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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 1,513 records · Page 84

Magneto-Structural Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors

A magneto-structural combined dimensional and topology optimization approach for interior permanent magnet synchronous machine (IPMSM) rotor design is proposed using the Solid Isotropic Material Penalization (SIMP) density-based topology optimization method. This method optimizes the location and dimensions of the permanent magnets (PMs) embedded in the rotor, while simultaneously optimizing the lamination flux barriers using topology optimization.To allow for the location and dimensions of the PMs to change while retaining the same number of mesh elements and connectivity, the mesh must be deformed. Mesh deformation is accomplished using a Laplace smoothing technique. To increase the range of PM displacement and size changes, the non-PM areas of the rotor design domain are divided into sub-regions along whose boundaries the mesh nodes are redistributed also using a Laplace smoothing algorithm. Three examples of IPMSM rotor optimizations are presented to demonstrate the proposed approach.

33 ADVANCED PROPULSION SYSTEMS↗

Synthesis of Platinum-nickel Nanowires and Optimization for Oxygen Reduction Performance

Platinum-nickel (Pt-Ni) nanowires were developed as fuel cell electrocatalysts, and were optimized for the performance and durability in the oxygen reduction reaction. Spontaneous galvanic displacement was used to deposit Pt layers onto Ni nanowire substrates. The synthesis approach produced catalysts with high specific activities and high Pt surface areas. Hydrogen annealing improved Pt and Ni mixing and specific activity. Acid leaching was used to preferentially remove Ni near the nanowire surface, and oxygen annealing was used to stabilize near-surface Ni, improving durability and minimizing Ni dissolution. These protocols detail the optimization of each post-synthesis processing step, including hydrogen annealing to 250 degrees C, exposure to 0.1 M nitric acid, and oxygen annealing to 175 degrees C. Through these steps, Pt-Ni nanowires produced increased activities more than an order of magnitude than Pt nanoparticles, while offering significant durability improvements. The presented protocols are based on Pt-Ni systems in the development of fuel cell catalysts. Furthermore, these techniques have also been used for a variety of metal combinations, and can be applied to develop catalysts for a number of electrochemical processes.

36 MATERIALS SCIENCE↗

Application of Taguchi methods to dual mixture ratio propulsion system optimization for SSTO vehicles

The application of advanced technologies to future launch vehicle designs would allow the introduction of a rocket-powered, single-stage-to-orbit (SSTO) launch system early in the next century. For a selected SSTO concept, a dual mixture ratio, staged combustion cycle engine that employs a number of innovative technologies was selected as the baseline propulsion system. A series of parametric trade studies are presented to optimize both a dual mixture ratio engine and a single mixture ratio engine of similar design and technology level. The effect of varying lift-off thrust-to-weight ratio, engine mode transition Mach number, mixture ratios, area ratios, and chamber pressure values on overall vehicle weight is examined. The sensitivity of the advanced SSTO vehicle to variations in each of these parameters is presented, taking into account the interaction of each of the parameters with each other. This parametric optimization and sensitivity study employs a Taguchi design method. The Taguchi method is an efficient approach for determining near-optimum design parameters using orthogonal matrices from design of experiments (DOE) theory. Using orthogonal matrices significantly reduces the number of experimental configurations to be studied. The effectiveness and limitations of the Taguchi method for propulsion/vehicle optimization studies as compared to traditional single-variable parametric trade studies is also discussed.

Stanley, Douglas O.↗

Sampling-Based Motion Planning Algorithms for Replanning and Spatial Load Balancing

The common theme of this dissertation is sampling-based motion planning with the two key contributions being in the area of replanning and spatial load balancing for robotic systems. Here, we begin by recalling two sampling-based motion planners: the asymptotically optimal rapidly-exploring random tree (RRT*), and the asymptotically optimal probabilistic roadmap (PRM*). We also provide a brief background on collision cones and the Distributed Reactive Collision Avoidance (DRCA) algorithm. The next four chapters detail novel contributions for motion replanning in environments with unexpected static obstacles, for multi-agent collision avoidance, and spatial load balancing. First, we show improved performance of the RRT* when using the proposed Grandparent-Connection (GP) or Focused-Refinement (FR) algorithms. Next, the Goal Tree algorithm for replanning with unexpected static obstacles is detailed and proven to be asymptotically optimal. A multi-agent collision avoidance problem in obstacle environments is approached via the RRT*, leading to the novel Sampling-Based Collision Avoidance (SBCA) algorithm. The SBCA algorithm is proven to guarantee collision free trajectories for all of the agents, even when subject to uncertainties in the knowledge of the other agents’ positions and velocities. Given that a solution exists, we prove that livelocks and deadlock will lead to the cost to the goal being decreased. We introduce a new deconfliction maneuver that decreases the cost-to-come at each step. This new maneuver removes the possibility of livelocks and allows a result to be formed that proves convergence to the goal configurations. Finally, we present a limited range Graph-based Spatial Load Balancing (GSLB) algorithm which fairly divides a non-convex space among multiple agents that are subject to differential constraints and have a limited travel distance. The GSLB is proven to converge to a solution when maximizing the area covered by the agents. The analysis for each of the above mentioned algorithms is confirmed in simulations.

