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At least 19 records

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

36 MATERIALS SCIENCE↗

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems (Final Report)

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all-ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

03 NATURAL GAS↗

Development of Agile and Cost Effective Routes for Manufacturing Reliable Ceramic Components for SOFC Systems (Final Scientific Report Updated)

Additive manufacturing routes were explored and developed to enable the low to medium volume manufacturing of ceramic components with a short lead time, flexibility for iterative design, and without the high CAPEX and tooling costs associated with green machining or injection molding. Agile manufacturing route of gelcasting and 3D printing were selected and work focused on the production of ceramic manifold components utilized in the balance of plant for Saint-Gobain’s all-ceramic SOFC stack. This work showed that both gelcasting and a specific version of 3D printing were able to create parts with the proper fidelity and at lower cost than traditional powder processing followed by green machining.

36 MATERIALS SCIENCE↗

LSE-319: LSST Science Platform Vision Document

This document defines and describes the "LSST Science Platform," a set of integrated web applications and services deployed at the LSST Data Access Centers (DACs) through which the scientific community will access, visualize, subset, and perform next-to-the-data analysis of the data collected by the Large Synoptic Survey Telescope (LSST). These services can be broken down to three different "Aspects": a web Portal, designed to provide essential data access and visualization services through a simple-to-use website, a Notebook environment, that will provide a Jupyter Notebook-like interface, based on JupyterLab, enabling next-to-the-data analysis, and an extensive set of Web APIs that the users will be able to use to remotely examine the LSST data set using tools they're already familiar with. This document lays out the high-level vision for the aforementioned Aspects and some associated backend services. It is intentionally brief, and meant to generally guide the flow-down of requirements and development of product specifications, prioritization, and plans for the Agile development of the relevant elements of the DM system.

79 ASTRONOMY AND ASTROPHYSICS↗

The development and evaluation of a medical imaging training immersive environment

A novel realistic 3D virtual reality (VR) application has been developed to allow medical imaging students at Queensland University of Technology to practice radiographic techniques independently outside the usual radiography laboratory. A flexible agile development methodology was used to create the software rapidly and effectively. A 3D gaming environment and realistic models were used to engender presence in the software while tutor-determined gold standards enabled students to compare their performance and learn in a problem-based learning pedagogy. Students reported high levels of satisfaction and perceived value and the software enabled up to 40 concurrent users to prepare for clinical practice. Student feedback also indicated that they found 3D to be of limited value in the desktop version compared to the usual 2D approach. A randomised comparison between groups receiving software-based and traditional practice measured performance in a formative role play with real equipment. The results of this work indicated superior performance with the equipment for the VR trained students (P = 0.0366) and confirmed the value of VR for enhancing 3D equipment-based problem-solving skills. Students practising projection techniques virtually performed better at role play assessments than students practising in a traditional radiography laboratory only. The application particularly helped with 3D equipment configuration, suggesting that teaching 3D problem solving is an ideal use of such medical equipment simulators. Ongoing development work aims to establish the role of VR software in preparing students for clinical practice with a range of medical imaging equipment.

07 ISOTOPE AND RADIATION SOURCES↗

PipeSight: A High-Performance Computing Platform for Pipeline Integrity Management

