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Results for “Tolerance design”

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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Optimum Tolerance Design Using Component-Amount and Mixture-Amount Experiments

One type of tolerance design problem involves optimizing component and assembly tolerances to minimize the total cost (sum of manufacturing cost and quality loss). Previous literature recommended using traditional response surface (RS) designs and models to solve this type of tolerance design problem. In this article, component-amount (CA) and mixture-amount (MA) approaches are proposed as more appropriate for solving this type of tolerance design problem. The advantages of the CA and MA approaches over the RS approach are discussed. Reasons for choosing between the CA and MA approaches are also discussed. The CA and MA approaches (experimental design, response modeling, and optimization) are illustrated using real examples.

component-amount experiment↗
DOE OSTI2015

SU-E-T-760: Tolerance Design for Site-Specific Range in Proton Patient QA Process Using the Six Sigma Model

Purpose: To show how tolerance design and tolerancing approaches can be used to predict and improve the site-specific range in patient QA process in implementing the Six Sigma. Methods: In this study, patient QA plans were selected according to 6 site-treatment groups: head &neck (94 cases), spine (76 cases), lung (89 cases), liver (53 cases), pancreas (55 cases), and prostate (121 cases), treated between 2007 and 2013. We evaluated a model of the Six Sigma that determines allowable deviations in design parameters and process variables in patient-specific QA, where possible, tolerance may be loosened, then customized if it necessary to meet the functional requirements. A Six Sigma problem-solving methodology is known as DMAIC phases, which are used stand for: Define a problem or improvement opportunity, Measure process performance, Analyze the process to determine the root causes of poor performance, Improve the process by fixing root causes, Control the improved process to hold the gains. Results: The process capability for patient-specific range QA is 0.65 with only ±1 mm of tolerance criteria. Our results suggested the tolerance level of ±2–3 mm for prostate and liver cases and ±5 mm for lung cases. We found that customized tolerance between calculated and measured range reduce that patient QA plan failure and almost all sites had failure rates less than 1%. The average QA time also improved from 2 hr to less than 1 hr for all including planning and converting process, depth-dose measurement and evaluation. Conclusion: The objective of tolerance design is to achieve optimization beyond that obtained through QA process improvement and statistical analysis function detailing to implement a Six Sigma capable design.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Three-Dimensional Particle-in-Cell Analysis of Mechanical Design Tolerances of the Scorpius Injector With Warp

Here, this article examines the mechanical design tolerances for the Scorpius injector using a 3-D particle-in-cell (PIC) code. In order to meet its objective as a high-fidelity, multipulse flash X-ray source, the accelerator has requirements for the electron beam in order to minimize the spot size of the beam focused onto a foil target to create high fluence X-rays at energies greater than 10 MeV. The requirements for alignment of the cathode, anode beam pipe, focusing solenoids, and transport solenoids specified using Trak and AMBER are independently verified using a 3-D electrostatic/magnetostatic model of the Scorpius injector, including transverse magnetic field errors that arise from mechanical alignment errors. It is predicted that the injector will meet the performance requirements for radiographic operation and has a design margin to correct for potentially unforeseen operating conditions.

42 ENGINEERING↗
DOE OSTI2014

Case Study for Enhanced Accident Tolerance Design Changes

The ability to better characterize and quantify safety margin is important to improved decision making about Light Water Reactor (LWR) design, operation, and plant life extension. A systematic approach to characterization of safety margins and the subsequent margin management options represents a vital input to the licensee and regulatory analysis and decision making that will be involved. In addition, as research and development in the LWR Sustainability (LWRS) Program and other collaborative efforts yield new data, sensors, and improved scientific understanding of physical processes that govern the aging and degradation of plant systems, structures, and components (SSCs) needs and opportunities to better optimize plant safety and performance will become known. To support decision making related to economics, reliability, and safety, the Risk Informed Safety Margin Characterization (RISMC) Pathway provides methods and tools that enable mitigation options known as risk informed margins management (RIMM) strategies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

Case Study for Enhanced Accident Tolerance Design Changes

The ability to better characterize and quantify safety margin is important to improved decision making about Light Water Reactor (LWR) design, operation, and plant life extension. A systematic approach to characterization of safety margins and the subsequent margin management options represents a vital input to the licensee and regulatory analysis and decision making that will be involved. In addition, as research and development in the LWR Sustainability (LWRS) Program and other collaborative efforts yield new data, sensors, and improved scientific understanding of physical processes that govern the aging and degradation of plant systems, structures, and components (SSCs) needs and opportunities to better optimize plant safety and performance will become known. To support decision making related to economics, reliability, and safety, the Risk Informed Safety Margin Characterization (RISMC) Pathway provides methods and tools that enable mitigation options known as risk informed margins management (RIMM) strategies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

