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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Comparative Study of Enhanced Geothermal System Supply Curves Across CONUS from Two Temperature Models Using the Renewable Energy Potential Model (reV)

Enhanced geothermal systems (EGS) have had recent breakthroughs within the geothermal sector. These breakthroughs are reflected in the National Renewable Energy Laboratory (NREL) 2024 Annual Technology Baseline and will result in updated EGS supply curves (i.e., the available resource capacity relative to cost). Our research uses NREL's Renewable Energy Potential (reV) model to compare EGS supply curves across the conterminous United States (CONUS) for two different temperature models: the Stanford temperature model (STM) and the Southern Methodist University temperature model (SMU). The reV model provides the levelized cost of energy (LCOE) at a consistent resolution across CONUS, taking into consideration transmission costs and constraints as well as technical exclusions pertaining to sensitive cultural, ecological, or infrastructure locations. In addition to a countrywide analysis of both models, we also conducted a regional analysis of Texas. We observed the STM had, on average, lower temperatures across different depths, resulting in slightly higher mean and median LCOEs as compared to the SMU temperature model at the same depths. In the regional analysis for Texas, however, when we compared only the common points between the two temperature models, the STM had lower median and mean LCOEs compared to SMU due to higher temperatures at depths greater than 5 km.

enhanced geothermal systems↗
DOE OSTI2024

Efficient sensitivity analysis of the thermal profile in powder bed fusion of metals using hypercomplex automatic differentiation finite element method

Rapid cyclic temperature fluctuation occurring in powder bed fusion of metals using a laser beam (PBF-LB/M) influences the formation of flaws in printed parts. Consequently, there is a pressing need to enhance the quality of printed parts by developing innovative methodologies that can predict thermal histories and help uncover the intricate relationships between process parameters and thermal profiles. Sensitivity Analysis (SA) emerges as an essential tool for this, offering the potential for process optimization and enhanced quality control. Nonetheless, conventional SA methodologies often incur in excessive computational costs and potential numerical approximation errors. Here, to address this technical challenge, we present a novel method for SA that integrates the HYPercomplex-based Automatic Differentiation (HYPAD) technique with transient thermal simulations conducted via the finite element method (FEM). Leveraging this methodology, we efficiently and accurately perform SA for PBF-LB/M processes in a post-processing step. Compared to traditional methods like Finite Differences (FD), HYPAD-FEM required 96 % less computational time for obtaining sensitivities for 22 process parameters, under a comparative study conducted within the context of the 2018–02 AM benchmark of the National Institute of Standards and Technology. In summary, HYPAD-FEM offers superior efficiency and accuracy in SA over conventional methods, delivering the best sensitivity of a model without the need for step-size selection and problem or parameter-based implementations.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advancing Concentrating Solar Thermal Modeling Using System Advisor Model (SAM)

Concentrating solar thermal (CST) technologies play a critical role in enabling dispatchable power and high-temperature industrial heat applications. Accurate and flexible modeling tools are essential for evaluating system performance, guiding technology research and development, and informing investment decisions. The National Laboratory of the Rockies's System Advisor Model (SAM) is a widely used techno-economic simulation platform for CST systems, providing detailed performance and financial modeling capabilities for multiple CST system configurations. SAM integrates physics-based performance models with financial analysis to simulate the behavior of complex energy systems under realistic operating conditions. For CST technologies (including tower, parabolic trough, and linear Fresnel), SAM enables hourly simulations using site-specific weather data that ensure feasible operating conditions and convergence of mass and energy between core system components (i.e., solar field, receiver, thermal energy storage, and power cycle). These capabilities allow researchers and developers to evaluate annual energy production, capacity factors, levelized cost of energy (LCOE), and system dispatch strategies. A key advantage of SAM lies in its flexibility for parametric analysis and large-scale computational studies. Users can vary system design parameters such as heliostat field layout, receiver dimensions, thermal energy storage capacity, power block sizing, and installation cost assumptions to investigate their impact on system performance and financial metrics. When combined with automated scripting through LK, SDKTool, or Python interfaces, SAM enables high-throughput simulation workflows that support sensitivity analysis, technology benchmarking, and optimization studies. These approaches are particularly valuable for next-generation CST concepts, where design spaces are large and system interactions are complex. Another important capability of SAM is its support for dispatch optimization and thermal energy storage modeling, which are central to the value proposition of CST technologies. The ability to simulate integrated storage and flexible power generation allows researchers to explore strategies that maximize grid value, improve capacity utilization, and enhance integration with variable resources such as photovoltaic and wind generation. This poster will present an overview of SAM's thermal system modeling capabilities including concentrating solar. Additionally, we will highlight new feature developments including: 1) implementing Google's OR-Tools optimization platform for faster and more robust dispatch optimization, 2) developing a new power load following controller for modeling behind-the-meter applications, 3) enabling direct modeling of CSP-PV hybrid systems with the inclusion of battery storage, and 4) developing a multi-receiver falling particle Gen3 system model.

