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

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At least 1,261 records · Page 70
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

DeepCwind Consortium Research Program: January 15, 2010 - March 31, 2013 (Final Technical Report)

This is the final technical report for the U.S. Department of Energy-funded program, DE-0002981: DeepCwind Consortium Research Program. The project objective was the partial validation of coupled models and optimization of materials for offshore wind structures. The United States has a great opportunity to harness an indigenous abundant renewable energy resource: offshore wind. In 2010, the National Renewable Energy Laboratory (NREL) estimated there to be over 4,000 GW of potential offshore wind energy found within 50 nautical miles of the US coastlines (Musial and Ram, 2010). The US Energy Information Administration reported the total annual US electric energy generation in 2010 was 4,120 billion kilowatt-hours (equivalent to 470 GW) (US EIA, 2011), slightly more than 10% of the potential offshore wind resource. In addition, deep water offshore wind is the dominant US ocean energy resource available comprising 75% of the total assessed ocean energy resource as compared to wave and tidal resources (Musial, 2008). Through these assessments it is clear offshore wind can be a major contributor to US energy supplies. The caveat to capturing offshore wind along many parts of the US coast is deep water. Nearly 60%, or 2,450 GW, of the estimated US offshore wind resource is located in water depths of 60 m or more (Musial and Ram, 2010). At water depths over 60 m building fixed offshore wind turbine foundations, such as those found in Europe, is likely economically infeasible (Musial et al., 2006). Therefore floating wind turbine technology is seen as the best option for extracting a majority of the US offshore wind energy resource. Volume 1 - Test Site; Volume 2 - Coupled Models; and Volume 3 - Composite Materials.

17 WIND ENERGY↗
DOE OSTI2020

Demand Driven Cycamore Archetypes

Future nuclear fuel cycle options may present advantages over today’s once-through fuel cycle. Nuclear fuel cycle simulation tools assess the performance of those fuel cycles as well as the dynamics of long-term technology transitions. In many nuclear fuel cycle simulation tools, it has historically been the responsibility of the user to manually define facility deployment schemes and all facility parameters. While this is straightforward in simple fuel cycles, transitions from one fuel cycle to another can be more complex. In particular, deployment schemes for supportive fuel cycle facilities beyond the reactor become complex if the analyst desires to avoid gaps in the nuclear fuel and power supply chain during those transition scenarios. As nuclear fuel cycle analysis approaches questions regarding the feasibility and performance of the deployment schemes and technology choices during technology transition, automation of this historically manual process is necessary. The main objective of this work was to develop and demonstrate Cyclus automation capabilities toward key nuclear fuel cycle transition scenarios. While deploying reactors to meet power demand is trivial, and existed in the earliest versions of CYCLUS, automated, predictive deployment and decommissioning of other facilities is more complex. These include mining, milling, enrichment, fuel fabrication, reprocessing, and others. For example, a balanced closed fuel cycle may require ensuring that there is enough fast reactor fuel for their operation and may drive deployment of a fleet of light water reactors. This concern comprises the main challenge that drove the project effort. The Demand-Driven Cycamore Archetype project (NEUP-FY16-10512) aimed to develop CYCAMORE demand-driven deployment capabilities and thereby automate transition scenario definition. The developed software package, d3ploy, in the form of a CYCLUS Institution agent, deploys Facilities to meet the front-end and back-end demands of the fuel cycle. The University of South Carolina and the University of Illinois applied multiple algorithmic approaches to this challenge. This project developed an in situ demand-driven development schedule calculation through non-optimizing, deterministic-optimizing, and stochastic-optimizing algorithms as CYCLUS archetypes and demonstrated these new archetypes in program-supporting fuel cycle transition scenarios. Both objectives were achieved. This report documents the results and deliverables obtained toward these achievements in detail.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Field Work Proposal ERKJ358: Black-box training for scientific machine learning models (Final Report)

