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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Enabling Exascale Hardware and Software Design through Scalable System Virtualization (Final Report)

The purpose of this project has been to extend the state of the art of systems software for high-end computing (HEC) platforms, and to use systems software to better enable the evaluation of potential future HEC platforms, for example exascale platforms. Such platforms, and their systems software, have the goal of providing scientific computation at new scales, thus enabling new research in the physical sciences and engineering. Over time, the innovations in systems software for such platforms also become applicable to more widely used computing clusters, data centers, and clouds. This was a five-institution project, centered on the Palacios virtual machine monitor (VMM) systems software, a project begun at Northwestern, and originally developed in a previous collaboration between Northwestern University and the University of New Mexico. In this project, Northwestern (including via our subcontract to the University of Pittsburgh) contributed to the continued development of Palacios, along with other team members. We took the leadership role in (1) continued extension of support for emerging Intel and AMD hardware, (2) integration and performance enhancement of overlay networking, (3) connectivity with architectural simulation, (4) binary translation, and (5) support for modern Non-Uniform Memory Access (NUMA) hosts and guests. We also took a supporting role in support for specialized hardware for I/O virtualization, profiling, configurability, and integration with configuration tools. The efforts we led (1-5) were largely successful and executed as expected, with code and papers resulting from them. The project demonstrated the feasibility of a virtualization layer for HEC computing, similar to such layers for cloud or datacenter computing. For effort (3), although a prototype connecting Palacios with the GEM5 architectural simulator was demonstrated, our conclusion was that such a platform was less useful for design space exploration than anticipated due to inherent complexity of the connection between the instruction set architecture level and the microarchitectural level. For effort (4), we found that a code injection approach proved to be more fruitful. The results of our efforts are publicly available in the open source Palacios codebase and published papers, all of which are available from the project web site, v3vee.org. Palacios is currently one of the two codebases (the other being Sandia’s Kitten lightweight kernel) that underlies the node operating system for the DOE Hobbes Project, one of two projects tasked with building a systems software prototype for the national exascale computing effort.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Water balance model (WBM) v.1.0.0: a scalable gridded global hydrologic model with water-tracking functionality

Abstract. This paper describes the University of New Hampshire Water Balance Model, WBM, a process-based gridded global hydrologic model that simulates the land surface components of the global water cycle and includes water extraction for use in agriculture and domestic sectors. The WBM was first published in 1989; here, we describe the first fully open-source WBM version (v.1.0.0). Earlier descriptions of WBM methods provide the foundation for the most recent model version that is detailed here. We present an overview of the model functionality, utility, and evaluation of simulated global river discharge and irrigation water use. This new version adds a novel suite of water source tracking modules that enable the analysis of flow-path histories on water supply. A key feature of WBM v.1.0.0 is the ability to identify the partitioning of sources for each stock or flux within the model. Three different categories of tracking are available: (1) primary inputs of water to the surface of the terrestrial hydrologic cycle (liquid precipitation, snowmelt, glacier melt, and unsustainable groundwater); (2) water that has been extracted for human use and returned to the terrestrial hydrologic system; and (3) runoff originating from user-defined spatial land units. Such component tracking provides a more fully transparent model in that users can identify the underlying mechanisms generating the simulated behavior. We find that WBM v.1.0.0 simulates global river discharge and irrigation water withdrawals well, even with default parameter settings, and for the first time, we are able to show how the simulation arrives at these fluxes by using the novel tracking functions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

A portable on-axis laser-heating system for near-90° X-ray spectroscopy: application to ferropericlase and iron silicide

A portable IR fiber laser-heating system, optimized for X-ray emission spectroscopy (XES) and nuclear inelastic scattering (NIS) spectroscopy with signal collection through the radial opening of diamond anvil cells near 90°with respect to the incident X-ray beam, is presented. The system offers double-sided on-axis heating by a single laser source and zero attenuation of incoming X-rays other than by the high-pressure environment. A description of the system, which has been tested for pressures above 100 GPa and temperatures up to 3000 K, is given. The XES spectra of laser-heated Mg 0.67 Fe 0.33 O demonstrate the potential to map the iron spin state in the pressure–temperature range of the Earth's lower mantle, and the NIS spectra of laser-heated FeSi give access to the sound velocity of this candidate of a phase inside the Earth's core. This portable system represents one of the few bridges across the gap between laser heating and high-resolution X-ray spectroscopies with signal collection near 90°.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

