Substructure Interface Reduction Techniques to Capture Nonlinearities in Bolted Structures.
Abstract not provided.
Singh, Aabhas↗
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Structural Health Monitoring: Using an Autoencoder to Identify Damage in a Bolted Joint [Capstone Project]
Los Alamos National Laboratory (LANL) is an important fixture in the United States Department of Energy’s (DOE) National Nuclear Security Agency (NNSA) complex. LANL is one of the largest national laboratories in the country, and the laboratory’s primary mission is to support the nation’s nuclear stockpile. The lab functions as a design agencies for the NNSA and performs extensive testing on weapons as part of that mission. The shock and vibration test team at LANL utilizes electrodynamic shaker systems for important qualification testing in support of the laboratory’s mission. Modern engineering relies heavily on bolted joints to connect two objects. During these shaker tests, engineers depend on bolted joints to secure the test article to a fixture and the fixture to the table. The test article may be hazardous and contain high explosives which could create a safety issue if a bolted joint failed. A loss of preload in a bolt will affect the way energy is input to the system and may introduce nonlinearities as the joint opens and closes. The loss of preload can create challenges controlling the test and make acquired signals useless. Being able to monitor preload within bolted joints during testing can improve the quality of the data and keep workers safe.
42 ENGINEERING↗
Comparative analysis of thermal management systems in electric vehicles at extreme weather conditions: Case study on Nissan Leaf 2019 Plus, Chevrolet Bolt 2020 and Tesla Model 3 2020
With the surge in electric vehicle (EV) adoption and the need for extended driving ranges, optimizing energy efficiency, particularly through thermal management, is critical, especially in extreme weather. Managing the substantial energy needed for cabin climate control and battery temperature regulation can increase energy demands by over 50 %, severely limiting range. This study conducts a comparative analysis of thermal management systems (TMS) in three popular EV vehicles, 2020 Chevrolet Bolt, 2019 Nissan Leaf Plus, and 2020 Tesla Model 3, evaluating their distinct TMS configurations and performance under varied weather conditions. Using both numerical simulations and experimental data collected on a controlled test bench at Argonne National Laboratory, we assess how TMS architecture and operational modes influence energy consumption and range. A comprehensive TMS model was developed, integrating cabin and battery thermal sub-models in the Autonomie software platform, to simulate temperature fluctuations and range impacts. Cabin climate was modeled using a mono-zonal approach, while battery cell temperature distribution was estimated through a 2D nodal structure. Each vehicle's distinct TMS setup was evaluated: the Chevrolet Bolt and Tesla Model 3 use a dual evaporator vapor compression cycle with a PTC heater for the cabin and a coolant loop for battery thermal management; the Nissan Leaf Plus employs a heat pump with a PTC heater for the cabin and air-cooling for the battery. Tests conducted at ambient temperatures of 35°C, 22°C, -7°C, and -18°C reveal significant differences in energy use and range reduction across both configurations and conditions. At 35°C, the Tesla Model 3, Chevrolet Bolt, and Nissan Leaf Plus have a range reduction of 8%, 9%, and 13%, respectively, due to air conditioning. In winter, heating technology is paramount; at -7°C, the Nissan Leaf's heat pump configuration achieves a lower range reduction (19.3%) compared to the Tesla and Chevrolet Bolt PTC heaters, which reduce range by 28.3% and 31%, respectively. Further, this study provides valuable insights for automotive engineers, EV technology researchers, and thermal management system designers aiming to enhance electric vehicle performance by understanding how different weather conditions and TMS architectures impact energy consumption and driving range.
33 ADVANCED PROPULSION SYSTEMS↗
Bolt installation and tensioning system
A bolt installation and removal (BIR) system is used for assembling and disassembling a nuclear vessel. The BIR system includes a platform with a stand for supporting the nuclear vessel. A track extends around an outside perimeter of the platform and multiple tool carts include wheels that roll on the track. Tool towers are located on the carts and include tool assemblies configured to install and remove bolts on the nuclear reactor vessel. Magazine towers also extend up from the tool carts next to the tool towers and include magazines that hold bolts for exchanging with the tool assemblies. Drive mechanisms move tool heads in the tool assemblies around a first vertical axis, vertically up and down, and laterally to more simply and reliably install and remove the bolts in a radioactive underwater environment.
Shaw, Steven W.↗
Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation
The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.