The Phase I feasibility study completed as part of this project has led to a number of innovative technologies being developed and has laid the foundation for a successful Phase II effort to commercialize a platform for managing the integrity of pipelines for the damage mechanisms of the new, hybrid-energy based economy. To ground the development efforts and direction of the project, an extensive market research and customer discovery effort was undertaken early in Phase I. Through this effort, a number of pipeline owners and operators were interviewed, and the following key findings were discovered about the pipeline industry: • Small pipeline operators do not have the central engineering groups necessary to perform their own independent analysis of inspection data, but instead rely on summarized tally sheets provided to them by inspection service providers. • The time it takes to go from an inspection to a completed engineering assessment, even for small segments of pipeline, can take anywhere from 30-120 days. During this delay, critical threats can (and have been known to) cause failures. • Uncertainty is often not accounted for in the assessment of pipeline integrity. The tally sheets provided by third-party service providers are almost always deterministic in nature, identifying threats that present a concern only to the current (not the future) integrity of the pipeline. • It is uncommon to apply the latest technologies to perform advanced assessments of damaged pipelines. There is a desire to use more advanced analysis capabilities to assess threats. Many pipeline operators indicated that they would often excavate a pipeline to perform an inspection and find that the damage was not as bad as they anticipated, thus using limited resources unnecessarily. Companies are not consistent in their use of inspection data to determine corrosion rates, and those that do only calculate deterministic corrosion rates. • The industry has prominently relied on time-based inspections but has recently started to transition to risk-based inspections. However, there appears to be no uniform guidance on how to do so while properly accounting for all sources of uncertainty. • Companies are not storing inspection data in a manner that allows for the ready determination of temporal trends. • Predictive maintenance principles and practices are beginning to be used by early adopters • Some pipelines are being re-purposed to transport different process fluids than they were designed for, e.g., H 2 and CO 2 rich process streams to serve the new hybrid-energy based economy, which are presenting new integrity concerns for the existing pipeline network that crisscrosses the United States. As a result of these discoveries, we were able to target the development efforts in Phase I to best serve the needs of the industry. In Phase I, we developed a way to correlate multiple large-scale scans of the pipeline to determine a probabilistic corrosion rate that accounts for all sources of error and uncertainty in the inspection process. This probabilistic corrosion rate can be used to predict the future thickness distribution of the pipe wall. We demonstrate how this analysis may be performed in an analytical fashion and has been implemented in such a manner that it can be readily distributed using GPU computing through integration of the Kokkos programming model. We also make a very novel extension of the analytical corrosion rate model to Bayesian Networks (an explainable AI technique) that can account for non-parametric distributions of corrosion rates. With the predictions made above for the probabilistic corrosion rate and corresponding future distribution of the pipe wall thickness, we can assess the integrity of the pipeline through the use of a probabilistic engineering assessment. We developed a novel screening data analysis approach that can rapidly identify ‘hotspots’ (local thin areas) where the integrity of the pipeline is a concern. Once more, we implemented this screening approach in C++ to leverage GPU computing via the Kokkos programming model. After the critical hotspots are identified, we developed a program that can automatically generate an advanced finite element model of the damaged regions. Since the number of damaged regions that require advanced analysis can number in the thousands, we integrated an open-source container-native workflow engine for orchestrating parallel jobs on the cloud. Initially, these advanced numerical models were only designed to account for loading due to internal pressure. However, in a slight pivot from the initial Phase I proposal, we developed a complete pipe stress analysis program (called Simflex) which can simulate the complete pipeline and its response to thermal expansion, pressure, thermal bowing, weight, wind, earthquake, support displacement, support friction and external forces. This pipe stress analysis program was written generically, to handle any piping system, but contains the features needed to model long pipelines (i.e., it incorporates a model for soil mechanics and can account for the nonlinear boundary conditions necessary to simulate long underground pipelines). This pipe stress analysis program can simulate any segment of the pipeline (simple or complex) under any set of conditions and loads, to determine the supplemental loads (axial forces and bending moments) at the location of damage. This enables the most accurate state of stress to be accounted for in the pipeline, which can prove critical when evaluating the integrity of a damaged region. In the process of developing the technologies to perform the integrity assessment of the pipeline, we also extended one of the industry standard approaches for performing the assessment of local thin areas that extend more in the circumferential direction than the longitudinal direction of the pipeline. This approach was presented to the API 579-1/AS ME FFS-1 steering committee in November 2021 for consideration in the next edition of the industry standard for Fitness-For-Service (expected to be released in 2023). To help pipeline operators make decisions with the results on any integrity assessment, we developed a new approach to the life-cycle management of pipelines which uses a Bayesian Decision Network. The network is designed to help pipeline operators plan and prioritize inspection activities and ultimately make smarter, more cost-effective decisions. The Bayesian approach accounts for all sources of uncertainty and carries them through to the final optimal decisions, providing a probabilistic framework for optimizing inspection intervals. The proof-of-concept networks developed in the feasibility study are complete, verified, and are focused on a subset of the pipeline. To expand this novel approach to the scale necessary for an entire network of pipelines in Phase II, we will leverage the DOE-funded Bengi solver for industrial-scale decision making with Bayesian Networks [22]. Once implemented, we will be able to provide the pipeline industry with a much-needed tool for optimal inspection planning using truly explainable artificial intelligence (XAI). To handle all of these advanced capabilities into a cloud-based platform, the architecture of the Equity Engineering Cloud (EEC) was extended to include Argo Workflows, a framework capable of distributing and managing a massive number of jobs that consume their own resources, such that thousands of serial finite element simulations can be run in parallel. As part of this substantial undertaking, we also integrated Argo Continuous Delivery (CD) into the EEC, to aid with the rapid prototyping and iterations that will be imperative to the success of the PipeSight platform’s Agile development process in Phase II. As part of the pipe stress analysis program, we also developed a custom visualizer that leverages the DOE-funded VTK visualization library. We added custom contouring capabilities and a means for interacting visually with both the inputs and outputs of the pipe stress analysis program. We also developed routines for automating the post-processing of the finite element simulations to determine if any failure criteria are met and to visualize the deformations, stresses and strains in ParaView using the exodus II file format (a subset of netCDF).

