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DOE OSTI2024

Measurement of Photovoltaic Module Deformation Dynamics During Hail Impact Using Digital Image Correlation

Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Furthermore, impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.

14 SOLAR ENERGY↗

DOE OSTI2026

Numerical simulation of vortex-induced vibration response of a single IEA 10-MW wind turbine blade

Three-dimensional simulation of vortex-induced vibration (VIV) of a single International Energy Agency (IEA) 10-MW reference wind turbine blade with a length of 97.325 m is performed using the ExaWind stack, an open-source suite of codes. This study aims to illustrate the spanwise VIV response characteristics and cross-validate the results with an existing commercial framework. Five near-body meshes and three time steps are selected for the convergence study. To improve computational efficiency, several VIV triggering methods are also compared to shorten the VIV development period. The ExaWind-based VIV simulation strategy for a single IEA 10-MW blade is determined. First, the modal shape is validated against published results. Then, spanwise VIV responses of four blade configurations under a fixed and varied incoming flow velocity are analyzed. Results show that the VIV response is dominated by the first edgewise (second overall) mode. Little first-mode contributions appear near the second-mode node, producing a pi phase jump, and a higher harmonics response occurs near the blade root. Rotational degrees of freedom are minor compared with translational motion. The response versus reduced velocity is analyzed, showing a two-branch behavior similar to that of VIV for a bluff cylinder. Across all tested cases, the dominant frequency remains locked to the natural frequency of the second mode with no observed desynchronization. A mild deviation is observed for the case of 90-degree pitch and 310-degree azimuth rotation near a reduced velocity of 6, which will be examined with additional cases in future work. These findings indicate that severe VIV responses can arise under specific configurations and flow conditions, thereby increasing the potential for VIV fatigue damage and requiring greater attention during operation.

17 WIND ENERGY↗

DOE OSTI2025

Injection locking and coupling dynamics in superconducting nanowire-based cryogenic oscillators

Oscillators designed to function at cryogenic temperatures play a critical role in superconducting electronics and quantum computing by providing stable, low-noise signals with minimal energy loss. Here, in this work, we present a comprehensive numerical study of injection locking and mutual coupling dynamics in superconducting nanowire (ScNW)-based cryogenic oscillators. Using the design space of a standalone ScNW-based oscillator, we investigate two critical mechanisms that govern frequency synchronization and signal coordination in cryogenic computing architectures: (1) injection locking induced by an external AC signal with a frequency near the oscillator's natural frequency, and (2) the mutual coupling dynamics between two ScNW oscillators under varying coupling strengths. We identify key design parameters—such as shunt resistance, nanowire inductance, and coupling strength—that govern the locking range. Additionally, we examine how the amplitude of the injected signal affects the amplitude of the locked oscillation, offering valuable insights for power-aware oscillator synchronization. Furthermore, we analyze mutual synchronization between coupled ScNW oscillators using capacitive and resistive coupling elements. Our results reveal that the phase difference between oscillators can be controlled by tuning the coupling strength, enabling programmable phase-encoded information processing. These findings could enable building ScNW-based oscillatory neural networks, synchronized cryogenic logic blocks, and on-chip cryogenic resonator arrays.

Artificial neural networks↗

DOE OSTI2024

Three-Dimensional Aerodynamics and Vortex-Shedding Characteristics of Wind Turbine Airfoils over 360-Degree Angles of Attack

In this work, we present the first three-dimensional (3D) computational investigation of wind turbine airfoils over 360° angles of attack to predict unsteady aerodynamic loads and vortex-shedding characteristics. To this end, static–airfoil simulations are performed for the FFA-W3 airfoil family at a Reynolds number of 107 with the Improved Delayed Detached Eddy Simulation turbulence model. Aerodynamic forces reveal that the onset of boundary-layer instabilities and flow separation does not necessarily coincide with the onset of stall. In addition, a comparison with two-dimensional simulation data and flat plate theory extension of airfoil polars, suggest that, in the deep stall regime, 3D effects remain critical for predicting both the unsteady loads and the vortex-shedding dynamics. For all airfoils, the vortex-shedding frequencies are found to be inversely proportional to the wake width. In the case of slender airfoils, the frequencies are nearly independent of the airfoil thickness, and their corresponding Strouhal number St is approximately 0.15. Based on the calculated St, the potential for shedding frequencies to coincide with the natural frequencies of the International Energy Agency 15 MW reference wind turbine blades is investigated. The analysis shows that vortex-induced vibrations occur primarily at angles of attack of around ±90° for all airfoils.

17 WIND ENERGY↗

DOE OSTI2025

VorLap

SAND2025-10210O VorLap is a vortex-induced vibration overlap prediction tool for static structures, such as parked wind turbines and marine turbines encountering fluid flow (water or air movement around them) that may induce vortex-induced vibration. This tool uses precomputed frequency domain data for specific cross-sectional shapes or a generalized shedding model, along with geometric data and structural natural frequency data, to identify areas and conditions where vortex-induced vibration may occur. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Moore, Kevin [Sandia National Lab. (SNL-CA), Liver↗

DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

This work presents the design of a transportation frame system for 650~MHz superconducting radio frequency cavities with high power couplers. Modal analysis identified the coupler antenna as the critical component with a 38~Hz natural frequency, leading to a dual-frame design with wire rope isolators that achieves 82\% vibration attenuation at the critical frequency. The system meets all transportation requirements, fits within standard shipping crates, and maintains structural integrity under 12g shock loads.

