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DOE OSTI2020

Hyper-Differential Sensitivity Analysis of Uncertain Parameters in PDE-Constrained Optimization

Many problems in engineering and sciences require the solution of large scale optimization constrained by partial differential equations (PDEs). Though PDE-constrained optimization is itself challenging, most applications pose additional complexity, namely, uncertain parameters in the PDEs. Uncertainty quantification (UQ) is necessary to characterize, prioritize, and study the influence of these uncertain parameters. Sensitivity analysis, a classical tool in UQ, is frequently used to study the sensitivity of a model to uncertain parameters. In this article, we introduce "hyper-differential sensitivity analysis" which considers the sensitivity of the solution of a PDE-constrained optimization problem to uncertain parameters. Our approach is a goal-oriented analysis which may be viewed as a tool to complement other UQ methods in the service of decision making and robust design. We formally define hyper-differential sensitivity indices and highlight their relationship to the existing optimization and sensitivity analysis literatures. Assuming the presence of low rank structure in the parameter space, computational efficiency is achieved by leveraging a generalized singular value decomposition in conjunction with a randomized solver which converts the computational bottleneck of the algorithm into an embarrassingly parallel loop. Two multi-physics examples, consisting of nonlinear steady state control and transient linear inversion, demonstrate efficient identification of the uncertain parameters which have the greatest influence on the optimal solution.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Xopt and Badger: a machine learning ecosystem for real-time accelerator control and optimization

Machine learning (ML)-based black-box optimization algorithms have demonstrated significant improvements in accelerator optimization speed, often by orders of magnitude. However, deploying these algorithms in real-time facility control remains challenging due to the specialized expertise and infrastructure required. To bridge this gap, we introduce the Xopt ecosystem, a versatile suite of tools designed to make advanced ML-based optimization accessible to the broader accelerator community. This ecosystem includes Xopt, a modular Python framework that facilitates the integration of ML-based optimization algorithms with arbitrary control problems, and Badger, a graphical user interface built on top of Xopt, which enables seamless deployment of ML algorithms in real-time control systems. The Xopt ecosystem has been successfully applied towards solving challenging real-time control problems at leading international accelerator facilities, including SLAC, LBNL, Argonne, Fermilab, BNL, DESY, and ESRF, demonstrating its effectiveness in real-world optimization tasks. In this presentation, we provide an overview of Xopt’s capabilities and illustrate its impact through case studies from SLAC accelerator facilities including LCLS, LCLS-II, and FACET-II.

Roussel, Ryan [SLAC]↗

DOE OSTI2024

Bayesian optimization scheme for the design of a nanofibrous high power target

High Power Targetry (HPT) R&D is critical in the context of increasing beam intensity and energy for next generation accelerators. Many target concepts and novel materials are being developed and tested for their ability to withstand extreme beam environments; the HPT R&D Group at Fermilab is developing an electrospun nanofiber material for this purpose. The performance of these nanofiber targets is sensitive to their construction parameters, such as the packing density of the fibers. Lowering the density improves the survival of the target, but reduces the secondary particle yield. Optimizing the lifetime and production efficiency of the target poses an interesting design problem, and in this paper we study the applicability of Bayesian optimization to its solution. We first describe how to encode the nanofiber target design problem as the optimization of an objective function, and how to evaluate that function with computer simulations. We then explain the optimization loop setup. Thereafter, we present the optimal design parameters suggested by the algorithm, and close with discussions of limitations and future refinements.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

Quantum Optimization and Approximation Algorithms

Shor's groundbreaking quantum algorithm for integer factoring provides an exponential speedup over the best-known classical algorithms. In the 20 years since Shor's algorithm was conceived, only a handful of fundamental quantum algorithmic kernels, generally providing modest polynomial speedups over classical algorithms, have been invented. To better understand the potential advantage quantum resources provide over their classical counterparts, one may consider other resources than execution time of algorithms. Quantum Approximation Algorithms direct the power of quantum computing towards optimization problems where quantum resources provide higher-quality solutions instead of faster execution times. We provide a new rigorous analysis of the recent Quantum Approximate Optimization Algorithm, demonstrating that it provably outperforms the best known classical approximation algorithm for special hard cases of the fundamental Maximum Cut graph-partitioning problem. We also develop new types of classical approximation algorithms for finding near-optimal low-energy states of physical systems arising in condensed matter by extending seminal discrete optimization techniques. Our interdisciplinary work seeks to unearth new connections between discrete optimization and quantum information science.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Thermomechanical design optimization for low metal footprint in hybrid metal-polymer heat exchanger

