Search NASA⌕ Search

SEARCH · Search NASA

Results for “Design for reliability”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6

Bayesian batch optimization for molybdenum versus tungsten inertial confinement fusion double shell target design

Access to reliable, clean energy sources is a major concern for national security. Much research is focused on the “grand challenge” of producing energy via controlled fusion reactions in a laboratory setting. For fusion experiments, specifically inertial confinement fusion (ICF), to produce sufficient energy, the fusion reactions in the ICF fuel need to become self-sustaining and burn deuterium-tritium (DT) fuel efficiently. The recent record-breaking NIF ignition shot was able to achieve this goal as well as produce more energy than used to drive the experiment. This achievement brings self-sustaining fusion-based power systems closer than ever before, capable of providing humans with access to secure, renewable energy. In order to further progress toward the actualization of such power systems, more ICF experiments need to be conducted at large laser facilities such as the United States's National Ignition Facility (NIF) or France's Laser Mega-Joule. The high cost per shot and limited number of shots that are possible per year make it prohibitive to perform large numbers of experiments. As such, experimental design relies heavily on complex predictive physics simulations for high-fidelity “preshot” analysis. These multidimensional, multi-physics, high-fidelity simulations have to account for a variety of input parameters as well as modeling the extreme conditions (pressures and densities) present at ignition. Such simulations (especially in 3D) can become computationally prohibitive to turn around for each ICF experiment. In this work, we explore using Bayesian optimization with Gaussian processes (GPs) to find optimal designs for ICF double shell targets, while keeping computational costs to manageable levels. These double shell targets have an inner shell that grades from beryllium on the outer surface to the higher Z material molybdenum, as opposed to the nominally used tungsten, on the inside in order to trade off between the high performance associated with high density inner shells and capsule stability. We describe our results for “capsule-only” xRAGE simulations to study the physics between different capsule designs, inner shell materials, and potential for future experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Application of Margin-Based Methods to Assess System Health

Health management of complex systems such as nuclear power plants is an essential task to guarantee system reliability. This task can be greatly enhanced by constantly monitoring asset status and performances and process such data (through anomaly detection, diagnostic, and prognostic computational algorithms) to identify asset degradation trends and faulty states. While such information and data are typically available for many of the assets, they are not propagated from the asset to the system level in order to identify the most critical assets and prioritize maintenance and surveillance activities. The main reason is driven by the fact that current reliability modeling techniques are inadequate to process such information/data. This is due to the nature of these techniques which are based on the concept of failure rate/probability that do not serve an operational context where quantitative asset health information is available. Simply stated, current reliability techniques serve a run-to-failure operational setting and not a predictive maintenance one where the goal is to perform maintenance and surveillance activities only when they are needed based on asset health. The risk informed asset management (RIAM) project is focusing on the development of a different kind of reliability modeling techniques designed to adequately serve a predictive operational setting. Such reliability techniques move aways from a failure rate/probability to a margin-based mindset where margin is here used as a metric to quantify asset health based only on current and past operational experience of the asset under consideration. In addition, margin-based reliability techniques are able to propagate asset health information from the component to system level and provide importance measure to each asset. This report summarizes a recent activity performed in collaboration with plant modernization pathway designed to integrate monitoring data into margin-based reliability models. Such activity focuses on a specific system of an existing nuclear power plant where large amount of historic monitoring data is used to monitor asset and system health.

