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At least 1,423 records · Page 79

Drivetrain Reliability from Inherent to Operational

Despite reliability improvements made to wind turbine drivetrains over the years, premature component failures are still challenging the wind industry. There are, however, opportunities to understand drivetrain reliability challenges and investigate potential mitigation solutions. This presentation discusses a few research and development (R&D) activities on drivetrain reliability carried out by the U.S. Department of Energy's National Renewable Energy Laboratory (NREL) over the last ten years. It covers two angles of reliability, inherent and operational, and goes into detail on specific R&D activities. Some inherent reliability challenges covered include gearbox planetary stage loads investigation, high speed shaft and main bearing operational condition understanding, dynamic modeling approaches, and recommended practices. The R&D activities on operational reliability improvements covered include benchmarking, performance and condition monitoring, and predictions on the remaining useful life of components. The presentation concludes with a list of necessary drivetrain reliability improvements that could close the loop between operational and inherent reliability efforts. The team hopes that some of these lessons learned can contribute to relevant international standards or recommended practices.

17 WIND ENERGY↗

Design Parameters Influencing Reliability of CCGA Assembly: A Sensitivity Analysis

Area Array microelectronic packages with small pitch and large I/O counts are now widely used in microelectronics packaging. The impact of various package design and materials/process parameters on reliability has been studied through extensive literature review. Reliability of Ceramic Column Grid Array (CCGA) package assemblies has been evaluated using JPL thermal cycle test results (-50(deg)/75(deg)C, -55(deg)/100(deg)C, and -55(deg)/125(deg)C), as well as those reported by other investigators. A sensitivity analysis has been performed using the literature da to study the impact of design parameters and global/local stress conditions on assembly reliability. The applicability of various life-prediction models for CCGA design has been investigated by comparing model's predictions with the experimental thermal cycling data. Finite Element Method (FEM) analysis has been conducted to assess the state of the stress/strain in CCGA assembly under different thermal cycling, and to explain the different failure modes and locations observed in JPL test assemblies.

reliability↗

Igniter adapter-to-igniter chamber deflection test

Testing was performed to determine the maximum RSRM igniter adapter-to-igniter chamber joint deflection at the crown of the inner joint primary seal. The deflection data was gathered to support igniter inner joint gasket resiliency predictions which led to launch commit criteria temperature determinations. The proximity (deflection) gage holes for the first test (Test No. 1) were incorrectly located; therefore, the test was declared a non-test. Prior to Test No. 2, test article configuration was modified with the correct proximity gage locations. Deflection data were successfully acquired during Test No. 2. However, the proximity gage deflection measurements were adversely affected by temperature increases. Deflections measured after the temperature rise at the proximity gages were considered unreliable. An analysis was performed to predict the maximum deflections based on the reliable data measured before the detectable temperature rise. Deflections to the primary seal crown location were adjusted to correspond to the time of maximum expected operating pressure (2,159 psi) to account for proximity gage bias, and to account for maximum attach and special bolt relaxation. The maximum joint deflection for the igniter inner joint at the crown of the primary seal, accounting for all significant correction factors, was 0.0031 in. (3.1 mil). Since the predicted (0.003 in.) and tested maximum deflection values were sufficiently close, the launch commit criteria was not changed as a result of this test. Data from this test should be used to determine if the igniter inner joint gasket seals are capable of maintaining sealing capability at a joint displacement of (1.4) x (0.0031 in.) = 0.00434 inches. Additional testing should be performed to increase the database on igniter deflections and address launch commit criteria temperatures.

Cook, M.↗

Scalable Unit Commitment with Security Constrained AC Power Flow via ADMM and Hybrid Modeling Strategies