36 MATERIALS SCIENCE↗
Observations of modal coupling due to bolted joints in an experimental benchmark structure
The goal of this paper is to present a set of measurements from a benchmark structure containing two bolted joints to support future efforts to predict the damping due to the joints and to model nonlinear coupling between the first two elastic modes. Bolted joints introduce nonlinearities in structures, typically causing a softening in the natural frequency and an increase in damping because of frictional slip between the contact interfaces within the joint. These nonlinearities pose significant challenges when characterizing the response of the structure under a large range of load amplitudes, especially when the modal responses become coupled, causing the effective damping and natural frequency to not only depend on the excitation amplitude of the targeted mode, but also the relative amplitudes of other modes. In this work, two nominally identical benchmark structures, known in some prior works as the S4 beam, are tested to characterize their nonlinear properties for the first two elastic modes. Detailed surface measurements are presented and validated through finite element analysis and reveal distinct contact interactions between the two sets of beams. The free-free test structures are excited with an impact hammer and the transient response is analyzed to extract the damping and frequency backbone curves. A range of impact amplitudes and drive points are used to isolate a single mode or to excite both modes simultaneously. Differences in the nonlinear response correlate with the relative strength of the modes that are excited, allowing one to characterize mode coupling. Each of the beams shows different nonlinear properties for each mode, which is attributed to the different contact pressure distributions between the parts, although the mode coupling relationship is found to be consistent between the two. Lastly, the test data key finding are presented in this paper and the supporting data is available on a public repository for interested researchers.
42 ENGINEERING↗
Static and Fatigue Characterization of Large Composite T-Bolt Connections in Marine Hygrothermal Environments
Fiber-reinforced polymer composites have been highlighted as ideal candidates for structural applications in marine renewable energy devices, such as tidal turbines and wave energy converters. It is well understood that harsh marine environments can cause strength degradation of composite laminates, which has been extensively researched at the coupon scale; however, no research has investigated how this translates into larger-scale composite structures. This paper presents a subcomponent-scale study which investigates the effects of hygrothermal aging and subsequent static and fatigue characterization of thick composite T-bolt connections as part of a large, multilaboratory materials research effort. Of the glass-reinforced epoxy and vinylester-epoxy matrix composites tested, both showed measurable static strength degradation (4–36%) after being hygrothermally aged, even though the composite specimens were only partially saturated with water. Under tension–tension fatigue loading, the epoxy specimens performed very well in their dry states but exhibited significant degradation after hygrothermal aging. In comparison, the vinylester-epoxy specimens had much shorter fatigue lives in their dry states but exhibited no degradation after hygrothermal aging. Overall, this research demonstrates that hygrothermal aging can have significant effects on the ultimate strengths and fatigue lives of even partially saturated thick composite T-bolt connections, indicating that degradation of the outer plies on thick composite laminates can have pronounced effects on the whole structure. It discusses the challenges of building an understanding of the effects of harsh marine environments in large-scale composite structures.
16 TIDAL AND WAVE POWER↗
Bolt: A Fast Solver for Kinetic Theories Using a High-Resolution Constrained Transport Scheme [Slides]
Our understanding of collisionless and semi-collisional plasmas in the nonlinear regime is limited by the expense of computing solutions numerically. Bolt is a fast, GPU-accelerated code for rapidly computing such solutions with accurate transport and an approximate collision operator. Such calculations are relevant to both problems in astrophysics, such as heat conduction and magnetic reconnection in accretion disks around black holes, and also to programmatic interests at LANL. The bolt code paper, demonstrating accuracy via a suite of test problems calculated on kodiak, is currently in preparation.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
bolt: A GPU-Accelerated Solver for Marginally Collisional Kinetic Physics Using a High- Resolution Constrained Transport Scheme
Collisionless and marginally collisional plasmas are very expensive to simulate due to high dimensionality and large scale separations, especially in global problems with additional length scales. bolt addresses this challenge by achieving high performance on GPUs using the arrayfire performance portability library. We have demonstrated accuracy on a range of test problems, and the bolt code paper is currently in preparation.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
A nut-and-bolt assembly of the bimodular large progenitor botulinum neurotoxin complex
Botulinum neurotoxin serotype A (BoNT/A) is naturally produced by bacteria along with four nontoxic neurotoxin-associated proteins (NTNH, HA70, HA33, and HA17), forming a bimodular large progenitor toxin complex (L-PTC). The BoNT/A–NTNH complex protects the toxin from adverse environment, while the complex consisting of HA proteins facilitates toxin absorption during oral intoxication. How these two independent modules assemble into the L-PTC remains unclear. Here, we report the crystal structure of the BoNT/A–NTNH–HA70 complex at ~2.9-Å resolution. The structure reveals that the BoNT/A–NTNH complex is anchored into a concentric double β-barrel channel of trimeric HA70 through a short β-hairpin of NTNH (termed nLoop), resembling a nut-and-bolt attachment. We find that the nLoop of NTNH is strictly conserved across HA-containing BoNT complexes and that NTNH–HA70 binding is interchangeable among them. Furthermore, we demonstrate that the nLoop functions as a minimal motif enabling attachment of a protein-of-interest to the HA complex, with potential applications in oral biologics delivery.
