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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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100 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Real-Time Defect Correction in Large-Scale Polymer Additive Manufacturing via Thermal Imaging and Laser Profilometer

Defects can result in a failed part and are costly in terms of time and material. This cost is even greater in the context of large-scale additive manufacturing where the objects can be very large. As a result, a great deal of research has focused on defect identification and mitigation. To address defects during object construction, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated an in-situ control system comprised of two sensors: a thermal camera and laser profilometer. This control system adjusted material flow and build speed to mitigate three types of defects: low layer times, underfill, and overfill. Several test objects were constructed. The control system was found to adjust build parameters to handle low layer times of approximately 15 seconds and height deviations from -100% underfill (the absence of a layer) to 50% overfill. Within two layers, height deviations could be returned to within 10% of the expected layer height. Further, preliminary results suggest the system can compensate for uneven build surfaces.

Borish, Michael↗
DOE OSTI2025

A real-time search for Type Ia Supernovae with late-time interactions with circumstellar material in ZTF data

While it is generally accepted that Type Ia supernovae (SNe Ia) are the terminal explosions of white dwarfs (WDs), the nature of their progenitor systems and the mechanisms that lead up to these explosions remain widely debated. In rare cases, the SN ejecta interact with circumstellar material (CSM) that had previously been ejected from the progenitor system. The longer the delay between the creation of the CSM and the SN explosion, the greater the distance between the SN explosion site and the CSM and the later the onset of the interaction. The unknown distance between the CSM and SN explosion site makes it impossible to predict when the interaction will start. If the time between the SN explosion and the onset of the CSM interaction is of the order of several months to years, the SN has generally faded and it is no longer actively followed up on. This makes it even more difficult to detect the interaction while it is happening. In this work, we report on a real-time monitoring programme running between 13 November 2023 and 9 July 2024. It monitored 6914 SNe Ia for signs of late-time rebrightening using the Zwicky Transient Facility (ZTF). Flagged candidates were rapidly followed up on with photometry and spectroscopy to confirm the late-time excess and its position. We report the discovery of a ∼50 day rebrightening event in SN 2020qxz around 1200 rest-frame days after the peak of its light curve. SN 2020qxz exhibited signs of an early CSM interaction, but had faded from view over two years before its reappearance. Initial follow-up spectroscopy revealed the presence of four emission lines, while later follow-up spectroscopy showed that these had faded shortly after the end of the ZTF-detected rebrightening event. Our best match for these emission lines are H β (blueshifted by ∼5900 km s −1 ) and Ca II λ8542 , N I λ8567 , and K I λλ8763, 8767 (all blueshifted by 5100 km s −1 ; although we note that the line identifications are uncertain). This shows that catching and following up on late-time interactions as they occur can offer new clues on the nature of the progenitor systems that produce these SNe by putting constraints on the possible type of donor star. The only way to do this systematically is to use large sky surveys such as ZTF and the upcoming Vera C. Rubin Observatory’s Legacy Survey of Space and Time (LSST) to monitor a large sample of objects for the rare events that reappear long after the object has faded from view.

circumstellar matter↗
DOE OSTI2023

Knowledge-Informed Uncertainty-Aware Machine Learning for Time Series Forecasting of Dynamical Engineered Systems

The high complexity and multiscale nature of many engineered systems—such as those in nuclear power plants—make representing and forecasting their dynamic behavior challenging. Physics-based models can be overly complex and computationally intractable, whereas machine learning (ML) tools are often data-hungry and prone to unphysical solutions. This study proposes a knowledge-informed ML-aided hybrid residual modeling approach that offers accurate and efficient time series forecasting for the operation of dynamical engineered systems. Hybrid residual modeling entails a baseline solution from domain knowledge and known physics expressions about the system dynamics integrated with an ML model to capture undiscovered information from the mismatch (i.e., residuals) between true states from measurements and baseline-predicted outputs. This study further quantifies the ML model uncertainty to provide trustworthy solutions. Real-time operational data from thermal-hydraulic flow loops of the cryogenic moderator system in Oak Ridge National Laboratory’s Spallation Neutron Source facility were used to demonstrate the potential of knowledge-informed uncertainty-aware ML in real-world applications. The state variables of the cryogenic helium loop were modeled with (1) first principles–based system identification (sysID), (2) long short-term memory (LSTM) neural network, and (3) hybrid sysID (baseline) + LSTM (residual). The superior predictive capability of the sysID+LSTM model versus stand-alone sysID and LSTM is confirmed by average performance metrics and individual data points across different prediction horizons. By creating a robust representation of the underlying physical system, the widely applicable hybrid residual modeling approach will enable the future development of digital twins for performance prediction, prognostics, and operation control.

