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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 OSTI2017

A NOVEL TOOL FOR IMPROVING THE DATA COLLECTION PROCESS DURING CONTROL ROOM MODERNIZATION HUMAN-SYSTEM INTERFACE TESTING AND EVALUATION ACTIVITIES

The U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program is developing a scientific basis to extend the existing U.S. nuclear power plant (NPP) operating life beyond the current 60-year licensing period and to ensure NPP long-term reliability, productivity, safety, and security. Under the Advanced Instrumentation, Information, and Control (II&C) Systems Technologies pathway, the LWRS Program conducts targeted research and development to address long-term aging and obsolescence of existing instrumentation and control technologies, as well as to implement and test new digital II&C technology that enables broad innovation and business improvement in the NPP operating model. To this end, the role of human factors engineering (HFE) is important as part of ensuring that the control room modernization (CRM) activities account for the operator’s cognitive and physiological characteristics. Part of the HFE process for CRM entails conducting tests and evaluations (T&Es) that will inform the design of new human-system interface (HSI) technologies. Qualitative data that captures operator feedback and important human-system interactions are an important part of T&E. However, the analyzing this qualitative data in order to provide actionable design recommendations can be time-consuming and error prone. This paper presents an early version of a tool that can be used to analyze this qualitative data to (1) sift through freeform text for improved design issue identification, (2) maintain consistency in theme coding conventions, and (3) readily provide actionable design guidance that can be traceable to state-of-the-art HFE guidelines such as NUREG-0700. A description of this tool is discussed next.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗
DOE OSTI2021

Differential structure and functional gene response to geochemistry associated with the suspended and attached shallow aquifer microbiomes from the Illinois Basin, IL

Despite the clear ecological significance of the microbiomes inhabiting groundwater and connected ecosystems, our current understanding of their habitats, functionality, and the ecological processes controlling their assembly have been limited. In this study, an efficient pipeline combining geochemistry, high-throughput Fluidigm TM functional gene amplification and sequencing was developed to analyze the suspended and attached microbial communities inhabiting five groundwater monitoring wells in the Illinois Basin, USA. The dominant taxa in the suspended and the attached microbial communities exhibited significantly different spatial and temporal changes in both alpha- and beta-diversity. Further analyses of representative functional genes affiliated with N 2 fixation (nifH), methane oxidation (pmoA), and sulfate reduction (dsrB, and aprA), suggested functional redundancy within the shallow aquifer microbiomes. While more diversified functional gene taxa were observed for the suspended microbial communities than the attached ones except for pmoA, different levels of changes over time and space were observed between these functional genes. Notably, deterministic and stochastic ecological processes shaped the assembly of microbial communities and functional gene reservoirs differently. While homogenous selection was the prevailing process controlling assembly of microbial communities, the neutral processes (e.g., dispersal limitation, drift and others) were more important for the functional genes. The results suggest complex and changing shallow aquifer microbiomes, whose functionality and assembly vary even between the spatially proximate habitats and fractions. As a result, this research underscored the importance to include all the interface components for a more holistic understanding of the biogeochemical processes in aquifer ecosystems, which is also instructive for practical applications.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Real-time biomass feedstock particle quality detection using image analysis and machine vision

Abstract A common and costly challenge in the nascent biorefinery industry is the consistent handling and conveyance of biomass feedstock materials, which can vary widely in their chemical, physical, and mechanical properties. Solutions to cope with varying feedstock qualities will be required, including advanced process controls to adjust equipment and reject feedstocks that do not meet a quality standard. In this work, we present and evaluate methods to autonomously assess corn stover feedstock quality in real time and provide data to process controls with low-cost camera hardware. We explore the use of neural networks to classify feedstocks based on actual processing behavior and pixel matrix feature parameterization to further assess particle attributes that may explain the variable processing behavior. We used the pretrained ResNet neural network coupled with a gated recurrent unit (GRU) time-series classifier trained on our image data, resulting in binary classification of feedstock anomalies with favorable performance. The textural aspects of the image data were statistically analyzed to determine if the textural features were predictive of operational disruptions. The significant textural features were angular second moment, prominence, mean height of surface profile, mean resultant vector, shade, skewness, variation of the polar facet orientation, and direction of azimuthal facets. Expansion of these models is recommended across a wider variety of labeled feedstock images of different qualities and species to develop a more robust tool that may be deployed using low-cost cameras within biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2026