SU-D-BRC-02: Application of Six Sigma Approach to Improve the Efficiency of Patient-Specific QA in Proton Therapy

Purpose: To show how the Six Sigma DMAIC (Define-Measure-Analyze-Improve-Control) can be used for improving and optimizing the efficiency of patient-specific QA process by designing site-specific range tolerances. Methods: The Six Sigma tools (process flow diagram, cause and effect, capability analysis, Pareto chart, and control chart) were utilized to determine the steps that need focus for improving the patient-specific QA process. The patient-specific range QA plans were selected according to 7 treatment site groups, a total of 1437 cases. The process capability index, Cpm was used to guide the tolerance design of patient site-specific range. We also analyzed the financial impact of this project. Results: Our results suggested that the patient range measurements were non-capable at the current tolerance level of ±1 mm in clinical proton plans. The optimized tolerances were calculated for treatment sites. Control charts for the patient QA time were constructed to compare QA time before and after the new tolerances were implemented. It is found that overall processing time was decreased by 24.3% after establishing new site-specific range tolerances. The QA failure for whole process in proton therapy would lead up to a 46% increase in total cost. This result can also predict how costs are affected by changes in adopting the tolerance design. Conclusion: We often believe that the quality and performance of proton therapy can easily be improved by merely tightening some or all of its tolerance requirements. This can become costly, however, and it is not necessarily a guarantee of better performance. The tolerance design is not a task to be undertaken without careful thought. The Six Sigma DMAIC can be used to improve the QA process by setting optimized tolerances. When tolerance design is optimized, the quality is reasonably balanced with time and cost demands.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗
DOE OSTI2016

State of knowledge and challenges of U-Si compounds for use in light water reactor accident tolerant fuel designs

Characterization of the properties of U-Si compounds first required synthesis of high purity material for each of the compositions. The four compounds targeted for investigation in this work were U{sub 3}Si, U{sub 3}Si{sub 2}, USi, and U{sub 3}Si{sub 5}. Specimens of U{sub 3}Si{sub 2}, U{sub 3}Si{sub 5}, and USi with specific geometries for individual testing procedures were prepared using a powder metallurgical method. Thermophysical properties of the U-Si compounds were determined within 100 K of their respective melt point or decomposition temperature. Thermal expansion was determined with a dilatometer, specific heat capacity by the ratio method in a differential scanning calorimeter using a sapphire standard, while thermal diffusivity was determined with a laser flash analyzer. Oxidation performance of the U-Si compounds was determined in a thermogravimetric analyzer (TGA), which measures the weight change of a sample as a function of gas composition and temperature. The results show that each of the U-Si compounds is electronically conductive leading to higher thermal conductivity values than the reference fuel UO{sub 2}. Higher thermal conductivity values will lead to enhanced safety margins within a reactor core and provide better economics over the lifetime of a fuel cycle. However, no improvements have been realized over the reference UO{sub 2} case with regards to oxidation performance in air although more testing is required to substantiate the differences especially in steam and corrosive aqueous LWR environments. Finally, there exists a lack of knowledge in the literature with regards to low burnup irradiation testing on all of the U-Si binary compounds, which would be necessary to simulate their performance in a reactor setting.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Using supervised machine-learning approaches to understand abiotic stress tolerance and design resilient crops

Abiotic stresses such as drought, heat, cold, salinity and flooding significantly impact plant growth, development and productivity. As the planet has warmed, these abiotic stresses have increased in frequency and intensity, affecting the global food supply and making it imperative to develop stress-resilient crops. In the past 20 years, the development of omics technologies has contributed to the growth of datasets for plants grown under a wide range of abiotic environments. Integration of these rapidly growing data using machine-learning (ML) approaches can complement existing breeding efforts by providing insights into the mechanisms underlying plant responses to stressful conditions, which can be used to guide the design of resilient crops. In this review, we introduce ML approaches and provide examples of how researchers use these approaches to predict molecular activities, gene functions and genotype responses under stressful conditions. Finally, we consider the potential and challenges of using such approaches to enable the design of crops that are better suited to a changing environment. This article is part of the theme issue ‘Crops under stress: can we mitigate the impacts of climate change on agriculture and launch the ‘Resilience Revolution’?’.