97 MATHEMATICS AND COMPUTING↗

HIDRA-MAT liquid metal droplet injector for liquid metal applications in HIDRA

A liquid metal droplet injector was explicitly designed for the Hybrid Illinois Device for Research and Applications Material Analysis Test-stand (HIDRA-MAT) at the University of Illinois Urbana-Champaign to prepare liquid metal plasma-facing components (PFCs) for plasma exposure. The design goals were to create a compact, reliable, and robust design that could apply liquid metal droplets in-vacuo to a variety of samples. The injector was designed for liquid metal use, and results discussed pertain to lithium. The injector can produce lithium droplets of consistent size by utilizing programmable piston movement. Here, droplet formation data is presented for four different piston step sizes (0.125 mm, 0.25 mm, 0.5 mm, and 1 mm) at three different nozzle temperatures (185 °C, 230 °C, and 270 °C). Droplets are formed on the injector nozzle tip and a linear shift mechanism vertically translates the droplet to the substrate for application. This design prevents the droplet from inadvertently detaching off the nozzle and falling to the sample. Application of the liquid metal droplet ensures placement consistency on the substrate and helps avoid damage to components in HIDRA-MAT that should not interact with liquid metals. A description of the liquid lithium droplet creation and application results is given and provides additional insight into the cooling and oxidation of lithium droplets under vacuum conditions. A second nozzle was fabricated and demonstrated repeatability in droplet diameter creation having a variance of ±0.14 mm for droplets created from the same number of piston steps. The end-use for the injector on HIDRA-MAT is to apply liquid metals to PFCs and expose them to HIDRA's plasma with subsequent intershot in-vacuo surface analysis in HIDRA-MAT for plasma-material interaction studies.

42 ENGINEERING↗

Cell-level reliability testing procedures for CIGS photovoltaics

The reliability of photovoltaics is commonly studied at the module level. Many reliability problems originate from module attributes, such as metal interconnections to cells, junction boxes. However, significant work in reliability can also be done prior to module design. Testing for reliability earlier in the research cycle increases the probability of avoiding common module reliability problems before cell changes are implemented on a large scale. Cell-level reliability studies can thus lower the rates of module failures in the field and provide confidence to investors that new technologies will perform as advertised. This report summarizes how we investigated three reliability concerns in Cu(In,Ga)Se 2 (CIGS) photovoltaics at the cell level: metastability, shading-induced damage, and potential-induced degradation (PID). We find that examining these concerns required developing robust measurement protocols including the fabrication of novel testing structures. This information will allow readers to incorporate sound metrics for investigating reliability phenomena and aid their studies of cell and module reliability improvements.

14 SOLAR ENERGY↗

Stellarators as a fast path to fusion

Herein this paper is focused on three points: (1) overcoming obstacles to tokamak power plants may require a configuration modification as large as that of a stellarator. (2) The demonstrated reliability of the computational design of stellarators should change fusion strategy. (3) Deployment of carbon-free energy sources is mandated by the thirty-year doubling of carbon dioxide emissions. Carbon-free energy options must be developed and fully deployed within a few doubling times. Unit size and cost of electricity are only relevant in comparison to alternative worldwide energy solutions. Intermittency, site specificity, waste management, and nuclear proliferation make fusion attractive as the basis for a carbon-free energy system compared to the alternatives. Nonetheless, fusion is not an option for deployment until a power plant has successfully operated. A critical element in a minimal time and risk program is the use of computational design as opposed to just extrapolation. Only the stellarator has an empirical demonstration of the reliable computational design through large changes in configuration properties and scale. The computational design of stellarators should proceed while the inventions necessary for a more tokamak-like power plant are sought. The cost of computational design is extremely small, but adequate time is required for the development of ideas that maximize attractiveness and minimize risk. Rapid power-plant construction without many intermediate steps may seem risky, but the price is small compared to the cost of trillions of dollars for each year's delay in addressing carbon-dioxide emissions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗

In Situ ATR-FTIR Study of the Cathode–Electrolyte Interphase: Electrolyte Solution Structure, Transition Metal Redox, and Surface Layer Evolution