Zhao, Xingang↗
DOE OSTI2020

Jefferson Laboratory C100 Superconducting Radio-Frequency Cavity Fault Data, 2020

The dataset was created to train machine learning models for the task of identifying the (1) cavity and (2) fault type from C100-type cryomodules at the Thomas Jefferson National Accelerator Facility (Jefferson Lab), thereby replacing the time-consuming efforts of a subject matter expert. Superconducting radio-frequency (SRF) cavity trips represent a significant source of accelerator downtime. Real-time – rather than post-mortem – identification of the offending cavity and classification of the fault type would give control room operators valuable feedback for corrective action planning. The anticipated benefit is increased beam-on-target time for users and provides performance metrics that can be used to improve future cavity designs. A series of 17 RF signals are recorded for each of the 8 cavities in a C100 cryomodule every time a cavity trips. These time-series signals are written to file using a specially designed data acquisition system. The dataset represents fault events recorded during Continuous Electron Beam Accelerator Facility (CEBAF) beam operations between January 18, 2019 and March 9, 2020. The following filtering steps were applied to collected data; (1) only 4 of the 17 signals per cavity are retained (GMES, GASK, CRFP, DETA2) (2) only events with data from each of the eight cavities in the cryomodule are kept, (3) only events that were sampled at 5 kHz were kept, (4) events from cryomodule 0L04 were neglected, (5) events occurring between February 4, 3PM and February 5, 12PM were neglected. As a result of preprocessing, the dataset is comprised of 2,375 unique events. The full dataset is comprised of three files: features.csv, cavity_labels.csv, fault_labels.csv. Each instance in faults.csv includes a timestamp (“date_time”), a label for the cryomodule which experienced the trip (“zone_label”), and 192 features (“feature_1”, “feature_2”... “feature_192”). The features correspond to 6 autoregressive features for each of 4 signals per cavity for each of the 8 cavities (6 × 4 signals/cavity × 8 cavities/cryomodule = 192). To deal with the large variation of signal amplitudes, time-series standardization via the z-score (standard score) function was applied prior to computing the features. For each instance, there is an associated label for the (1) cavity which faulted first (cavity_labels.csv) and (2) the type of fault that caused the trip (fault_labels.csv). The cavity identification can take values of [0, 1, 2, 3, 4, 5, 6, 7, 8] and the fault type can take values of [‘Microphonics’, ‘Quench_100ms’, ‘Controls_Fault’, ‘E_Quench’, ‘Quench_3ms’, ‘Single_Cav_Turn_Off’ , ‘Heat_Riser_Choke’, ‘Multi_Cav_Turn_Off’].

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Superconducting Radio-frequency Cavity Fault Classification Using Machine Learning at Jefferson Laboratory

We report on the development of machine learning models for classifying C100 superconducting radiofrequency (SRF) cavity faults in the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab. Of the 418 SRF cavities in CEBAF, 96 are designed with a digital low-level RF system configured such that a cavity fault triggers recordings of RF signals for each of eight cavities in the cryomodule. Subject matter experts analyze the collected time-series data and identify which of the eight cavities faulted first and classify the type of fault. This information is used to find trends and strategically deploy mitigations to problematic cryomodules. However, manually labeling the data is laborious and time-consuming. By leveraging machine learning, near real-time - rather than postmortem - identification of the offending cavity and classification of the fault type has been implemented. We discuss the performance of the machine learning models during a recent physics run. We also discuss efforts for further insights into fault types through unsupervised learning techniques and present preliminary work on cavity and fault prediction using data collected prior to a failure event.