The overarching goal of this project is to develop a scalable black-box training capability for scientific machine learning (SciML) problems that are non-trainable with existing automatic differentiation (AD)-based algorithms. AD assumes that a loss function can be decomposed into a sequence of elementary operations whose derivatives are known. This assumption is violated when the loss function includes a black-box physical model (e.g., a legacy simulator). The current strategy, converting a black-box simulator to an AD-enabled code via differential programming, is inflexible and time-, labor-consuming. Thus, black-box optimization is a main workhorse for training SciML models, e.g., in scientific reinforcement learning, hyper-parameter fine tuning, designing SciML models with adversarial robustness, etc.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Evaluation of Thermal Neutron Scattering Cross Section of Uranium Silicide with Ab Initio Lattice Dynamics

Uranium silicide (U 3 Si 2 ) is a candidate material for the high-density nuclear fuel in commercial light water reactors [1], [2]. Its higher uranium density, 11.3 g-U/cm3, compared to that of uranium dioxide (UO 2 ), 9.7 g-U/cm3, can improve the performance of a nuclear reactor while using low enriched uranium (LEU) and diversify the choice of cladding materials [1]–[3]. It also has a higher thermal conductivity than UO 2 , which can reduce the thermal stress on the material caused by a temperature gradient across the fuel pellet and provide a larger margin for some postulated accidents [1], [2], [4]. Furthermore, compared to U3Si, another high-density fuel candidate, it has better resistance to in-pile swelling due to less irradiation-induced rapid amorphization [1], [3]. Corresponding to its importance in nuclear engineering, many previous studies have reported the properties of U3Si2. Experiments showed that U 3 Si 2 is a paramagnetic (PM) metal, where a slight linear increase in magnetic susceptibility was measured with increasing temperature [5], [6]. In addition, thermodynamic quantities such as thermal expansion coefficient, heat capacity, and thermal conductivity were experimentally determined over a wide temperature range [1], [7], [8]. In several computational studies, ab initio atomistic simulations based on density functional theory (DFT) were performed to calculate various properties including elastic constants, electronic density of states (DOS), and phonon dispersion curves [9]–[12]. Nevertheless, thermal neutron scattering cross sections, which are critical to the prediction of the parameters in reactor physics that are ultimately related to reactor criticality, have not yet been evaluated for U3Si2. The scattering cross section can be calculated from the phonon DOS, or the energy spectrum of lattice vibrations, of the crystalline system [13], [14]. However, there is also no experimental data available for the phonon DOS of U 3 Si 2 . While some computational studies reported the phonon DOS and/or dispersion curves from ab initio simulations [9]–[12], the accuracy cannot be guaranteed because it is unclear whether the spin-polarization behavior of PM U 3 Si 2 was properly described. In the present study, the thermal neutron scattering cross section for U 3 Si 2 is evaluated for the first time by calculating the phonon DOS for U3Si2 from ab initio lattice dynamics (AILD) simulations based on DFT. First, U 3 Si 2 is modeled based on the experimental structure, and AILD simulations are performed on the modeled U3Si2 to optimize the structure. Next, AILD simulations are performed for supercells with atomic displacement to calculate Hellmann-Feynman forces. Based on the calculated forces, partial phonon DOSs for U and Si are obtained, and the thermal neutron scattering law (TSL) for U 3 Si 2 is finally evaluated. To verify the accuracy of the calculations in the present study, the calculation results are compared with experimental data on the structure and heat capacity of U3Si2 [1], [7], [8], [15].

Geometry Optimization↗
DOE OSTI2025

Microreactor Program Technology Maturation MACS system reports

This submission contains several reports associated with the DOE Microreactor Program Technology Maturation MACS system. These include milestone reports: M3AT-24IN0804031-Optimized MACS architecture M3AT-24IN0804033-Light and temp sensor integration M4AT-23IN0804055-Update Microreactor Automated Control System (MACS) hardware based on input from demonstration M2AT-23IN0804054-Demonstrate actuation of control system using Microreactor Automated Control System (MACS)

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2018

Reinforcement Learning for Generating Toolpaths in Additive Manufacturing

Generating toolpaths plays a key role in additive manufacturing processes. In the case of 3-Dimensional (3D) printing, these toolpaths are the pathways the printhead will follow to fabricate a part in a layer-by-layer fashion. Most toolpath generators use nearest neighbor (NN), branch-and-bound, or linear programming algorithms to produce valid toolpaths. These algorithms often produce sub-optimal results or cannot handle large sets of traveling points. In this paper, the researchers at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) propose using a machine learning (ML) approach called reinforcement learning (RL) to produce toolpaths for a print. RL is the process of two agents, the player and the critic, learning how to maximize a score based upon the actions of the player in a defined state space. In the context of 3D printing, the player will learn how to find the optimal toolpath that reduces printhead lifts and global print time.