97 MATHEMATICS AND COMPUTING↗

Digital controllers for VTOL aircraft

Using linear-optimal estimation and control techniques, digital-adaptive control laws have been designed for a tandem-rotor helicopter which is equipped for fully automatic flight in terminal area operations. Two distinct discrete-time control laws are designed to interface with velocity-command and attitude-command guidance logic, and each incorporates proportional-integral compensation for non-zero-set-point regulation, as well as reduced-order Kalman filters for sensor blending and noise rejection. Adaptation to flight condition is achieved with a novel gain-scheduling method based on correlation and regression analysis. The linear-optimal design approach is found to be a valuable tool in the development of practical multivariable control laws for vehicles which evidence significant coupling and insufficient natural stability.

Stengel, R. F.↗

Handling Qualities Optimization for Rotorcraft Conceptual Design

Over the past decade, NASA, under a succession of rotary-wing programs has been moving towards coupling multiple discipline analyses to evaluate rotorcraft conceptual designs. Handling qualities is one of the component analyses to be included in such a future Multidisciplinary Analysis and Optimization framework for conceptual design of VTOL aircraft. Similarly, the future vision for the capability of the Concept Design and Assessment Technology Area of the U.S Army Aviation Development Directorate also includes a handling qualities component. SIMPLI-FLYD is a tool jointly developed by NASA and the U.S. Army to perform modeling and analysis for the assessment of the handling qualities of rotorcraft conceptual designs. Illustrative scenarios of a tiltrotor in forward flight and singlemain rotor helicopter at hover are analyzed using SIMPLI-FLYD and the conceptual design sizing tool, NDARC, integrated in a single process. The effects of variations of design parameters such as horizontal tail and tail rotor size were evaluated in the form of margins to fixed- and rotary-wing handling qualities metrics and the computed vehicle empty weight. The handling qualities design margins are shown to vary across the flight envelope due to both changing flight dynamic and control characteristics and changing handling qualities specification requirements. The current SIMPLI-FLYD capability and future developments are discussed in the context of an overall rotorcraft conceptual design process.

Rotorcraft Conceptual Design↗

Total Protein Analysis in Algae via Bulk Amino Acid Detection: Optimization of Amino Acid Derivatization after Hydrolysis with O -Phthalaldehyde 3-Mercaptopropionic Acid (OPA-3MPA)

The analysis of protein in algal biomass is one of the most critical areas of commercial development of algae characterization for nutritional or other high value applications. A new rapid and accurate method is required that can be widely implemented and that is free from interferences from the complex algal biomass matrix. We developed a simple spectrophotometric method for primary amino acid quantification bulk measurement in an acid hydrolyzed algal biomass preparation, as an alternative to the more labor-intensive amino HPLC acid analysis or less specific nitrogen-to-protein conversion. We have validated an O -phthalaldehyde (OPA)-based derivatization method, showing accurate and linear quantification for standard reference amino acids as well as mixtures, mimicking the amino acid complexity found in algal biomass. The presence of interferences that may be derived from the complex biomass biochemical composition was tested during the method validation phase. We document the application of a novel method of OPA derivatization with 3-mercaptopropionic acid (3MPA) to determine the total amino acid content of harvested algal biomass collected from different, controlled cultivation conditions and demonstrated a within 10% accuracy against a reference measurement of amino acid content in at least 4 species and 10 algal biomass samples, across early, mid, and late-stages of cultivation.

