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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

DOE OSTI2024

Physics-coupled data-driven design of high-temperature alloys

We present a materials design loop, which streamlines physics-coupled machine learning (ML) surrogate models to discover new alloy chemistries with improved properties. The efficacy is demonstrated by discovering a high-temperature alumina-forming austenitic (AFA) stainless steel with enhanced creep, followed by experimental validation. The ML models have been trained using a well-curated, highly consistent experimental dataset augmented with synthetic microstructural features from a computational thermodynamic approach. We have populated a large number of hypothetical AFA alloys to explore the high-dimensional composition space and have predicted their creep properties by providing the same synthetic input features obtained from the trained ML models. Uncertainties from the ML training were taken as thresholds for truncating predicted results to identify alloys with improved or deteriorated creep. Individual elemental compositions have been determined via probability density distribution analysis from the group of alloys at the top and bottom of the predicted creep values for further virtual and experimental validations. In conclusion, we anticipate that this workflow can be applied to screen desired conditions, such as chemistry and processing parameters, in high-dimensional space through physics-guided data analytics.

Alloy design↗

DOE OSTI2026

Noise-aware optimization in nominally identical manufacturing and measuring systems for high-throughput parallel workflows

Device-to-device variability in experimental noise critically impacts reproducibility, especially in automated, high-throughput systems like additive manufacturing farms. While manageable in small labs, such variability can escalate into serious risks at larger scales, such as architectural 3D printing, where noise may cause structural or economic failures. This contribution presents a noise-aware decision-making algorithm that quantifies and models device-specific noise profiles to manage variability adaptively. It uses distributional analysis and pairwise divergence metrics with clustering to choose between single-device and robust multi-device Bayesian optimization strategies. Unlike conventional methods that assume homogeneous devices or enforce generic robustness, the proposed framework explicitly determines whether shared optimization across devices is appropriate based on the degree of inter-device noise heterogeneity. This enables improved performance, reproducibility, and efficiency. An experimental case study involving three nominally identical 3D printers (same brand, model, and close serial numbers) demonstrates reduced redundancy, lower resource usage, and improved reliability, along with improved convergence stability and solution quality through the selection of the appropriate optimization strategy based on the degree of inter-device noise heterogeneity. Overall, this framework establishes a general approach for precision- and resource-aware optimization in scalable, automated experimental platforms, demonstrated here on a representative multi-device 3D printing case study.

Schenk, Christina↗

DOE OSTI2024

On the role of geometrically necessary dislocations in void formation and growth in response to shock loading conditions in wrought and additively manufactured Ta

This study investigates the role of geometrically necessary dislocations (GNDs) and microstructure on void nucleation and growth in wrought and additively manufactured (AM) tantalum subjected to high-strain rate loading. Multi-modal 3D data was collected using TriBeam tomography to calculate GND densities and their spatial relationship to voids. A microstructural comparison between the wrought and AM samples identified distinct void shapes and locations, with intragranular voids and more spherical voids frequently observed in the AM dataset. Results indicate that voids preferentially form at both high-angle grain boundaries and low-angle subgrain boundaries, the latter of which are frequently observed in the AM material. Through a radial distribution analysis of all voids in the datasets, significant GND localization to near-void-surface regions was observed in both samples. 3D crystal plasticity simulations were employed to extend the experimental observations, revealing higher void growth rates in [111] oriented grains when compared to [001] grains. The simulations also suggest that GNDs can be generated as part of the void growth process, with more GND accumulation for growth in a [111] grain than a [001] grain. These findings provide valuable insights into the links between nanoscale void nucleation, mesoscale void growth, and microstructural effects in dynamically loaded tantalum.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Reorganization of Water at Aqueous Aluminum Chloride (AlCl 3 ) Interfaces: Vibrational Sum Frequency Generation and Molecular Dynamics Simulations