Patrick, Steven↗
DOE OSTI2013

Lattice cell and full core physics of internally cooled annular fuel in heavy water moderated reactors

A program is underway at Atomic Energy of Canada Limited (AECL) to develop a new fuel bundle concept to enable greater burnups for PT-HWR (pressure tube heavy water reactor) cores. One option that AECL is investigating is an internally cooled annular fuel (ICAF) element concept. ICAF contains annular cylindrical pellets with cladding on the inner and outer diameters. Coolant flows along the outside of the element and through the centre. With such a concept, the maximum fuel temperature as a function of linear element rating is significantly reduced compared to conventional, solid-rod type fuel. The preliminary ICAF bundle concept considered in this study contains 24 half-metre long internally cooled annular fuel elements and one non-fuelled centre pin. The introduction of the non-fuelled centre pin reduces the coolant void reactivity (CVR), which is the increase in reactivity that occurs on voiding the coolant in accident scenarios. Lattice cell and full core physics calculations of the preliminary ICAF fuel bundle concept have been performed for medium burnups of approximately 18 GWd/tU using WIMS-AECL and reactor fuel simulation program (RFSP). The results will be used to assist in concept configuration optimization. The effects of radial and axial core power distributions, linear element power ratings, refuelling rates and operational power ramps have been analyzed. The results suggest that burnups of greater than 18 GWd/tU can be achieved in current reactor designs. At approximately 18 GWd/tU, expected maximum linear element ratings in a PT-HWR with online-refuelling are approximately 90 kW/m. These conditions would be prohibitive for solid-rod fuel, but may be possible in ICAF fuel given the reduced maximum fuel temperature as a function of linear element rating. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Partial program correctness

Explore the source record for details and available documents.

C++, optimization, undefined behavior, contracts↗
DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Decoding quantum error-correcting codes is a key challenge in enabling fault-tolerant quantum computation. In the classical setting, linear programming (LP) decoders offer provable performance guarantees and can leverage fast practical optimization algorithms. Although LP decoders have been proposed for quantum codes, their performance and limitations remain relatively underexplored. In this work, we uncover a key limitation of LP decoding for quantum low-density parity-check (LDPC) codes: certain constant-weight error patterns lead to ambiguous fractional solutions that cannot be resolved through independent rounding. To address this issue, we incorporate a post-processing technique known as ordered statistics decoding (OSD), which significantly enhances LP decoding performance in practice. Our results show that LP decoding, when augmented with OSD, can outperform belief propagation with the same post-processing for intermediate code sizes of up to hundreds of qubits. These findings suggest that LP-based decoders, equipped with effective post-processing, offer a promising approach for decoding near-term quantum LDPC codes.

Gu, Shouzhen [Yale U.]↗
DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Decoding quantum error-correcting codes is a key challenge in enabling fault-tolerant quantum computation. In the classical setting, linear programming (LP) decoders offer provable performance guarantees and can leverage fast practical optimization algorithms. Although LP decoders have been proposed for quantum codes, their performance and limitations remain relatively underexplored. In this work, we uncover a key limitation of LP decoding for quantum low-density parity-check (LDPC) codes: certain constant-weight error patterns lead to ambiguous fractional solutions that cannot be resolved through independent rounding. To address this issue, we incorporate a post-processing technique known as ordered statistics decoding (OSD), which significantly enhances LP decoding performance in practice. Our results show that LP decoding, when augmented with OSD, can outperform belief propagation with the same post-processing for intermediate code sizes of up to hundreds of qubits. These findings suggest that LP-based decoders, equipped with effective post-processing, offer a promising approach for decoding near-term quantum LDPC codes.