We present a study of the lithium nickel manganese cobalt oxide (LiNi 0.6 Mn 0.2 Co 0.2 O 2 , NMC622) cathode-electrolyte interphase (CEI) during galvanostatic charging and discharging using in situ attenuated total reflectance Fourier transform infrared (ATR-FTIR) methods to investigate the voltage dependent electrolyte solution structure changes at the interface, transition metal (TM) redox chemistry, and cathode/electrolyte interfacial layer evolution. Furthermore, our in situ cell design provides both reliable electrochemical device testing and strong FTIR vibrational absorption signals near the cathode surface. Specifically, advanced spectral analysis elucidates changes of near-surface Li+ ion (de)solvation by solvent molecules during galvanostatic cycling. Moreover, cathode metal-oxygen vibrational absorptions, sensitive to TM redox behaviors and subsequent local structural variations, were correlated to cathode de-lithiation (and lithiation) and electrolyte solution structure changes. In addition, we have detected the formation and evolution of a CEI surface layer on the NMC622 cathode that contributes to the cell's capacity fade.

25 ENERGY STORAGE↗

Novel subnanosecond rise, flattop, 100 kV high voltage pulse generator (ASAP-LDRD-22-0122)

We looked to build a new type of 100 kV pulse generator that we hope will avoid many of the problems seen with other commercially available pulse generators. We looked to exploit recent improvements in both lasers and solid-state pulse charge units along with an alternative triggering layout to build something new. For the pulse charging unit, we collaborated with Texas Tech to leverage their knowledge and expertise in pulse transformers and solid-state switching. The final result of the LDRD looks promising. Texas Tech was able to build a pulse charge unit that meets our specifications regarding output, and we were able to integrate it with a switch and a laser to create a device that meets the goals of the LDRD. There is still much work to do to advance the design further and improve reliability, but the proto-type design satisfies the goals we set for this LDRD.

42 ENGINEERING↗

User Objectives and Design Approaches for Microgrids: Options for Delivering Reliability and Resilience, Clean Energy, Energy Savings, and Other Priorities

In fall 2019, the National Association of Regulatory Utility Commissioners (NARUC) and the National Association of State Energy Officials (NASEO) initiated a joint Microgrids State Working Group (MSWG), funded by the U.S. Department of Energy (DOE) Office of Electricity (OE). The MSWG aimed to bring together NARUC and NASEO members to explore the capabilities, costs, and benefits of microgrids; discuss barriers to microgrid development; and develop strategies to plan, finance, and deploy microgrids to improve resilience. Based on member input, the MSWG developed two companion briefing papers to answer key questions about microgrids: (1) User Objectives and Design Approaches for Microgrids: Options for Delivering Reliability and Resilience, Clean Energy, Energy Savings, and Other Priorities and (2) Private Sector, State, and Federal Funding and Financing Options to Enable Resilient, Affordable, and Clean Microgrids. Read together, these resources provide readers with an understanding of both why and how customers—whether an investor-owned, cooperative, or municipal utility; federal, state, or local government entity; individual or group of residential, commercial, and/or industrial customers; or other organization—select, design, and pay for microgrid projects.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Opportunities and data requirements for data-driven prognostics and health management in liquid hydrogen storage systems

During the past decade, Prognostics and Health Management (PHM) has become an important set of tools in various areas of industry and academic reliability engineering. PHM consists of a variety of mathematical and computational methods used to support data-driven decision-making to increase the safety, availability, and reliability of complex engineering systems. In particular, PHM can provide crucial insight into reliability and safety design improvements for developing technologies where historical performance and failure data are limited. This is the case of hydrogen fueling and storage technologies. This work presents a high-level approach for designing data-driven PHM applications for bulk liquid hydrogen (LH 2 ) storage systems for hydrogen fueling stations. This paper addresses core aspects of the design, development, and implementation of data-driven PHM applications that can improve the reliability assessment of hydrogen components. The analysis focuses on the relationship between data availability and diagnostic/prognostic capabilities; potential challenges; and integration schemes for current risk mitigation measures. We identify potential condition-monitoring data sources for key components in an LH 2 storage system, including storage tanks, piping, and pumps. Further, we determine that the short-term goals for the implementation of data-driven models in PHM frameworks in hydrogen systems should focus on developing adequate data collection and analysis strategies, as well as exploring the effect on reliability, safety, and regulations for hydrogen systems.