AlCl 3 hydration states and complexation are not well understood both in solutions and at the air–aqueous interface despite their potential significance in natural waters and their industrial and energy-related applications. Here, we investigated Al 3+ and Cl – ion behaviors in an AlCl 3 aqueous bulk solution and at the air–aqueous interface using interface-selective vibrational sum frequency generation (SFG), Raman and infrared spectroscopies, molecular dynamics (MD) simulation, as well as molecular-informed reduced modeling. Our reduced modeling reveals relatively long-range effects for Al 3+ as compared to monovalent ions such as Na + indicating that the interfacial depth of trivalent ions can be significantly larger than that of monovalent ions at the air–water interface. MD simulations reveal interfacial stratification and multiple layering of the ions. Compression of the Al 3+ and Cl – distributions with increasing concentrations from 0.5 to 2.5 m is also observed in the subsurface regions. Significant SSP- and PPP-polarized SFG OH spectral intensity increases are observed from 0.5 to 1.5 m and 0.5 to 2.5 m, respectively, indicative of interfacial depth increases and a change in average orientation above 1.5 m. Extensive evaluation of SFG spectra, Fresnel-corrected using several approaches, shows the same trends. The nonmonotonic trend points to a changing structure in surface and subsurface water orientation and hydrogen bonding environment generally consistent with the MD simulation of stratification and water orientation changes. Furthermore, solvent-shared ion pairing is implicated with MD simulation radial distribution analysis and consistent with infrared spectral identification of the hexaaqua aluminum ion in the solution phase. Spectral evidence of a strong Al 3+ hydration shell and the acidic behavior of the Al 3+ ions is obvious in the Raman and infrared spectra of the bulk solution. In conclusion, we show that the MD dipole potential is directly related to the MD second-order susceptibility of the interface, χ SFG–MD (2) , both of which correlate up to ∼35 Å with the spectral observations of increasing and then saturating intensities, suggesting that both ion stratification and interfacial depth determine the water orientations at an air–water interface of 1-3 electrolyte solutions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Molecular mechanisms underlying the extreme mechanical anisotropy of the flaviviral exoribonuclease-resistant RNAs (xrRNAs)

Mechanical anisotropy is an essential property for many biomolecules to assume their structures, functions and applications, however, the mechanisms for their direction-dependent mechanical responses remain elusive. Herein, by using a single-molecule nanopore sensing technique, we explore the mechanisms of directional mechanical stability of the xrRNA1 RNA from ZIKA virus (ZIKV), which forms a complex ring-like architecture. We reveal extreme mechanical anisotropy in ZIKV xrRNA1 which highly depends on Mg 2+ and the key tertiary interactions. The absence of Mg 2+ and disruption of the key tertiary interactions strongly affect the structural integrity and attenuate mechanical anisotropy. The significance of ring structures in RNA mechanical anisotropy is further supported by steered molecular dynamics simulations in combination with force distribution analysis. We anticipate the ring structures can be used as key elements to build RNA-based nanostructures with controllable mechanical anisotropy for biomaterial and biomedical applications.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Monolayer organic thin films as particle-contamination–resistant coatings

Abstract Three organic monolayers coatings were developed and tested for their effectiveness to increase cleaning efficiency of attached microscale particles by air flows. The experiments were performed using silica substrates coated with these organic thin films and subsequently exposed to stainless-steel and silica microparticles as a model of contamination. Laser-induced–damage tests confirmed that the coatings do not affect the laser-induced–damage threshold values. The particle exposure results suggest that although the accumulation of particles is not significantly affected under the experimental conditions used in this work, the coated substrates exhibit significantly improved cleaning efficiency with a gas flow. A size-distribution analysis was conducted to study the adsorption and cleaning efficiency of particles of different sizes. It was observed that larger size (> 5-μm) particles can be removed from coated substrates with almost 100% efficiency. It was also determined that the coatings improve the cleaning efficiency of the smaller particles (≤ 5 μm) by 17% to 30% for the stainless steel metal and 19% to 38% for the silica particles.

36 MATERIALS SCIENCE↗

DOE OSTI2024

BigPanDA monitoring system evolution in the ATLAS Experiment

Monitoring services play a crucial role in the day-to-day operation of distributed computing systems. The ATLAS Experiment at LHC uses the Production and Distributed Analysis workload management system (PanDA WMS), which allows a million computational jobs to run daily at over 170 computing centers of the WLCG and opportunistic resources, utilizing 600k cores simultaneously on average. The BigPanDA monitor is an essential part of the monitoring infrastructure for the ATLAS Experiment that provides a wide range of views, from top-level summaries to a single computational job and its logs. Over the past few years of the PanDA WMS advancement in the ATLAS Experiment, several new components were developed, such as Harvester, iDDS, Data Carousel, and Global Shares. Due to its modular architecture, the BigPanDA monitor naturally grew into a platform where the relevant data from all PanDA WMS components and accompanying services are accumulated and displayed in the form of interactive charts and tables. Moreover the system has been adopted by other experiments beyond HEP. In this paper we describe the evolution of the BigPanDA monitor system, the development of new modules, and the integration process into other experiments.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

