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DOE OSTI2024

L-PBF High-Throughput Data Pipeline Approach for Multi-modal Integration

Abstract Metal-based additive manufacturing requires active monitoring solutions for assessing part quality. Multiple sensors and data streams, however, generate large heterogeneous data sets that are impractical for manual assessment and characterization. In this work, an automated pipeline is developed that enables feature extraction from high-speed camera video and multi-modal data analysis. The framework removes the need for manual assessment through the utilization of deep learning techniques and training models in a weakly supervised paradigm. We demonstrate this pipeline’s capability over 700,000 high-speed camera frames. The pipeline successfully extracts melt pool and spatter geometries and links them to corresponding pyrometry, radiography, and processparameter information. 715 individual prints are examined to reveal melt pool areas that exceeds 0.07 mm 2 and pyrometry signal over a threshold (375 pyrometry units) were more likely to have defects. These automated processes enable massive throughput of characterization techniques.

36 MATERIALS SCIENCE↗

DOE OSTI2026

The ever-evolving active site: transformation of single atoms to extended structures during the Rh-catalyzed reverse water–gas shift reaction

At low temperatures (< 400°C), single atoms of Rh supported on rutile TiO 2 (rTiO 2 ) are responsible for the formation of CO during the reverse water gas shift (RWGS), while methane production is associated with the Rh-TiO 2 interface due to the correlation between methane formation rates and the volume-averaged Rh nanoparticle diameter. As the temperature is increased to >540°C, there is a notable increase in CO selectivity and methane production rates tend towards zero. The time to reach zero depends on the temperature but independent of the initial Rh structure (single atoms and/or nanoparticles), which is controlled by the catalyst preparation method (wetness impregnation versus colloidal nanoparticles). At 600°C and > 4 h time on stream, the catalytic behaviour becomes completely agnostic to the initial Rh structure as well as weight loading, and the catalysts are highly selective for the reverse water gas-shift reaction. Post-reaction HR-TEM image analysis confirms Rh nanoparticles crystallize/order during the reaction; at 400°C, most of the Rh particles are disordered, while at 600°C, they are more ordered (i.e., development of defined faceting). Infrared spectroscopy of CO adsorption on Rh nanoparticles confirms the appearance of defined facets after annealing in nitrogen at high temperatures. Annealing the Rh/rTiO 2 catalysts prior to the RWGS reaction demonstrates the structural transformation of Rh depends only on time and temperature and not on reactant or product fugacity. Sites responsible for stabilizing Rh single atoms are no longer competent at higher temperatures, enabling their integration into existent nanoparticles. As the reaction temperature is increased to temperatures >540°C, the dominant active site for CO production evolves from single atoms to extended Rh structures.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Towards a complete parametrization of the ordinary-mode electromagnetic instability in counterstreaming plasmas. II. Ion effects

The linear marginal instability analysis of the ordinary perpendicular mode instability of drifting bi-Maxwellian plasma particle distributions with and without temperature anisotropy is extended by including the modifications of heavier ion species. For general values of the temperature anisotropy, the streaming velocity, and the parallel plasma beta, accurate marginal stability conditions are derived, which enable a better understanding of the interplay of counterstreaming and temperature anisotropy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

The resilience value of residential solar + storage systems in the continental U.S.

Abstract Behind the meter rooftop solar plus storage (PVESS) has the potential to benefit the hosting customers by providing affordability, environmental, and reliability and resilience value. Whereas the bill reduction and environmental benefits of PVESS are well studied, its monetary resilience benefits are less understood. The increasing trend of power interruptions driven by extreme weather events heightens the need to understand these benefits. This study leverages various publicly available datasets to perform a cost benefit analysis of adding to determine the resilience value of PVESS for a typical single family home in each county in the continental U.S. We find that PVESS is very effective to technically mitigate interruptions across the country. However, the monetary benefits in the base case only cover about 14% of battery costs, with no county exceeding 60%. This is somewhat expected, given that PVESS provide other monetary benefits that are not part of this analysis. Through sensitivities, we find that higher frequency of extreme weather events roughly triples the resilience value of PVESS and that higher values of lost load double the same metric. Our sensitivity analysis shows that the benefit cost ratio of PVESS for customers living in areas with higher-than-average frequency of long duration interruptions and value of lost load is already above one even without considering other value streams. We conclude with recommendations that regulators and utilities could implement to enable customers to calculate and capture the resilience value of PVESS more efficiently.