08 HYDROGEN↗

Design and structural assessment of the Spallation Neutron Source 2.0 MW target

The Proton Power Upgrade (PPU) project is underway at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory. The project will double the proton accelerator power from 1.4 MW to 2.8 MW, increase power to the First Target Station (FTS), and enable a future Second Target Station (STS). The power increase partly comes from raising proton energy from 1.0 GeV to 1.3 GeV. The STS will operate at 0.7 MW at 15 Hz when completed. Until then, PPU will provide the capability to operate the FTS at 2.0 MW at 60 Hz. Maximum power at the FTS to date has been 1.4 MW at 60 Hz with 1.0 GeV protons. A new mercury target module design to operate reliably under PPU conditions has been completed after a multi-year effort. The design philosophy and assessment of the structural analysis are described here. This target underwent an unprecedented design and analysis process for SNS using the latest engineering techniques and incorporating years of operating lessons and outcomes from R&D to meet structural design criteria. Finally, it also incorporates high-flow gas injection to further mitigate pulse fatigue stresses as well as cavitation damage to the mercury vessel.

47 OTHER INSTRUMENTATION↗

Modeling and Characterization of Surface Discharges in Insulating Material for Spacers: Electrode Shape, Discharge Mode, and Revision of the Creepage Concept

In the design of MV AC and DC spacers, the predominant factors are surface and interface conditions. Design is generally carried out on specifications and standards which are based on long-term experience and lab testing. However, the diffusion of power electronics with a trend to increase electric field, switching frequency, and rise time to achieve higher power density calls for an innovative, global approach to optimized insulation system design. A new methodology, based on field simulation, discharge modeling, and partial discharge inception measurements, called the three-leg approach, can form the basis to optimize insulation design for any type of supply voltage waveform. This paper focuses on the influence of the type of electrode on the inception and phenomenology of surface discharges and, as a consequence, on the interpretation of the results used for application of the three-leg approach. It is demonstrated that a typical electrode system used for insulating material testing can generate both gas and surface discharges at the triple point, when the electrodes have a smooth profile that is used to avoid corona or flashover. Hence, testing partial discharge may not provide a straightforward indication of the surface discharge inception and, thus, be partially misleading for insulation design. Another takeover is that such analysis must benefit from PD testing tools endowed with analytics able to provide automatic identification of the type of defect generating PD, i.e., internal, surface, and corona, since design and remedy actions can be taken, and adequate insulating materials developed, only knowing the type of source generating PD. Hence, testing partial discharge may not provide a straightforward indication of surface discharge inception and, thus, be partially misleading for insulation design. In addition to the importance of the three-leg approach to favor reliable and optimized design of insulation systems, there is a clear need to have a PD testing tool endowed with analytics. It should preferably be able to provide automatic identification of the type of defect generating PD, i.e., internal, surface, and corona.

36 MATERIALS SCIENCE↗

Evaluating design safety margins in the American Society of Mechanical Engineers graphite core components design-by-analysis assessments

Graphite is an important material being used for core components in next-generation high-temperature gas-cooled nuclear reactors. The selection of graphite grade for a specific Designer is a complex task, dependent on reactor conditions, component functionality, and required reliability. The American Society of Mechanical Engineers (ASME) provides two semi-probabilistic design-by-analysis assessments to evaluate graphite core components against design reliability targets. The simplified assessment uses a 2-parameter Weibull distribution to describe the graphite grade’s tensile-strength distribution to establish component stress limits. The full assessment uses the 3-parameter Weibull distribution and a modified Weakest-Link Theory approach to calculate a component design probability of failure. The paper defines recommended assessment rules, which are the as-written simplified assessment and the full assessment with parameter lower bounds, the modulus update with threshold reduction, and the 2027 grouping rules. Code rules are applied to three grades: 2114, IG-110, and NBG-18. The baseline margin calculation is developed using the experimental tensile dogbone specimen. Percent margin is defined as the percent reduction in the median experimental load to obtain the allowable load per ASME assessments. Under the recommended rules, the SRC–1 margin in the simplified assessment ranged from 40.2 % to 52.7 % among the grades in this study and from 36.1 % to 49.8 % in the full assessment. The full assessment only decreases the margins by 2.5–4.5 % for the SRC-1 components and 0–1.5 % for the SRC-2 components for this baseline case. Margin is inversely related to material median strength (i.e., the strongest grade, 2114, has the lowest margin).

