Being an open-source, public-domain project, the MLDP is intended for broadest possible impact by increasing accessibility and minimizing the required expertise for installation and operation. The MLDP can also be deployed at user facilities for experimental data collection, archiving, and analysis. It is capable of acquisition and archiving of heterogeneous data from experimental equipment (e.g., images, arrays, structures, etc.) along with system hardware configurations (e.g., scalars, tables), control system process variables, and any metadata required for provenance. Thus, the MLDP can manage experimental data through its entire lifecycle, from acquisition and archiving, through analysis and investigation, to release and final publication.

43 PARTICLE ACCELERATORS↗

Formation Flying for Satellites and Unmanned Aerial Vehicles

The shrinking size of satellites and unmanned aerial vehicles (UAVs) is enabling lower cost missions. As sensors and electronics continue to downsize, the next step is multiple vehicles providing different perspectives or variations for more precise measurements. While flying a single satellite or UAV autonomously is a challenge, flying multiple vehicles in a precise formation is even more challenging. The goal of this project is to develop a scalable mesh network between vehicles (satellites or UAVs) to share real-time position data and maintain formations autonomously. Newly available low-cost, commercial off-the-shelf credit card size computers will be used as the basis for this network. Mesh networking techniques will be used to provide redundant links and a flexible network. The Small Projects Rapid Integration and Test Environment Lab will be used to simulate formation flying of satellites. UAVs built by the Aero-M team will be used to demonstrate the formation flying in the West Test Area. The ability to test in flight on NASA-owned UAVs allows this technology to achieve a high Technology Readiness Level (TRL) (TRL-4 for satellites and TRL-7 for UAVs). The low cost of small UAVs and the availability of a large test range (West Test Area) dramatically reduces the expense of testing. The end goal is for this technology to be ready to use on any multiple satellite or UAV mission.

Merrill, Garrick↗

Overview of Predictive Simulation Capability Development for Crater Evolution and Ejecta in Continuum/Rarefied Flows

As part of the Game Changing Development (GCD) Program, funded by NASA’s Space Technology Mission Directorate (STMD), the development of simulation capability for the prediction of extra-terrestrial Plume Surface Interaction (PSI) environments has been undertaken by the Fluid Dynamics Branch at NASA/MSFC. The Predictive Simulation Capability (PSC) Element is focused on creating simulation capability for the reliable and accurate prediction of PSI in Martian (~650 Pa) and Lunar (vacuum) ambient environments. In addition to the predictive simulation capability, the GCD Program also contains a companion Ground Testing Element for development of focused datasets for validation of predictive capability as well as a Flight-focused Instrumentation Element. The focus of this paper is to provide an overview and a brief status on one area of capability development through this GCD PSI project - capturing the effects of mixed continuum/rarefied flow on crater development and ejecta sheets. This includes both capability enhancements and maturation of the predictive tool, Loci/GGFS, into a production capable tool as well as validation of the tool against PSI data in Martian and Lunar environments. There are six newly developed capabilities that will be production ready by the end of the fiscal year. Newly developed capabilities must first be verified prior to being production ready, and this process includes capability demonstration, solution verification, and performance evaluation. An overview of the newly developed capabilities with respect to several test cases, including cratering simulations of the Apollo Lunar Module, will be presented. Several validation analyses have been performed to validate in Martian and more Lunar-like environments, including simulations of cratering from a subsonic flow test at Planetary Aeolian Lab (PAL) conducted in a Martian-like environment and pre-test cratering predictions of Physics Focused Ground Test (PFGT) tests planned to be performed in Martian-like and more Lunar-like environments. An overview of these validation analyses as it pertains to the capability development will be presented.

Andrew Weaver↗

Initial CEED API (CEED-MS10)

Key components of CEED software development involve fast finite element operator storage and evaluation, architecture optimizations, performant algorithms for all orders, global kernels for finite element operators, efficient use of the memory sub-system, optimal data locality and motion, enhanced scalability and parallelism, and fast tensor contractions. As ultimate goals of the project, CEED is exploring and identifying the best algorithms for the full range of discretizations and applying algorithmic and software development to support ECP applications’ needs. In this milestone, we initiated the development and implementation of a common CEED API consisting of two main components: low-level and high-level APIs. We accomplished the goal of having the low-level component ready for the release of CEED v1.0 in the next quarter, see CEED-MS13. In this report we also provide a highlight from CEED’s integration with the MARBL app and the corresponding Laghos miniapp. A main theme in this work has been the systematic transition of advanced algorithms, developed and tested in Laghos, to the large-scale multi-physics settings of the MARBL code. The low-level CEED API provides a set of FE kernels and components for writing new low-level kernels. Examples include: vector and sparse linear algebra, element matrix assembly over a batch of elements, partial assembly and action for efficient high-order operators like mass, diffusion, advection, etc. The main goal of the low-level API is to establish the basis for the high-level API. Also, identifying such low-level kernels and providing a reference implementation for them serves as the basis for collaboration with vendors and STs. Another goal for the low-level API is to make it easy for applications with their own discretization infrastructure, who do not want to switch directly to using the high-level CEED API, to still evaluate and use the core operations provided by the low-level API. One of the challenges with high-order methods is that a global sparse matrix is no longer a good representation of a high-order linear operator, both with respect to the FLOPs needed for its evaluation, as well as the memory transfer needed for a matvec. Thus, another important question we tried to address while developing the low-level API is: is it possible to abstract out in a natural and efficient way the different implementations and data structures that arise when dealing with various computational device types: CPUs, GPUs, etc. Fully answering this question is beyond the scope of this particular milestone, since that requires longer time as we develop and expand the devices we support. The future high-level API will be the frontend provided by CEED consisting of high-level abstractions such as meshes, finite element spaces and solutions, bilinear forms, solvers, etc. At this high-level, an important aspect of the API will be to provide a uniform abstraction layer for writing code in a portable manner. To achieve that, we plan to utilize the MPI programming model combined with a device abstraction layer (DAL) for finite element computations that we will develop. The DAL will serve as the bridge between the low- and the high-level APIs, allowing a variety of programming models to be used for the low-level kernel implementations. The software artifacts delivered as part of this milestone include an initial CEED API software implementation (libCEED) provided through the CEED website, http://ceed.exascaleproject.org and the CEED GitHub organization, http://github.com/ceed. In addition to details and results from the above R&D efforts, in this document we are also reporting on other project-wide activities performed in Q1 of FY18, including: the Nek5000 v17.0 MFEM v3.3.2 and PETSc v3.8 releases, collaborations with ECP/ST and SciDAC projects, the inaugural Nek5000 hackathon and various outreach activities.