Baik, Sunhee↗

DOE OSTI2021

Physical, resource supply, and biological controls on nutrient processing along the river continuum

Nutrient impairment has led to damages to US surface and groundwater systems in excess of 100 billion dollars per year. Therefore, there is a strong need to develop methods to predict the transport, uptake, and export of nutrients along fluvial networks. We present results that are based on a data-driven mechanistic understanding of three factors that largely control nutrient uptake and export: 1) interactions between transport-related processes (mass transfer to metabolically active zones), 2) resource supply dynamics (nutrient concentration, stoichiometric constraints, etc.), and 3) biological controls (microbial community structure and function). Our results were generated from column experiments conducted along the Jemez River-Rio Grande continuum, which spans four orders of magnitude in mean annual discharge, more than 2000 m in altitude, and more than 500 km of stream longitude. Two resource supply injections were performed on each of the columns, i.e., a nitrate only addition, followed by a stoichiometrically ‘balanced’ 106Carbon:16Nitrogen:1Phosphorus addition. We quantified NO3-N uptake kinetics while constraining three variables: stream order, sediment type and type of injection (N vs stoichiometrically ‘balanced’ C:N:P). Following the laboratory nutrient uptake experiments, the columns were destructively sampled and the contents were homogenized to collect subsamples for DNA sequencing. Amplicon analysis was carried out as described by the Earth Microbiome Protocol for 16s and ITS sequencing.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Techno-Economic Analysis of Chemical Precipitation Followed by Low Hydraulic Residence Time Biological Treatment, Including Ultrafiltration

This National Energy Technology Laboratory (NETL) analysis is a techno-economic evaluation of chemical precipitation followed by low hydraulic residence time biological treatment, which was identified as Best Available Technology for treatment and control of selenium emissions from wet flue gas desulfurization wastewater streams.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Gypsum and clay-based additives to MSW for pre-combustion enhancement of syngas and solid residue improvement (Final Scientific/Technical Report)

This project was focused on the development of a cost-effective and practical approach for the recovery of metals and syngas from municipal solid waste (MSW) thermally processed in a gasification or combustion (i.e. waste-to-energy (WTE)) facility with the inclusion of other waste streams. The goal of additional waste inclusion was targeted to change the oxidation of critical and precious elements to enable them to be more efficiently recovered. The project had two main components: laboratory testing and techno-economic analysis (TEA). The additional waste included with MSW as gypsum and spent FCC (sFCC) catalyst as additives to improve material recovery and energy efficiency in MSW and WTE ash.

36 MATERIALS SCIENCE↗

NASA NTRS1976

Application of a run around coil system to a roof fan house at Michoud Assembly Facility at New Orleans, Louisiana

Analysis of the proposed run around coil system indicates that it offers a decrease in steam, electricity and water consumptions. The run around coil system consist of two coils, a precooling coil which will be located at up stream and a reheating coil which will be located at down stream of the chilled water spray chamber. This system will provide the necessary reheat in summer, spring and fall. At times, if the run around coil system can not provide the necessary reheat, the existing reheat coil could be utilized.

Source record↗

NASA NTRS1979

Multisensor analysis of hydrologic features in the Wind River Range, Wyoming with emphasis on the SEASAT SAR

The author has identified the following significant results. Analysis of imagery obtained over west-central Wyoming indicates that Seasat SAR has capability for hydrologic mapping. Both the L-Band (Seasat) and the X-Band (aircraft) SAR imagery were useful for observing drainage detail. Streams have bright signatures on the SAR imagery because the riparian vegetation produces a rough surface and thus high radar returns. Lakes appear relatively bright on the Seasat image presumably in response to surface ripples and waves induced by wind action. SAR imagery did not reveal snow at either the 23.5 cm (L-Band) or 2.8 cm (X-Band) wavelengths. Comparing Seasat and X-Band aircraft SAR imagery to LANDSAT RBV imagery, U-2 photography, and topographic maps of the Wind River Range, it appears that the SAR data do not seem to provide as much hydrologic information as do the other sensors in the visible and near infrared portions of the spectrum.

Foster, J. L.↗

NASA NTRS1981

Scaling of the beam-plasma discharge

A theoretical analysis is presented of the scaling of the critical beam current required for ignition and the narrow band emissions observed for beam currents less than critical in a beam plasma discharge experiment. The theory of the two-stream interaction between a nonrelativistic cold electron beam and a plasma in the presence of a magnetic field is developed, and conditions for the two-stream instability and the resulting amplification are derived. It is shown that the experimentally observed scaling is consistent with the assumption that the ignition triggering occurs when an instability near the electron plasma frequency is excited. Finally, it is shown that the wave emissions observed in the subthreshold range can be explained by the excitation of the kinetic instability of the upper branch and convective saturation.