This research introduces a more efficient way to optimize power grid operations, breaking the problem into manageable steps and using advanced mathematical techniques to speed up calculations. By incorporating smart heuristics, improved preprocessing, and contingency analysis, the approach allows operators to make better decisions faster. These innovations enhance our understanding of how to optimize energy generation, making it possible to anticipate failures before they happen, reduce system costs, and improve overall grid performance. Ultimately, this research helps bridge the gap between theoretical models and real-world applications, paving the way for a smarter, more resilient power grid. This research directly benefits the public by making electricity more affordable, reliable, and sustainable. By improving how power grids schedule and distribute electricity, the project helps energy providers reduce operational costs, which can lead to lower electricity prices for consumers. Additionally, the ability to predict and prevent power system failures enhances grid reliability, reducing the likelihood of blackouts that can disrupt homes, businesses, and critical infrastructure such as hospitals. From an environmental perspective, optimizing power generation reduces energy waste and lowers carbon emissions, contributing to cleaner air and a more sustainable energy system. Furthermore, with extreme weather events becoming more frequent, these advancements make the power grid more resilient, ensuring communities are better prepared for emergencies and natural disasters. By strengthening the nation's energy infrastructure, this research plays a crucial role in improving economic stability, public safety, and environmental sustainability.

24 POWER TRANSMISSION AND DISTRIBUTION↗

High Accuracy Signal Validation Framework for Sensor Calibration Assessment in NPPs

Effective and efficient health management of sensing channels and instrumentation supports reliable and accurate process monitoring capacities in any industry. Current practice in the nuclear industry relies on periodic calibration assessment and correction activities. This time based maintenance technique consists of three steps: i) removal of sensor to a test environment, ii) testing and recalibration, and iii) reinstallation of sensor into its working environment. This procedure is highly labor intensive, adds to the outage cost and timeline, and contributes to worker radiation exposure and ALARA requirements. Furthermore, the human element contributes to error factors in all stages of the procedure. The effectiveness of this calibration procedure after sensors are returned to working environmental variables also raises concerns, and the practicability of this periodic approach is uncertain for future reactor designs with longer operating cycles between refueling outages. Studies indicate that periodic calibration assessment find only 10% of sensing instrumentations with calibration issues during a single outage (18- 24 months), meaning at least 90% of sensors are undergoing unnecessary maintenance actions. This provides an opportunity to maintain the current levels of safety and functional integrity with fewer, more targeted maintenance actions and lower economic burden. Performance-based maintenance planning shows much promise over current periodic maintenance approaches. Specifically, online monitoring (OLM) utilizes the continually collected process data to non-intrusively monitor the calibration status of process instrumentation and detect the onset of de-calibration, thereby minimizing the number of recalibration procedures required. Ultimately, this can lead to termination of time based recalibration at NPPs. OLM utilizes the process measurements made for process monitoring and control to evaluate the calibration status of the sensors and instrumentation making the measurements. OLM can detect and differentiate sensor faults and process anomalies, thus providing a valuable tool to suit the industry's and regulatory body's requirements. Though supported by more than a decade of research, OLM for sensor calibration assessment is yet to be implemented in the US fleet due to regulatory requirements and constraints. As shown in Figure 1, OLM utilizes process data to train statistical models that predict normal, error-free process behavior. Measured process values are compared with error-corrected predictions to ascertain the presence of faults. The reliability of OLM is dependent on the quality of its predictions, measured in part by the uncertainty in these predictions. This research develops a framework to accurately quantify the prediction uncertainty based on Bayesian inference techniques to provide the required confidence levels for OLM systems. The expected outcomes include signal validation by high-accuracy, high-confidence uncertainty quantification for variable sensor types and operating ranges. Furthermore, the framework will facilitate fault detection capacities and so-called virtual sensors, a capability to replace faulty sensor measurements with error-corrected values when a sensor fault is detected. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Phase field modeling of discontinuous dynamic recrystallization in hot deformation of magnesium alloys

We have developed a quantitative phase field model of discontinuous dynamic recrystallization (PF-DDRX) for investigating grain structure evolution and its impact on mechanical response in magnesium alloy during hot deformation. A set of isothermal compression tests were conducted by Gleeble thermo-mechanical simulator and used to determine PF-DDRX model parameters such as critical stresses of recrystallization, activation energies of dislocation, grain boundaries and recrystallization grain nucleation. In the simulations, the experimentally measured average grain size and distribution were used to generate initial microstructures. The results show that the typical ‘necklace’ microstructures observed in DDRX forms at the earlier stage of recrystallization. The inhomogeneity of microstructures first increases rapidly and then decreases gradually and reaches a constant with the increase of dynamic recrystallization volume fraction. Both predicted grain structure and mechanical response are in good agreement with experimental results. This demonstrates that the model parameters determined by experimental data are reliable for the developed PF-DDRX model to predict the grain structure evolution and flow behavior of AZ80 magnesium alloy under hot deformation. This work presents a path to combine experiments and modeling to give quantitative prediction and minimize experimental cost.