09 BIOMASS FUELS↗

High-dimensional Data-driven Energy optimization for Multi-Modal Transit Agencies (HD-EMMA) (Final Technical Report)

Public bus transit services in the U.S. are responsible for at least 19.7 million metric tons of CO 2 emission annually. Electric vehicles (EVs) can have a much lower environmental impact than comparable internal combustion engine vehicles (ICEVs), especially in urban areas. Unfortunately, EVs are also much more expensive than ICEVs. As a result, many public transit agencies can afford only mixed fleets of transit vehicles, consisting of EVs, hybrids (HEVs), and ICEVs. Transit agencies that operate such mixed fleets of vehicles face a challenging optimization problem: these agencies need to decide which vehicles are assigned to serving which transit trips. Since the advantage of EVs over ICEVs varies depending on the route and time of day (e.g., the benefit of EVs is higher in slower traffic with frequent stops and lower on highways), the assignment can have a significant effect on energy use and, hence, environmental impact. Through this project, we have developed reference data about energy collections and constructed a set of machine learning models that can accurately predict the energy consumption for the whole fleet at the level of each trip. We have used these models to develop a scheduling and assignment strategy that can rotate the different vehicle types across the transit agencies’ routes. The optimization algorithm ensures that the vehicles are matched to trips considering weather patterns, expected congestion, and road gradients to minimize the overall energy usage. We list the key observations from our project for other practitioners below. Details are available in the report, and the list of source code and our publications are included in the appendix. 1. We have demonstrated the feasibility of collecting, merging and analyzing large volumes of high-resolution real-world telemetry data from a mixed vehicle fleet. To mitigate the inherent noise of the recorded GPS points, the team developed an algorithm that filters data and maps the points onto a street. The algorithm considers previous and subsequent location measurements and different characteristics of nearby streets to determine how likely the vehicle travels on them. Then, the team segmented the time series into disjoint contiguous samples based on adjacent road segments and repeated the outlier detection and removal. For each data point, the team added features corresponding to elevation changes within the samples, weather features, such as temperature, and traffic data, such as speed ratio between actual speed and free-flow speed. 2. We have developed two forms of machine learning models that be used to understand and analyze the energy operations of a mixed vehicle transit fleet. The micro prediction model provides estimates of instantaneous energy prediction for all types of buses (diesel, hybrid, and electric). Such a model is important in evaluating the energy impacts of real-time bus operation strategies, but it is challenging due to diversified driving cycles of transit buses. The model can help the drivers understand the impact of their driving behaviors and short-term congestions. The macro prediction models estimate average energy consumption across the whole trip considering the features: distance traveled, various road-type features, elevation change, day of the week, time of day, various weather features (temperature, humidity, etc.), and traffic features (speed ratio and jam factor). 3. We have demonstrated that it is possible to transfer the machine learning models we have developed in this project to other teams and cities by using inductive transfer learning. We also showed that the performance of the macro energy prediction models can be improved using a multi-task learning approach where the learning parameters are shared between the models being developed for different vehicle types. The advantage of this approach is improved learning performance as the models can exploit common spatio-temporal and environmental characteristics. 4. Finally, we have developed trip and vehicle assignment and scheduling algorithms that use the energy prediction models and develop a trip to vehicle type (diesel, electric, hybrid) assignment for the whole operation to reduce overall emissions and cost. We have shown through simulations that the proposed algorithms can save $\$$ 48,910 in energy costs and 175 metric tons of CO 2 emission annually for CARTA.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Noise of Embedded High Aspect Ratio Nozzles