14 SOLAR ENERGY↗
DOE OSTI2020

Optimal Sizing of PV and Energy Storage in an Electric Vehicle Extreme Fast Charging Station

This paper proposes an optimization model for the optimal sizing of photovoltaic (PV) and energy storage in an electric vehicle extreme fast charging station considering the coordinated charging strategy of the electric vehicles. The proposed model minimizes the annualized cost of the extreme fast charging station, including investment and maintenance cost of PV and energy storage, cost of purchasing energy from utility and demand charge. The decision variables are capacity of invested PV and the power and energy ratings of invested energy storage. To further reduce the annualized cost of the extreme fast charging station, the charging strategy of electric vehicles are integrated into the optimization model and coordinated with the power output of PV and charging/discharging of energy storage. Results of numerical simulations indicate that investment of PV and energy storage could help reduce the annualized cost of the extreme fast charging station significantly. Meanwhile, the impacts of various parameters on the optimal solution are investigated by sensitivity analysis.

Liu, Guodong↗
DOE OSTI2020

Multitask Recommender Systems for Cancer Drug Response

The problem we are currently trying to address is that there are many types of cancer drugs and many types of cancers and there is not always experimental data for a specific cancer type and cancer drug interaction. While there is a large possible set of feasible drug and cancer combinations, testing each pair is not realistic due to the high monetary cost of cell-based assays. Thus, this leaves researchers with a difficult choice of what drugs they should test on specific cancer types. This issue is known as the cold-start problem. Our focus is on developing recommender systems capable of addressing the cold-start problem as it relates to interaction between cancer types and cancer drugs. One of the most effective ways to address the cold-start problem is through large data analysis, however due to the cost prohibitive nature of cancer research the largest available data set size is the Genomics of Drug Sensitivity in Cancer with 494,973 genomic associations. To achieve optimal model performance on the cold-start problem, it is advantageous to employ multitask algorithms that are capable of transferring information between cancer datasets. The aim of this report is to draw from adaptations and state of the art developments in both algorithms for recommender systems and multitask learning to model the interaction between cancer cell lines and cancer drugs. Cancer cell lines are defined by the US National Cancer Institute as "cancer cells that keep dividing and growing over time, under certain conditions in a laboratory". This paper will focus on evaluating the performance of Neural Collaborative Filtering and Gaussian Processes, as well as their multitask adaptations, on cancer datasets from CCLE, NCI60, GDSC and CTRP. These methods will be evaluated on model performance in regression prediction but also in interpretability.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

The impacts of convex piecewise linear cost formulations on AC optimal power flow

Despite strong connections through shared application areas, research efforts on power market optimization (e.g., unit commitment) and power network optimization (e.g., optimal power flow) remain largely independent. A notable illustration of this is the treatment of power generation cost functions, where nonlinear network optimization has largely used polynomial representations and market optimization has adopted piecewise linear encodings. This work combines state-of-the-art results from both lines of research to understand the best mathematical formulations of the nonlinear AC optimal power flow problem with piecewise linear generation cost functions. An extensive numerical analysis of non-convex models, linear approximations, and convex relaxations across fifty-four realistic test cases illustrates that nonlinear optimization methods are surprisingly sensitive to the mathematical formulation of piecewise linear functions. The results indicate that a poor formulation choice can slow down algorithm performance by a factor of ten, increasing the runtime from seconds to minutes. Furthermore, these results provide valuable insights into the best formulations of nonlinear optimal power flow problems with piecewise linear cost functions, an important step towards building a new generation of energy markets that incorporate the nonlinear AC power flow model.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Application of sensitivity analysis in DYMOND/Dakota to fuel cycle transition scenarios