ROOT’s RNTuple I/O Subsystem: The Path to Production

The RNTuple I/O subsystem is ROOT’s future event data file format and access API. It is driven by the expected data volume increase at upcoming HEP experiments, e.g. at the HL-LHC, and recent opportunities in the storage hardware and software landscape such as NVMe drives and distributed object stores. RNTuple is a redesign of the TTree binary format and API and has shown to deliver substantially faster data throughput and better data compression both compared to TTree and to industry standard formats. In order to let HENP computing workflows benefit from RNTuple’s superior performance, however, the I/O stack needs to connect efficiently to the rest of the ecosystem, from grid storage to (distributed) analysis frameworks to (multithreaded) experiment frameworks for reconstruction and ntuple derivation. With the RNTuple binary format soon arriving at its first production release, we present RNTuple’s feature set, integration efforts, and its performance impact on the time-to-solution. We show the latest performance figures of RDataFrame analysis code of realistic complexity, comparing RNTuple and TTree as data sources. We discuss RNTuple’s approach to functionality critical to the HENP I/O (such as multithreaded writes, fast data merging, schema evolution) and we provide an outlook on the road to its use in production.

Blomer, Jakob↗

DOE OSTI2025

Investigation of Anchor Link Magnetohydrodynamic Effects in the Toroidally Symmetric Lead-Lithium (TSLL) Blanket Concept

This paper presents a comprehensive study on the magnetohydrodynamic (MHD) flow in a slotted channel with a cylindrical anchor link, which is an imperative component of the toroidally symmetric lead-lithium (TSLL) blanket concept. Following the validation of the MHD solver implemented in COMSOL and a proposed subtraction approach to compute the anchor link pressure drop, the effects of computational domain size on the pressure drop and velocity distribution are examined. The results show that the pressure drop associated with the anchor link and the maximum flow velocity follow an asymptotic trend as the domain width increases, with wall-induced pressure drop being more dominant than that of the anchor link. The velocity distribution analysis revealed the formation of an internal boundary layer extending along the magnetic field direction, which is a unique feature of the investigated MHD flow. An estimation of the total MHD pressure drop associated with the array of anchor links under the TSLL blanket conditions suggests ~0.3 MPa, which is significantly lower than the recommended maximum allowable blanket pressure drop of 2 MPa. In conclusion, this work offers valuable insights into the anchor link–associated MHD phenomena and serves as a foundation for further development of the TSLL blanket concept for future fusion reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Measurement of the mean excitation energy of liquid argon

The mean excitation energy (I-value) of liquid argon is a critical input for energy estimation in neutrino oscillation experiments. It is measured to be 199 +4 -5 eV using the range of 402.2 MeV protons from the Fermilab Linac. This compares to the author's recent evaluation of (197 ± 7) eV based on a combination of an oscillator strength distribution analysis, gaseous argon range measurements, sparse stopping power data on solid argon, and an extrapolation of data on the effect of phase from other substances. Using all sources of information, we recommend a value of (198 ± 4) eV for liquid argon, which is significantly higher than 188 eV, from ICRU-37's gaseous argon evaluation, commonly used in Monte Carlo codes such as Geant4.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Level structure of the T z = –1 nucleus 34 Ar and its relevance for nucleosynthesis in ONe novae

The 24 Mg+ 12 C fusion reaction was used to perform a detailed γ-ray spectroscopy study of the astrophysically important nucleus 34 Ar. In particular, an experimental setup, coupling the advanced γ-ray tracking array GRETINA with the well-established Argonne fragment mass analyzer (FMA), was employed to obtain excitation energies and spin-parity assignments for excited states in 34 Ar, both above and below the proton separation energy. For the first time, an angular distribution analysis of in-beam γ rays from fusion-evaporation reactions, using a tracking array, has been performed and Coulomb energy differences of analog states in the T = 1, A = 34 mirror system, explored from 0 to 6 MeV. Lastly, we present a comprehensive discussion of the astrophysical 33 Cl(p,γ) stellar reaction rate, together with implications for the identification of nova presolar grains from sulfur isotopic abundances.