Gu, Shouzhen [Yale U.]↗
DOE OSTI2025

Power and Limitations of Linear Programming Decoder for Quantum LDPC Codes

Decoding quantum error-correcting codes is a key challenge in enabling fault-tolerant quantum computation. In the classical setting, linear programming (LP) decoders offer provable performance guarantees and can leverage fast practical optimization algorithms. Although LP decoders have been proposed for quantum codes, their performance and limitations remain relatively underexplored. In this work, we uncover a key limitation of LP decoding for quantum low-density parity-check (LDPC) codes: certain constant-weight error patterns lead to ambiguous fractional solutions that cannot be resolved through independent rounding. To address this issue, we incorporate a post-processing technique known as ordered statistics decoding (OSD), which significantly enhances LP decoding performance in practice. Our results show that LP decoding, when augmented with OSD, can outperform belief propagation with the same post-processing for intermediate code sizes of up to hundreds of qubits. These findings suggest that LP-based decoders, equipped with effective post-processing, offer a promising approach for decoding near-term quantum LDPC codes.

Gu, Shouzhen [Yale U.]↗
DOE OSTI2024

Validation of the Scientific Program for the Dark Energy Spectroscopic Instrument

The Dark Energy Spectroscopic Instrument (DESI) was designed to conduct a survey covering 14,000 deg$^{2}$ over 5 yr to constrain the cosmic expansion history through precise measurements of baryon acoustic oscillations (BAO). The scientific program for DESI was evaluated during a 5 month survey validation (SV) campaign before beginning full operations. This program produced deep spectra of tens of thousands of objects from each of the stellar Milky Way Survey (MWS), Bright Galaxy Survey (BGS), luminous red galaxy (LRG), emission line galaxy (ELG), and quasar target classes. These SV spectra were used to optimize redshift distributions, characterize exposure times, determine calibration procedures, and assess observational overheads for the 5 yr program. In this paper, we present the final target selection algorithms, redshift distributions, and projected cosmology constraints resulting from those studies. We also present a One-Percent Survey conducted at the conclusion of SV covering 140 deg$^{2}$ using the final target selection algorithms with exposures of a depth typical of the main survey. The SV indicates that DESI will be able to complete the full 14,000 deg$^{2}$ program with spectroscopically confirmed targets from the MWS, BGS, LRG, ELG, and quasar programs with total sample sizes of 7.2, 13.8, 7.46, 15.7, and 2.87 million, respectively. These samples will allow exploration of the Milky Way halo, clustering on all scales, and BAO measurements with a statistical precision of 0.28% over the redshift interval z < 1.1, 0.39% over the redshift interval 1.1 < z < 1.9, and 0.46% over the redshift interval 1.9 < z < 3.5.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
DOE OSTI2023

A Sparse Distributed Gigascale Resolution Material Point Method

In this paper, we present a four-layer distributed simulation system and its adaptation to the Material Point Method (MPM). The system is built upon a performance portable C++ programming model targeting major High-Performance-Computing (HPC) platforms. A key ingredient of our system is a hierarchical block-tile-cell sparse grid data structure that is distributable to an arbitrary number of Message Passing Interface (MPI) ranks. We additionally propose strategies for efficient dynamic load balance optimization to maximize the efficiency of MPI tasks. Our simulation pipeline can easily switch among backend programming models, including OpenMP and CUDA, and can be effortlessly dispatched onto supercomputers and the cloud. Finally, we construct benchmark experiments and ablation studies on supercomputers and consumer workstations in a local network to evaluate the scalability and load balancing criteria. We demonstrate massively parallel, highly scalable, and gigascale resolution MPM simulations of up to 1.01 billion particles for less than 323.25 seconds per frame with 8 OpenSSH-connected workstations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2013

UP2 400 High Activity Oxide Legacy Waste Retrieval Project Scope and Progress-13048