A family of high aspect ratio nozzles were designed to provide a parametric database of canonical embedded propulsion concepts. Nozzle throat geometries with aspect ratios of 2:1, 4:1, and 8:1 were chosen, all with convergent nozzle areas. The transition from the typical round duct to the rectangular nozzle was designed very carefully to produce a flow at the nozzle exit that was uniform and free from swirl. Once the basic rectangular nozzles were designed, external features common to embedded propulsion systems were added: extended lower lip (a.k.a. bevel, aft deck), differing sidewalls, and chevrons. For the latter detailed Reynolds-averaged Navier-Stokes (RANS) computational fluid dynamics (CFD) simulations were made to predict the thrust performance and to optimize parameters such as bevel length, and chevron penetration and azimuthal curvature. Seventeen of these nozzles were fabricated at a scale providing a 2.13 inch diameter equivalent area throat." ! The seventeen nozzles were tested for far-field noise and a few data were presented here on the effect of aspect ratio, bevel length, and chevron count and penetration. The sound field of the 2:1 aspect ratio rectangular jet was very nearly axisymmetric, but the 4:1 and 8:1 were not, the noise on their minor axes being louder than the major axes. Adding bevel length increased the noise of these nozzles, especially on their minor axes, both toward the long and short sides of the beveled nozzle. Chevrons were only added to the 2:1 rectangular jet. Adding 4 chevrons per wide side produced some decrease at aft angles, but increased the high frequency noise at right angles to the jet flow. This trend increased with increasing chevron penetration. Doubling the number of chevrons while maintaining their penetration decreased these effects. Empirical models of the parametric effect of these nozzles were constructed and quantify the trends stated above." Because it is the objective of the Supersonics Project that future design work be done more by physics-based computations and less by experiments, several codes under development were evaluated against these test cases. Preliminary results show that the RANS-based code JeNo predicts the spectral directivity of the low aspect ratio jets well, but has no capability to predict the non-axisymmetry. An effort to address this limitations, used in the RANS-based code of Leib and Goldstein, overpredicted the impact of aspect ratio. The broadband shock noise code RISN, also limited to axisymmetric assumptions, did a good job of predicting the spectral directivity of underexpanded 2:1 cold jet case but was not as successful on high aspect ratio jets, particularly when they are hot. All results are preliminary because the underlying CFD has not been validated yet. An effort using a Large Eddy Simulation code by Stanford University predicted noise that agreed with experiments to within a few dB.

Bridges, James E.↗

Special Analysis: Impact of Updated GSA Flow Model on E-Area Low-Level Waste Facility Groundwater Performance

In March 2018, the Savannah River National Laboratory (SRNL) notified Solid Waste Management (SWM) of new information that could potentially impact groundwater (GW) disposal limits and possibly require temporary protective measures (Crowley 2018). GW flow directions in the E-Area Low-Level Waste Facility (LLWF) Slit Trenches (STs), Engineered Trenches (ETs), and the Low Activity Waste Vault (LAWV) have notably changed in the new 2018 General Separations Area (GSA) flow model (Flach 2018a). The 2018 GSA flow model had been updated using 20 years of new hydrologic field data and model calibration methods that employed mathematical optimization software. It was later determined that the primary reason for the change in GW flow directions was due to the influence of low permeability caps that had been placed over the Old Burial Grounds and the Low Level Radioactive Waste Disposal Facility (LLRWDF). Updated flow directions in the model produce a higher degree of plume overlap for disposal units (DU’s) in the southeastern portion of E-Area than had been predicted in the 2008 E-Area LLWF Performance Assessment (PA). SWM and SRNL outlined the scope for this Special Analysis (SA) and proposed a set of interim measures (IM’s) to protect trench operations from exceeding Performance Objectives (PO’s) during the preparation of this SA, both of which were approved by the SWM Performance Assessment Review Committee (PARC) (Mooneyhan 2018).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Proximal Galerkin: A Structure-Preserving Finite Element Method for Pointwise Bound Constraints

The proximal Galerkin finite element method is a high-order, low iteration complexity, nonlinear numerical method that preserves the geometric and algebraic structure of pointwise bound constraints in infinite-dimensional function spaces. This paper introduces the proximal Galerkin method and applies it to solve free boundary problems, enforce discrete maximum principles, and develop a scalable, mesh-independent algorithm for optimal design with pointwise bound constraints. This paper also introduces the latent variable proximal point (LVPP) algorithm, from which the proximal Galerkin method derives. When analyzing the classical obstacle problem, we discover that the underlying variational inequality can be replaced by a sequence of second-order partial differential equations (PDEs) that are readily discretized and solved with, e.g., the proximal Galerkin method. Throughout this work, we arrive at several contributions that may be of independent interest. These include (1) a semilinear PDE we refer to as the entropic Poisson equation; (2) an algebraic/geometric connection between high-order positivity-preserving discretizations and certain infinite-dimensional Lie groups; and (3) a gradient-based, bound-preserving algorithm for two-field, density-based topology optimization. The complete proximal Galerkin methodology combines ideas from nonlinear programming, functional analysis, tropical algebra, and differential geometry and can potentially lead to new synergies among these areas as well as within variational and numerical analysis. Open-source implementations of our methods accompany this work to facilitate reproduction and broader adoption.