SU-E-T-499: Comparison of Measured Tissue Phantom Ratios (TPR) Against Calculated From Percent Depth Doses (PDD) with and Without Peak Scatter Factor (PSF) in 6MV Open Beam

Purpose: To examine the accuracy of measured tissue phantom ratios (TPR) values with TPR calculated from percentage depth dose (PDD) with and without peak scatter fraction (PSF) correction. Methods: For 6MV open beam, TPR and PDD values were measured using PTW Semiflex (31010) ionization field and reference chambers (0.125cc volume) in a PTW MP3-M water tank. PDD curves were measured at SSD of 100cm for 7 square fields from 3cm to 30cm. The TPR values were measured up to 22cm depth for the same fields by continuous water draining method with ionization chamber static at 100cm from source. A comparison study was performed between the (a) measured TPR, (b) TPR calculated from PDD without PSF, (c) TPR calculated from PDD with PSF and (d) clinical TPR from RadCalc (ver 6.2, Sun Nuclear Corp). Results: There is a field size, depth dependence on TPR values. For 10cmx10cm, the differences in surface dose (DDs), dose at 10cm depth (DD10) <0.5%; differences in dmax (Ddmax) <2mm for the 4 methods. The corresponding values for 30cmx30cm are DDs, DD10 <0.2% and Ddmax<3mm. Even though for 3cmx3cm field, DDs and DD10 <1% and Ddmax<1mm, the calculated TPR values with and without PSF correction differed by 2% at >20cm depth. In all field sizes at depths>28cm, (d) clinical TPR values are larger than that from (b) and (c) by >3%. Conclusion: Measured TPR in method (a) differ from calculated TPR in methods (b) and (c) to within 1% for depths < 28cm in all 7 fields in open 6MV beam. The dmax values are within 3mm of each other. The largest deviation of >3% was observed in clinical TPR values in method (d) for all fields at depths < 28cm.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

hIPPYlib-MUQ: A Bayesian Inference Software Framework for Integration of Data with Complex Predictive Models under Uncertainty

Bayesian inference provides a systematic framework for integration of data with mathematical models to quantify the uncertainty in the solution of the inverse problem. However, the solution of Bayesian inverse problems governed by complex forward models described by partial differential equations (PDEs) remains prohibitive with black-box Markov chain Monte Carlo (MCMC) methods. We present hIPPYlib-MUQ, an extensible and scalable software framework that contains implementations of state-of-the art algorithms aimed to overcome the challenges of high-dimensional, PDE-constrained Bayesian inverse problems. These algorithms accelerate MCMC sampling by exploiting the geometry and intrinsic low-dimensionality of parameter space via derivative information and low rank approximation. The software integrates two complementary open-source software packages, hIPPYlib and MUQ. hIPPYlib solves PDE-constrained inverse problems using automatically-generated adjoint-based derivatives, but it lacks full Bayesian capabilities. MUQ provides a spectrum of powerful Bayesian inversion models and algorithms, but expects forward models to come equipped with gradients and Hessians to permit large-scale solution. By combining these two complementary libraries, we created a robust, scalable, and efficient software framework that realizes the benefits of each and allows us to tackle complex large-scale Bayesian inverse problems across a broad spectrum of scientific and engineering disciplines. To illustrate the capabilities of hIPPYlib-MUQ, we present a comparison of a number of MCMC methods available in the integrated software on several high-dimensional Bayesian inverse problems. These include problems characterized by both linear and nonlinear PDEs, various noise models, and different parameter dimensions. The results demonstrate that large (~ 50×) speedups over conventional black box and gradient-based MCMC algorithms can be obtained by exploiting Hessian information (from the log-posterior), underscoring the power of the integrated hIPPYlib-MUQ framework.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Ultra-sensitive isotope probing to quantify activity and substrate assimilation in microbiomes