Rowland, H. L.↗

NASA NTRS1983

A simple Lagrangian forecast system with aviation forecast potential

A trajectory forecast procedure is developed which uses geopotential tendency fields obtained from a simple, multiple layer, potential vorticity conservative isentropic model. This model can objectively account for short-term advective changes in the mass field when combined with fine-scale initial analyses. This procedure for producing short-term, upper-tropospheric trajectory forecasts employs a combination of a detailed objective analysis technique, an efficient mass advection model, and a diagnostically proven trajectory algorithm, none of which require extensive computer resources. Results of initial tests are presented, which indicate an exceptionally good agreement for trajectory paths entering the jet stream and passing through an intensifying trough. It is concluded that this technique not only has potential for aiding in route determination, fuel use estimation, and clear air turbulence detection, but also provides an example of the types of short range forecasting procedures which can be applied at local forecast centers using simple algorithms and a minimum of computer resources.

Petersen, R. A.↗

NASA NTRS1986

Three-dimensional structure of the heliospheric current sheet

Using a modification of the kinematic method of Hakamada and Akasofu (1982), those solar wind streams which originate near the magnetic neutral line on the source surface are followed to map the three-dimensional structure of the heliospheric current sheet (HCS) out to 5 AU for several Carrington rotations. The Stanford potential analysis magnetic field information of Hoeksema et al. (1983) is used to specify the source surface field.

Fry, C. D.↗

NASA NTRS1994

Experimental studies of transonic flow field near a longitudinally slotted wind tunnel wall

The results of detailed parametric experiments are presented for the near-wall flow field of a longitudinally slotted transonic wind tunnel. Existing data are reevaluated and new data obtained in the Langley 6- by 19-inch Transonic Wind Tunnel are presented and analyzed. In the experiments, researchers systematically investigate many pertinent wall-geometry variables such as the wall openness and the number of slots along with the free stream Mach number and model angle of attack. Flow field surveys on the plane passing through the centerline of the slot were conducted and are presented. The effects of viscosity on the slot flow are considered in the analysis. The present experiments, combined with those of previous investigations, give a more complete physical characterization of the flow near and through the slotted wall of a transonic wind tunnel.

Everhart, Joel L.↗

NASA NTRSDate not supplied

Artemis I Liftoff Measurements Issues and Corrections

The SLS rocket was instrumented to collect liftoff environment data during Artemis I launch. The instruments were microphones and pressure transducers. Most data were acceptable for analysis, but required corrections for port resonance, mean signal drift, data system delays, and data spikes. The data were all transmitted via telemetry and in this process some of the measurements experienced unexpectedly long gaps in the data stream. A time validated reconstruction algorithm failed when encountering the long gaps and required use of data from a simpler reconstruction process, with manually inserted data delay corrections. This paper discusses the issues and the corrections that were necessary for the launch data to determine the true physics of the acoustics occurring during launch.

environments↗

NASA NTRSDate not supplied

Artemis I Liftoff Measurements Issues and Corrections

environments↗

DOE OSTI2020

Process design tools and techno-economic analysis for capacitive deionization

Capacitive deionization (CDI) devices use cyclical electrosorption on porous electrode surfaces to achieve water desalination. Process modeling and design of CDI systems requires accurate treatment of the coupling among input electrical forcing, input flow rates, and system responses including salt removal dynamics, water recovery, energy storage, and dissipation. Techno-economic analyses of CDI further require a method to calculate and compare between a produced commodity (e.g. desalted water) versus capital and operational costs of the system. In this work, we demonstrate a new modeling and analysis tool for CDI developed as an installable Matlab program that allows direct numerical simulation of CDI dynamics and calculation of key performance and cost parameters. The program is provided for free and is used to run open-source Simulink models. The Simulink environment sends information to the program and allows for a drag and drop design space where users can connect CDI cells to relevant periphery blocks such as grid energy, battery, solar panel, waste disposal, and maintenance/labor cost streams. The program allows for simulation of arbitrary current forcing and arbitrary flow rate forcing of one or more CDI cells. We employ validated well-mixed reactor formulations together with a non-linear circuit model formulation that can accommodate a variety of electric double layer sub-models (e.g. for charge efficiency). The program includes a graphical user interface (GUI) to specify CDI plant parameters, specify operating conditions, run individual tests or parameter batch-mode simulations, and plot relevant results. The techno-economic models convert among dimensional streams of species (e.g. feed, desalted water, and brine), energy, and cost and enable a variety of economic estimates including levelized water costs.

