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DOE OSTI2025

Investigating lab-scaled offshore wind aerodynamic testing failure and developing solutions for early anomaly detections

As offshore wind systems become more complex, the risk of human error or equipment malfunction increases during experimental testing. This study investigates a lab-scale incident involving a 1 : 50 scale 5 MW wind turbine, where a generator failure led to rotor overspeed and a blade–tower strike. To improve early fault detection, we propose a data-driven method based on multivariate long short-term memory (LSTM) models. High-frequency measurements are projected onto principal components, and anomalies are identified using reconstruction error and its time derivative. Two models are trained on different healthy datasets and tested using single- and multi-principal component (1PC and MPC) variations. Results show that combining both error and error derivative improves detection accuracy. The 1PC model detects faults faster, has a higher recall rate, and achieves a 43 % improvement in anomaly detection accuracy, while the MPC model yields higher precision. This approach provides a simple and effective tool for early anomaly detection in lab-scale experiments, helping to reduce the risk of future failures during the testing of new technologies.

17 WIND ENERGY↗

DOE OSTI2018

Impact of Model Simplification on Optimal Control of Combustion Engine and Electric Vehicles Considering Control Input Constraints

This paper analyzes the impact of model simplification on optimal control for electric and conventional engine-powered vehicles. An optimal control problem is formulated to minimize energy/fuel consumption subject to control input constraints and solved analytically using the Pontryagin's Minimum Principle. We found that simplified solutions without nonlinear aerodynamic drag are sub-optimal, and their loss of optimality increases with average travel speed. The energy/fuel savings of each control approach are evaluated using the intelligent driver model to capture driving behavior of a driver. Simulation case studies are presented for illustration.

Han, Jihun↗

DOE OSTI2019

Efficient Distributed Optimization of Wind Farms Using Proximal Primal-Dual Algorithms: Preprint

This paper presents a distributed approach to perform real-time optimization of large wind farms. Wind turbines in a wind farm typically operate individually to maximize their own performance regardless of the impact of aerodynamic interactions on neighboring turbines. This paper optimizes the overall power produced by a wind farm by formulating and solving a nonconvex optimization problem where the yaw angles are optimized to allow some turbines to operate in misaligned conditions and shape the aerodynamic interactions in a favorable way. The solution of the nonconvex smooth problem is tackled using a proximal primal-dual gradient method, which provably identifies a first-order stationary solution in a global sublinear manner. By adding auxiliary optimization variables for every pair of turbines that are coupled aerodynamically and properly adding consensus constraints into the underlying problem, a distributed algorithm with turbine-to-turbine message passing is obtained; this allows for turbines to be optimized in parallel using local information rather than information from the whole wind farm. This algorithm is computationally light, as it involves closed-form updates. This approach is demonstrated on a large wind farm with 60 turbines. The results indicate that similar performance can be achieved as with finite-difference gradient-based optimization at a fraction of the computational time and thus approach real-time control/optimization.

17 WIND ENERGY↗

DOE OSTI2019

Efficient Distributed Optimization of Wind Farms Using Proximal Primal-Dual Algorithms

This paper presents a distributed approach to performing real-time optimization of large wind farms. Wind turbines in a wind farm typically operate individually to maximize their own performance regardless of the impact of aerodynamic interactions on neighboring turbines. This paper optimizes the overall power produced by a wind farm by formulating and solving a nonconvex optimization problem where the yaw angles are optimized to allow some turbines to operate in misaligned conditions and shape the aerodynamic interactions in a favorable way. The solution of the nonconvex smooth problem is tackled using a proximal primal-dual gradient method, which provably identifies a first-order stationary solution in a global sublinear manner. By adding auxiliary optimization variables for every pair of turbines that are coupled aerodynamically, and properly adding consensus constraints into the underlying problem, a distributed algorithm with turbine-to-turbine message passing is obtained; this allows for turbines to be optimized in parallel using local information rather than information from the whole wind farm. This algorithm is computationally light, as it involves closed-form updates. This approach is demonstrated on a large wind farm with 60 turbines. The results indicate that similar performance can be achieved as with finite-difference gradient-based optimization at a fraction of the computational time and thus approaching real-time control/optimization.

