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French, Roger H.

Publications and source records attributed to French, Roger H..

8 records
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DOE OSTI2024

Image-Based Fracture Surface Defect Characterization Methods for Additively Manufactured Ti-6Al-4V Tested in Fatigue

Abstract Fatigue initiation in additively manufactured samples/parts often occurs at processed-induced defects such as lack-of-fusion (LoF), keyhole, or other morphological/microstructural defects that have unique characteristics and measurable qualities. Attempts at identifying and minimizing such defects have utilized optimized processing conditions along with in situ and ex situ characterization that includes metallography and/or X-ray computed tomography (XCT). This paper highlights the benefits of using fracture surface analyses to detect and quantify defects that may not be detected by metallography/XCT due to sectioning and resolution limits. In addition to using manual quantification of fatigue initiating LoF and keyhole defects on fracture surfaces, image-based machine learning using convolutional neural networks such as U-Net were also used to automate the process. Statistical analyses were used to identify the extreme cases of defects that initiated and accelerated fatigue and to model the distribution of defect size and shape characteristics to distinguish the type of defect. Initial results show agreement between trained machine learning models and ground truth data in defect segmentation, and the distributions of defect characteristics are distinguishable to particular process-induced defect types.

Materials Science↗
DOE OSTI2024

Demonstration and Validation of a Virtual Energy Audit Tool for DoD Buildings

Electricity consumption has been in the spotlight as part of the battle for sustainability resulting in legislative measures to try and reduce the amount of energy used. EISA 432 and the Energy Act of 2020 are two examples that require federal facilities to investigate buildings and find saving opportunities through energy audits. EDIFES solves this problem by providing fully virtual audits. Only five inputs are needed (15-minute interval electricity consumption, location, square footage, number of stories, and building end use) to produce complete energy audits. The virtual audit is automated, making them inexpensive and the small number of inputs allows a large number of buildings to be entered quickly. During this project, EDIFES performed energy audits on hundreds of buildings to ensure proper functionality and workflow. Over 250 DoD buildings received energy audits that then had their results posted to an interactive dashboard with portfolio rankings. Several validation methods were employed. All confirmed that EDIFES's methods worked as expected and with a high degree of accuracy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Towards 50 Year Lifetime PV Modules: Double Glass vs. Glass/Backsheet

This award aims to increase the lifetime of c-Si modules by lowering the power degradation rate to the goal of 0.2 %/year, while also increasing the harvested irradiance per module using bifacial cells to achieve the 2030 SunShot goal of $0.03/kWh. Increasing the durability and lifetime of modules requires improved module packaging material choices and module architectures to exploit new cell improvements. Bifacial PERC cells (with backside aluminum fingers) are becoming a primary PV technology due to their decreased rear surface recombination and increased light absorption compared to traditional monofacial Al-BSF cells. Bifacial modules with double glass architectures have been deployed to capture the rear-side irradiance thereby increasing the light captured. The choice of a double glass (DG) or glass/backsheet (GB) module leads to two very different chemical (e.g., O 2 , H 2 O) and mechanical environments (e.g., mechanical stress levels) inside the PV module that impact the cell’s operational conditions. The recipient will fabricate 4-cell DG and GB minimodules with various module architectures or constructions (mono- & bifacial cells, transparent & white encapsulants), and conduct stepwise accelerated exposures and characterization.

14 SOLAR ENERGY↗
DOE OSTI2024

Using spatio-temporal graph neural networks to estimate fleet-wide photovoltaic performance degradation patterns

Accurate estimation of photovoltaic (PV) system performance is crucial for determining its feasibility as a power generation technology and financial asset. PV-based energy solutions offer a viable alternative to traditional energy resources due to their superior Levelized Cost of Energy (LCOE). A significant challenge in assessing the LCOE of PV systems lies in understanding the Performance Loss Rate (PLR) for large fleets of PV systems. Estimating the PLR of PV systems becomes increasingly important in the rapidly growing PV industry. Precise PLR estimation benefits PV users by providing real-time monitoring of PV module performance, while explainable PLR estimation assists PV manufacturers in studying and enhancing the performance of their products. However, traditional PLR estimation methods based on statistical models have notable drawbacks. Firstly, they require user knowledge and decision-making. Secondly, they fail to leverage spatial coherence for fleet-level analysis. Additionally, these methods inherently assume the linearity of degradation, which is not representative of real world degradation. To overcome these challenges, we propose a novel graph deep learning-based decomposition method called the Spatio-Temporal Graph Neural Network for fleet-level PLR estimation (PV-stGNN-PLR). PV-stGNN-PLR decomposes the power timeseries data into aging and fluctuation components, utilizing the aging component to estimate PLR. PV-stGNN-PLR exploits spatial and temporal coherence to derive PLR estimation for all systems in a fleet and imposes flatness and smoothness regularization in loss function to ensure the successful disentanglement between aging and fluctuation. We have evaluated PV-stGNN-PLR on three simulated PV datasets consisting of 100 inverters from 5 sites. Experimental results show that PV-stGNN-PLR obtains a reduction of 33.9% and 35.1% on average in Mean Absolute Percent Error (MAPE) and Euclidean Distance (ED) in PLR degradation pattern estimation compared to the state-of-the-art PLR estimation methods.