42 ENGINEERING↗

DOE OSTI2025

Using Separation-Enhanced Isotope Ratio Mass Spectrometry to Enable Increased Renewable Carbon Content in Transportation Fuels (CRADA 525)

Stable isotope ratio measurements of carbon atoms using isotope ratio mass spectrometry (IRMS) can be an effective tool for quantifying biogenic carbon in co-processed fuels, with results approaching the precision and accuracy of accelerator mass spectrometry (AMS). The lower cost of an IRMS may enable deployment to refineries, improving access and analysis turnaround times (≤2 hours), and, by extension, provide data that can allow process optimization to maximize renewable carbon in desired refinery products. This project explored the integration of chemical separation with IRMS analyses to enable highly detailed tracking of biogenic carbon into fuel product streams separated by boiling point range, chemical class, or specific compound. Forty-nine fuels and fuel components of fossil and biogenic origin, spanning gasoline and diesel boiling point ranges, were received from three refiners and were analyzed for their δ 13 C values via IRMS. Results spanned a 13 C range from ca. 10‰ to 44‰ and reflect materials derived from sustainable sources (e.g., C4 or C3 plants, animal-based pathways, syngas) or from fossil-derived fuels. Common ranges are approximately 18‰ to 9‰ and approximately 30‰ to 20‰ for C4 and C3 plants, respectively, and approximately 34‰ to 24‰ and approximately 70‰ to 33‰ for petroleum-derived fuels and methane, respectively. Fuel-like standards were developed and tested using direct-injection elemental analyzer (EA) IRMS for liquid fuels. This method was compared with the published methods, yielding statistically similar results. Four blend curve sets were produced ranging from 0% to 100% of a fuel containing biogenic carbon, focusing on 0% to 10% biogenic carbon. Linear fits were the most applicable for two of the four blend curve sets; however, two sets were found to exhibit slightly quadratic behavior, which was more pronounced in low biogenic blend samples, necessitating second-order fits. The origin of the slight quadratic behavior remains unclear; however, the discussion points to possible interpretations. CanmetENERGY thoroughly characterized a majority of the samples using one- and two-dimensional gas chromatography (GC and GC×GC, respectively) and other analyses. Selected samples were subjected to solid phase extraction (SPE) for saturate, olefin, aromatic, and polar (SOAP) analysis, and the resulting solvent-diluted fractions containing saturates and aromatics were returned to Pacific Northwest National Laboratory (PNNL), where the solvent was removed via evaporation or physical separation using GC techniques. Characterization and separations provided an understanding of saturate and aromatic content, as well as boiling point ranges for each sample and sample fraction. Samples resulting from SPE were examined using EA-IRMS and gas chromatography combustion IRMS (GC-C-IRMS) analyses. Both approaches suggest that the range in values between end-members can be increased by selecting the paraffinic or aromatic fraction of the end-member or by selecting among individual compounds resulting from GC separation of the paraffinic fractions. Considerable work remains to put these approaches into practice and statistically validate the benefit for using a fraction or individual compound over bulk analysis of a sample. However, initial results suggest that separations provide advantages for samples having blend ratios of less than 10% biogenic blendstocks. 13 C results showed statistically similar biofuel blend results to those obtained at PNNL, although additional work is needed to obtain better reproducibility. Select samples were sent to Los Alamos National Laboratory (LANL) for IRMS measurements and Beta Analytics for AMS measurements. This work suggests that IRMS and AMS yield closely comparable results and in some circumstances, IRMS could serve as a surrogate for AMS. While additional work is needed to better resolve statistical advantages for separations and better show the comparable nature of IRMS and AMS in both the biogenic carbon analysis of bulk chemical classes, initial results from this study suggest that these should be pursued in order to proliferate this approach for quantifying biogenic carbon in transportation fuels to the refinery level, thereby potentially enabling process optimization in co-processing scenarios.

09 BIOMASS FUELS↗

NASA NTRS2002

Developing A New Sampling and Analysis Method for Hydrazine and Monomethyl Hydrazine

Solid phase microextraction (SPME) will be used to develop a method for detecting monomethyl hydrazine (MMH) and hydrazine (Hz). A derivatizing agent, pentafluorobenzoyl chloride (PFBCl), is known to react readily with MMH and Hz. The SPME fiber can either be coated with PFBCl and introduced into a gaseous stream containing MMH, or PFBCl and MMH can react first in a syringe barrel and after a short equilibration period a SPME is used to sample the resulting solution. These methods were optimized and compared. Because Hz and MMH can degrade the SPME, letting the reaction occur first gave better results. Only MMH could be detected using either of these methods. Future research will concentrate on constructing calibration curves and determining the detection limit.

Allen, John R.↗