The ability to perform sensitivity analysis has been enabled for the nuclear fuel cycle simulator DYMOND through its coupling with the design and analysis toolkit Dakota. To test and demonstrate these new capabilities, a transition scenario and multi-parameter study were devised. The transition scenario represents a partial transition from the US nuclear fleet to a closed fuel cycle with small modular LWRs and fast reactors fueled by reprocessed used nuclear fuel. Four uncertain parameters in this transition were studied – start date of reprocessing, total reprocessing capacity, the nuclear energy demand growth, and the rate at which the fast reactors are deployed – with respect to their impact on four response metrics. The responses – total natural uranium consumed, maximum annual enrichment capacity required, total disposed mass, and total cost of the nuclear fuel cycle – were chosen based on measures known to be of interest in transition scenarios and to be significantly impacted by the varying parameters. Furthermore, analysis of this study was performed both from the direct sampling and through surrogate models developed in Dakota to calculate the global sensitivity measures Sobol’ indices. This example application of this new capability showed that the most consequential parameter to most metrics was the share of new build capacity that is fast reactors. However, for the cost metric, the scaling factor of the energy demand growth was significant and had synergistic behavior with the fast reactor new build share.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Prototype-Wise Sensitivity Analysis of Urban Building Energy Simulation Surrogate Modeling Accuracy

Urban Building Energy Modeling (UBEM) is an important reference for urban energy-related policymaking. Because of the significant impact of urban microclimates on the energy simulation, UBEM requires simulations of many microclimate-prototype pairs. Surrogate modeling is commonly used to reduce the cost of simulation computations. In UBEM surrogate modeling, it is important to determine the percentage of microclimates related to a prototype used for generating surrogate model training data. This study analyzes the prototype-wise variations and sensitivities of surrogate model estimation accuracy to the microclimate sampling ratios. The results of the study can help determine the number of simulations used for generating surrogate modeling data, avoid redundant simulations, and reduce the computational cost for UBEM surrogate modeling and its time.

Pan, Xiyu↗
DOE OSTI2020

Modeling Flexible Generator Operating Regions via Chance- constrained Stochastic Unit Commitment

Here, we introduce a novel chance-constrained stochastic unit commitment model to address uncertainty in renewables' production uncertainty in power systems operation. For most thermal generators,underlying technical constraints that are universally treated as "hard" by deterministic unit commitment models are in fact based on engineering judgments, such that system operators can periodically request operation outside these limits in non-nominal situations, e.g., to ensure reliability. We incorporate this practical consideration into a chance-constrained stochastic unit commitment model, specifically by in-frequently allowing minor deviations from the minimum and maximum thermal generator power output levels. We demonstrate that an extensive form of our model is computationally tractable for medium-sized power systems given modest numbers of scenarios for renewables' production. We show that the model is able to potentially save significant annual production costs by allowing infrequent and controlled violation of the traditionally hard bounds imposed on thermal generator production limits. Finally, we conduct a sensitivity analysis of optimal solutions to our model under two restricted regimes and observe similar qualitative results.

42 ENGINEERING↗
DOE OSTI2022

Measurement of ( n, γ ) cross section of 90 Zr [Abstract]

The isotopes of Zr with A = [90, 91, 92, 94] make up more than 97% of naturally occurring Zr and are important to many nuclear applications such as nuclear reactors. One of the attractive qualities of naturally occurring Zr isotopes is that they have a low σγ/σt ratio at most neutron energies, such that they improve the neutron economy in reactors by preferentially scattering neutrons rather than absorbing them. This same quality also presents a challenge to measuring the capture cross section, σγ, of Zr isotopes. The ENDF/B-VIII.0 library has a relative uncertainty of approximately 10-20% for incident neutron energies < 0.1 MeV, and uncertainty greater than 20% for energies > 0.1 MeV for the majority of natural Zr isotopes. This motivated the Nuclear Criticality Safety Program (NCSP) to embark on a campaign to accurately measure and evaluate these isotopes of Zr. Here we will show energy-dependent neutron capture cross section measurements for the first enriched sample to be measured: 90 Zr. The measurements of isotopically enriched samples are being carried out at the Geel Electron Linear Accelerator (GELINA) facility of the Joint Research Center - Geel (JRC-Geel) of the European Union. As isotopic enrichment is a costly process we are careful not to activate any of the samples, as this may hinder future radiation-sensitive measurements. The activation analysis is presented in a report by Brown et al.. Once we were satisfied that the Zr samples would not be activated by the measurements, the 90 Zr sample was fabricated at Oak Ridge National Laboratory (ORNL) and shipped to GELINA. The dimensions of the cylindrical sample are approximately 0.12 cm thick and a radius of 2.5 cm. Since 90 Zr is not chemically reactive to air, bare metallic samples were employed. The sample was measured at a flight path (FP) length of 60 m, using four C 6 D 6 detectors on FP14. The final paper will include experimental details and measured cross section data for 90 Zr compared to current evaluated nuclear data libraries.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2021

