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At least 181 records · Page 10

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DOE OSTI2022

Laser-induced patterning for a diffraction grating using the phase change material of Ge 2 Sb 2 Te 5 (GST) as a spatial light modulator in X-ray optics: a proof of concept

The proposed X-ray spatial light modulator (SLM) concept is based on the difference of X-ray scattering from amorphous and crystalline regions of phase change materials (PCMs) such as Ge 2 Sb 2 Te 5 (GST). In our X-ray SLM design, the “ on” and “ off” states correspond to a patterned and homogeneous state of a GST thin film, respectively. The patterned state is obtained by exposing the homogeneous film to laser pulses. In this paper, we present patterning results in GST thin films characterized by microwave impedance microscopy and X-ray small-angle scattering at the Stanford Synchrotron Radiation Lightsource.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Photocatalytic Hydrogen Evolution by a De Novo Designed Metalloprotein that Undergoes Ni–Mediated Oligomerization Shift

De novo metalloprotein design involves the construction of proteins guided by specific repeat patterns of polar and apolar residues, which, upon self-assembly, provide a suitable environment to bind metals and produce artificial metalloenzymes. While a wide range of functionalities have been realized in de novo designed metalloproteins, the functional repertoire of such constructs towards alternative energy-relevant catalysis is currently limited. Here we show the application of de novo approach to design a functional H 2 evolving protein. The design involved the assembly of an amphiphilic peptide featuring cysteines at tandem a/d sites of each helix. Intriguingly, upon Ni II addition, the oligomers shift from a major trimeric assembly to a mix of dimers and trimers. The metalloprotein produced H 2 photocatalytically with a bell-shape pH dependence, having a maximum activity at pH 5.5. Transient absorption spectroscopy is used to determine the timescales of electron transfer as a function of pH. Selective outer sphere mutations are made to probe how the local environment tunes activity. Finally, a preferential enhancement of activity is observed via steric modulation above the Ni II site, towards the N-termini, compared to below the Ni II site towards the C-termini.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Computational Study of Additively Manufactured Internally Cooled Airfoils for Industrial Gas Turbine Applications

Internal cooling features such as pin-fins, impingement jets, and rib-turbulators are necessary to keep turbine components cool, but if sufficiently advanced can potentially also eliminate the need for film cooling on turbine blades particularly in industrial gas turbines where temperatures are not extreme. Furthermore, by leveraging additive manufacturing, other advanced designs such as lattice and incremental impingement configurations are possible and have recently been experimentally tested. While the performance of such configurations has been quantified through means of overall cooling effectiveness, it is not as clear why certain designs were better than others, or what the mechanisms were behind the observed external cooling patterns. The purpose of this study was to computationally analyze different advanced turbine blade internal cooling designs previously tested by the National Energy Technology Laboratory.

CFD↗

DOE OSTI2023

Urban land patterns can moderate population exposures to climate extremes over the 21st century

Abstract Climate change and global urbanization have often been anticipated to increase future population exposure (frequency and intensity) to extreme weather over the coming decades. Here we examine how changes in urban land extent, population, and climate will respectively and collectively affect spatial patterns of future population exposures to climate extremes (including hot days, cold days, heavy rainfalls, and severe thunderstorm environments) across the continental U.S. at the end of the 21st century. Different from common impressions, we find that urban land patterns can sometimes reduce rather than increase population exposures to climate extremes, even heat extremes, and that spatial patterns instead of total quantities of urban land are more influential to population exposures. Our findings lead to preliminary suggestions for embedding long-term climate resilience in urban and regional land-use system designs, and strongly motivate searches for optimal spatial urban land patterns that can robustly moderate population exposures to climate extremes throughout the 21st century.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Differential Property Prediction: A Machine Learning Approach to Experimental Design in Advanced Manufacturing