24 POWER TRANSMISSION AND DISTRIBUTION↗

CLARA: CLAS12 Reconstruction and Analysis Framework

In this paper we present SOA based CLAS12 event Reconstruction and Analyses (CLARA) framework. CLARA design focus is on two main traits: real-time data stream processing, and service-oriented architecture (SOA) in a flow based programming (FBP) paradigm. Data driven and data centric architecture of CLARA presents an environment for developing agile, elastic, multilingual data processing applications. The CLARA framework presents solutions capable of processing large volumes of data interactively and substantially faster than batch systems.

Gyurjyan, Vardan↗

Component based dataflow processing framework

In this paper we present SOA based CLAs12 event Reconstruction and Analyses (CLARA) framework used to develop Earth Science multi-sensor data fusion, processing, and analytics applications (NAIADS: NASA JLAB collaboration). CLARA design focus is on two main traits: a) real-time data stream processing, and b) service oriented architecture (SOA) in a flow based programming (FBP) paradigm. Data driven and data centric architecture of CLARA presents an environment for developing agile, elastic, multilingual data processing applications. The CLARA framework presents solutions, capable of processing large volumes of data interactively and substantially faster than batch systems.

Gyurjyan, V.↗

An Extensible Software and Communication Platform for Distributed Energy Resource Management

This paper introduces a novel Distributed Extensible Grid Control (DEGC) software and communication platform to facilitate the control of distributed energy resources on electric grids. The DEGC software platform leverages state-of-the-art advances in secure, distributed communication and decentralized authorization and authentication. We discuss how these advances enable the kind of robust and secure communication required for a distributed grid control platform, and show how DEGC applies these technologies to the agile development and deployment of grid software through an extensible and flexible API. Here, we describe how DEGC can implement both Volt-VAR voltage magnitude control and Phasor-Based Control as sample applications and demonstrate the DEGC platform in hardware with the demanding Phasor-Based Control test case, and provide performance metrics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

ECP Milestone Memo for 2.3.1.04.14

The DARMA many-task framework provides asynchronous communication and load balancing functionality. This functionality is embedded in standard, modern C++ through the use of the template wrapper classes similar to futures. DARMA previously functioned as a single, large repository. This simplified building and installation, but hindered agile development as individual components could not be easily updated or reused in other projects. DARMA components can now be developed independently and reused in other ECP projects. Through Spack and modern CMake, a complete DARMA package can be easily configured and installed with automatic dependency management for each of the configuration options.