17 WIND ENERGY↗

DOE OSTI2025

Using system identification in modeling the yaw response of tail fins for small wind turbines with bearing friction

Here, we describe three main developments of our previous study of the nonlinear yaw dynamics of the tail fins for small wind turbines [Khedr et al., J. Renewable Sustainable Energy 16, 053305 (2024)]. First, the model constants derived from archived computational and experimental studies are adjusted by employing system identification (SI) to maximize the model's agreement with wind tunnel tests. This adjustment was done for high wind speeds, where yaw bearing friction can be ignored. When starting a turbine at low wind speed, however, friction can become important. Our second development is to implement a model for the frictional resistive torque and use SI to maximize its accuracy. These developments used wind tunnel experiments on generic delta, elliptical, and rectangular planforms that were described by Khedr et al. [J. Renewable Sustainable Energy 16, 053305 (2024)]. Since the aerodynamic and friction models employ a large number of constants, we describe ways to constrain the values using linearized solutions of the response equations for small and large yaw angles. Third, we test the generality of the aerodynamic and friction modeling using the complex planform from a commercial small turbine, for which limited theoretical and computational guidance is available in selecting the model constants. The model implemented with SI is shown to provide an accurate description of the yaw response of the complex planform. Guidelines are given for the use of wind tunnel tests to determine the model constants for tail fins of any planform.

17 WIND ENERGY↗

DOE OSTI2022

Learning Optimal Aerodynamic Designs

This project created a framework for efficient, accurate, and scalable deep neural network representations of design optimization problem solutions. The inputs to these DNN representations are the vector of design requirement parameters, the outputs are the optimal design variables, and the goal is to learn the map from inputs to outputs (i.e., inverse design). The team addressed the problem of the optimal shape design of aerodynamic lifting surfaces—in particular aircraft wings—using a Reynolds-Average Navier Stokes model to govern the CFD-based aerodynamic shape optimization. The inverse design map for such problems is very complex and high-dimensional, involving inputs and outputs on the order of 1000s. To approximate this inverse design map, the team developed algorithms to construct parsimonious DNN architectures, which automatically identify low-dimensional manifolds in which design requirements affect optimal shape parameters, and trained these architectures with multifidelity optimization methods. The resulting methodology accurately and automatically designs optimal aerodynamic lifting surfaces with very high accuracy (99%) at interactive speeds, of the order of milliseconds, resulting in factors of one million or more speedup relative to CFD-based design optimization.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

A digital twin solution for floating offshore wind turbines validated using a full-scale prototype

Abstract. In this work, we implement, verify, and validate a physics-based digital twin solution applied to a floating offshore wind turbine. The digital twin is validated using measurement data from the full-scale TetraSpar prototype. We focus on the estimation of the aerodynamic loads, wind speed, and section loads along the tower, with the aim of estimating the fatigue lifetime of the tower. Our digital twin solution integrates (1) a Kalman filter to estimate the structural states based on a linear model of the structure and measurements from the turbine, (2) an aerodynamic estimator, and (3) a physics-based virtual sensing procedure to obtain the loads along the tower. The digital twin relies on a set of measurements that are expected to be available on any existing wind turbine (power, pitch, rotor speed, and tower acceleration) and motion sensors that are likely to be standard measurements for a floating platform (inclinometers and GPS sensors). We explore two different pathways to obtain physics-based models: a suite of dedicated Python tools implemented as part of this work and the OpenFAST linearization feature. In our final version of the digital twin, we use components from both approaches. We perform different numerical experiments to verify the individual models of the digital twin. In this simulation realm, we obtain estimated damage equivalent loads of the tower fore–aft bending moment with an accuracy of approximately 5 % to 10 %. When comparing the digital twin estimations with the measurements from the TetraSpar prototype, the errors increased to 10 %–15 % on average. Overall, the accuracy of the results is promising and demonstrates the possibility of using digital twin solutions to estimate fatigue loads on floating offshore wind turbines. A natural continuation of this work would be to implement the monitoring and diagnostics aspect of the digital twin to inform operation and maintenance decisions. The digital twin solution is provided with examples as part of an open-source repository.