Advanced manufacturing techniques have enabled the production of materials with state-of-the-art properties. In many cases however, the development of physics-based models of these techniques lags behind their development in the lab. This means that material and process development proceeds largely via trial and error. This is sub-optimal since experiments are cost-, time-, and labor-intensive. In this work we propose a machine learning framework, differential property classification (DPC), which enables an experimenter to leverage machine learning's unparalleled pattern matching capability to pursue data-driven experimental design. DPC takes two possible experiment parameter sets and outputs a prediction of which will produce a material with a more desirable property specified by the operator. We demonstrate the success of DPC on AA7075 tube manufacturing process and mechanical property data using shear assisted processing and extrusion (ShAPE), an emerging solid phase processing technology. We show that by focusing on the experimenter's need to choose between multiple candidate experimental parameters, we can reframe the challenging regression task of predicting material properties from processing parameters, into a classification task on which machine learning models can achieve good performance.

advanced manufacturing, machine learning, ShAPE↗

DOE OSTI2022

Tuning Catalyst Activation and Utilization Via Controlled Electrode Patterning for Low-Loading and High-Efficiency Water Electrolyzers

An anode electrode concept of thin catalyst-coated liquid/gas diffusion layers (CCLGDLs), by integrating Ir catalysts with Ti thin tunable LGDLs with facile electroplating in proton exchange membrane electrolyzer cells (PEMECs), is proposed. The CCLGDL design with only 0.08 mg Ir cm -2 can achieve comparative cell performances to the conventional commercial electrode design, saving ~97% Ir catalyst and augmenting a catalyst utilization to ~24 times. CCLGDLs with regulated patterns enable insight into how pattern morphology impacts reaction kinetics and catalyst utilization in PEMECs. A specially designed two-sided transparent reaction-visible cell assists the in situ visualization of the PEM/electrode reaction interface for the first time. Oxygen gas is observed accumulating at the reaction interface, limiting the active area and increasing the cell impedances. In this work, it is demonstrated that mass transport in PEMECs can be modified by tuning CCLGDL patterns, thus improving the catalyst activation and utilization. The CCLGDL concept promises a future electrode design strategy with a simplified fabrication process and enhanced catalyst utilization. Furthermore, the CCLGDL concept also shows great potential in being a powerful tool for in situ reaction interface research in PEMECs and other energy conversion devices with solid polymer electrolytes.

08 HYDROGEN↗

DOE OSTI2026

Steric Mapping, Ligand Dynamics, and Cycloisomerization Catalysis with Redox Robust Mn I/0/-I Dicarbenes

Manganese is perhaps the most electronically versatile element, yet the redox properties, reactivity, and catalytic applications of low-valent Mn 0 /Mn −I complexes remain underexplored due to the propensity for Mn 0 to dimerize, quenching highenergy metalloradicals. We report a series of redox-active monometallic Mn I , Mn 0 and Mn −I complexes containing a BH 2 - bridged dicarbene, characterized using a suite of experimental and cutting-edge computational (DFT) methods. Slow electron transfer kinetics at Mn I/0 are observed, with computations and electrochemical simulations in excellent agreement with experimental values. Despite the lack of steric bulk at the BH 2 -bridged Mn 0 , the t Bu groups at the dicarbene provide adequate steric protection to prevent dimerization, with percent buried volume (% V bur ) serving as a valuable steric ranking tool. We also show that a %V bur > 83% prevents dimerization for a diverse array of Mn 0 complexes from the literature. Ligand sterics of BPh 2 -and BH 2 -bridged complexes dictate reaction outcomes when Mn I and Mn −I are exposed to nucleophiles and electrophiles, respectively, while Mn0 facilitates the radical cycloisomerization catalysis of 6-iodo-1- hexene at room temperature. Furthermore, this work underscores the importance of ligand sterics in rationalizing reactivity patterns at Mn and provides valuable insights for designing chelating ligands that can selectively leverage Mn I/0/‑I states in redox-mediated catalytic reactions.

Ligands↗

DOE OSTI2021

Single-shot x-ray phase-contrast and dark-field imaging based on coded binary phase mask

We introduce a coded-mask-based multi-contrast imaging method for high-resolution phase-contrast and dark-field imaging. The method uses a binary phase mask designed to provide an ultra-high-contrast pattern and reference-free single-shot measurement and an algorithm based on maximum-likelihood optimization and automatic differentiation to perform simultaneous reconstruction of absorption, phase, and dark-field object images. Further, we demonstrate that the method has great potential for real-time quantitative phase imaging and wavefront sensing when combined with deep learning.