14 SOLAR ENERGY↗
DOE OSTI2024

Phase Identification in Synchrotron X-ray Diffraction Patterns of Ti–6Al–4V Using Computer Vision and Deep Learning

X-ray diffraction patterns contain information about the atomistic structure and microstructure (defect population) of materials, extracting detailed information from diffraction patterns is complex, demanding and relies on prior knowledge. Here, we hypothesize that deep-learning techniques can help to perform an effective and accurate analysis with high throughput rates. To demonstrate this concept, we applied a novel deep learning framework to determine the evolution of the β-phase volume fraction in a Ti–6Al–4V alloy during heat-treatment from video sequences of 2D diffraction patterns recorded in transmission and with highly monochromatic radiation in a synchrotron beamline. In particular, we studied the impact of network design on prediction reliability and computational performance. Networks of different architectures were trained using 3008 experimental 2D patterns. A well-tuned model was found to reproduce the phase fractions of another experimental data set, consisting of 1100 diffraction patterns, with a mean-square error as small as 2.6 x 10 -4 . The average prediction error of β-phase volume fraction was within 1.6 x 10 -2 (in each diffraction pattern) of the values obtained by conventional methods. Our work demonstrates that convolutional neural networks can evaluate high energy X-ray diffraction patterns with a remarkable level of reliability. Furthermore, it demonstrates the significance of network design on the reliability of predictions and computational performance. The most complex models do not necessarily result in highest accuracy and may even fail to learn from the data.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Image Processing Pipeline for Fluoroelastomer Crystallite Detection in Atomic Force Microscopy Images

Phase transformations in materials systems can be tracked using atomic force microscopy (AFM), enabling the examination of surface properties and macroscale morphologies. In situ measurements investigating phase transformations generate large datasets of time-lapse image sequences. The interpretation of the resulting image sequences, guided by domain-knowledge, requires manual image processing using handcrafted masks. Here this approach is time-consuming and restricts the number of images that can be processed. Her in this study, we developed an automated image processing pipeline which integrates image detection and segmentation methods. We examine five time-series AFM videos of various fluoroelastomer phase transformations. The number of image sequences per video ranges from a hundred to a thousand image sequences. The resulting image processing pipeline aims to automatically classify and analyze images to enable batch processing. Using this pipeline, the growth of each individual fluoroelastomer crystallite can be tracked through time. We incorporated statistical analysis into the pipeline to investigate trends in phase transformations between different fluoroelastomer batches. Understanding these phase transformations is crucial, as it can provide valuable insights into manufacturing processes, improve product quality, and possibly lead to the development of more advanced fluoroelastomer formulations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Lifetime and Degradation Study of Poly(Methyl Methacrylate) via a Data-Driven Study Protocol Approach

We report to optimize and extend the service life of polymeric materials in outdoor environments, a domain knowledge-based and data-driven approach was utilized to quantitatively investigate the temporal evolution of degradation modes, mechanisms, and rates under various stepwise accelerated exposure conditions. Six formulations of poly(methyl methacrylate) (PMMA) with different combinations of stabilizing additives, including one unstabilized formulation, were exposed in three accelerated weathering conditions. Degradation was dependent on wavelength as samples in UV light at 340 nm (UVA) exposure showed the most yellowing. The unstabilized PMMA formulation showed much higher yellowness index values (59.5) than stabilized PMMA formulations (2–12). Urbach edge analysis shows a shift toward longer wavelength from 285 to 500 nm with increasing exposure time and an increased absorbance around 400 nm of visible region as the unstabilized samples increase in yellowing. The degradation mechanisms of PMMA were tracked using induced absorbance to dose at specific wavelengths that correspond to known degradation mechanisms. The degradation pathway of PMMA was modeled in a framework using network structural equation modeling (netSEM). netSEM showed changes in degradation pathway as PMMA transition stages of degradation.

36 MATERIALS SCIENCE↗