The High Activity Oxide facility (HAO) reprocessed sheared and dissolved 4500 metric tons of light water reactor fuel the fuel of the emerging light water reactor spent fuel between 1976 and 1998. Over the period, approximately 2200 tons of process waste, composed primarily of sheared hulls, was produced and stored in a vast silo in the first place, and in canisters stored in pools in subsequent years. Upon shutdown of the facility, AREVA D and D Division in La Hague launched a thorough investigation and characterization of the silos and pools content, which then served as input data for the definition of a legacy waste retrieval and reconditioning program. Basic design was conducted between 2005 and 2007, and was followed by an optimization phase which lead to the definition of a final scenario and budget, 12% under the initial estimates. The scenario planned for the construction of a retrieval and reconditioning cell to be built on top of the storage silo. The retrieved waste would then be rinsed and sorted, so that hulls could subsequently be sent to La Hague high activity compacting facility, while resins and sludge would be cemented within the retrieval cell. Detailed design was conducted successfully from 2008 until 2011, while a thorough research and development program was conducted in order to qualify each stage of the retrieval and reconditioning process, and assist in the elaboration of the final waste package specification. This R and D program was defined and conducted as a response and mitigation of the major project risks identified during the basic design process. Procurement and site preparatory works were then launched in 2011. By the end of 2012, R and D is nearly completed, the retrieval and reconditioning process have been secured, the final waste package specification is being completed, the first equipment for the retrieval cell is being delivered on site, while preparation works are allowing to free up space above and around the silo, to allow for construction which is scheduled to being during the first semester of 2013. The elaboration of the final waste package is still undergoing and expected to be completed by then end of 2013, following some final elements of R and D required to demonstrate the full compatibility of the package with deep geological repository. The HAO legacy waste retrieval project is so far the largest such project entering operational phase on the site of La Hague. It is on schedule, under budget, and in conformity with the delivery requirements set by the French Safety Authority, as well as other stakeholders. This project paves the way for the successful completion of AREVA La Hague other legacy waste retrieval projects, which are currently being drafted or already in active R and D phase. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Developing a Hybrid Electric Vehicle Eco-Cooperative Adaptive Cruise Control System at Signalized Intersections.

This study develops an eco-driving strategy for hybrid electric vehicles (HEVs) in the vicinity of signalized intersections, entitled HEV Eco-Cooperative Adaptive Cruise Control at Intersections (Eco-CACC-I). The proposed system computes real-time, energy-optimized vehicle trajectories using HEV vehicle dynamics and energy consumption models. In the proposed system, a simple HEV energy model is used to compute the instantaneous fuel consumption. This HEV energy model is selected since it is general, transferable, and can be easily used to compute instantaneous energy consumption levels for HEVs without the additional input of vehicle engine data or complicated power control strategies. In addition, a vehicle dynamics model is used to capture the relationship between speed, acceleration level, and tractive/resistance forces on vehicles. The energy-optimum problem is formulated as an optimization problem with constraints, which is solved using a moving-horizon dynamic programming approach. The proposed HEV Eco-CACC-I system was tested to evaluate its performance for various speed limits, roadway grades, and signal timings. Lastly, the proposed HEV controller was implemented in a microscopic traffic simulation software to test its network-wide performance. The test results from an arterial corridor with three signalized intersections demonstrate that the proposed system can effectively reduce stop-and-go traffic in the vicinity of signalized intersections producing savings of 7.4% in energy consumption, 5.8% in traffic delay and 23% vehicle stops, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

Final Scientific/Technical Report

In this work, we have built upon our results from previous DOE funding (DEFG 0204ER25655), where we developed new and more efficient methods for solving certain optimization problems with many inequality constraints. This past work resulted in efficient algorithms (and analysis of their convergence) for linear programming, convex quadratic programming, and the training of support vector machines. The algorithms are based on using constraint reduction in interior point methods: at each iteration we consider only a smaller subset of the inequality constraints, focusing on the constraints that are close enough to be relevant. Surprisingly, we have been able to show theoretically that such algorithms are globally convergent and to demonstrate experimentally that they are much more efficient than standard interior point methods.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