97 MATHEMATICS AND COMPUTING↗

Volume III. DUNE far detector technical coordination

The preponderance of matter over antimatter in the early universe, the dynamics of the supernovae that produced the heavy elements necessary for life, and whether protons eventually decay -- these mysteries at the forefront of particle physics and astrophysics are key to understanding the early evolution of our universe, its current state, and its eventual fate. The Deep Underground Neutrino Experiment (DUNE) is an international world-class experiment dedicated to addressing these questions as it searches for leptonic charge-parity symmetry violation, stands ready to capture supernova neutrino bursts, and seeks to observe nucleon decay as a signature of a grand unified theory underlying the standard model. The DUNE far detector technical design report (TDR) describes the DUNE physics program and the technical designs of the single- and dual-phase DUNE liquid argon TPC far detector modules. Volume III of this TDR describes how the activities required to design, construct, fabricate, install, and commission the DUNE far detector modules are organized and managed. This volume details the organizational structures that will carry out and/or oversee the planned far detector activities safely, successfully, on time, and on budget. It presents overviews of the facilities, supporting infrastructure, and detectors for context, and it outlines the project-related functions and methodologies used by the DUNE technical coordination organization, focusing on the areas of integration engineering, technical reviews, quality assurance and control, and safety oversight. Because of its more advanced stage of development, functional examples presented in this volume focus primarily on the single-phase (SP) detector module.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

LCLS-II Cryomodules Production Experience and Lessons Learned at Fermilab

LCLS-II is a planned upgrade project for the linear co-herent light source (LCLS) at SLAC. The LCLS-II Linac will consist of thirty-five 1.3 GHz and two 3.9 GHz super-conducting RF continuous wave (CW) cryomodules that Fermilab and Jefferson Lab are currently producing in collaboration with SLAC. The LCLS-II 1.3 GHz cryomodule design is based on the European XFEL pulsed-mode cryomodule design with modifications needed for CW opera-tion. Two prototype cryomodules had been assembled and tested. After prototype cryomodule tests, both laboratories have increased their cryomodule production rate to meet the challenging LCLS-II project installation schedule requirements of approximately one cryomodule per month per laboratory. To date, Fermilab has completed the assembly and testing of eighteen 1.3GHz cryomodules. Fermilab has successfully shipped nine cryomodules to SLAC and will continue to ship approximately every two weeks. The first 3.9 GHz cryomodule assembly is scheduled to start in June 2019. Production readiness verifications are currently in process. This paper presents LCLS-II 1.3GHz cryomodule assembly and production experience, emphasizing the challenges, mitigations, and lessons learned.

43 PARTICLE ACCELERATORS↗

Excavationless Exterior Foundation Insulation Field Study - Minnesota

The NorthernSTAR Building America Partnership team implemented an innovative, minimally invasive foundation insulation upgrade technique on an existing home. The approach consisted of using hydrovac excavation technology combined with a liquid insulating foam. Two houses were originally selected for this field study. One was not ready for retrofit at the time of study and had to be eliminated. The collaborative nature of the one field installation, however, enabled the team to advance the methodology as the work progressed. Improvements to the method of installation and reduction of costs were developed on site. This is a repository for all "excavationless" foundation insulation retrofit projects performed by the NorthernSTAR research team. Minneapolis, MN 55411 - Test house for first NorthernSTAR excavationless foundation insulation retrofit.

Array↗

Information expectations from Landsat-D

The first satellite of the Landsat-D Project is to be launched in the third quarter of 1982 with a second satellite to be prepared for launch 12 to 15 months later. Both spacecraft are to include the familiar Multispectral Scanner (MSS) and the advanced multispectral scanner called the Thematic Mapper (TM). The ground data processing system for the MSS data is to be ready to produce 200 scenes a day in 1982. The data processing systems for the TM are to be fully operational at the 50 to 100 scenes a day level in early 1985. The fabrication of the system components has proceeded well in recent months, and integration of the total system is under way. The procedures for processing the data and meeting specifications are nearly completed for the MSS and are outlined in detail for the TM. An outline of an investigation program stressing systems performance has been developed for the period 1982 to 1985.

Salomonson, V. V.↗