Performance and cost analysis of liquid fuel production from H 2 and CO 2 based on the Fischer-Tropsch process

Electro-fuels can be produced from concentrated sources of carbon dioxide and hydrogen using electricity generated from renewable sources; this process enables energy storage at high volumetric energy density. Among the electro-fuels options, FT (Fischer-Tropsch) fuel is attractive for heavy-duty trucks and non-road transportation applications. This study conducts a techno-economic analysis of FT liquid fuel production from H 2 and CO 2 using a detailed performance analysis. Minimum fuel selling price is estimated for a broad range of H 2 and CO 2 prices and for a range of potential CO 2 credits. The analysis indicates that H 2 price has the largest impact on the minimum selling price of FT fuel. FT fuel production with a CO 2 price of $17.3/metric ton requires an H 2 price of $0.8/kg to be cost-competitive with the pre-tax petroleum diesel price of $3.1/gal in 2050 (before the application of any CO 2 credits). When the H 2 price is $2.0/kg from central water electrolysis (2020 target), the minimum selling price of the FT fuel is $5.4–5.9/gal. A sensitivity analysis shows that future system optimization of FT fuel production could focus on improving the H 2 and CO 2 recycle contributions and FT fuel conversion ratio. The analysis results can be combined with various upstream systems for H 2 and CO 2 production.

08 HYDROGEN↗
DOE OSTI2023

Sensitivity analysis of an automated fault detection algorithm for residential air-conditioning systems

The state of the art of fault detection and diagnosis (FDD) for residential air-conditioning systems is expensive and not yet amenable to widespread implementation. FDD for homes can significantly reduce utility costs, and increase the lifespan of the equipment. The cost barriers currently, however, make FDD for homes economically unviable for large scale implementation. In prior work, we offered a solution to reduce FDD costs by proposing an automated fault detection algorithm to serve as a screening step before more expensive FDD tests can be conducted. The algorithm uses only the home thermostat and local weather information to identify thermodynamic parameters and detect high-impact air-conditioning faults, including those that occur during equipment installation. We had tested the algorithm on a single EnergyPlus™ model of a home in Orlando, Florida. The thermodynamic parameter identification process is highly nonconvex involving several local optimal solutions. In this paper we propose a novel method to select the best model for fault detection from among the list of local optimal solutions to make the algorithm more robust to homes of different construction, without which the fault detection process would be infeasible. Another unique contribution of the paper is implementing the solution on real-world data. We also bring the algorithm closer to market by testing it on real-world data. We implement the algorithm on data obtained from experiments conducted by the Florida Solar Energy Center (FSEC) on a laboratory home equipped with a heat pump where faults were intentionally added for a period of seven months. The algorithm successfully detected an undercharge fault with 70.6% accuracy, concurrent duct leakage and undercharge faults with 85.2% accuracy, and duct leakage faults with 69.1% accuracy. A sensitivity analysis is also performed on EnergyPlus models of nine types of homes that vary in construction to demonstrate the robustness of the algorithm. Finally, the algorithm achieves an average accuracy of 71% for no-fault condition, 77% for 40% undercharge fault, and 76% for duct-leak fault.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Data and scripts associated with the manuscript "Using Mutual Information for Global Sensitivity Analysis on Watershed Modeling"