abiotic stress↗
DOE OSTI2022

Maximizing Scrap Recycling by Designing Cu Tolerant Steel Compositions

Residual elements from scrap steel recycling, most notably copper, are known to result in hot shortness during thermomechanical processing and casting. As the concentration of copper and other residuals in steel scrap streams increases, Electric Arc Furnace (EAF) scrap recycling heats commonly use pig iron to dilute residuals below current limits. This work focuses on establishing residual element tolerant compositions and concomitant processing windows that can simultaneously mitigate issues from residuals during thermomechanical processing and, if possible, use these residuals to improve properties, yielding a more sustainable steel manufacturing pathway with a substantially smaller carbon footprint.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

A Misalignment Tolerant Magnetic Coupler Design and Implementation for Wireless Charging of Unmanned Aerial Vehicles (UAVs)

Wireless power transfer technology is getting more attention these days as a part of expanded battery charging infrastructure and network at a wide range of power levels. Charging Unmanned aerial vehicles (UAVs) is one wireless charging application, and charging their batteries can be challenging because they have short flight times and are frequently charged. For wireless charging of UAVs, the misalignment performance of the magnetic coupler pads is critical because landing on a charging pad at a perfectly aligned position is difficult and can be time-consuming. Different coil shapes and system structures have been proposed in the literature to overcome this challenge. A new design with a high misalignment tolerance is needed; therefore, to fill this gap, a wireless power transfer system has been designed for a 250 W UAV battery charging system with a new magnetic coupler design. A 3D model of the proposed design was created, and finite element simulations were performed. To prove the proposed design, the magnetic coupler prototypes were developed, and experimental results are presented herein. The misalignment tolerance of the proposed system was observed for various rotational positions of the secondary coil, from 0° to 360°. The results demonstrate that DC–DC efficiency varies between 80% and 85% within full 360° rotation of the receiver coil. This result enables the proposed system to address the misalignment problem for wireless charging of UAVs.

UAVs↗
DOE OSTI2014

Fault-tolerant dynamic task graph scheduling

In this paper, we present an approach to fault tolerant execution of dynamic task graphs scheduled using work stealing. In particular, we focus on selective and localized recovery of tasks in the presence of soft faults. We elicit from the user the basic task graph structure in terms of successor and predecessor relationships. The work stealing-based algorithm to schedule such a task graph is augmented to enable recovery when the data and meta-data associated with a task get corrupted. We use this redundancy, and the knowledge of the task graph structure, to selectively recover from faults with low space and time overheads. We show that the fault tolerant design retains the essential properties of the underlying work stealing-based task scheduling algorithm, and that the fault tolerant execution is asymptotically optimal when task re-execution is taken into account. Experimental evaluation demonstrates the low cost of recovery under various fault scenarios.

fault tolerance↗
DOE OSTI2015

Severe Accident Scoping Simulations of Accident Tolerant Fuel Concepts for BWRs

Accident-tolerant fuels (ATFs) are fuels and/or cladding that, in comparison with the standard uranium dioxide Zircaloy system, can tolerate loss of active cooling in the core for a considerably longer time period while maintaining or improving the fuel performance during normal operations. It is important to note that the currently used uranium dioxide Zircaloy fuel system tolerates design basis accidents (and anticipated operational occurrences and normal operation) as prescribed by the US Nuclear Regulatory Commission. Previously, preliminary simulations of the plant response have been performed under a range of accident scenarios using various ATF cladding concepts and fully ceramic microencapsulated fuel. Design basis loss of coolant accidents (LOCAs) and station blackout (SBO) severe accidents were analyzed at Oak Ridge National Laboratory (ORNL) for boiling water reactors (BWRs). Researchers have investigated the effects of thermal conductivity on design basis accidents, investigated silicon carbide (SiC) cladding, as well as the effects of ATF concepts on the late stage accident progression. These preliminary analyses were performed to provide initial insight into the possible improvements that ATF concepts could provide and to identify issues with respect to modeling ATF concepts. More recently, preliminary analyses for a range of ATF concepts have been evaluated internationally for LOCA and severe accident scenarios for the Chinese CPR1000 and the South Korean OPR-1000 pressurized water reactors (PWRs). In addition to these scoping studies, a common methodology and set of performance metrics were developed to compare and support prioritizing ATF concepts. A proposed ATF concept is based on iron-chromium-aluminum alloys (FeCrAl). With respect to enhancing accident tolerance, FeCrAl alloys have substantially slower oxidation kinetics compared to the zirconium alloys typically employed. During a severe accident, FeCrAl would tend to generate heat and hydrogen from oxidation at a slower rate compared to the zirconium-based alloys in use today. The previous study, [2], of the FeCrAl ATF concept during station blackout (SBO) severe accident scenarios in BWRs was based on simulating short term SBO (STSBO), long term SBO (LTSBO), and modified SBO scenarios occurring in a BWR-4 reactor with MARK-I containment. The analysis indicated that FeCrAl had the potential to delay the onset of fuel failure by a few hours depending on the scenario, and it could delay lower head failure by several hours. The analysis demonstrated reduced in-vessel hydrogen production. However, the work was preliminary and was based on limited knowledge of material properties for FeCrAl. Limitations of the MELCOR code were identified for direct use in modeling ATF concepts. This effort used an older version of MELCOR (1.8.5). Since these analyses, the BWR model has been updated for use in MELCOR 1.8.6, and more representative material properties for FeCrAl have been modeled. Sections 2 4 present updated analyses for the FeCrAl ATF concept response during severe accidents in a BWR. The purpose of the study is to estimate the potential gains afforded by the FeCrAl ATF concept during BWR SBO scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Radiopaque Resists for Two-Photon Lithography To Enable Submicron 3D Imaging of Polymer Parts via X-ray Computed Tomography