Methanol mixing controlled combustion process enabled by methanol dehydration to dimethyl ether

This work demonstrates an initial proof-of-concept approach for operating a compression ignition off-road and marine relevant engine using neat methanol. The approach utilizes mixing controlled compression ignition (MCCI) of methanol that is enabled by a homogeneous charge compression ignition (HCCI) pre-burn of premixed dimethyl ether (DME). Although two fuels are used, this work explores and evaluates the opportunity and performance to generate the premixed fuel via. methanol catalytic dehydration over an alumina catalyst at engine relevant temperatures, pressures, and space velocities. Conversion purity and species output results from catalytic dehydration bench flow reactor studies were coupled with single cylinder experiments of the characterized output species for pre-burn HCCI performance. Subsequent initial methanol MCCI performance is also evaluated and compared relative to conventional diesel combustion. The detailed flow reactor results show that the catalytic dehydration conversion efficiency of methanol to DME is a function of system pressure, temperature, and space velocity. The engine results demonstrate that a 100% conversion of methanol to DME is not required for successful pre-burn HCCI, and the water formed during the dehydration process does not need to be removed to achieve the desired HCCI event from this pre-burn mixture. Subsequent methanol MCCI combustion results show that the level of methanol slip in the dehydration process affects the pre-burn HCCI phasing, low temperature heat release process, and magnitude of energy released, all of which can dictate the available window for direct injection of methanol for MCCI combustion.

Jatana, Gurneesh [ORNL] (ORCID:0000000288903225)↗
DOE OSTI2018

Contamination control and assay results for the Majorana Demonstrator ultra clean components

The Majorana Demonstrator is a neutrinoless double beta decay experiment utilizing enriched Ge-76 detectors in 2 separate modules inside of a common solid shield at the Sanford Underground Research Facility. The Demonstrator has utilized world leading assay sensitivities to develop clean materials and processes for producing ultra-pure copper and plastic components. This experiment is now operating, and initial data provide new insights into the success of cleaning and processing. Post production copper assays after the completion of Module 1 showed an increase in U and Th contamination in finished parts compared to starting bulk material. A revised cleaning method and additional round of surface contamination studies prior to Module 2 construction have provided evidence that more rigorous process control can reduce surface contamination. In conclusion, this article describes the assay results and discuss further studies to take advantage of assay capabilities for the purpose of maintaining ultra clean fabrication and process design.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Cluster 1: commercializing additive manufacturing—hurdles in materials characterization and testing

A major challenge in the commercialization of additive manufactured (AM) materials and processes is the ability to achieve acceptance of processes and products. There has been some progress towards acceptance has been made by adapting legacy qualification paradigms to match with the very limited process control and monitoring offered by AM machines. The opportunity for in-situ measurement can provide process monitoring and control perhaps changing the way we qualify parts however it is limited by lack of adequate process measurement methods. New measurement techniques, sensors and correlations to relevant phenomena are needed that enable process control and monitoring for consistently producing high quality articles. Beyond process data we need to characterize uncertainties of performance in all aspects of material, process and final part. These are prerequisites to achieving articles that are indeed worthy of materials characterization efforts that establish a microstructural reference of desirable performance through process-structure-property relations. Only then can industry apply physics based understanding of the material, part and process to probabilistically predict performance of an AM part. Our paper provides a brief overview, discussion of hurdles and key areas where R&D investment is needed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Regulatory Aspects of the Human Factors Engineering Process in Control Room Modernization

This report describes the basic aspects of control room modernization projects in the U.S. nuclear industry and the need for supplementary guidance on the integration of human factors considerations into the licensing and regulatory aspects of digital upgrades. The report pays specific attention to the integration of principles described in NUREG-0711 (Human Factors Engineering Program Review Model) and how supplementary guidance can help to raise general awareness in the industry regarding the complexities of control room modernization projects created by many interdependent regulations, standards and guidelines. The report also describes how human factors engineering principles and methods provided by various resources and international standards can help in navigating through the process of licensing digital upgrades. In particular, the integration of human factors engineering guidance and requirements into the process of licensing digital upgrades can help reduce uncertainty related to development of technical bases for digital upgrades that will avoid the introduction of new failure modes.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Mapping Glacier Basal Sliding Applying Machine Learning