97 MATHEMATICS AND COMPUTING↗

REYNO: A Reactive Hydrodynamics Modeling Suite

REYNO is a Python library that is primarily designed as a platform for the agile development and testing of novel reactive flow models. Equations of state and multi-step rate laws can be implemented using the provided class hierarchy with different thermodynamic closure conditions. The library includes a one-dimensional Lagrangian hydrodynamic solver to simulate multi-material reactive or inert problems in planar, cylindrical, or spherical coordinates. Custom time-dependent boundary conditions are also available for problems such as ramp compression. This document describes the different numerical methods and algorithms that are included in REYNO.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Flattening the Radial Temperature Profile across the Transformational Challenge Reactor Core

The Transformational Challenge Reactor (TCR) program is demonstrating an agile development approach to advanced nuclear reactor design, which has traditionally utilized a linear design process. In leveraging artificial intelligence, additive manufacturing, advanced materials, and cutting-edge modeling and simulation, the TCR program aims to minimize the high cost and lengthy deployment timelines now standard in the nuclear industry. Within a relatively short period of time, a robust and mature advanced gas-cooled reactor was iteratively designed under the TCR program, using these cutting-edge technologies. The TCR is a 3 MWt gas-cooled microreactor fueled with uranium nitride (UN) tristructural isotropic (TRISO) fuel particles. Though manufactured via traditional means, these UN TRISO particles are loaded into additively manufactured silicon carbide (SiC) cans [4]. Once loaded with TRISO particles, the SiC cans are densified using a chemical vapor infiltration process. The additively manufactured SiC enables significantly more freedom in the design of the fuel form than could ever be achieved using traditionally manufactured SiC. The helium coolant, pressurized to 5 MPa, enters the core at 300°C and nominally exits it at 500°C. Typically, the most thermally limiting components in any reactor design are the fuel assemblies in the core center. To provide a wide thermal margin in these central fuel assemblies, the flow may be biased toward the center of the core to more effectively cool these fuel assemblies with more power deposition and flatten the core’s radial temperature distribution. An analytical fluid model of the TCR core was developed to explore methods for biasing the flow away from the cooler outer fuel assemblies and towards the hotter inner ones. Higher-fidelity models developed in STAR-CCM+ 2020.3.1, a computational fluid dynamics code, were then utilized to verify the analytical model’s findings.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Verifiable Security Templates for Hardware

High-level synthesis (HLS) research generally focuses on transferring "software engineering virtues" (e.g., modularity, abstraction, extensibility, etc.) to hardware development with the ultimate goal of making hardware development as agile as software development. And recent HLS research has focused on transferring ideas and techniques from high assurance software formal methods to hardware development. Just as it has introduced software engineering virtues, we believe HLS can also become a vector for adapting software formal methods to the challenge of high assurance security in hardware. This paper introduces the Device Calculus and its mechanization in the Agda proof checking system. The Device Calculus is a starting point for exploring the formal methods and security of high-level synthesis flows. We illustrate the Device Calculus with a number of examples of formally verifiable security templates-i.e., functions in the Device Calculus that express common security structures at a high-level of abstraction.

Harrison, Bill↗

An Agile/XP software development process for modernizing the accelerator control system at Fermilab

Fermilab is undergoing the most ambitious upgrade to its accelerator control system of the 21st century. As part of the ACORN project, hundreds of legacy control system applications written in C/C++ will be re-imagined and developed from the ground up. In addition, applications to support Fermilab’s new super-conducting linear accelerator are already under construction. To manage the development of modern controls applications, the Controls department has adopted an Agile software development process based on eXtreme Programming. In this paper we will describe our process and detail our experience applying it to the development of two case studies.

Diamond, John [Fermilab]↗

GDSA PFLOTRAN Development (FY2021)

The Spent Fuel & Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Spent Fuel & Waste Disposition (SFWD) is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). A high priority for SFWST disposal R&D is to develop a disposal system modeling and analysis capability for evaluating disposal system performance for nuclear waste in geologic media. This report describes fiscal year (FY) 2021 advances of the PFLOTRAN Development group of the SFWST Campaign. The mission of this group is to develop a geologic disposal system modeling capability for nuclear waste that can be used to probabilistically assess the performance of generic disposal concepts. In FY 2021, development proceeded along three main thrusts: software infrastructure, code performance, and process model advancement. Software infrastructure improvements included implementing an Agile software development framework and making improvements to the QA Test Suite. Code performance improvements included development of advanced linear and nonlinear solvers as well as design of flexible smoothing algorithms for capillary pressure functions. Process modeling advancements included the addition of flexible thermal conductivity function definitions and refinement of multi-continuum reactive transport to support Sandia’s participation in DECOVALEX

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