magnesium alloy, Phase field method, dynamic recry↗

Phase Composition and Phase Transformation of Additively Manufactured Nickel Alloy 718 AM Bench Artifacts

Additive manufacturing (AM) technologies offer unprecedented design flexibility but are limited by a lack of understanding of the material microstructure formed under their extreme and transient processing conditions and its subsequent transformation during post-build processing. As part of the 2022 AM Bench Challenge, sponsored by the National Institute of Standards and Technology, this study focuses on the phase composition and phase evolution of AM nickel alloy 718, a nickel-based superalloy, to provide benchmark data essential for the validation of computational models for microstructural predictions. Here, we employed high-energy synchrotron X-ray diffraction, in situ synchrotron X-ray scattering, as well as high-resolution transmission electron microscopy for our analyses. The study uncovers critical aspects of the microstructure in its as-built state, its transformation during homogenization, and its phase evolution during subsequent aging heat treatment. Specifically, we identified secondary phases, monitored the dissolution and coarsening of microstructural elements, and observed the formation and stability of γ ’ and γ ” phases. The results provide the rigorous benchmark data required to understand the atomic and microstructural transformations of AM nickel alloy 718, thereby enhancing the reliability and applicability of AM models for predicting phase evolution and mechanical properties.

36 MATERIALS SCIENCE↗

Comparing the reliability of related populations with the probability of agreement

Combining information from different populations to improve precision, simplify future predictions, or improve underlying understanding of relationships can be advantageous when considering the reliability of several related sets of systems. Using the probability of agreement to help quantify the similarities of populations can help to give a realistic assessment of whether the systems have reliability that are sufficiently similar for practical purposes to be treated as a homogeneous population. In addition, the new method is described and illustrated with an example involving two generations of a complex system where the reliability is modeled using either a logistic or probit regression model. Note that supplementary materials including code, datasets, and added discussion are available online.

97 MATHEMATICS AND COMPUTING↗

Exploring the Model Design Space for Battery Health Management

Battery Health Management (BHM) is a core enabling technology for the success and widespread adoption of the emerging electric vehicles of today. Although battery chemistries have been studied in detail in literature, an accurate run-time battery life prediction algorithm has eluded us. Current reliability-based techniques are insufficient to manage the use of such batteries when they are an active power source with frequently varying loads in uncertain environments. The amount of usable charge of a battery for a given discharge profile is not only dependent on the starting state-of-charge (SOC), but also other factors like battery health and the discharge or load profile imposed. This paper presents a Particle Filter (PF) based BHM framework with plug-and-play modules for battery models and uncertainty management. The batteries are modeled at three different levels of granularity with associated uncertainty distributions, encoding the basic electrochemical processes of a Lithium-polymer battery. The effects of different choices in the model design space are explored in the context of prediction performance in an electric unmanned aerial vehicle (UAV) application with emulated flight profiles.

Saha, Bhaskar↗

Evaluation of copper, aluminum, and nickel interatomic potentials on predicting the elastic properties