During the RESOLVE project (“High-resolution imaging in subsurface geophysics: development of a multi-instrument platform for interdisciplinary research”), continuous surface displacement and seismic array observations were obtained on Glacier d’Argentière in the French Alps for 35 days in May 2018. The data set is used to perform a detailed study of targeted processes within the highly dynamic cryospheric environment. In particular, the physical processes controlling glacial basal motion are poorly understood and remain challenging to observe directly. Especially in the Alpine region for temperate based glaciers where the ice rapidly responds to changing climatic conditions and thus, processes are strongly intermittent in time and heterogeneous in space. Spatially dense seismic and Global Positioning System (GPS) measurements are analyzed applying machine learning to gain insight into the processes controlling glacial motions of Glacier d’Argentière. Using multiple bandpass-filtered copies of the continuous seismic waveforms, we compute energy-based features, develop a matched field beamforming catalog and include meteorological observations. Features describing the data are analyzed with a gradient boosting decision tree model to directly estimate the GPS displacements from the seismic noise. We posit that features of the seismic noise provide direct access to the dominant parameters that drive displacement on the highly variable and unsteady surface of the glacier. The machine learning model infers daily fluctuations and longer term trends. The results show on-ice displacement rates are strongly modulated by activity at the base of the glacier. The techniques presented provide a new approach to study glacial basal sliding and discover its full complexity.

58 GEOSCIENCES↗
DOE OSTI2021

Lower Tropospheric Processes: A Control on the Global Mean Precipitation Rate

The spread in global mean precipitation among climate models is explored in two ensembles using the complementary perspectives of surface evaporation and energy budgets. Models with higher global mean precipitation have stronger oceanic evaporation, driven by drier near-surface air. The drier surface conditions occur alongside increases in near-surface temperature and moisture at 925 hPa, which point to stronger boundary layer mixing. Correlations suggest that the degree of lower tropospheric mixing explains 18%–49% of the intermodel precipitation variance. To test this hypothesis, the degree of mixing is indirectly varied in a single-model experiment by adjusting the relative humidity threshold that controls low-cloud fraction. Indeed, increasing lower tropospheric mixing results in more global mean precipitation. Energetically, increased precipitation rates are associated with more downwelling longwave radiation to the surface and weaker sensible heat fluxes. These results highlight how lower-tropospheric processes must be better constrained to reduce the precipitation discrepancy among climate models.

58 GEOSCIENCES↗
DOE OSTI2020

Causal Trends for Occurrences at Sandia National Laboratories

A variety of issues and occurrences are reported at Sandia National Laboratories every year. The challenge is to filter through these occurrences and determine whether there are any notable trends related to work planning and control processes and whether some of the common problems can be mitigated or prevented. The hope is that some of the more common issues can be improved through training, communication, and/or documentation. These causal trends may also help to improve current training and work planning and control processes by revealing some opportunities for improvement.

42 ENGINEERING↗
DOE OSTI2016

PREDICTION OF FORBIDDEN ULTRAVIOLET AND VISIBLE EMISSIONS IN COMET 67P/CHURYUMOV–GERASIMENKO

Remote observation of spectroscopic emissions is a potential tool for the identification and quantification of various species in comets. The CO Cameron band (to trace CO{sub 2}) and atomic oxygen emissions (to trace H{sub 2}O and/or CO{sub 2}, CO) have been used to probe neutral composition in the cometary coma. Using a coupled-chemistry-emission model, various excitation processes controlling the CO Cameron band and different atomic oxygen and atomic carbon emissions have been modeled in comet 67P/Churyumov–Gerasimenko at 1.29 AU (perihelion) and at 3 AU heliocentric distances, which is being explored by ESA's Rosetta mission. The intensities of the CO Cameron band, atomic oxygen, and atomic carbon emission lines as a function of projected distance are calculated for different CO and CO{sub 2} volume mixing ratios relative to water. Contributions of different excitation processes controlling these emissions are quantified. We assess how CO{sub 2} and/or CO volume mixing ratios with respect to H{sub 2}O can be derived based on the observed intensities of the CO Cameron band, atomic oxygen, and atomic carbon emission lines. The results presented in this work serve as baseline calculations to understand the behavior of low out-gassing cometary coma and compare them with the higher gas production rate cases (e.g., comet Halley). Quantitative analysis of different excitation processes governing the spectroscopic emissions is essential to study the chemistry of inner coma and to derive neutral gas composition.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Automated instant labeling chemistry workflow for real-time monitoring of monoclonal antibody N -glycosylation