Abstract Background Stable isotope probing (SIP) approaches are a critical tool in microbiome research to determine associations between species and substrates, as well as the activity of species. The application of these approaches ranges from studying microbial communities important for global biogeochemical cycling to host-microbiota interactions in the intestinal tract. Current SIP approaches, such as DNA-SIP or nanoSIMS allow to analyze incorporation of stable isotopes with high coverage of taxa in a community and at the single cell level, respectively, however they are limited in terms of sensitivity, resolution or throughput. Results Here, we present an ultra-sensitive, high-throughput protein-based stable isotope probing approach (Protein-SIP), which cuts cost for labeled substrates by 50–99% as compared to other SIP and Protein-SIP approaches and thus enables isotope labeling experiments on much larger scales and with higher replication. The approach allows for the determination of isotope incorporation into microbiome members with species level resolution using standard metaproteomics liquid chromatography-tandem mass spectrometry (LC–MS/MS) measurements. At the core of the approach are new algorithms to analyze the data, which have been implemented in an open-source software ( https://sourceforge.net/projects/calis-p/ ). We demonstrate sensitivity, precision and accuracy using bacterial cultures and mock communities with different labeling schemes. Furthermore, we benchmark our approach against two existing Protein-SIP approaches and show that in the low labeling range used our approach is the most sensitive and accurate. Finally, we measure translational activity using 18 O heavy water labeling in a 63-species community derived from human fecal samples grown on media simulating two different diets. Activity could be quantified on average for 27 species per sample, with 9 species showing significantly higher activity on a high protein diet, as compared to a high fiber diet. Surprisingly, among the species with increased activity on high protein were several Bacteroides species known as fiber consumers. Apparently, protein supply is a critical consideration when assessing growth of intestinal microbes on fiber, including fiber-based prebiotics. Conclusions We demonstrate that our Protein-SIP approach allows for the ultra-sensitive (0.01 to 10% label) detection of stable isotopes of elements found in proteins, using standard metaproteomics data.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

The efficacy of aerosol–cloud radiative perturbations from near-surface emissions in deep open-cell stratocumuli

Aerosol–cloud radiative effects are determined and quantified in simulationsof deep open-cell stratocumuli observed during the VAMOS Ocean-Cloud-Atmosphere-LandStudy Regional Experiment (VOCALS-REx) campaign offthe west coast of Chile. The cloud deck forms in a boundarylayer 1.5 km deep, with cell sizes reaching 50 km in diameter. Global databases of shiptracks suggest that these linear structures are seldom found in boundarylayers this deep. Here, we quantify the changes in cloud radiative propertiesto a continuous aerosol point source moving along a fixed emission linereleasing 10 17 particles per second. We show that a spatially coherentcloud perturbation is not evident along the emission line. Yet our modelsimulates an increase in domain-mean all-sky albedo of 0.05, corresponding toa diurnally averaged cloud radiative effect of 20 W m -2 , given theannual mean solar insolation at the VOCALS-REx site. Therefore, markedchanges in cloud radiative properties in precipitating deep open cells may bedriven by anthropogenic near-surface aerosol perturbations, such as thosegenerated by ships.Furthermore, we demonstrate that these changes in cloud radiative propertiesare masked by the naturally occurring variability within the organised cloudfield. A clear detection and attribution of cloud radiative effects to aperturbation in aerosol concentrations becomes possible when sub-filtering ofthe cloud field is applied, using the spatio-temporal distribution of theaerosol perturbation. Therefore, this work has implications for the detectionand attribution of effective cloud radiative forcing in marine stratocumuli,which constitutes one of the major physical uncertainties within the climatesystem. Our results suggest that ships may sometimes have a substantialradiative effect on marine clouds and albedo, even when ship tracks are notreadily visible.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Deploying E3’s RESERVE Tool to Enable Advanced Operation of Clean Grids