Choice of appropriate force field is one of the main concerns of any atomistic simulation that needs to be seriously considered in order to yield reliable results. Since investigations on the mechanical behavior of materials at micro/nanoscale have been becoming much more widespread, it is necessary to determine an adequate potential which accurately models the interaction of the atoms for desired applications. In this framework, reliability of multiple embedded atom method based interatomic potentials for predicting the elastic properties was investigated. Assessments were carried out for different copper, aluminum, and nickel interatomic potentials at room temperature which is considered as the most applicable case. Examined force fields for the three species were taken from online repositories of National Institute of Standards and Technology, as well as the Sandia National Laboratories, the LAMMPS database. Using molecular dynamic simulations, the three independent elastic constants, C{sub 11}, C{sub 12}, and C{sub 44}, were found for Cu, Al, and Ni cubic single crystals. Voigt-Reuss-Hill approximation was then implemented to convert elastic constants of the single crystals into isotropic polycrystalline elastic moduli including bulk modulus, shear modulus, and Young's modulus as well as Poisson's ratio. Simulation results from massive molecular dynamic were compared with available experimental data in the literature to justify the robustness of each potential for each species. Eventually, accurate interatomic potentials have been recommended for finding each of the elastic properties of the pure species. Exactitude of the elastic properties was found to be sensitive to the choice of the force fields. Those potentials that were fitted for a specific compound may not necessarily work accurately for all the existing pure species. Tabulated results in this paper might be used as a benchmark to increase assurance of using the interatomic potential that was designated for a problem.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Performance Evaluation of Gray-box and Machine Learning Models of a Thermal Energy Storage System with Active Insulation

An interior partition wall integrated with active thermal storage and a dynamic insulation system was built and then installed in an office building in Oak Ridge, Tennessee, TN. This smart wall, termed the Empower Wall, was equipped with embedded pipes in the building envelope core component and an additional pipe network enclosing rigid insulation to switch on and off the active insulation dynamically. The performance of the wall's contribution to cooling load reduction under different parameters has been investigated in previous publications. Aiming to be deployed into model predictive control and other optimization methods, simplified and reliable models for the developed wall and the room accommodating it are required. They are needed to characterize the properties and thermal response of both Empower Wall and building envelope, which form an essential component for accurate indoor temperature or cooling/heating demand prediction. In this study, simplified gray-box and regression models as well as machine learning model were developed and the performance of them were compared and analyzed.

Cui, Borui↗

Teaching Game Theory to Kids and Limits of Prediction

I have once been asked to read a lecture to a group of 6th graders on Game Theory. After agreeing to it, I realized that explaining the game theory basics to 6th graders my be difficult, given that terms such as Nash equilibrium, minimax, maximin, optimization may not resonate in a 6th grade classroom. Instead I've introduced game theory using the rock-paper-scissors (RPS) game. Turns out kids are excellent gametheoreticians. In RPS, they understood both the benefits of randomizing their own strategy and of predicting their opponent's moves. They offered a number of heuristics both for the prediction and opening move. These heuristics included optimizing against past opponent moves, such as not playing rock if the opponent just played scissors, and playing a specific opening hand, such as "paper". Visualizing the effects of such strategic choices on-the-fly would be interesting and educational. This brief essay attempts demonstrating and visualizing the value of a few different strategic options in RPS. Specifically, we would like to illustrate the following: 1) what is the value of being unpredictable?; and 2) what is the value of being able to predict your opponent? In regard to prediction of human players, the question 2) has been reflected in Jon McLoone's entry in Wolfram Blog from January 20, 2014[1]. McLoone created a predictive algorithm for playing against human opponents, that learns to beat human opponents reliably after approximately 30 - 40 games. I use McLoone's implementation to represent a predictive and random strategies. The rest of this documents 1) investigates performance of this predictive strategy against a random strategy (which is optimal in RPS) and in 2) attempts to turn this predictive power against the predictive strategy by allowing the opponent the full knowledge of the predictor's strategy (but not the choices made using the strategy). This exposes a weakness in predictions made without taking risks into account by illustrating that predictive strategy may make the predictor predictable as well.

97 MATHEMATICS AND COMPUTING↗

Model-Data Fusion Approaches for Retrospective and Predictive Assessment of the Pan-Arctic Scale Permafrost Carbon Feedback to Global Climate