Material and maintenance costs of metal-based heat exchangers surpass profits in waste heat recovery (WHR) from ultra-low temperature (<100C) sources [1]. A low-cost alternative like polymer pipes suffer from poor thermal conductivity (~0.2 W/mK), and a low overall heat transfer coefficient. Polymers’ thermal conductivity have previously been enhanced through systematic molecular alignment by stretching [2], chemical vapor deposition of extended polymers [3], surface grating [4], etc. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [3], and thermomechanical considerations [5]. In this work, we propose novel hybrid metal-polymer heat exchangers that are made from polymer-copper strips. Through finite element method (FEM) simulations, we first optimize the placement of copper around polymer strips to enhance the transverse thermal conductivity of the strips. The copper cladded polymer strips are wound helically in a roll-to-roll system to form the pipes for a heat exchanger. We then optimize the design of helically wound pipes to reduce thermomechanical strains to < 0.2 % at 100C and 40 psi working conditions. At 25 % volume fraction of copper in the pipe, we predict up to 20 % enhancement in overall heat transfer from a base polymer with a thermal conductivity of 0.2 W/mK. We also compare and contrast the thermomechanical performance of the optimized metal-polymer strips to random metal matrix composites. Finally, we experimentally verify the thermal conductivity of the optimized strips through bulk thermal conductivity and thermal interface resistance measurement setup. By systematically improving the design through FEM and experimental measurements, we provide an optimized design of hybrid metal-polymer pipes that provides a low metal footprint and cost-effective means for harvesting waste heat from ultra-low temperature sources. Thekdi, Arvind, and Sachin U. Nimbalkar. Oak Ridge National Lab, 2015 Shen, Sheng, et al. Nature nanotechnology 5.4 (2010): 251. Xu, Yanfei, et al. Science advances 4.3 (2018): 3031. Smith, M. K., Singh, V., Kalaitzidou, K., & Cola, B. A. (2015). ACS nano, 9(2), 1080-1088. Aymonier, C., Bortzmeyer, D., Thomann, R., & Mülhaupt, R. (2003). Chemistry of Materials, 15(25), 4874-4878.

C Rajagopal, Manjunath↗

DOE OSTI2019

Introduction to Mixed Variable Optimization (MVO) [Slides]

Mixed Variable Optimization (MVO) is an optimization method that uses discrete (categorical) and continuous variables in its optimization process. This method of optimization is applicable to highly nonlinear problems where the information used in the optimization is of poor quality of has minor inaccuracies in the data sets.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Sustainable Data Evolution Technology (SDET) for Power Grid Optimization (Final Report)

This project develops an innovative sustainable data evolution technology (SDET) to create open-access power grid datasets and facilitate updates to these datasets by the power grid community. The lack of open-access, realistic large-scale datasets significantly limits the ability of researchers, developers and ultimately end users to develop, benchmark and compare new methods and tools for optimizing the operation and planning of the grid, which leads to slow adoption by end users. Available open datasets include the IEEE sponsored 14-300 bus transmission test cases and distribution test feeders, the Edinburgh Power Systems Test Case Archive (39-2224 buses), and the Polish cases (2383-3375 buses) available with MATPOWER. These datasets serve certain purposes, but for power grid optimization, they are insufficient in one or more of these aspects: 1) they are too small; 2) they are incomplete in both models and scenarios for optimization purposes; and 3) they are static and are not keeping up with grid needs. The SDET technology delivers large-scale realistic datasets and data-creation tools capable of generating new datasets. We work closely with the Category-2 data repository project awarded by the same GRID DATA program. The generated datasets and data creation tools are compatible with and available through the data repository. The objective is to make this a sustained effort within and beyond the ARPA-E GRID DATA program so that the datasets can evolve over time and meet the current and future needs for power grid optimization and potentially other applications in power grid operation and planning. The novel and disruptive features of SDET differentiate itself from prior work in the following aspects: 1) SDET derives features and metrics for both transmission and distribution (T&D) systems by analyzing many public and private datasets provided by our industry partners National Rural Electric Cooperative Association (NRECA) and PJM Interconnection (PJM). 2) SDET develops data-creation tools and use these tools to generate large-scale open-access realistic datasets that comply with the metrics for both T&D systems. 3) SDET validates the created datasets using industry tools provided by our vendor partner GE Energy Solution. The data creation tools, as well as the created datasets, are integrated into the data repository (DR. POWER) funded by ARPA-E GRID DATA program in Category 2. Users can use the datasets and access these data creation tools to create and update datasets, thus datasets can evolve per user requirements and power grid development. The SDET is a novel and disruptive technology compared to current ad hoc and static dataset generation. It is expected the SDET technology will fundamentally enhance the development, assessment, and adoption of new methods and tools for power grid optimization and other applications, which in turn would significantly improve the reliability, resiliency, and efficiency of the power grid – a major ARPA-E mission objective.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Innovations in optimization and control of accelerators using methods of differential geometry and genetic algorithms (Final Report)