This package contains the data and scripts used in "Using Mutual Information for Global Sensitivity Analysis on Watershed Modeling" (Jiang et al., 2022). The ARW_SWAT.zip file contains the SWAT simulation and the sensitivity analysis result in the American River Watershed. The Portage_SWAT.zip file contains the SWAT simulation and the sensitivity analysis result in the Portage River Watershed. The src folder contains the source code of sensitivity analysis and plotting functions. The notebooks folder contains the Jupyter notebooks for performing sensitivity analysis and other post analyses.Global Sensitivity Analysis (GSA) often is applied to assess the sensitivity of model outputs to their inputs using ensemble simulations. However, increasing model complexity and the associated computational cost have limited the use of most GSA approaches for process-based watershed models. We propose to use Mutual Information (MI) as a computationally efficient GSA method for watershed modeling. Such MI computed from several hundred realizations usually can capture nonlinear relationships between inputs and outputs of interest. We perform MI-based watershed sensitivity analyses in studies of the Portage River Watershed in Ohio and the American River Watershed in Washington. In these studies, MI is used to evaluate the sensitivity of river discharges simulated by the Soil and Water Assessment Tool to no less than 20 parameters for each watershed. Our MI-based sensitivity analyses achieved convergence with about 300~500 realizations, a small fraction of the ensemble size (i.e., several thousand) required by the Sobol method. Nevertheless, MI yields similar sensitivity ranking compared to the Sobol method, especially for sensitive parameters. Our study thus sheds new light on the use of MI as an affordable GSA method for computationally intensive models such as the hyper-resolution, watershed hydrobiogeochemical models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Carbon storage cost modeling for the offshore Gulf of Mexico

Groundbreaking for geologic carbon storage (GCS) projects in the offshore Gulf of Mexico is imminent, and there is great interest in utilizing this region for GCS projects. Offshore saline reservoirs provide a significant and accessible resource for GCS. However, conducting GCS in the offshore environment will pose distinct challenges pertaining to site selection, operations, infrastructure use, and monitoring compared to operating onshore that ultimately affect technoeconomic assessment of offshore GCS projects. Carbon storage and transport costs are critical to project developers looking to deploy carbon storage in the offshore environment. We present CO2_S_COM_Offshore, a model developed by the National Energy Technology Laboratory (NETL) as a screening-level offshore saline GCS cost modeling tool. Based on NETL’s widely used CO2_S_COM cost model for onshore saline CS, CO2_S_COM_Offshore enables technoeconomic analysis of GCS in offshore areas. This model comprehensively incorporates multiple facets of offshore GCS projects, from regional evaluation and site selection to permitting, transport, operations, monitoring, site closure, and decommissioning. In general, the model can explore the cost implications for potential offshore GCS project(s) by enabling the user to change several project operational and financial attribute configurations. Key inputs include offshore storage formation options, CO2 injection rate and duration, infrastructure types, monitoring intensity, project financing, and post-injection site care duration. Supporting cost algorithms within CO2_S_COM_Offshore were compiled utilizing S&P Global’ s QUE$TORTM cost estimation software alongside a variety of open-source scientific literature. In addition to reviewing key model components, we discuss several sensitivity analyses, input variabilities, and results on analysis of break-even CO2 price required by a project based on different regulation/policy and operational scenarios for the offshore Gulf of Mexico. These results indicate the value of modeling offshore GCS specifically, and the potential of offshore GCS within a decarbonization value chain. Presented at the 41st USAEE/IAEE North American Conference, 3-6 November 2024, Baton Rouge, LA, United States.

Mark-Moser, Mackenzie K.↗
DOE OSTI2021

The phylogenetic roots of addiction: compulsive drug seeking, natural and drug-sensitive reward, and the acquisition of learned habits

Our rational faculties permit us humans to maximize the utility of our actions. We perform a fundamental type of cost-benefit analysis in which we frame a problem, assign values to the different paths, and then choose from among a set of available options, the course that promises the most favorable outcome. So why then does addiction appear to be so impervious to the associated costs, so unaffected by undesired consequences, and ultimately so resistant to cognitive oversight? The answer may likely be found in the fact that the drivers for compulsive drug seeking and drug taking are located in affective brain circuits, circuits that are structured and patterned by learning with repeated activation. These deep processes exhibit significant resistance to control by our cognitive faculties. The general consensus is that addiction arises from mechanisms that overvalue the magnitude of reward, discount the associated risks, and thereby bias individuals towards compulsive pursuit of addictive drugs. Behavioral disruption and dependence appear to arise at the intersection of a number of connected but separate phenomena: expectations for the occurrence of specific events, behaviors that seek encounters with them, the ability to notice and learn nonrandom, co-occurring conditions, the prediction and valuation of consequences, the forming of enduring memories, and the drivers of focused behavior through compulsion, habits, and acquired routines. It is important to recognize that each one of these individual faculties are present and well developed across the entire phylogenetic tree of bilateral metazoans. The goal of this special volume is dedicated to exploring the degree to which inherent elements can account for addiction and addiction-associated phenomena. In much of the literature on addiction, the underlying processes are often viewed as distinctly mammalian, arising, in part, from the strong cognitive capacities of this taxon. Some phenomena may even be regarded to exist only in primates, or even solely in humans. This supposition arises from the fact that studies are conducted almost exclusively in mammals and primates, while evolutionary antecedents of the behavior are rarely considered. A more comprehensive perspective that examines drug reward and reinforcement in a wider range of organisms demonstrates that many of the component traits are actually well developed across the greater metazoan lineage, and they may well predate the emergence of a mammalian clade by a wide margin. The collection of papers assembled here supports the notion that the capacity to associate cues and quences has not arisen in mammals de novo. Rather, the neural mechanisms for detecting contingencies and for predicting future outcomes are very deeply rooted across broad phylogenetic divisions. Our understanding of an ability to associate paired events has been enriched by work in invertebrate preparations in both classical and operant conditioning scenarios [Cook and Carew, 1986, 1989a, 1989b]. The ability to learn allows us to connect cues and behavioral actions to their associated consequences. Pavlovian conditioning enriches surrounding cues with predictive value. Outcomes with positive valence generate appetitive responses and approach to the associated cues, while those perceived as aversive bring cue avoidance and withdrawal. Humans are not the only life forms capable of such short- and long-term modulations of behavior