Energy and Environmental Economics, Inc. (E3) developed an open-source machine learning model, RESERVE, for deriving ancillary services timeseries in deeply decarbonized electricity grids. E3 used a bespoke PLEXOS production simulation model of the California Independent System Operator’s (CAISO) balancing area to validate RESERVE’s ability to enable production cost, greenhouse gas emissions (GHG), and renewable energy curtailment savings. These savings were modeled by comparing PLEXOS cases with RESERVE’s outputs to PLEXOS cases with CAISO’s incumbent reserve product in the Western Energy Imbalance Market (EIM)’s 15-minute market. E3 also tested cases with solar operating flexibly to provide reserves. E3 found that, in a 2030 modeling year, using RESERVE and flexible solar enabled significant production cost, GHG and curtailment savings versus the incumbent CAISO method in cases with low penetrations of lithium-ion batteries. However, with the full 14 gigawatts (about 30% of peak CAISO demand) of 4-hour lithium-ion batteries that are expected to be installed by 2030, these savings approach zero due to batteries saturating ancillary services markets. E3 also found significant savings under a 2019 benchmarking year.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

What can we learn from decarbonization of the energy sector?

This is a chapter that will be part of an Open Source e-book published by the International Water Association Publishing House. The co-editors are Professors Z. Jason Ren and Krishna Pagilla. Decarbonizing water and wastewater treatment is an enormous challenge, but it is substantially smaller, in total carbon emissions, than decarbonizing the energy sector. When planning, executing, and assessing strategies for decarbonizing the water sector, water experts should partner with the energy sector and heed that sector’s lessons-learned in its ongoing process of decarbonization. In the energy sector, decarbonization pathways can be as simple as a supply-side technology that converts fuel to electricity more efficiently, reducing net carbon emissions for every kilowatt-hour generated. The pathways can be much more complex, however, as is the case with the demand-side reordering of behavior as seen with online shopping or working from home during a public health crisis. Both of those pathways reduce demand for private-vehicle fuel and shift some work, and associated carbon emissions, to other parts of the economy. This chapter explores decarbonization pathways that have been followed by the energy sector and assesses their applicability to the water sector.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

X-ray pinhole camera setups used in the Atomki ECR Laboratory for plasma diagnostics

Imaging of the electron cyclotron resonance (ECR) plasmas by using CCD camera in combination with a pinhole is a non-destructive diagnostics method to record the strongly inhomogeneous spatial density distribution of the X-ray emitted by the plasma and by the chamber walls. This method can provide information on the location of the collisions between warm electrons and multiple charged ions/atoms, opening the possibility to investigate the direct effect of the ion source tuning parameters to the plasma structure. The first successful experiment with a pinhole X-ray camera was carried out in the Atomki ECR Laboratory more than 10 years ago. The goal of that experiment was to make the first ECR X-ray photos and to carry out simple studies on the effect of some setting parameters (magnetic field, extraction, disc voltage, gas mixing, etc.). Recently, intensive efforts were taken to investigate now the effect of different RF resonant modes to the plasma structure. Comparing to the 2002 experiment, this campaign used wider instrumental stock: CCD camera with a lead pinhole was placed at the injection side allowing X-ray imaging and beam extraction simultaneously. Additionally, Silicon Drift Detector (SDD) and High Purity Germanium (HPGe) detectors were installed to characterize the volumetric X-ray emission rate caused by the warm and hot electron domains. In this paper, detailed comparison study on the two X-ray camera and detector setups and also on the technical and scientific goals of the experiments is presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Impact- and Thermal-Resistant Epoxy Resin Toughened with Acacia Honey