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Probabilistic Failure Criterion of SiC/SiC Composites Under Multiaxial Loading

Owing to its excellent mechanical properties and stability under high temperature and neutron irradiation conditions, SiC/SiC composites have emerged as a promising material for light water reactors (LWRs) in the development of accident-tolerant fuel (ATF) systems. Structural integrity and retention of hermeticity are two crucial requirements for SiC/SiC claddings during normal operations, and both of them are closely related to the proportional limit stress (PLS) of the material. Understanding the behavior of SiC/SiC composites under multiaxial stress states and developing a probabilistic approach for evaluating the structural vulnerability are of paramount importance for reliability-based analysis and design of SiC/SiC composite claddings. So far, there has been very limited effort towards experimental and analytical investigations of probabilistic failure of SiC/SiC claddings. This critical knowledge gap motivates this research. A probabilistic failure criterion for SiC/SiC composites under multi-axial loading is developed, and this criterion is incorporated into reliability analysis of the structural integrity of SiC/SiC fuel cladding. The research consists of two parts: 1) experimental investigation of multiaxial failure behavior of SiC/SiC composites, and 2) theoretical modeling of time-dependent probabilistic failure of SiC/SiC cladding. In the experimental investigation, the PLS is determined through the examination of stress-strain response, the acoustic emission measurement, as well as the X-ray computed tomography. The theoretical framework is derived by combin- ing the finite weakest-link statistical model and the subcritical damage growth model. This theoretical model captures the time-dependent failure mechanism of the material, which has a major consequence for predicting the lifetime distribution of the cladding. Meanwhile, the model also predicts that the failure statistics of the cladding depends strongly on the cladding length. The results of the multiaxial experiments reveal the level of statistical variation of the PLS of SiC/SiC materials under different stress states. The theoretical model provides a robust analytical tool for extrapolation of small-scale laboratory test results to the behavior of full-scale claddings. These findings establish a scientific foundation for the development of reliability-based design of SiC/SiC fuel claddings, which will play an essential role in improving the structural safety and integrity of LWRs.

42 ENGINEERING↗

Reliability-based hull geometry optimisation of a point-absorber wave energy converter with power take-off structural reliability objectives

Recent studies have focused on optimising wave energy converter (WEC) designs, maximising their power performance and techno-economic feasibility. Reliability has yet to be fully considered in these formulations, despite its impact on cost and performance. In this study, this gap is addressed by developing a reliability-based design optimisation framework for WEC hull geometries to explore the trade-off between power performance and power take-off (PTO) system damage equivalent loading (DEL). Optimised hull geometries for two sites are considered (from the centre of the North Sea and off the west coast of Norway), and two directions of motions (heave and surge). Results indicate that site characteristics affect the potential power production and DEL for an optimal WEC design. These are also affected by the direction of motion for power extraction, which also significantly changes optimal hull shape characteristics. Optimal surging WEC designs have edges facing oncoming wave directions, while heaving WECs have pointed bottoms, both to streamline movement. Larger, more convex WECs result in greater power production and DEL, while smaller, more concave WECs result in lesser power production and DEL. These findings underline the importance of considering WEC hull geometry in early design processes to optimise cost, power production, and reliability.