17 WIND ENERGY↗

DOE OSTI2020

A gravo-aeroelastically scaled wind turbine rotor at field-prototype scale with strict structural requirements

A new sub-scale field-prototype design solution is developed to realize the dynamics, structural response, and distributed loads (gravitational, aerodynamic, centrifugal) that are characteristic of a full-scale large, modern wind turbine rotor. Prior work in sub-scale wind turbine testing has focused on matching aerodynamic/aero-elastic characteristics of full-scale rotors at wind tunnel scale. However, large-scale rotor designs must expand beyond this limited set of scaling parameters for cost-effective prototyping and meet strict requirements for structural safety for field testing. Here, the challenge lies in producing a structural design meeting two competing objectives: novel scaling objectives that prescribe the sub-scale blade to have low mass and stiffness; and traditional structural safety objectives that drive the design to have higher stiffness and mass. A 20% gravo-aeroelastically scaled wind turbine blade is developed successfully that satisfies these competing objectives. First, it achieved close agreement for non-dimensional tip deflection and flap-wise blade frequency (both within 2.1%) with a blade mass distribution constrained to produce target gravitational and centrifugal loads. Second, the entire blade structure was optimized to ensure a safe, manufacturable solution meeting strict strength requirements for a testing site that can experience up to 45 m/s wind gusts. The prototype-scale blade was fabricated and successfully proof-load tested.

17 WIND ENERGY↗

DOE OSTI2023

Optimal sensor placement for reconstructing wind pressure field around buildings using compressed sensing

Deciding how to optimally deploy sensors in a large, complex, and spatially extended structure is critical to ensure that the surface pressure field is accurately captured for subsequent analysis and design. In some cases, reconstruction of missing data is required in downstream tasks such as the development of digital twins. Here, this paper presents a data-driven sparse sensor selection algorithm, aiming to provide the most information contents for reconstructing aerodynamic characteristics of wind pressures over tall building structures parsimoniously. The algorithm first fits a set of basis functions to the training data, then applies a computationally efficient QR algorithm that ranks existing pressure sensors in order of importance based on the state reconstruction to this tailored basis. The findings of this study show that the proposed algorithm successfully re- constructs the aerodynamic characteristics of tall buildings from sparse measurement locations, generating stable and optimal solutions across a range of conditions. As a result, this study serves as a promising first step toward leveraging the success of data-driven and machine learning algorithms to supplement traditional genetic algorithms currently used in wind engineering.

42 ENGINEERING↗

DOE OSTI2022

Towards new zero-thermal-expansion materials: Li-free quartz solid solutions stuffed with transition metal cations

Stuffed aluminosilicate quartz solid solutions (Qss) represent the main functional component of state-of-the-art zero-thermal-expansion glass-ceramics. For the first time, we present the synthesis of Li-, Mg- and Zn-free Qss solely stuffed with transition metal cations (Fe 2+ , Ni 2+ , Co 2+ ); partial Li + co-doping enables also significant Mn 2+ incorporation. Further, they were obtained by glass powder crystallization; Qss crystals exhibit compositionally tunable coefficients of thermal expansion (CTEs), from - 2 × 10 -6 K -1 to ~10 × 10 -6 K -1 in the range 30–300 °C. Co 2+ -bearing crystals exhibit the closest-to-zero CTE value (0.2 ×10 -6 K -1 ) and the most isotropic behavior in the whole Qss family, opening up new perspectives for the development of Li-free low-expansion materials. From a structural point of view, we identified the unit cell volume (and not the pseudo-hexagonality of the aluminosilicate framework) as the key structural parameter leading to low or negative CTEs in Qss, with a linear correlation extending to non-stuffed non-silicate quartz-like phases.

36 MATERIALS SCIENCE↗

DOE OSTI2021

An investigation of aqueous ammonium nitrate aerosols with soft X-ray spectroscopy

Aqueous aerosols are important in atmospheric chemistry, drug delivery, and human health. X-ray photoelectron spectroscopy (XPS), a surface-sensitive technique and near-edge X-ray absorption fine structure (NEXAFS) spectroscopy which informs on the bulk, is deployed to study the solvation of ammonium nitrate (NH 4 NO 3 ). Aerosolised solutions of NH 4 NO 3 were introduced into a photoelectron spectrometer via an aerodynamic lens, and interrogated with soft X-ray photons, the resulting electrons were imaged via velocity map imaging. Density functional theory calculations were performed to compare with the measured binding energies of NH 4 + and NO 3 - solvated in water. The results reveal that the nitrate anion has a slight propensity for the surface, while both ammonium and nitrate ions are present in equal measure in the bulk.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2018