High performance polymers with bio-based modifiers are promising materials in terms of applications and environmental impact. In this work, raw acacia honey was used as a bio-modifier for epoxy resin, as a rich source of functional groups. The addition of honey resulted in the formation of highly stable structures that were observed in scanning electron microscopy images as separate phases at the fracture surface, which were involved in the toughening of the resin. Structural changes were investigated, revealing the formation of a new aldehyde carbonyl group. Thermal analysis confirmed the formation of products that were stable up to 600 °C, with a glass transition temperature of 228 °C. An energy-controlled impact test was performed to compare the absorbed impact energy of bio-modified epoxy containing different amounts of honey with unmodified epoxy resin. The results showed that bio-modified epoxy resin with 3 wt% of acacia honey could withstand several impacts with full recovery, while unmodified epoxy resin broke at first impact. The absorbed energy at first impact was 2.5 times higher for bio-modified epoxy resin than it was for unmodified epoxy resin. In this manner, by using simple preparation and a raw material that is abundant in nature, a novel epoxy with high thermal and impact resistance was obtained, opening a path for further research in this field.

36 MATERIALS SCIENCE↗
DOE OSTI2014

SU-E-T-601: Output Factor Calculation of Irregular Shape Electron Cutout at Extended SSD

Purpose: To calculate the output factor of irregular shape electron beam at extended SSD using modified lateral build-up-ratio method. Methods: Circular cutouts from 2.0cm diameter to maximum possible sizes were prepared for applicator cone size of 15×15cm. In addition, different irregular cutouts were prepared. Percentage depth dose (PDD) curves were measured for each cutout using 6, 9, 12 and 16-MeV at the standard SSD of 100cm. The scanning was done using Multidata system and Scanditronix diodes on 2100SC Varian LINAC. In addition, for each cutout and electron beam energy doses were measured at SSD values of 100, 105, 110, 115cm using EDR2 films and diodes. Results: The measured PDD were normalized to the depth of 1.0mm. The lateral build-up-ratio (LBR) and the lateral scatter parameter (sigma) were calculated for each circular cutout using the open 15X15-cm2 field as the reference field. Taking the linear increase of sigma with cutout size into account, PDD of the irregular cutouts were calculated at 100 cm SSD. Furthermore, using the dose measured at different SSDs, the effective SSD value for each circular cutout and electron beam energy was determined. Employing the LBR and the effective-SSD values of the circular cutouts along with the calculated PDD of the irregular cutouts, the output factors of the irregular cutout at different extended SSD values were calculated. Finally, the calculated output factors were compared with the measured values. Conclusion: In this research, it is shown that output factor of irregular shape electron beam at extended SSD can be determined by using the LBR and the effective SSD values of circular cutouts. The percentage difference of the calculated output factor from the measured output factor for irregular cutouts at extended SSD were within 3.0%.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2020

Janus: A Python Package for Agent-Based Modeling of Land Use and Land Cover Change

Janus is an open source Python package for agent-based modeling (ABM) of land use and land cover change (LULCC). Many ABMs of LULCC have been created across platforms, some of which are not ideal for large scale, high resolution scenarios. This model provides a simple object-oriented framework for creating ABMs specific to LULCC. The organizational philosophy of the modeling framework is to create software objects (agents) that are associated with specific and contextual attributes which are isolated from where those agents exist in the spatial setting of the model, yet provide clear linkages between the agent, their environment, and other agents in the simulation. In this way, the framework allows for assembly of LULCC ABMs with low (programmatic) overhead, making the models extensible and providing clear mechanisms for integrating them with process-oriented biophysical models. Provided with Janus is a suite of geospatial data preprocessing tools that can use arbitrary land cover products as an input. Crop choice decisions are based on potential crop prices, these can be created synthetically, or drawn from integrated human-Earth systems models such as the GCAM. Janus is publicly accessible through GitHub and provides an example dataset for testing.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Risk-based area of review estimation in overpressured reservoirs to support injection well storage facility permit requirements for CO 2 storage projects