42 ENGINEERING↗

DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

Argento, Marco [Fermilab]↗

DOE OSTI2026

Modeling frequency instability in high-quality resonant experiments

Modern resonant sensing tools can achieve increasingly high quality factors, which correspond to extremely narrow linewidths. In such systems, time variation of the resonator’s natural frequency can potentially impact its ability to accumulate power and its resulting sensitivity. One such example is the Dark SRF experiment, which utilizes superconducting radio frequency (SRF) cavities with quality factors of Q ∼ 10 10 . Microscopic deformations of the cavity lead to stochastic jittering of its resonant frequency with amplitude 20 times its linewidth. Naively, one may expect this to lead to a large suppression in accumulated power. In this work, we study in detail the effects of frequency instability on high-quality resonant systems, utilizing the Dark SRF experiment as a case study. We show that the timescale of jittering is crucial to determining its effect on power accumulation. Namely, when the resonant frequency varies sufficiently quickly, the system accumulates power as if there were no jittering at all. This implies that the sensitivity of a jittering resonator is comparable to that of a stable resonator. In the case of Dark SRF, we find that jittering only induces a ∼ 10 % loss in power. Our results allow the dark-photon exclusion bound from Dark SRF’s pathfinder run to be refined, leading to a constraint that is an order of magnitude stronger than previously reported (corresponding to a signal-to-noise ratio that is four orders of magnitude larger). This result represents the world-leading constraint on dark photons over a wide range of masses below 6 μ eV and translates to the best laboratory-based limits on the photon mass m γ < 2.9 × 10 - 48 g .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Bayesian stability and force modeling for uncertain machining processes

Accurately simulating machining operations requires knowledge of the cutting force model and system frequency response. However, this data is collected using specialized instruments in an ex-situ manner. Bayesian statistical methods instead learn the system parameters using cutting test data, but to date, these approaches have only considered milling stability. This paper presents a physics-based Bayesian framework which incorporates both spindle power and milling stability. Initial probabilistic descriptions of the system parameters are propagated through a set of physics functions to form probabilistic predictions about the milling process. The system parameters are then updated using automatically selected cutting tests to reduce parameter uncertainty and identify more productive cutting conditions, where spindle power measurements are used to learn the cutting force model. The framework is demonstrated through both numerical and experimental case studies. Results show that the approach accurately identifies both the system natural frequency and cutting force model.

42 ENGINEERING↗

DOE OSTI2025

Design of a shipping fixture for a compact cryomodule hermetic assembly

Two conduction-cooled 915 MHz superconducting radio frequency hermetic assemblies must be safely transported from the Jefferson Lab in Newport News, VA to General Atomics in San Diego, CA for perfor-mance testing in a custom horizontal test cryostat. One hermetic assembly consists of a 2-cell 915 MHz cavity, a coaxial fundamental power coupler, and the warm-to-cold transition beam tubes. The second hermetic assembly consists of a 2-cell 915 MHz cavity only. The assemblies will be transported on a flatbed air-ride trailer over the approximate 4000 km distance. Design requirements included adequate attenuation of 4g vertical axis, 5g beamline axis, and 1.5g lateral axis shock events. The isolation system was designed using helical wire-rope isolators with modal and transient finite element analysis performed in Ansys. Results show shock attenuation of a 10 ms half-sine pulse input to < 1g in the vertical axis, < 1.5g in the beam-line axis, and < 0.5g in the lateral axis for both assem-blies at the specified design loads and all structural stresses are kept below the material yield limits. Addi-tionally, the natural frequencies of both isolation sys-tems adequately attenuate the fundamental modes of the critical structures.

Accelerator Physics↗

DOE OSTI2024

Monodomain Liquid‐Crystal Elastomer Lattices for Broad Strain‐Rate Mechanical Damping

Designing structures that effectively dissipate energy across a broad range of mechanical loading rates, including those from compression, shock, and vibration, poses a significant engineering challenge. In this study, liquid‐crystal elastomers (LCEs), which possess anisotropic properties due to the alignment of their polymer backbone, are explored. As a result, LCEs exhibit a soft elastic response under mechanical loading, making them ideal for energy dissipation. Advances in additive manufacturing (AM) enable simple fabrication of foamlike dissipative structures with complex lattice geometries. Herein, direct ink write 3D printing, an extrusion AM method, is used to fabricate aligned, monodomain LCE lattice structures for broad strain‐rate mechanical damping. In this work, it is shown that these structures can dissipate strain energy in quasi‐static environments, comparable to traditional elastomeric lattices, and provide improved damping under high strain‐rate drop testing due to LCE soft elasticity. Additionally, under dynamic mechanical vibration, monodomain LCE lattices enhance damping at structural natural frequencies and provide high‐frequency attenuation. Finally, in these findings, a promising method is presented for fabricating mechanical damping devices that effectively dissipate energy across a broad range of loading rates.