Two-photon lithography (TPL) is a high-resolution additive manufacturing (AM) technique capable of producing arbitrarily complex three-dimensional (3D) microstructures with features 2–3 orders of magnitude finer than human hair. This process finds numerous applications as a direct route toward the fabrication of novel optical and mechanical metamaterials, miniaturized optics, microfluidics, biological scaffolds, and various other intricate 3D parts. As TPL matures, metrology and inspection become a crucial step in the manufacturing process to ensure that the geometric form of the end product meets design specifications. X-ray-based computed tomography (CT) is a nondestructive technique that can provide this inspection capability for the evaluation of complex internal 3D structure. However, polymeric photoresists commonly used for TPL, as well as other forms of stereolithography, poorly attenuate X-rays due to the low atomic number (Z) of their constituent elements and therefore appear relatively transparent during imaging. We present the development of optically clear yet radiopaque photoresists for enhanced contrast under X-ray CT. We have synthesized iodinated acrylate monomers to formulate high-Z photoresist materials that are capable of forming 3D microstructures with sub-150 nm features. In addition, we have developed a formulation protocol to match the refractive index of the photoresists to the immersion medium of the objective lens so as to enable dip-in laser lithography, a direct laser writing technique for producing millimeter-tall structures. Our radiopaque photopolymer then resists increase X-ray attenuation by a factor of more than 10 times without sacrificing the sub-150 nm feature resolution or the millimeter-scale part height. Thus, our resists can successfully replace existing photopolymers to generate AM parts that are suitable for inspection via X-ray CT. By providing the “feedstock” for radiopaque AM parts, our resist formulation is expected to play a critical role in enabling fabrication of functional polymer parts to tight design tolerances.

36 MATERIALS SCIENCE↗
DOE OSTI2014

NDE reliability and probability of detection (POD) evolution and paradigm shift

The subject of NDE Reliability and POD has gone through multiple phases since its humble beginning in the late 1960s. This was followed by several programs including the important one nicknamed “Have Cracks – Will Travel” or in short “Have Cracks” by Lockheed Georgia Company for US Air Force during 1974–1978. This and other studies ultimately led to a series of developments in the field of reliability and POD starting from the introduction of fracture mechanics and Damaged Tolerant Design (DTD) to statistical framework by Bernes and Hovey in 1981 for POD estimation to MIL-STD HDBK 1823 (1999) and 1823A (2009). During the last decade, various groups and researchers have further studied the reliability and POD using Model Assisted POD (MAPOD), Simulation Assisted POD (SAPOD), and applying Bayesian Statistics. All and each of these developments had one objective, i.e., improving accuracy of life prediction in components that to a large extent depends on the reliability and capability of NDE methods. Therefore, it is essential to have a reliable detection and sizing of large flaws in components. Currently, POD is used for studying reliability and capability of NDE methods, though POD data offers no absolute truth regarding NDE reliability, i.e., system capability, effects of flaw morphology, and quantifying the human factors. Furthermore, reliability and POD have been reported alike in meaning but POD is not NDE reliability. POD is a subset of the reliability that consists of six phases: 1) samples selection using DOE, 2) NDE equipment setup and calibration, 3) System Measurement Evaluation (SME) including Gage Repeatability and Reproducibility (Gage R and R) and Analysis Of Variance (ANOVA), 4) NDE system capability and electronic and physical saturation, 5) acquiring and fitting data to a model, and data analysis, and 6) POD estimation. This paper provides an overview of all major POD milestones for the last several decades and discuss rationale for using Integrated Computational Materials Engineering (ICME), MAPOD, SAPOD, and Bayesian statistics for studying controllable and non-controllable variables including human factors for estimating POD. Another objective is to list gaps between “hoped for” versus validated or fielded failed hardware.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