Qiao, Zhi (ORCID:0000000286285320)↗

DOE OSTI2023

Computational Fluid Dynamics Simulations to Assess Spatial Variability and Optimal Ventilation Scenarios for Biological Laboratory Exposures

A significant amount of uncertainty exists regarding potential human exposure to laboratory biomaterials and organisms in Biosafety Level 2 (BSL-2) research laboratories. Computational fluid dynamics (CFD) modeling is proposed as a way to better understand potential impacts of different combinations of biomaterials, laboratory manipulations, and exposure routes on risks to laboratory workers. Here, in this study, we use CFD models to simulate airborne concentrations of contaminants in an actual BSL-2 laboratory under different configurations. Results show that ventilation configuration, sampling location, and contaminant source location can significantly impact airborne concentrations and exposures. Depending on the source location and airflow patterns, the transient and time-integrated concentrations varied by several orders of magnitude. Contaminant plumes from sources located near a return vent (or exhaust like a fume hood or ventilated biosafety cabinet) are likely to be more contained than sources that are further from the exhaust. Having a direct flow between the source and the exhaust (through-flow condition) may reduce potential exposures to individuals outside the air flow path. Designing a BSL-2 room with ventilation and airflow patterns that maximize through-flow conditions to the return/exhaust vents and minimize dispersion and mixing throughout the room is, therefore, recommended. CFD simulations can also be used to assist in characterizing the impacts of supply and return vent locations, room layout, and source locations on spatial and temporal contaminant concentrations. In addition, proper placement of particle sensors can also be informed by CFD simulations to provide additional characterization and monitoring of potential exposures in BSL-2 facilities.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗

DOE OSTI2026

Data-Driven Modeling of High-Resolution Residential Load Profiles Using Low-Resolution Smart Meter Measurements

Accurate and high-resolution residential load profiles are essential for power system modeling, demand response planning, and effective grid operation. As the energy sector moves towards a more actively managed distribution system, the ability to understand residential energy consumption at a minute-by-minute scale becomes increasingly critical. High-resolution load profiles provide key insights into demand patterns and user behavior, enabling grid operators to design more effective energy solutions; however, residential load measurements in the field are typically recorded at low resolutions, such as 15-60 minutes, which makes it hard to study the characteristics of different residential customers. This paper addresses these challenges by introducing a data-driven approach to generate realistic, high-resolution residential load profiles based on lowre-solution measurements and weather information. The proposed method retains the key features of the actual residential load measurements while offering appliance-level energy consumption details for each residential building. The results demonstrate the effectiveness of the proposed load profile generator, proving its capability to support utilities in optimizing residential energy management and ensuring a more reliable and resilient grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Data-Driven Approaches for Bead Geometry Prediction Via Melt Pool Monitoring

In the realm of additive manufacturing, the selection of process parameters to avoid over and under deposition entails a time-consuming and resource-intensive trial-and-error approach. Given the distinct characteristics of each part geometry, there is a pressing need for advancing real-time process monitoring and control to ensure consistent and reliable part dimensional accuracy. Here, this research shows that support vector regression (SVR) and convolutional neural network (CNN) models offer a promising solution for real-time process control due to the models’ abilities to recognize complex, non-linear patterns with high accuracy. A novel experiment was designed to compare the performance of SVR and CNN models to indirectly detect bead height from a coaxial image of a melt pool from a single-layer, single bead build. The study showed that both SVR and CNN models trained on melt pool data collected from a coaxial optical camera can accurately predict the bead height with a mean absolute percentage error of 3.67% and 3.68%, respectively.

36 MATERIALS SCIENCE↗

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 OSTI2021

Effect of Glacial/Interglacial Recharge Conditions on Flow of Meteoric Water Through Deep Orogenic Faults: Insights Into the Geothermal System at Grimsel Pass, Switzerland