97 MATHEMATICS AND COMPUTING↗

Handling Qualities Optimization for Rotorcraft Conceptual Design

Over the past decade, NASA, under a succession of rotary-wing programs has been moving towards coupling multiple discipline analyses in a rigorous consistent manner to evaluate rotorcraft conceptual designs. Handling qualities is one of the component analyses to be included in a future NASA Multidisciplinary Analysis and Optimization framework for conceptual design of VTOL aircraft. Similarly, the future vision for the capability of the Concept Design and Assessment Technology Area (CD&A-TA) of the U.S Army Aviation Development Directorate also includes a handling qualities component. SIMPLI-FLYD is a tool jointly developed by NASA and the U.S. Army to perform modeling and analysis for the assessment of flight dynamics and control aspects of the handling qualities of rotorcraft conceptual designs. An exploration of handling qualities analysis has been carried out using SIMPLI-FLYD in illustrative scenarios of a tiltrotor in forward flight and single-main rotor helicopter at hover. Using SIMPLI-FLYD and the conceptual design tool NDARC integrated into a single process, the effects of variations of design parameters such as tail or rotor size were evaluated in the form of margins to fixed- and rotary-wing handling qualities metrics as well as the vehicle empty weight. The handling qualities design margins are shown to vary across the flight envelope due to both changing flight dynamic and control characteristics and changing handling qualities specification requirements. The current SIMPLI-FLYD capability and future developments are discussed in the context of an overall rotorcraft conceptual design process.

Handling Qualities↗

Optimizing Satellite Communications With Adaptive and Phased Array Antennas

A new adaptive antenna array architecture for low-earth-orbiting satellite ground stations is being investigated. These ground stations are intended to have no moving parts and could potentially be operated in populated areas, where terrestrial interference is likely. The architecture includes multiple, moderately directive phased arrays. The phased arrays, each steered in the approximate direction of the satellite, are adaptively combined to enhance the Signal-to-Noise and Interference-Ratio (SNIR) of the desired satellite. The size of each phased array is to be traded-off with the number of phased arrays, to optimize cost, while meeting a bit-error-rate threshold. Also, two phased array architectures are being prototyped: a spacefed lens array and a reflect-array. If two co-channel satellites are in the field of view of the phased arrays, then multi-user detection techniques may enable simultaneous demodulation of the satellite signals, also known as Space Division Multiple Access (SDMA). We report on Phase I of the project, in which fixed directional elements are adaptively combined in a prototype to demodulate the S-band downlink of the EO-1 satellite, which is part of the New Millennium Program at NASA.

Ingram, Mary Ann↗

Optimal charging management and infrastructure planning for free-floating shared electric vehicles

Recently, major car-sharing service providers have begun to include electric vehicles (EVs) in free-floating car-sharing fleets. For these EVs, downtime due to charging, including time spent traveling to and waiting in queues at charging stations in a sparse charging infrastructure network, is a major barrier to sustainable operation. An intuitive solution to overcome this barrier is to increase the number of fast-charging stations in the fleet service area. This paper studies the relationship between fleet vehicle downtime and the number of charging stations by modeling the fleet operations of a major car-sharing service provider. An integer programming model is developed that jointly optimizes charging station allocation, in terms of the number and location of charging stations, and the assignment of EVs to charging stations. Case study results showed that fleet vehicle charging time comprises 72-75% of the total downtime spent on charging trips. This indicates that charging time, as opposed to travel time or waiting time, is the dominant component of total fleet downtime for charging. The study also shows that by adding 5 to 20 new charging stations reduces total fleet downtime and travel time during charging trips by 2-4% and 26-49%, respectively. Although adding new charging stations to the fleet service area reduces total charging trip travel time significantly, it does not reduce total downtime significantly. Results also show that if the EV battery state of the charge (SOC) threshold—below which a charging trip is initiated—is less than 18%, not all EVs in the car-sharing fleet can be charged using the existing direct current fast chargers (DCFCs) in the fleet’s service area. Furthermore, this implies that adequate charging infrastructure coverage is required to ensure that EVs of a given range can operate in the car-sharing fleet.