Science & Technology - Other Topics↗
Bolt pre-tensioning in Diablo: A step-by-step guide [Slides]
A new bolt-pretensioning feature has been added to Diablo. This provides a more automated alternative to previous approaches.
42 ENGINEERING↗
Analysis of Deformation and Fracture Mechanisms in the Harvested Low-Dose Baffle Former Bolt via Advanced Mechanical Tests
This report details the production of tensile specimens from in-service irradiated baffle former bolts (BFBs) and presents the results of a pilot in-situ SEM/EBSD test conducted at Oak Ridge National Laboratory’s Low Activation Materials Development and Analysis (LAMDA) facility. The SEM/EDS results confirmed that the material is AISI 316L steel, not AISI 347, and that no Nb addition was detected in several analyzed locations. EBSD analysis of the microstructure revealed in-grain misorientation gradients indicative of cold work, likely caused by material processing, and no retained ferrite was identified. During straining, dislocation channel formation was the primary deformation mechanism, with twinning also observed in favorably oriented grains at local strains as small as ~1.5%. No strain-induced phase instability was observed, likely due to the fact that the Ni and Cr content reached the upper limits for the 316L steel specification. Multiple microfracture events were observed during the tensile test. Fine strain-induced pores formed at the channel-grain boundary intersection points, while coarser microcracks were associated with non-metallic inclusions. Data analysis is ongoing, and additional tests are planned in the near future to provide more statistics and details.
36 MATERIALS SCIENCE↗
Computer vision-based rock bolt detection in orthomosaic imagery obtained in the Waste Isolation Pilot Plant underground facility
Assessing structural integrity of large underground tunnel facilities is often a time consuming and human-labor intensive task. Thus, research using various modes of sensing and automated detection of key structural components in mines is posed to aid in safety assessments and establishing overall structural health. We propose an approach utilizing off-the-shelf camera and lidar technology fixed to a custom sensing platform, image stitching techniques, fine-tuned object detection models, and specialized model-inference methods to automatically detect, count, and map roof bolts for assessment of structural safety in man-made underground tunnels. Results show a novel workflow for effective object counting in orthomosaic tunnel ceiling images generated from collections in GPS-denied mining environments. Additionally, we demonstrate effective fine-tuning of EfficientDet object detectors utilizing state-of-the-art image augmentation techniques known as the mosaic and mixup transformations. Our work is demonstrated on sensed data and imagery collected from the Department of Energy (DOE) Waste Isolation Pilot Plant (WIPP) where miles of tunnel ceiling must be assessed for structural integrity.
42 ENGINEERING↗
Fundamentals of Solar PV Bolted Joint Loosening and Prevention
The photovoltaic (PV) industry has long reported anecdotal accounts of systems exhibiting intermittent or chronic fastener loosening, including joints that fail to maintain preload despite multiple re-tightening attempts. These occurrences are frequently, and often incorrectly, attributed to installer errors, vibration, or loading beyond design expectations (e.g., extreme weather events). Loose fasteners have serious implications and can significantly impact solar PV systems’ performance, reliability, and safety. However, effective bolted joint design and proper assembly practices can mitigate or eliminate loosening. Until the US Department of Energy’s Solar Energy Technologies Office (SETO) funded research on fasteners and solar PV structures, there was a notable gap in understanding the causes of loosening in solar PV systems.
14 SOLAR ENERGY↗
Numerical Bolted Joint Identification
Slides showing work done to identify bolted joint dynamics during summer internship.
Jackson, Mark William [Sandia National Laboratorie↗
Resilient Solar PV Structures a.k.a. the "Nuts and Bolts" of PV Resilience
Solar photovoltaic (PV) systems can and has survived many extreme weather events. On occasion, however, solar PV systems have been damaged. This damage is related more to the features of individual PV systems rather than the magnitude of the weather events. Much of this damage can be avoided with relatively simple, cost-effective measures that include design, installation, inspection, and O&M best practices.
14 SOLAR ENERGY↗
Bolt Preload Loss due to Modal Excitation of a C-Beam Structure.
Abstract not provided.
Miller, Mr. Max↗
Nonlinear Variability due to Mode Coupling in a Bolted Benchmark Structure.
Abstract not provided.
Wall, Mitchell P.J.↗