Online tuning of particle accelerators is necessary in order to achieve optimal machine performance. However, it is also a major challenge due to the large parameter space which must be searched and the fact that many of the desir- able objectives compete with one another, and so will not reach their optimal values simultaneously. In order to mitigate these issues, we have explored using dimension-reduction techniques to reduce the size of the parameter space which must be searched and multi-objective genetic algorithms to obtain the sets of tuning parameters which provide pareto-optimal values for the objectives. These methods have enabled us to obtain improved values of the vertical emittance at the Cornell Electron Storage Ring (CESR), and to do so with greater control of orbit errors. Algorithmic tuning is a multidisciplinary endeavour, requiring expertise in beam dynamics, diagnostics, control systems and computer science, and thus a key practical problem is to formulate a common language in which experts with different specialties can communicate. We developed a solution to this problem in the form of a generic accelerator software interface that allows for rapid prototyping of optimization and control algorithms. Our interface is built on the Experimental Physics and Industrial Control Systems (EPICS) and makes possible testing control code in simulation before deployment on real accelerators, as well as deployment of third-party optimization code.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Application of a machine learning algorithm (XGBoost) to offline RHIC luminosity optimization

The operation parameter optimization in 2020 RHIC low energy run is difficult. First, the RHIC luminosity is affected by many RHIC operation parameters, as well as affected by many Low Energy RHIC electron Cooling (LEReC) operation parameters. Second, the luminosity signal in this run is noisy and not sensitive to these parameter changes, especially when these parameters are very close to their optimized values. It is not easy to distinguish the effects of one parameter from all other operation parameters separately. Therefore, it is difficult to optimize the luminosity by varying these parameters one by one. To find a way for luminosity optimization, we analyze some operation parameters via a machine learning algorithm - XGBoost. After constructing a black-box surrogate model from XGBoost and plotting their partial dependency plots (PDF) and SHAP value plots for different operation parameters, we can find the effects of an individual parameter on the RHIC luminosity and optimize it accordingly.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Concurrent Shape and Topology Optimization

The typical topology optimization workflow uses a design domain that does not change during the optimization process. Consequently, features of the design domain, such as the location of loads and constraints, must be determined in advance and are not optimizable. A method is proposed herein that allows the design domain to be optimized along with the topology. This approach uses topology and shape derivatives to guide nested optimizers to the optimal topology and design domain. The details of the method are discussed, and examples are provided that demonstrate the utility of this approach.

42 ENGINEERING↗

DOE OSTI2020

Multi-Stage and Multi-Timescale Robust Co-Optimization Planning for Reliable and Sustainable Power Systems. Final Report

In this project, Clarkson University, in collaboration with Southern Methodist University and University of Pittsburgh, conducted the research to model, design, and implement a sophisticated generation and transmission co-optimization planning decision tool, called Multi-stage and Multi-timescale robust Co-Optimization Planning (MMCOP). The MMCOP decision tool intends to facilitate generation and transmission co-optimization planning of emerging power systems, while mitigating risks and uncertainties in both short-term operation dynamics and long-term policy and technology changes. Long-term power system planning aims at optimizing asset utilization by investing in a proper mix of various generation technologies and transmission lines to supply the future load growth. In particular, the Clean Power Plan (CPP), which is designed to combat climate change and reduce carbon emissions by setting a national limit on carbon pollution from power plants, may dramatically change the landscape of the power industry by further promoting clean energy and phasing out emissions-intensive generation technologies. In addition, novel non-wire alternatives (e.g., demand response (DR), distributed generation (DG), energy efficiency (EE), and smart grid technologies) and the computational complexity for large-scale systems significantly complicate the system planning procedure even further. However, existing conventional planning approaches neglect short-term variability and uncertainty of renewable energy, hourly chronological operation details, and physical nonlinear characteristics of the alternating current transmission network. As a result, existing conventional planning approaches may not work properly, and power systems reliability could be in jeopardy. In observing the limitations of existing conventional planning approaches and addressing new challenges of emerging power systems, the main scope of this project to develop co-optimization planning models within a multi-stage and multi-timescale framework. In particular, random contingencies, key uncertainty factors, and AC power flows are included to derive expansion plans while considering both long-term reliability and short-term flexibility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Optimization of artificial viscosity in production codes based on Gaussian Regression surrogate models