Large eddy simulation/dynamic thickened flame modeling of a high Karlovitz number turbulent premixed jet flame

Due to the complex multiscale interaction between intense turbulence and relatively weak flames, turbulent premixed flames in the thin and broken reaction zones regimes exhibit strong finite-rate chemistry and strain effects and are hence challenging to model. Here, in this paper, a laboratory premixed jet flame in the broken reaction zone, which has recently been studied using direct numerical simulation (DNS), is modeled using a large eddy simulation (LES)/dynamic thickened flame (DTF) approach with detailed chemistry. The presence of substantial flame thickening due to strong turbulence-chemistry interactions, which can be characterized by a high Karlovitz number ( Ka ), requires the DTF model to thicken the flame in an adaptive way based on the local resolution of flame scales. Here, an appropriate flame sensor and strain-sensitive flame thickness are used to automatically determine the thickening location and thickening factor, respectively. To account for finite-rate chemistry and strain effects, the chemistry is described in two different ways: (1) detailed chemistry denoted as full transport and chemistry (FTC), and (2) tabulated chemistry based on a strained premixed flamelet (SPF) model. The performance of the augmented LES/DTF approach for modeling the high Ka premixed flame is assessed through detailed a posteriori comparisons with DNS of the same flame. It is found that the LES/DTF/FTC model is capable of reproducing most features of the high Ka turbulent premixed flame including accurate CO and NO prediction. The LES/DTF/SPF model has the potential to capture the impact of strong turbulence on the flame structure and provides reasonable prediction of pollutant emissions at a reasonable computational cost. In order to identify the impact of aerodynamic strain, the turbulent flame structure is analyzed and compared with unstrained and strained premixed flamelet solutions. Lastly, the results indicate that detailed strain effects should be considered when using tabulated methods to model high Ka premixed flames.

42 ENGINEERING↗

DOE OSTI2025

Soft x-ray spectroscopy of ammonium sulfate aerosols at varied pH conditions

Aqueous aerosols are useful model systems for understanding the physical chemistry that takes place in the Earth’s atmosphere, as well as the chemistry of other solar system objects. Ammonium sulfate aerosols are impacted by anthropogenic sources such as farming and shipping and are understood to be important seeds of cloud nucleation in the atmosphere, affecting climate. X-ray photoelectron spectroscopy and near edge x-ray absorption fine structure spectroscopy were used in tandem to probe the surface and bulk properties of aqueous (NH 4 ) 2 SO 4 , respectively. Aerosolized solutions of (NH 4 ) 2 SO 4 , some altered with NaOH to modify pH, were introduced via an aerodynamic lens to a velocity map imaging instrument for detection. The results show that as pH and sodium cation concentration increase, sulfate anion and ammonia become more prevalent at the surface, and the aerosol surface appears to become drier. However, most of the aerosol remains aqueous, with ion concentrations insensitive to the addition of NaOH. Density functional theory calculations were also performed to probe the coordination environment at the aerosol surfaces to understand the underlying phenomena. Finally, the changes seen on the surface of the aerosol underscore the importance of pH in regulating the structure and chemical properties of atmospherically relevant aerosols.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

An efficient approach to explore the solution space of a wind turbine rotor design process

This study proposes a novel approach to explore the solution space of a wind turbine rotor design process. The goal is to offer to blade designers the possibility to select an optimal rotor for given market conditions, assessing trade-offs and alternatives in a matter of minutes. The design process consists of sequential aerodynamic-structural optimizations, where the two loops are linked via a blade-loading parameter that can be varied by the user. A design study is performed starting from the IEA Wind Task 37 land-based reference wind turbine. The solution space is characterized for rotor diameters in the range of 130–160 m, rated generator power values in the range of 3.0–6.0 MW, and tip-speed ratios in the range of 7.5–12.5. Results are discussed highlighting optimal design decisions and trade-offs.