Tennant, C. D.↗
DOE OSTI2020

Machine Learning Based Cavity Fault Classification and Prediction

We report on the development of machine learning models for classifying C100 superconducting radio frequency (SRF) cavity faults in the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab. CEBAF is a continuous-wave recirculating linac utilizing 418 SRF cavities to accelerate electrons up to 12 GeV through 5-passes. Of these, 96 cavities (12 cryomodules) are designed with a digital low-level RF system configured such that a cavity fault triggers waveform recordings of 17 RF signals for each of the eight cavities in the cryomodule. Subject matter experts (SME) can analyze the collected time-series data, identify which of the eight cavities faulted first, and classify the type of fault. This information is used to find trends and strategically deploy mitigations to problematic cryomodules. However, manually labeling the data is laborious and time-consuming. By leveraging machine learning, near real-time – rather than post-mortem – identification of the offending cavity and classification of the fault type has been implemented. We discuss the performance of the ML models during a recent physics run.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration (FY2020 Final Report)

R2R processing is used to manufacture a wide range of products for various applications which span many industrial business sectors. The overall R2R methodology has been in use for decades and this continuous technique traditionally involves deposition of material(s) onto moving webs, carriers or other continuous belt-fed or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Established methods that typify R2R processing include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating, and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier and membrane materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multilayer technologies have the potential to be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, the means must be available to enable manufacture of these products in a cost-competitive manner that is affordable. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches. However, more early-stage research is needed to solve the challenge of linking the materials (particles, polymers, solvents, additives) used in ink and slurry formulations and the coating and drying processes to the ultimate performance of the final R2R product, especially for a process that uses multiple layers of deposition to achieve the end product. To solve the problems associated with these challenges, the R2R Collaboration is executing a research program with outcomes that will ultimately link modeling, processing, metrology and defect detection tools, thereby directly relating the properties of constituent particles and processing conditions to the performance of final devices. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy materials development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this project leverages the capabilities and expertise at each of five National Laboratories to further the development of multilayer technologies that will enable high-volume, cost-competitive platforms. A typical R2R process has three steps: (1) mixing of particles and various constituents in a slurry, (2) coating of the ink/slurry mixture on a substrate, and (3) drying/curing and processing of the coating. Final performance of devices made via R2R processes is dependent on the active materials (e.g., electrochemical particles in battery or fuel cell electrodes) and the device structure that stems from the governing component interactions within the various steps. However, a fundamental understanding of the underlying mechanisms and phenomena is still lacking, which is why industrial-scale R2R process development and manufacturing is still largely empirical in nature. The FY 2019 through FY 2021 program addresses aspects of the following two targets from the AMO Multi-Year Program Plan: (1) Target 8.1 Develop technologies to reduce the cost per manufactured throughput of continuous R2R manufacturing processes. (A) Increasing throughput of R2R processes by 5 times for batteries (to 50 square feet per minute (50 ft 2 /min)) and capacitors and 10 times for printed electronics and the manufacture of other substrates and MEs used in support of these products. (B) Developing resolution capabilities to enable registration and alignment that will detect, align, and co-deposit multiple layers of coatings and print < 1-micron (1 µm) features using continuous process scalable for commercial production. (C) Developing scalable and reliable R2R processes for solution deposition of ultra-thin (<10 nm) films for active and passive materials. (D) Develop in-line multilayer coating technology on thin films with yields greater than 95%. (2) Target 8.2 Develop in-line instrumentation tools that will evaluate the quality of single and multilayer materials in-process. (A) Developing in-line QC technologies and methodologies for real-time identification of defects and expected product properties “in-use/application” during continuous processing at all size-scales with a focus on the “micro” and “nano” scale traces, lines, and devices, i.e., <1 μm at 300 ft./min for R2R processing in air and <10 nm at 20 ft./min for vacuum (B) Developing technologies to increase the measurement frequency of surface rheology without significant cost increases with a goal of a 10-nanometer in-line profilometry at a production rate of 100,000 square millimeters per minute (100,000 mm 2 /min).

42 ENGINEERING↗
DOE OSTI2023

Electrical Fault Detection, Power Quality, Distributed Energy Resource Use Cases, and Cyber Event Applications with the Cyber Grid Guard System Using Distributed Ledger Technology