25 ENERGY STORAGE↗

Low Altitude AVIRIS Data for Mapping Land Form Types on West Ship Island, Mississippi

Barrier islands help protect the southern and southeastern U.S. shoreline from hurricanes and severe storms. They are important for coastal resource management and geologic research, especially in studies that involve changes in island areas and surface environments, and they display a dynamically changing and diverse mix of landform and vegetative cover habitats. Many Gulf Coast barrier islands have undergone dramatic decreases in areal extent, often due to hurricane and severe storm damage. For example, Louisiana's barrier islands have lost 55 percent of their surface area over the past 100 years. Aerial photography and Landsat data have been used to monitor changes in barrier island areal extent, although neither data source is optimal for making maps of detailed landform types at site-specific scales. High spatial resolution hyperspectral imagery, such as that obtained from the high spatial resolution Airborne Visible/Infrared Imaging Spectrometer (AVIRIS) sensor, may enable improved mapping of landform types, which would benefit studies of the dynamics of barrier island environments. During the summers of 2000 and 2001, a study was conducted to assess low-altitude AVIRIS data for mapping the landform types of West Ship Island, a barrier island in Harrison County, Mississippi. This study area was selected because of the availability of low-altitude AVIRIS data acquired on July 22, 1999, and because of the area's accessibility to the investigating team. West Ship Island is one of the six barrier islands that belong to the Gulf Shores National Seashore, which is managed by the National Park Service. This island contains an impressive range of landform categories. Surface types include beach, dune, and sand flat environments. West Ship Island also harbors Fort Massachusetts, a historic fort used during the Civil War. Because it is located near Stennis Space Center, the island is frequently imaged by NASA's airborne and spaceborne sensors.

Spruce, Joseph P.↗

Xanthos-Lake Model Source Code

This repository contains the source code for Xanthos-Lake, a lake-modeling extension of the Xanthos framework that introduces a coupled lake component comprising the Xanthos-Lake Snow and Ice Model (xLSIM) and the Xanthos-Lake Water Balance Model (xLWBM). xLSIM is a basin-aware machine-learning model for lake snow, ice, and thermal conditions. It predicts monthly lake ice thickness, snow depth, snow-cover fraction, mixing-layer temperature, and lake ice fraction from meteorological forcing and lake surface-area information. It uses sequence-based deep-learning architectures, including Transformer and hybrid Long Short-Term Memory–Transformer (LSTM–Transformer) models, together with seasonal encoding, multi-lake learning, physical masking, and basin-level cryospheric and non-cryospheric classification. The training workflow uses Ray for scalable execution and includes optional Ray Tune hyperparameter optimization. Model predictions, observations, diagnostics, and feature-importance outputs are written in NetCDF. xLWBM is the water-balance component of the new lake framework. It simulates monthly lake storage, surface area, evaporation, inflow, outflow, and lake–groundwater exchange. It combines physical water-balance equations with calibrated bathymetric relationships, weir-based outlet flow, modified Penman open-water evaporation, groundwater head relaxation, Penman–Monteith snow and ice sublimation, and snow, ice, and thermal conditions supplied by xLSIM. The model calibrates lake parameters against satellite-derived surface-area data, using evaporation-based calibration where surface-area data are unavailable, and supports small, medium, and large lake classes. For large lakes, xLWBM is integrated with the managed-routing workflow so that lake storage and outflow interact directly with downstream river routing and reservoir operations. Together, xLSIM and xLWBM provide Xanthos with a coupled lake-modeling capability. xLSIM supplies the snow, ice, and thermal conditions that affect lake evaporation and snow- and ice-related water exchanges, while xLWBM translates those conditions into dynamic lake storage, surface area, evaporation, and discharge. In return, xLWBM supplies evolving lake surface area to xLSIM. This coupling enables Xanthos to represent lakes as active hydrologic components within basin-scale water-availability and routing simulations.

Machine Learning↗

LSSA large area silicon sheet task continuous Czochralski process development

A Czochralski crystal growing furnace was converted to a continuous growth facility by installation of a premelter to provide molten silicon flow into the primary crucible. The basic furnace is operational and several trial crystals were grown in the batch mode. Numerous premelter configurations were tested both in laboratory-scale equipment as well as in the actual furnace. The best arrangement tested to date is a vertical, cylindrical graphite heater containing small fused silicon test tube liner in which the incoming silicon is melted and flows into the primary crucible. Economic modeling of the continuous Czochralski process indicates that for 10 cm diameter crystal, 100 kg furnace runs of four or five crystals each are near-optimal. Costs tend to asymptote at the 100 kg level so little additional cost improvement occurs at larger runs. For these conditions, crystal cost in equivalent wafer area of around $20/sq m exclusive of polysilicon and slicing was obtained.

Rea, S. N.↗