16 TIDAL AND WAVE POWER↗

Development of a Comparison Framework for Evaluating Environmental Contours of Extreme Sea States

Environmental contours of extreme sea states are often utilized for the purposes of reliability-based offshore design. Many methods have been proposed to estimate environmental contours of extreme sea states, including, but not limited to, the traditional inverse first-order reliability method (I-FORM) and subsequent modifications, copula methods, and Monte Carlo methods. These methods differ in terms of both the methodology selected for defining the joint distribution of sea state parameters and in the method used to construct the environmental contour from the joint distribution. It is often difficult to compare the results of proposed methods to determine which method should be used for a particular application or geographical region. The comparison of the predictions from various contour methods at a single site and across many sites is important to making environmental contours of extreme sea states useful in practice. The goal of this paper is to develop a comparison framework for evaluating methods for developing environmental contours of extreme sea states. This paper develops generalized metrics for comparing the performance of contour methods to one another across a collection of study sites, and applies these metrics and methods to develop conclusions about trends in the wave resource across geographic locations, as demonstrated for a pilot dataset. These proposed metrics and methods are intended to judge the environmental contours themselves relative to other contour methods, and are thus agnostic to a specific device, structure, or field of application. The metrics developed and applied in this paper include measures of predictive accuracy, physical validity, and aggregated temporal performance that can be used to both assess contour methods and provide recommendations for the use of certain methods in various geographical regions. The application and aggregation of the metrics proposed in this paper outline a comparison framework for environmental contour methods that can be applied to support design analysis workflows for offshore structures. This comparison framework could be extended in future work to include additional metrics of interest, potentially including those to address issues pertinent to a specific application area or analysis discipline, such as metrics related to structural response across contour methods or additional physics-based metrics based on wave dynamics.

54 ENVIRONMENTAL SCIENCES↗

Disjunctive optimization model and algorithm for long-term capacity expansion planning of reliable power generation systems

This paper proposes a new optimization model and algorithm for long-term capacity expansion planning of reliable power generation systems. The model optimizes both investment decisions (e.g., size, location, and time to install, retire and decommission facilities) and operation decisions (e.g., on/off status, operating capacity, and expected power output). It is also able to optimize reserve systems (or backup systems), as well as the main systems, to improve power systems reliability. An impact of operational strategies of generators (i.e., participating in electricity production vs. remaining as idle units during operation) on power systems reliability is considered. Probability of equipment failures and capacity failure states are used to rigorously estimate the power systems reliability depending on design and operation strategies. The optimization model is formulated with Generalized Disjunctive Programming (GDP), which is reformulated as a mixed-integer linear programming (MILP) model using the Hull relaxation. Two reliability-related penalties, such as downtime penalty and unmet demand penalty, are included in the objective function to maximize reliability while minimizing the total net present cost. Furthermore, a bilevel decomposition with tailored cuts is developed to reduce computational times of the multi-scale optimization model. The effectiveness of the proposed model is shown by comparing the results with the results obtained from the expansion planning models that do not explicitly consider reliability. In conclusion, we also show that the proposed bilevel decomposition is computationally efficient for solving large scale problems through 5-years and 10-years planning case studies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Assessing decision boundaries under uncertainty

In order to make design decisions, engineers may seek to identify regions of the design domain that are acceptable in a computationally efficient manner. A design is typically considered acceptable if its reliability with respect to parametric uncertainty exceeds the designer’s desired level of confidence. Despite major advancements in reliability estimation and in design classification via decision boundary estimation, the current literature still lacks a design classification strategy that incorporates parametric uncertainty and desired design confidence. To address this gap, this paper offers a novel interpretation of the acceptance region by defining the decision boundary as the hypersurface which isolates the designs that exceed a user-defined level of confidence given parametric uncertainty. This work addresses the construction of this novel decision boundary using computationally efficient algorithms that were developed for reliability analysis and decision boundary estimation. The approach proposed in this paper is verified on two physical examples from structural and thermal analysis using Support Vector Machines and Efficient Global Optimization-based contour estimation.

97 MATHEMATICS AND COMPUTING↗