Policy decisions regarding climate change mitigation and adaptation rely on having reliable projections of future climate change. Coupled climate-carbon models predict that the northern high latitudes will serve as a substantial land carbon sink during the 21stcentury, but these models lack many of the key processes governing high-latitude ecosystem processes. Arctic tundra and boreal forests are unique from other biomes particularly because of the presence of snow, ice and frozen ground, and it is important to understand the mechanisms that drive interconnected processes in these landscapes. Increasing our confidence in climate projections requires an integrated approach where existing, on-going and planned observational and experimental studies of high-latitude ecosystem processes are organized and analyzed in a framework designed to target improvements in understanding key ecosystem-climate feedbacks. For this project we designed an approach to improve our scientific understanding of the permafrost carbon feedback through broad-scale assessment of the drivers and responses of the Arctic system carbon cycle using data-driven models of simple-to-intermediate complexity. The made a valuable contribution to the first of its kind, data-driven quantitative assessment of the impact of permafrost thaw on pan-Arctic scale carbon cycle feedbacks to the global climate system. The approach drew on a conceptual framework for integrating the key system components and their underlying data within a “book-keeping” framework for assessment of the key processes driving the permafrost carbon feedback. The results provided quantitative model-data benchmarking to constrain future projections of carbon cycle responses to a warming Arctic. The framework used environmental proxy data sets examining recent-era geomorphologic land-form transitions and vegetation dynamics, through remotely-sensed data, to guide the extrapolation of site-based data on the key system components to larger regions. These products contribute to the development of finer-scale, more complex representation of permafrost carbon processes in terrestrial biogeochemistry models, to operate within coupled Earth system modeling frameworks.

54 ENVIRONMENTAL SCIENCES↗

Stochastic-Strength-Based Damage Simulation of Ceramic Matrix Composite Laminates

The Finite Element Analysis-Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to characterize and predict the progressive damage response of silicon-carbide-fiber-reinforced reaction-bonded silicon nitride matrix (SiC/RBSN) composite laminate tensile specimens. Studied were unidirectional laminates [0] (sub 8), [10] (sub 8), [45] (sub 8), and [90] (sub 8); cross-ply laminates [0 (sub 2) divided by 90 (sub 2),]s; angled-ply laminates [plus 45 (sub 2) divided by -45 (sub 2), ]s; doubled-edge-notched [0] (sub 8), laminates; and central-hole laminates. Results correlated well with the experimental data. This work was performed as a validation and benchmarking exercise of the FEAMAC/CARES program. FEAMAC/CARES simulates stochastic-based discrete-event progressive damage of ceramic matrix composite and polymer matrix composite material structures. It couples three software programs: (1) the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC), (2) the Ceramics Analysis and Reliability Evaluation of Structures Life Prediction Program (CARES/Life), and (3) the Abaqus finite element analysis program. MAC/GMC contributes multiscale modeling capabilities and micromechanics relations to determine stresses and deformations at the microscale of the composite material repeating-unit-cell (RUC). CARES/Life contributes statistical multiaxial failure criteria that can be applied to the individual brittle-material constituents of the RUC, and Abaqus is used to model the overall composite structure. For each FEAMAC/CARES simulation trial, the stochastic nature of brittle material strength results in random, discrete damage events that incrementally progress until ultimate structural failure.

composite structures↗

Making Phase-Picking Neural Networks More Consistent and Interpretable

Improving the interpretability of phase-picking neural networks remains an important task to facilitate their deployment to routine, real-time seismic monitoring. The popular phase-picking neural networks published in the literature lack interpretability because their output prediction scores do not necessarily correspond with the reliability of phase picks and can even be highly inconsistent depending on how we window the waveform data. Here, we show that systematically shifting the waveforms during training and using an antialiasing filter within the neural network architecture can substantially improve the consistency of the output prediction scores and can even make them scale with the signal-to-noise ratios of the waveforms. We demonstrate the improvements by applying these approaches to a commonly used phase-picking neural network architecture and using waveform data from the 2019 Ridgecrest earthquake sequence.