To accurately model flows with shock waves using staggered-grid Lagrangian hydrodynamics, artificial viscosity has to be introduced to convert kinetic energy into internal energy, thereby increasing the entropy across shocks. Determining the appropriate strength of the artificial viscosity is an art and strongly depends on the particular problem and experience of the researcher. The objective of this study is to pose the problem of finding the appropriate strength of artificial viscosity as an optimization problem and solve this problem using machine learning (ML) tools, specifically using surrogate models based on Gaussian Process regression and Bayesian analysis. We describe the optimization method and discuss various practical details of its implementation. The shock-containing problems for which we apply this method all have been implemented in the LANL code FLAG. First, we apply ML to find optimal values to isolated shock problems of different strengths. Second, we apply ML to optimize viscosity for a 1D propagating detonation problem based on Zel’dovich-von Neumann-Doring (ZND) detonation theory using a reactive burn model. We compare results for default (currently used values in FLAG) and optimized values of artificial viscosity for these problems demonstrating the potential for significant improvement in the accuracy of computations.

42 ENGINEERING↗

DOE OSTI2022

Dynamics Informed Optimization for Resilient Energy Systems

Optimal mitigation planning for highly disruptive contingencies to a transmission-level power system requires optimization with dynamic power system constraints, due to the key role of dynamics in system stability to major perturbations. We formulate a generalized disjunctive program to determine optimal grid component hardening choices for protecting against major failures, with differential algebraic constraints representing system dynamics (specifically, differential equations representing generator and load behavior and algebraic equations representing instantaneous power balance over the transmission system). We optionally allow stochastic optimal pre-positioning across all considered failure scenarios, and optimal emergency control within each scenario. This novel formulation allows, for the first time, analyzing the resilience interdependencies of mitigation planning, preventive control, and emergency control. Using all three strategies in concert is particularly effective at maintaining robust power system operation under severe contingencies, as we demonstrate on the Western System Coordinating Council (WSCC) 9-bus test system using synthetic multi-device outage scenarios. Towards integrating our modeling framework with real threats and more realistic power systems, we explore applying hybrid dynamics to power systems. Our work is applied to basic RL circuits with the ultimate goal of using the methodology to model protective tripping schemes in the grid. Finally, we survey mitigation techniques for HEMP threats and describe a GIS application developed to create threat scenarios in a grid with geographic detail.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Light Water Sustainability Program: Optimizing Information Automation Using a New Method Based on System-Theoretic Process Analysis