With the transition toward continuous bioprocessing, process analytical technology (PAT) is becoming necessary for rapid and reliable in-process monitoring during biotherapeutics manufacturing. Bioprocess 4.0 is looking to build end-to-end bioprocesses that include PAT-enabled real-time process control. This is especially important for drug product quality attributes that can change during bioprocessing, such as protein N-glycosylation, a critical quality attribute for most monoclonal antibody (mAb) therapeutics. Glycosylation of mAbs is known to influence their efficacy as therapeutics and is regulated for a majority of mAb products on the market today. Currently, there is no method to truly measure N-glycosylation using on-line PAT, hence making it impractical to design upstream process control strategies. We recently described the N-GLYcanyzer workflow: an integrated PAT unit that measures mAb N-glycosylation within 3 hours of automated sampling from a bioreactor. Here, we integrated Agilent's Instant Procainamide (InstantPC) based chemistry workflow into the N-GLYcanyzer PAT unit to allow for nearly 10× faster near real-time analysis of mAb glycoforms. Furthermore, our methodology is explained in detail to allow for replication of the PAT workflow as well as present a case study demonstrating the use of this PAT to autonomously monitor a mammalian cell perfusion process at the bench scale to gain increased knowledge of mAb glycosylation dynamics during continuous biologics manufacturing using Chinese hamster ovary (CHO) cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Process control-enabled mitigation of microstructural and plastic heterogeneities in additively manufactured Grade 91 steel

Synergizing wire arc-directed energy deposition (WA-DED) additive manufacturing (AM) with particle-strengthened creep strength-enhanced ferritic (CSEF) steels enables fabrication and repair of critical power-plant components. Investigations focused on fusion-welded particle-strengthened CSEF steels, such as Grade 91 steel, have linked microstructurally heterogeneous regions—forming due to heat affected zones (HAZ)—with premature failure during elevated temperature service. Fusion-based AM, including WA-DED, likewise generates microstructurally and plastically heterogeneous regions due to spatiotemporally varying thermokinetics during deposition. However, works investigating such microstructural heterogeneities, their implications for mechanical behavior, and strategies to mitigate their formation remain scarce. This work identifies microstructurally and plastically heterogeneous regions within the WA-DED-processed Grade 91 steel. Spatial microhardness variations in the as-fabricated specimen correlate with the variation in the attributes of grain, martensitic microstructure, and precipitates across the fusion zone and HAZ. Digital image correlation-enabled tensile tests performed at 500 °C revealed pronounced deformation localization and a wave-like strain distribution, with wavelength close to the melt pool depth, indicating susceptibility of the as-fabricated components to premature creep failure. Such heterogeneity in microstructural and mechanical behavior was attributed to recurring solid-state phase transformations. Subsequently, an interlayer temperature control strategy was implemented, wherein maintaining interlayer temperature above the martensitic start temperature mitigated the heterogeneous microstructural and plastic response in the as-fabricated condition. Findings open pathways to achieving deformation-localization- and creep-resistant microstructures in WA-DED fabricated particle-strengthened CSEF steel components, reducing reliance on post-welding heat treatments—conventionally required to enhance creep resistance—and enabling on-demand, short lead-time fabrication of next-generation power-plant components.

Heat affected zones↗
DOE OSTI2016

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Stress corrosion crack initiation of alloy 600 in PWR primary water

Stress corrosion crack (SCC) initiation of three mill-annealed (MA) alloy 600 heats in simulated pressurized water reactor primary water has been investigated using constant load tests equipped with in-situ direct current potential drop (DCPD) measurement capabilities. SCC initiation times were greatly reduced by a small amount of cold work. Shallow intergranular (IG) attack and/or cracks were found on most high-energy grain boundaries intersecting the surface with only a small fraction evolving into larger cracks and IGSCC growth. Crack depth profiles were measured and related to DCPD-detected initiation response. Processes controlling the SCC initiation in MA alloy 600 are discussed. IN PRESS, CORRECTED PROOF, 05/02/2017 - mfl

alloy↗