3D printings↗

DOE OSTI2024

Validation of a Tapered Impact Damper for Traffic Signal Structure Vibrations Using the Method of Harmonic Balance

Significant vibration amplitudes and cycles can be produced when traffic signal structures with low inherent damping are excited near one of their natural frequencies. For the mitigation of wind-induced vibrations, dynamic vibration absorbers coupled to the structure are often used. Here, this research investigates the performance of a tapered impact damper, consisting of a hanging spring-mass oscillator inside a housing capable of reducing vibration amplitude over a broader frequency range than the conventional tuned mass damper. A nonlinear, two degree-of-freedom model is developed with coordinates representing the traffic structure and the tapered impact damper. This research focuses on the application of the harmonic balance method to approximate the periodic solutions of the nonlinear equations to compute the nonlinear dynamics of the damped traffic signal structure. After designing and manufacturing a tapered impact damper, the traffic signal structure is tested with and without the damper using free vibration snapback tests. The experimental frequency and damping backbone curves are used to validate the analytical model, and the effectiveness of the damper is discussed.

42 ENGINEERING↗

DOE OSTI2024

Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

42 ENGINEERING↗

DOE OSTI2026

OC7 Project Phase II: Code Comparison and Experimental Validation of Hydroelastic Effects and Member-Level Loads in Floating Structures

This paper presents results from Phase II of the OC7 project, focusing on hydroelastic modeling and member-level load prediction for a flexible floating offshore structure. Numerical predictions from 11 academic and industrial partners are validated against experimental measurements obtained from a 1:70-scale test of the VolturnUS-S semisubmersible platform. A comprehensive set of verification and validation cases is examined. The results demonstrate that hydrodynamic added mass has a significant impact on predicted elastic natural frequencies. Under regular wave excitation, the numerical models reproduce platform motions and mooring line tensions with good accuracy. Member-level loads are also predicted with reasonable accuracy. Some discrepancies are observed for potential-flow models not accounting for higher-order effects associated with the instantaneous wetted surface.

17 WIND ENERGY↗

DOE OSTI2025

Maturing Rational Design Methodologies and Industry Consensus Engineering Standards: Critical Fastened Joints - Solar PV Industry

Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.

14 SOLAR ENERGY↗

DOE OSTI2025

Modal Analysis and Testing of a Cantilever Beam: Results and Guide

This report discusses modal analysis and testing of a cantilever beam including an introduction to modal testing, simulation, analysis, and a comparison of results. An accompanying presentation can be found from the LLNL CASIS website. Modal testing and analysis are essential for characterizing the response of a structure during vibration environments. Determining natural frequencies and mode shapes helps determine whether resonances will be reached during operations and if so, how the structure will respond and how the response can be tuned. The goal of this work is to convey the basics of modal testing and analysis through a simple project. This can be applied later to more complex, applicable structures. This includes a variety of work including data collection, finite element analysis and data processing. For this project a cantilever beam was chosen because it is a simple, well-characterized structure.

42 ENGINEERING↗

DOE OSTI2025

Finite Element Analysis of the TRUST Nonlinear Dynamics Testbed

This paper builds on prior work conducted within the Los Alamos National Laboratory (LANL) Testbeds to Reduce Uncertainty in Simulations and Tests (TRUST) program. Specifically, it builds on finite element (FE) modeling efforts for the TRUST program’s Nonlinear Dynamics (ND) testbed. Historically, the FE model for the ND testbed has exclusively utilized a Lanczos eigensolver that linearly extracts the system’s natural frequencies. This paper investigates the Abaqus 2024’s explicit dynamic solver, which implements a central difference explicit solver. The central difference method used in Abaqus can capture nonlinear material responses in structural dynamic simulations making it suitable for the ND FE model.

42 ENGINEERING↗

DOE OSTI2026

OC6 Phase Ia - Nonlinear hydrodynamic loading validation dataset

Two validation campaigns were examined within the Offshore Code Comparison Collaboration, Continued, with Correlation and unCertainty (OC6) Phase 1 project to examine the modeling tools' underprediction of loads and motion of a floating wind semisubmersible (semi) at their surge and pitch natural frequencies. These campaigns were performed at the Maritime Research Institute Netherlands (MARIN) in 2017 and 2018. The load cases (LC) considered include: LC1 – Load measurements across semi under current loading; LC2 - Load measurements across semi under forced surge oscillation; LC3 – Load measurements across semi under wave loading, while held fixed; LC4 – Free-decay motion measurements in surge, pitch, and heave; and LC5 – Motion measurements under wave loading. Details on the results from the OC6 Phase Ia project can be found in the reference, “OC6 Phase 1: Investigating the underprediction of low-frequency hydrodynamic loads and responses of floating wind turbines”, J Phys: Conf Series 1618 032033.

17 WIND ENERGY↗