This report describes the interim progress for research supporting the design and optimization of information automation systems for nuclear power plants. Much of the domestic nuclear fleet is currently focused on modernizing technologies and processes, including transitioning toward digitalization in the control room and elsewhere throughout the plant, along with a greater use of automation, artificial intelligence, robotics, and other emerging technologies. While there are significant opportunities to apply these technologies toward greater plant safety, efficiency, and overall cost-effectiveness, optimizing their design and avoiding potential safety and performance risks depends on ensuring that human-performance-related organizational and technical design issues are identified and addressed. This report describes modeling tools and techniques, based on sociotechnical system theory, to support these design goals and their application in the current research effort. The report is intended for senior nuclear energy stakeholders, including regulators, corporate management, and senior plant management. We have developed and employed a method to design an optimized information automation ecosystem (IAE) based on the systems-theoretic constructs underlying sociotechnical systems theory in general and the Systems-Theoretic Accident Modeling and Processes (STAMP) approach in particular. We argue that an IAE can be modeled as an interactive information control system whose behavior can be understood in terms of dynamic control and feedback relationships amongst the system’s technical and organizational components. Up to this point, we have employed a Causal Analysis based on STAMP (CAST) technique to examine a performance- and safety-related incident at an industry partner’s plant that involved the unintentional activation of an emergency diesel generator. This analysis provided insight into the behavior of the plant’s current information control structure within the context of a specific, significant event. Our ongoing analysis is focused on identifying near-term process improvements and longer-term design requirements for an optimized IAE system. The latter analyses will employ a second STAMP-derived technique, System-Theoretic Process Analysis (STPA). STPA is a useful modeling tool for generating and analyzing actual or potential information control structures. Finally, we have begun modeling plantwide organizational relationships and processes. Organizational system modeling will supplement our CAST and STPA findings and provide a basis for mapping out a plantwide information control architecture. CAST analysis findings indicate an important underlying contributor to the incident under investigation, and a significant risk to information automation system performance, was perceived schedule pressure, which exposed weaknesses in interdepartmental coordination between and within responsible plant organizations and challenged the resilience of established plant processes, until a human caused the initiating event. These findings are discussed in terms of their risk to overall system performance and their implications for information automation system resilience and brittleness. We present two preliminary information automation models. The proactive issue resolution model is a test case of an information automation concept with significant near-term potential for application and subsequent reduction in significant plant events. The IAE model is a more general representation of a broader, plantwide information automation system. From our results, we have generated a set of preliminary system-level requirements and safety constraints. These requirements will be further developed over the remainder of our project in collaboration with nuclear industry subject matter experts and specialists in the technical systems under consideration. Additionally, we will continue to pursue the system analyses initiated in the first part of our effort, with a particular emphasis on STPA as the main tool to identify weak or weakening control structures that affect the resilience of organizations and programs. Our intent is to broaden the scope of the analysis from an individual use case to a related set of use cases (e.g., maintenance tasks, compliance tasks) with similar human-system performance challenges. This will enable more generalized findings to refine the Proactive Issue Resolution and IAE models, as well as their system-level requirements and safety constraints. We will use organizational system modeling analyses to supplement STPA findings and model development. We conclude the report with a set of summary recommendations and an initial draft list of system-level requirements and safety constraints for optimized information automation systems.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Optimizing Information Automation Using a New Method Based on System-Theoretic Process Analysis: Tool Development and Method Evaluation

This report is an update to a prior report that describes progress and findings for a program of research supporting the design and optimization of information automation systems for nuclear power plants. Much of the domestic nuclear fleet is currently focused on modernizing technologies and processes, including transitioning toward digitalization in the control room and throughout the plant, along with a greater interest in the use of automation, artificial intelligence, robotics, and other emerging technologies. While there are significant opportunities to apply these technologies toward greater plant safety, efficiency, and overall cost-effectiveness, optimizing their design and avoiding potential safety and performance risks depends on ensuring that human performance-related organizational and technical design issues are identified and addressed early in the design process. This report describes modeling tools and techniques, based on sociotechnical systems theory, to support these design goals and their application in the current research effort. The report is primarily intended for senior nuclear energy stakeholders, including regulators, corporate management, and senior plant management. We have developed and employed a method to design an optimized information automation ecosystem (IAE) based on the systems-theoretic constructs underlying sociotechnical systems theory in general and the Systems-Theoretic Accident Modeling and Processes (STAMP) approach in particular. We argue that an IAE can be modeled as an interactive information control system whose behavior can be understood in terms of dynamic control, feedback, and communication relationships amongst the system’s technical and organizational components. We have employed two STAMP-based tools in this effort. The first is Causal Analysis based on STAMP (CAST), an accident and incident analysis technique that was used to examine a performance- and safety-related incident at an industry partner’s plant involving the unintentional activation of an emergency diesel generator. This analysis provided insight into the behavior of the plant’s current information control structure within the context of a specific, significant event. The second tool is Systems Theoretic Process Analysis (STPA) which is a proactive risk analysis tool used to examine existing and potential, planned sociotechnical systems. STPA was used to identify risk factors in the current design of a generic nuclear power plant (NPP) preventive maintenance system. Our analyses focused on identifying near-term system improvements and longer-term design requirements for an optimized IAE system. CAST analysis findings indicate an important underlying contributor to the incident under investigation, and a significant risk to information automation system performance, was perceived time and schedule pressure, which exposed weaknesses in interdepartmental coordination between and within responsible plant organizations and challenged the resilience of established plant processes, until a human caused the eventual event. These findings are discussed in terms of their risk to overall system performance and their implications for information automation system resilience and brittleness. STPA findings exposed several areas of concern in the design of current preventive maintenance systems. We also present two preliminary information automation models. The proactive issue resolution (PIR) model is a test case of an information automation concept with significant near-term potential for application and subsequent reduction in significant plant events. The IAE model is a more general representation of a broader, plantwide information automation system and represents an end-state vision for our work. From our results, we have generated an initial set of preliminary system-level requirements and safety constraints for these models. We have also focused on early development of easy to learn, easy to use “transportable” tools for sociotechnical systems analysis. We intend these to be used by NPP personnel as a means of gaining reliable and relatively quick insight into (1) sociotechnical systems factors impacting incidents and accidents, (2) potential sociotechnical risk factors in existing or planned system designs, and (3) potential weaknesses in a system’s safety and/or information control structure. We conclude the report with a set of summary recommendations, a discussion of planned and potential follow-on research and development, and a draft list of system-level requirements and safety constraints for optimized information automation systems.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Development and Validation of Home Comfort System for Total Performance Deficiency/Fault Detection and Optimal Comfort Control