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Innovative approach to counterfeit and noncompliant refrigerant detection: A cost-effective, portable solution

The increasing prevalence of counterfeit and incompatible refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC&R) systems, including compromised equipment performance, safety hazards, and non-compliance. This article details the development of a novel, cost-effective, and portable detection device designed to accurately verify refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing feedback within a 2-minute duration. Laboratory validation demonstrated the device’s high accuracy (>95 % based on correct identification of compliant vs. non-compliant blends) in detecting unauthorized refrigerant blends. The projected cost of the product stands at ∼ $150, based on the retail pricing of individual components. Laboratory validation demonstrated the device’s high accuracy (>95 % for composition identification, 100 % rejection of tested counterfeit/incorrect blends) in detecting unauthorized refrigerant blends with a response time <2 min. The device correctly identified authentic R-454A/B/C blends and reliably rejected R-407F and closely related counterfeit mixtures. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks, enhances safety in HVAC&R operations, and mitigates the risks associated with counterfeit refrigerants.

Counterfeit refrigerants↗
DOE OSTI2021

Island scanning pattern optimization for residual deformation mitigation in laser powder bed fusion via sequential inherent strain method and sensitivity analysis

Laser powder bed fusion (L-PBF) has emerged as one of the mainstream additive manufacturing approaches for fabricating metal parts with complex geometries and intricate internal structures. However, large deformation associated with rapid heating and cooling can lead to build failure and requires post-processing which may increase manufacturing cost and prolong the production period. Here in this work, an island scanning pattern design method is proposed to optimize the scanning direction of each island in order to reduce part deformation after cutting off the build platform. The objective of this optimization is to minimize the upward bending of the part after sectioning, which allows the part deformation to satisfy the tolerance requirement or reduce the post heat treatment time. Inherent strain method is employed in the sequential finite element analysis consisting of layer-by-layer activations and sectioning for fast residual distortion prediction. Full sequential sensitivity analysis for the formulated optimization is provided to update the island scanning directions. To show the feasibility and effectiveness of the proposed method, the scanning patterns of a block structure and a connecting rod were designed and parts were fabricated using an open architecture L-PBF machine. The fabrication experiments demonstrated that the residual deformation of both parts fabricated by optimized scanning pattern can be reduced by over 50% compared to the initial scanning patterns, which demonstrate the effectiveness of the proposed method.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Electrical Substation Configuration Effect on Substation Reliability

It is crucial that the U.S. electrical grid be reliable, due to its critical role in the economy and our national defense/security. Many common tasks and industrial operations rely on proper electrical power distribution. In designing new bus systems or evaluating existing ones, the type of configuration employed affects the level of risk, reliability, maintenance, and cost involved. The present work utilizes Systems Analysis Programs for Hands-on Integrated Reliability Evaluations (SAPHIRE) to perform a probabilistic risk assessment (PRA)-based sensitivity study on substation reliability in regard to different bus configurations. This study examines single bus, main and transfer, breaker and a half, double bus/double breaker, and ring bus configurations applied to busses with different numbers of lines. The case variances, methods, and rankings presented herein can help guide bus configurations for electrical grid design/analysis in the future.

24 POWER TRANSMISSION AND DISTRIBUTION↗