Many meteoric-recharged, fault-hosted geothermal systems in amagmatic orogenic belts have been active through the Pleistocene glacial/interglacial climate fluctuations. The effects of such climate-induced recharge variations on fluid flow patterns and residence times of the thermal waters are complex and may influence how the geothermal and mineralization potential of the systems are evaluated. We report systematic thermal–hydraulic simulations designed to reveal the effects of recharge variations, using a model patterned on the orogenic geothermal system at Grimsel Pass in the Swiss Alps. Fault-bound circulation of meteoric water through the Grimsel fault is driven to depths of ~10 km by the high alpine topography. Simulations suggest that the current single pass flow is typical of interglacial periods, during which 1) meteoric recharge into the fault is high (above tens of centimeters per year), 2) conditions are at or somewhat below the critical Rayleigh number, and 3) the hydraulic connectivity along the fault plane is extensive (an extent of at least 10 km into increasingly higher terrain is required to explain the 10 km penetration depth). The subcritical condition constrains the bulk fault permeability to < 1e-14 m2. In contrast, the limited recharge during the numerous Pleistocene glaciation events likely induced a layered flow system with single pass flow confined to shallow depths while non-Rayleigh convection occurred in the deep fault. The same layering can be observed at low aspect ratios (length/depth) of the fault plane, when the available recharge area limits the flux through the fault.

58 GEOSCIENCES↗

DOE OSTI2022

Optimization of irradiation configuration using spherical t-designs for laser-direct-drive inertial confinement fusion

Abstract A new class of beam configurations is proposed for symmetric-direct-drive inertial confinement fusion laser systems. These configurations are based on spherical t -designs that are studied in spherical design theory in mathematics (Delsarte et al 1977 Geom. Dedicata 6 363). Employing t -design configurations offers elimination of spherical-harmonic intensity modulations for modes ℓ ⩽ t . Additionally, these configurations provide fast decay of intensity nonuniformities with increasing number of beams and symmetric intensity patterns on the surface of the target. Methods developed in spherical design theory offer a convenient, systematic way of obtaining beam configurations for an arbitrary number of beams.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Strain‐Driven Mixed‐Phase Domain Architectures and Topological Transitions in Pb 1− x Sr x TiO 3 Thin Films

Abstract The potential for creating hierarchical domain structures, or mixtures of energetically degenerate phases with distinct patterns that can be modified continually, in ferroelectric thin films offers a pathway to control their mesoscale structure beyond lattice‐mismatch strain with a substrate. Here, it is demonstrated that varying the strontium content provides deterministic strain‐driven control of hierarchical domain structures in Pb 1− x Sr x TiO 3 solid‐solution thin films wherein two types, c / a and a 1 / a 2 , of nanodomains can coexist. Combining phase‐field simulations, epitaxial thin‐film growth, detailed structural, domain, and physical‐property characterization, it is observed that the system undergoes a gradual transformation (with increasing strontium content) from droplet‐like a 1 / a 2 domains in a c / a domain matrix, to a connected‐labyrinth geometry of c / a domains, to a disconnected labyrinth structure of the same, and, finally, to droplet‐like c / a domains in an a 1 / a 2 domain matrix. A relationship between the different mixed‐phase modulation patterns and its topological nature is established. Annealing the connected‐labyrinth structure leads to domain coarsening forming distinctive regions of parallel c / a and a 1 / a 2 domain stripes, offering additional design flexibility. Finally, it is found that the connected‐labyrinth domain patterns exhibit the highest dielectric permittivity.

Kavle, Pravin↗

DOE OSTI2022

Understanding and Leveraging the I/O Patterns of Emerging Machine Learning Analytics

The scientific community is currently experiencing unprecedented amounts of data generated by cutting-edge science facilities. Soon facilities will be producing up to 1 PB/s which will force scientist to use more autonomous techniques to learn from the data. The adoption of machine learning methods, like deep learning techniques, in large-scale workflows comes with a shift in the workflow’s computational and I/O patterns. These changes often include iterative processes and model architecture searches, in which datasets are analyzed multiple times in different formats with different model configurations in order to find accurate, reliable and efficient learning models. This shift in behavior brings changes in I/O patterns at the application level as well at the system level. These changes also bring new challenges for the HPC I/O teams, since these patterns contain more complex I/O workloads. In this paper we discuss the I/O patterns experienced by emerging analytical codes that rely on machine learning algorithms and highlight the challenges in designing efficient I/O transfers for such workflows. We comment on how to leverage the data access patterns in order to fetch in a more efficient way the required input data in the format and order given by the needs of the application and how to optimize the data path between collaborative processes. We will motivate our work and show performance gains with a study case of medical applications.

Gainaru, Ana↗