In this project, we developed and tested a learning-based home thermal model that facilitates the operation of a model predictive control (MPC)-based optimization agent and an automated fault detection and diagnosis (AFDD) agent. The home thermal model was constructed using a two-node resistor-capacitor model. Moreover, two accompanying parameter identification methods were introduced, least-squares and optimization. Based on the home thermal model, the MPC-based optimization agent was developed to optimize residential HVAC operation. Using two FDD methods, the AFDD agent was constructed to detect and diagnose two prevalent residential AC faults, airflow reduction and refrigerant undercharge. The home thermal model, along with the MPC-based optimization agent and AFDD agent, were tested at the Norman Test House, Miami Test House, Pacific Northwest National Laboratory (PNNL) Test House A, and PNNL Test House B. Finally, they were also field tested in nine demonstration homes with real occupants.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Bayesian Optimization Scheme for the Design of a Nanofibrous High Power Target

High Power Targetry (HPT) R\&D is critical in the context of increasing beam intensity and energy for next generation accelerators. Many target concepts and novel materials are being developed and tested for their ability to withstand extreme beam environments; the HPT R\&D Group at Fermilab is developing an electrospun nanofiber material for this purpose. The performance of these nanofiber targets is sensitive to their construction parameters, such as the packing density of the fibers. Lowering the density improves the survival of the target, but reduces the secondary particle yield. Optimizing the lifetime and production efficiency of the target poses an interesting design problem, and in this paper we study the applicability of Bayesian optimization to its solution. We first describe how to encode the nanofiber target design problem as the optimization of an objective function, and how to evaluate that function with computer simulations. We then explain the optimization loop setup. Thereafter, we present the optimal design parameters suggested by the algorithm, and close with discussions of limitations and future refinements.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Multiphysics Design Optimization and Additive Manufacturing of Nuclear Components (Final CRADA Report - Executive Summary)

Westinghouse Electric Company (WEC) actively participated in the advancement of the nuclear fuel and reactor design space and requested the help of Oak Ridge National Laboratory (ORNL) in the creation of a new design tool set. This report details the creation of a collection of software tool sets that are linked together to collectively assist WEC design engineers in developing novel ideas outside the normal scope of traditional nuclear fuel and reactor design formulas. Specifically, Siemens HEEDS, a design space exploration and parametric optimization software, monitored and changed parameters in a collection of softwares to meet the team’s objective. The HEEDS parametric optimization method, SHERPA, was developed to control the Siemens NX CAD platform to adjust the native CAD of a hexahedral spacer grid. This new geometry can be used to execute a topological design optimization by the NX Topology software add-in. The resulting geometry is additively manufacturable. This topological optimization occurred twice—once on the spacer grid’s spring, and once on the dimple geometry. These new geometries were imported by Siemens’ STAR-CCM+, a multiphysics structural and fluid dynamic computational solver in which the spring geometry is deflected to match the rod insertion configuration. Along with the dimple geometry, this new deflected spring was used to complete a hydraulic assessment of a single-unit cell comprising one rod, one spring, and two dimples. The HEEDS SHERPA algorithm ranks the design based on the final mass of the unit cell and the hydraulic pressure drop performance. The ORNL team demonstrated the ability to use this software and provided engineering judgement to apply modern aerospace aerodynamic design. The effort has been focused on thinking outside the conventional design space and redesigning a spacer grid to perform beyond the WEC set objectives. Furthermore, the ORNL team also demonstrated that the HEEDS optimization routine can independently develop a design that meets the WEC design goals. Although these designs were at a low technology readiness level, their demonstration confirmed the team’s capability to create novel advanced nuclear concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