17 WIND ENERGY↗

DOE OSTI2024

Non-uniform active learning for Gaussian process models with applications to trajectory informed aerodynamic databases

The ability to non-uniformly weight the input space is desirable for many applications, and has been explored for space-filling approaches. Increased interests in linking models, such as in a digital twinning framework, increases the need for sampling emulators where they are most likely to be evaluated. In particular, here we apply non-uniform sampling methods for the construction of aerodynamic databases. This paper combines non-uniform weighting with active learning for Gaussian Processes (GPs) to develop a closed-form solution to a non-uniform active learning criterion. We accomplish this by utilizing a kernel density estimator as the weight function. We demonstrate the need and efficacy of this approach with an atmospheric entry example that accounts for both model uncertainty as well as the practical state space of the vehicle, as determined by forward modeling within the active learning loop.

42 ENGINEERING↗

DOE OSTI2025

Nonseeded linewise temperature measurements by resonantly ionized photoemission thermometry in a Mach 4 Ludwieg tube

A one-dimensional (1D) thermometry using oxygen-tagging resonantly ionized photoelectron thermometry (O 2 RIPT) was employed to investigate thermal gradients within a Mach 4 Ludwieg tube. The Ludwieg tube is pulsed with a test duration of approximately 100 ms, providing a cold supersonic flow at Mach 4 ideal for studying aerothermal effects. This study focused on measuring freestream temperatures, capturing shock-induced heating behind a detached bow shock from a blunt cylinder, and resolving sharp temperature variations across a bow shock generated by a cylinder. The O 2 RIPT technique produced strong emission signals extending approximately 4 cm long, demonstrating its capability for precise temperature measurements in high-speed wind tunnel environments. The results confirm that O 2 RIPT is well-suited for applications in large-scale aerodynamic testing facilities, particularly in regions with strong compression effects, enabling the resolution of sharp thermal gradients. This method presents a promising solution for thermometry in dynamic flow conditions relevant to various experimental ground-test facilities.

McCord, Walker (ORCID:0000000179747550)↗

DOE OSTI2025

Unsteady aerodynamic loads on pitching aerofoils represented by Gaussian body force distributions

The actuator line model (ALM) is an approach commonly used to represent lifting and dragging devices like wings and blades in large-eddy simulations (LES). The crux of the ALM is the projection of the actuator point forces onto the LES grid by means of a Gaussian regularisation kernel. The minimum width of the kernel is constrained by the grid size; however, for most practical applications like LES of wind turbines, this value is an order of magnitude larger than the optimal value that maximises accuracy. This discrepancy motivated the development of corrections for the actuator line, which, however, neglect the effect of unsteady spanwise shed vorticity. In this work we develop a model for the impact of spanwise shed vorticity on the unsteady loading of an aerofoil modelled as a Gaussian body force distribution, where the model is applicable within the regime of unsteady attached flow. The model solution is derived both in the time and frequency domain and features an explicit dependence on the Gaussian kernel width. We verify the model with ALM-LES for both pitch steps and periodic pitching. The model solution is compared with Theodorsen theory and validated with both computational fluid dynamics using body fitted grids and experiment. It is concluded that the optimal kernel width for unsteady aerodynamics is approximately 40 % of the chord. The ALM is able to predict the magnitude of the unsteady loading up to a reduced frequency of 𝑘 ≈ 0.2.

17 WIND ENERGY↗

DOE OSTI2021

Design of a 3.4-MW wind turbine with integrated plasma actuator-based load control

Historically, cost reduction in wind energy has been accomplished by increasing hub heights and rotor diameters to capture more energy per turbine. The growth in rotor and turbine costs with increasing turbine sizes is also driven by the additional structure that must be added to withstand unsteady aerodynamic loads caused by turbulence, gusts, wind shear, misaligned yaw, upwind wakes, and the tower shadow. In this paper, we present a holistic design solution to integrate active load control using a controllable Gurney flap based on plasma actuators. We illustrate the design solution for a land-based 3.4-MW wind turbine rotor. Comparisons to a baseline reference 3.4-MW wind turbine show significant load reduction (15–18% DEL reduction for flap-wise blade root moments), rotor mass reduction (5–8%), and LCOE reduction (1.16–3.11%). To achieve these results, a comprehensive sequential-iterative design procedure is introduced to integrate the controllable Gurney flap into the turbine design and to drive the design solution toward the best LCOE reduction solution. Results are presented for mapping fatigue load reductions into cost reductions. In addition, an evaluation of active load control extended from Region-III to also include Region-II showed a further 34% reduction in DEL.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