Electrical utilities continue to deploy more intelligent electronic devices (IEDs) inside and outside electrical substation and are associated with distributed energy resources (DERs). The integrity and confidentiality of data from IEDs is crucial, and distributed ledger technology (DLT) could improve the resilience of microgrids by helping to make these data more secure. The most popular applications using blockchain technology for electrical utilities is in the field is based on energy trading. However, the dynamism of the penetration of customer owned DERs and the deployment of sensors with IEDs have led to the identification of new applications using DLT that are focused on other areas, such as monitoring, operation and management of the grid and its assets. In addition, the majority of studies on electrical grid applications with blockchain were validated with software simulations. Although general monitoring of power systems for using DLT could be evaluated in operational electric grids, other DLT research applications such as defense against cyber-attacks and/or electrical fault detection are not likely to be performed in a real infrastructure because of possible risks to the network/equipment security. This report summarizes the application of power system applications using distributed ledger technology (DLT), providing a secure DLT framework for collecting data from IEDs like power meters and protective relays inside and outside of an electrical substation and/or between two different electrical utilities. In this study, the use case scenarios were created and assessed for different power system application by using DLT. The electrical fault detection for faulted phases (1), power quality monitoring of phase voltage magnitudes, frequency levels and load power factor (2), DERs use case monitoring (3), and cyber-event applications (4) were performed in a test bed with a Cyber-Grid Guard (CGG) system using DLT. It had a real-time simulator with power meters and protective relays in-the-loop. The first section of this report presents a literature review of power system applications using blockchain at research level. The second section shows the theory and equations used on this report. The third section shows the description of the test bed, equipment, architecture, and electrical grid diagrams. The fourth section shows the experimental models and use case scenarios that were performed for the electrical fault detection, power quality, DERs use case, and cyber event applications with the CGG system using DLT. The fifth section shows the results collected from the tests based on comparing the time stamped events of the analog signals from the IEDs, DLT computer and real time simulator. The sixth section performed the discussion of the results for the use case scenarios. Finally, section seven presents the conclusions for this report were presented.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Advanced Monitoring and Control in the ANL METL Facility Using an Engineering Digital Twin

The potential benefits of using an engineering digital twin to achieve greater autonomy for monitoring and control functions in advanced reactors was investigated for the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The METL sodium purification system served as a representative system as it requires significant human in-the-loop interaction to accomplish its design function. The objective was to demonstrate how real-time operation could be automated while preserving oversight of the operator for ensuring that the system design functions are met. A digital twin model of the purification system was developed for both the cold trap purification loop and plugging meter diagnostic loop using information from the METL piping and instrumentation diagram (P&ID). Automated monitoring and diagnosis of component degradation in the METL facility was demonstrated in tests using the PRO-AID health monitoring software with the digital twin model incorporated in the library of components. Component failures were introduced and were successfully diagnosed in real time. These tests serve to demonstrate an advanced monitoring capability able to differentiate sensor degradation from component degradation, to generate a rank ordering of probabilities of different failure mechanisms that serves to circumvent the false alarm problem with current anomaly detection methods, and how facility monitoring can be transformed from anomaly detection to identification of a specific fault. Automated control of the purification system was demonstrated through simulations that exercised a model predictive controller designed using the digital twin model. Results of these simulations compared favorably with experimental data showing very good reference tracking response with negligible overshoot. In conclusion, these pilot tests and simulations successfully demonstrated the use of a digital twin for improved automation of monitoring and control. It was shown how the digital twin enables switching between control modes from cold trap operation where impurities are removed to plugging meter operation where impurity concentrations are measured.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Ultrasonic Characterization of Lithium Ion Thermal Runaway Conditions for Real-time Ultrasonic Enabled BMS Integration

The demand for energy storage is growing, and lithium-ion batteries are a promising technology to meet this need due to their high power/energy density, high round-trip efficiency, rapid response time, and portability. However, recent catastrophic events caused by thermal runaway have slowed their adoption, highlighting the need for an early warning system for battery failure. In this work, ultrasound is used to detect physical changes in 950 mAh batteries by identifying material property changes independent of voltage and current. [Ultrasound signal features (e.g., time of flight, maximum frequency component) were extracted as the batteries were cycled and subjected to both constant current and constant voltage overcharge and were used to develop two metrics identifying failure: a warning to detect the start of overcharge and an emergency stop (E-stop) to immediately take the battery out of service. The identification method involved locating magnitude differences of several ultrasound features compared to baseline operation considering different currents and temperatures, and the warning/stopping metrics were consistent across all experiments. For an average overcharge time of 140 minutes, the average warning was issued 124 minutes before the failure and the average E-stop was triggered 94 minutes before failure. As a test of using ultrasound for early warning detection, a battery was forced into overcharge and returned to normal cycling conditions based on the previously determined warning metric. Both the voltage profile and the ultrasound measurements returned to their baseline behavior, indicating that ultrasonic detection can not only identify battery failure before a catastrophic event, but can also provide early enough warnings such that overcharges can be detected and corrected quickly enough so the battery does not need to be decommissioned.]

25 ENERGY STORAGE↗