58 GEOSCIENCES↗

Fiber Optic Instrumentation in High Temperature Irradiation Environments

The extremely harsh conditions of advanced reactor designs pose serious challenges for nuclear fuels and materials. Traditional instrumentation (thermocouples, strain gauges, etc.) are not well suited for extended operation in such a harsh environment. This work discusses the potential for using fiber optic-based instrumentation in high temperature irradiation experiments. The primary limitation of fiber optic instrumentation in irradiation experiments is signal darkening due to attenuation in the fiber material. A computational model has been developed to predict broadband optical attenuation in fused silica fiber materials as a function of time, temperature, and dose. Preliminary results obtained using this model are shown for one cycle of irradiation in the high flux isotope reactor at various temperatures. An irradiation campaign has been initiated to provide temperature-dependent optical attenuation data at high dose in order to validate the predictive model. Demonstration of the safety and reliability of new and enhanced nuclear fuels and materials is essential for improving the safety and reliability of existing nuclear power plants and for the licensing and operation of advanced nuclear reactor technologies. Experimental validation of fuel performance codes requires high fidelity measurements during instrumented irradiation experiments. Therefore, a clear need exists for sensors of unprecedented accuracy, resolution, time/space/energy spectrum dependence, reduced size, and, perhaps most importantly, performance in harsh environments. The harsh environment during accelerated irradiation testing could include temperatures from 300 deg. C up to 2600 deg. C, and radiation damage levels ranging from 1 to greater than 100 dpa. Optical fiber-based sensors are a promising candidate for instrumentation in high temperature irradiation environments. Optical fibers are small, inexpensive, chemically inert, immune to electromagnetic interference, and made of high temperature radiation-hard materials. The ability to make distributed measurements of temperature or strain using a single inexpensive optical fiber currently exists for non-extreme environments as commercially available technology. Other advanced sensing technologies such as laser ultrasound, borescopes, and laser-induced breakdown spectroscopy use fiber optic light delivery as a critical component of the sensor design. Some potential applications for optical fiber-based sensors in instrumented irradiation experiments include in-situ measurements of thermal conductivity, ultrasonic measurement of elastic constants (with fiber optic delivery of signal for generation and detection of ultrasonic wave), and distributed measurements of temperature and/or strain (i.e., swelling). The primary limitation for the use of optical technologies for harsh environment (e.g., high neutron flux reactor environments) instrumentation is the attenuation of the light signal due to the effects of temperature and/or irradiation. This work summarizes initial efforts towards developing a predictive model of temperature-dependent radiation-induced attenuation in fused silica optical fibers at high dose. If there is adequate transmission in the fibers, fiber optic-based instrumentation could provide highly accurate distributed measurements during instrumented fuel/material irradiation experiments. Preliminary results show attenuation on the order of 5- 10 dB/m in the wavelength range of 750-900 nm at temperatures of 300 deg. C and below after one HFIR cycle (24 days). At higher temperatures (600 and 900 deg. C), the attenuation is reduced below 5 dB/m in the same wavelength range. This amount of attenuation is acceptable for most fiber optic based sensor systems with a dynamic range on the order of 20-50 dB for a reasonable length (1-2 meters) of fiber in the high flux region. Many optical components use a wavelength of 850 nm, which lies in the low attenuation window. In order to refine and ultimately validate the predictive model of optical fiber attenuation, a reactor irradiation campaign has been initiated. Rabbit irradiation capsules have been designed to irradiate optical fiber material (low and high OH fused silica, as well as single crystal sapphire) specimens in the HFIR at temperatures ranging from 100 to 1200 deg. C. (authors)

42 ENGINEERING↗

Data-driven prediction of scaling and ignition of inertial confinement fusion experiments

Recent advances in inertial confinement fusion (ICF) at the National Ignition Facility (NIF), including ignition and energy gain, are enabled by a close coupling between experiments and high-fidelity simulations. Neither simulations nor experiments can fully constrain the behavior of ICF implosions on their own, meaning pre- and postshot simulation studies must incorporate experimental data to be reliable. Linking past data with simulations to make predictions for upcoming designs and quantifying the uncertainty in those predictions has been an ongoing challenge in ICF research. We have developed a data-driven approach to prediction and uncertainty quantification that combines large ensembles of simulations with Bayesian inference and deep learning. The approach builds a predictive model for the statistical distribution of key performance parameters, which is jointly informed by past experiments and physics simulations. The prediction distribution captures the impact of experimental uncertainty, expert priors, design changes, and shot-to-shot variations. We have used this new capability to predict a 10× increase in ignition probability between Hybrid-E shots driven with 2.05 MJ compared to 1.9 MJ, and validated our predictions against subsequent experiments. We describe our new Bayesian postshot and prediction capabilities, discuss their application to NIF ignition and validate the results, and finally investigate the impact of data sparsity on our prediction results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