This paper by the Energy & Environmental Research Center presents a workflow and modeling approach for delineating a risk-based area of review (AOR) to support a U.S. Environmental Protection Agency (EPA) Class VI permit for a carbon dioxide (CO 2 ) storage project. The approach combines semianalytical solutions for estimating formation fluid leakage through a hypothetical leaky wellbore with the results of numerical reservoir simulations to define the AOR. The modeling utilizes 1) semianalytical solutions from the peer-reviewed literature for formation fluid leakage through abandoned wellbores by Raven (1990) and Avci (1994), 2) a FORTRAN model compiled and described in Cihan et al. (2011, 2012) called ASLMA (Analytical Solution for Leakage in Multilayered Aquifers), and 3) a computational framework for estimating a risk-based AOR first proposed by Oldenburg et al. (2014, 2016). Therefore, the approach builds upon well-established research and underlying hydrogeological principles that have been upheld for nearly three decades. Moreover, the ASLMA model has been broadly applied to an array of storage projects. The work presented herein extends these earlier works using a custom wrapper written in the software environment, R (R Core Team, 2020), which was developed to perform multiple runs of the ASLMA model using given ranges for one or more input parameters. In addition, the current work simulates the pressure buildup within the storage reservoir in response to CO 2 injection using a compositional simulator to better accommodate the temporospatial evolution of pressure buildup within the storage reservoir that is more accurately modeled using a heterogeneous geologic model and a compositional simulator that accounts for the multiphase interactions. The workflow is demonstrated using a case study for a 180,000-metric-ton-per-year storage project located in the PCOR (Plains CO 2 Reduction) Partnership region. For the storage project evaluated here, under the scenario where the leaky wellbore is open to a saline aquifer (thief zone) between the overlying seal (cap rock) and the underground sources of drinking water (USDW), the risk-based AOR essentially collapses to the areal extent of the CO 2 plume in the storage reservoir because the pressure buildup in the storage reservoir beyond the CO 2 plume is insufficient to drive formation fluids up a hypothetical leaky wellbore into the USDW. However, even under the conservative assumption that the leaky wellbore is not open to a thief zone, beyond the areal extent of the CO 2 plume, the incremental leakage is less than 400 m 3 over 20 years, which represents ~0.0001% or less of the total volume of water contained within the USDW rock volume. As discussed in the text, the threshold criterion for defining the risk-based AOR is site-specific and should be informed by the results of the sensitivity analysis and available site characterization data. The approach outlined in this paper is designed to be protective of USDWs and, therefore, comply with the Safe Drinking Water Act requirements and provisions for the U.S. EPA Class VI Underground Injection Control (UIC) Program (Class VI Rule) and North Dakota Administrative Code Chapter 43-05-01.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Electron–phonon physics from first principles using the EPW code

EPW is an open-source software for ab initio calculations of electron–phonon interactions and related materials properties. The code combines density functional perturbation theory and maximally localized Wannier functions to efficiently compute electron–phonon coupling matrix elements, and to perform predictive calculations of temperature-dependent properties and phonon-assisted quantum processes in bulk solids and low-dimensional materials. Here, we report on significant developments in the code since 2016, namely: a transport module for the calculation of charge carrier mobility under electric and magnetic fields using the Boltzmann transport equation; a superconductivity module for calculations of phonon-mediated superconductors using the anisotropic multi-band Eliashberg theory; an optics module for calculations of phonon-assisted indirect transitions; a module for the calculation of small and large polarons without supercells; and a module for calculating band structure renormalization and temperature-dependent optical spectra using the special displacement method. For each capability, we outline the methodology and implementation and provide example calculations.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures

This report summarizes the final product developed for the US DOE Small Business Innovation Research (SBIR) Phase II grant made to Engineering Mechanics Corporation of Columbus (Emc 2 ) between April 16, 2014 and August 31, 2016 titled ‘Adoption of High Performance Computational (HPC) Modeling Software for Widespread Use in the Manufacture of Welded Structures’. Many US companies have moved fabrication and production facilities off shore because of cheaper labor costs. A key aspect in bringing these jobs back to the US is the use of technology to render US-made fabrications more cost-efficient overall with higher quality. One significant advantage that has emerged in the US over the last two decades is the use of virtual design for fabrication of small and large structures in weld fabrication industries. Industries that use virtual design and analysis tools have reduced material part size, developed environmentally-friendly fabrication processes, improved product quality and performance, and reduced manufacturing costs. Indeed, Caterpillar Inc. (CAT), one of the partners in this effort, continues to have a large fabrication presence in the US because of the use of weld fabrication modeling to optimize fabrications by controlling weld residual stresses and distortions and improving fatigue, corrosion, and fracture performance. This report describes Emc 2 ’s DOE SBIR Phase II final results to extend an existing, state-of-the-art software code, Virtual Fabrication Technology (VFT®), currently used to design and model large welded structures prior to fabrication - to a broader range of products with widespread applications for small and medium-sized enterprises (SMEs). VFT® helps control distortion, can minimize and/or control residual stresses, control welding microstructure, and pre-determine welding parameters such as weld-sequencing, pre-bending, thermal-tensioning, etc. VFT® uses material properties, consumable properties, etc. as inputs. Through VFT®, manufacturing companies can avoid costly design changes after fabrication. This leads to the concept of joint design/fabrication where these important disciplines are intimately linked to minimize fabrication costs. Finally service performance (such as fatigue, corrosion, and fracture/damage) can be improved using this product. Emc 2 ’s DOE SBIR Phase II effort successfully adapted VFT® to perform efficiently in an HPC environment independent of commercial software on a platform to permit easy and cost effective access to the code. This provides the key for SMEs to access this sophisticated and proven methodology that is quick, accurate, cost effective and available “on-demand” to address weld-simulation and fabrication problems prior to manufacture. In addition, other organizations, such as Government agencies and large companies, may have a need for spot use of such a tool. The open source code, WARP3D, a high performance finite element code used in fracture and damage assessment of structures, was significantly modified so computational weld problems can be solved efficiently on multiple processors and threads with VFT®. The thermal solver for VFT®, based on a series of closed form solution approximations, was extensively enhanced for solution on multiple processors greatly increasing overall speed. In addition, the graphical user interface (GUI) was re-written to permit SMEs access to an HPC environment at the Ohio Super Computer Center (OSC) to integrate these solutions with WARP3D. The GUI is used to define all weld pass descriptions, number of passes, material properties, consumable properties, weld speed, etc. for the structure to be modeled. The GUI was enhanced to make it more user-friendly so that non-experts can perform weld modeling. Finally, an extensive outreach program to market this capability to fabrication companies was performed. This access will permit SMEs to perform weld modeling to improve their competitiveness at a reasonable cost.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Individual NSLS-II Multipole Magnet Alignment by Laser Trackers

The magnet alignment of the 90 th and final multipole girder assembly was completed January 17 th , 2013. Our procedure of “rough” pre-alignment by laser trackers and final alignment by vibrating wire & “Differential Variable Reluctance Transducers” (DVRT) has been quite successful, achieving magnet to magnet alignment well under the 30 micron specification. The pre-alignment accuracy is verified by the initial scan from the vibrating wire. The alignment residuals can be calculated from the offsets of a best fit line. The results are impressive, especially considering the environment of the Building 902 Annex (which has a large bay door that would open during pre-alignment, without fail), the sloppiness of the magnets’ fiducials, and especially the fact that the girders were pre-aligned to their mechanical centers, but the vibrating wire reports the magnetic centers which may be considerably different. This result hints at the potential feasibility of alignment with laser trackers for replacement magnets of NSLS-II and maybe even all magnets of future accelerators. But, it is difficult to predict the achievable accuracy until the main three error sources (a.k.a. Survey group excuses) are eliminated: measuring environment, bad magnet fiducials, and mechanical/magnetic center differences. The test performed on a large aperture quadrupole on girder assembly C19G4 was designed to answer the following questions with the aforementioned error sources either eliminated or simulated: 1) How accurately can a NSLS-II multipole be realigned after repair or other disturbance given the existing fiducials? 2) How accurately can a replacement NSLS-II multipole be installed in situ if its magnetic center is known relative to good fiducials? 3) If the current NSLS-II spares are never magnetically fiducialized, how well can they be installed using only mechanical data? 4) Could the magnets of a future accelerator (with similar alignment specifications as NSLS-II) be aligned using commercially available metrology instruments? This paper will answer these questions.

36 MATERIALS SCIENCE↗