20 ≤ A ≤ 38↗

DOE OSTI2021

Efficient Phasor-Based Dynamic Volt/VAr and Volt/Watt Analysis of Large Distribution Grid with High Penetration of Smart Inverters

As the penetration of power-electronics based smart inverters (SIs) is increasing in distribution grids, it adds computational challenges in solving dynamic models of large-scale distribution feeders. Voltage and reactive power (Volt/VAr), and voltage and active power (Volt/Watt) dynamics have been analyzed at slower time scales akin to the control of legacy grid devices. However, smart inverters, being power-electronics based devices, can provide dynamic active/reactive power support at a faster time scale, which necessitates Volt/VAr and Volt/Watt dynamics to be analyzed at a faster time scale. The existing dynamic models are overly detailed and computationally intractable for distribution feeders with a large number of inverters. In this context, this proposed work aims towards developing a computationally tractable, scalable, and accurate phasor-based model for dynamic Volt/VAr and Volt/Watt analyses of large distribution systems with high penetration of smart inverters. Case studies demonstrate that the proposed phasor-based model sufficiently captures the Volt/VAr and Volt/Watt dynamics, and is computationally faster by one order of magnitude compared to the average model and by two orders of magnitude compared to the detailed switching model. Case studies also demonstrate the efficacy and scalability of the proposed model in analyzing Volt/VAr and Volt/Watt dynamics of large-scale power networks with hundreds of SIs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Draft genome of multiple resistance donor plant Sinapis alba: An insight into SSRs, annotations and phylogenetics

Sinapis alba is a wild member of the Brassicaceae family reported to possess genetic resistance against major biotic and abiotic stresses of oilseed brassicas. However, the resistance nature of S. alba was not exploited generously due to the unavailability of usable genome sequences in public databases. Therefore, the present study was conducted to assemble the first draft genome from raw whole genome shotgun sequences with annotation and develop simple sequence repeat markers for molecular genetics and marker-assisted breeding. Results The raw genome sequences had 96x coverage on the Illumina platform with 170 Gbp data. The developed assembly by SOAPdenovo2 has ~459 Mbp genome size covered in 403,423 contigs with an average size of 1138.04 bp. The assembly was BLASTX with Arabidopsis thaliana which showed 32.9% positive hits between both plants. The top hit species distribution analysis showed the highest similarity with A. thaliana. A total of 809,597 GO level annotations were recorded after BLASTX results, and 34,012 sequences were annotated with different enzyme codes grouped under seven classes. The gene prediction tool AUGUSTUS identified 113,107 probable genes with an average size of 684 bp. The biochemical pathway annotation assigned 16,119 potential genes to 152 KEGG maps and 1751 enzyme codes. The development of potential SSRs from the de-novo assembly yielded 70731 unique primer pairs. Out of 159 randomly selected SSR markers for validation, 149 successfully amplified in S. alba. However, 10 SSR markers did not amplify during the validation experiment. Conclusion The annotated genome assembly with a large number of SSRs was developed in the present study. To the best of our knowledge, this is the first report of S. alba genome assembly development, annotation, and SSRs mining to date. The data presented here will be a very important resource for future crop improvement programs, especially for resistant breeding.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Improving Cloud-based Performance of Distribution Planning - Improvements to GridLAB-D

This report provides a high-level summary of the improvements to the GridLAB-D distribution analysis software, including work with GridUnity to focus the areas of improvement and test the final implementation. The improvements allow repetitive, time-series-based simulations, such as renewable hosting capacity studies, to show a 30% or more improvement in execution time. All improvements from this project are available on GridLAB-D’s open-source repository, with most of the changes migrated into the upcoming version 4.3 release of the software.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Fermilab s Transition to Token Authentication

Fermilab is the first High Energy Physics institution to transition from X.509 user certificates to authentication tokens in production systems. All of the experiments that Fermilab hosts are now using JSON Web Token (JWT) access tokens in their grid jobs. Many software components have been either updated or created for this transition, and most of the software is available to others as open source. The tokens are defined using the WLCG Common JWT Profile. Token attributes for all the tokens are stored in the Fermilab FERRY system which generates the configuration for the CILogon token issuer. High security-value refresh tokens are stored in Hashicorp Vault configured by htvault-config, and JWT access tokens are requested by the htgettoken client through its integration with HTCondor. The Fermilab job submission system jobsub was redesigned to be a lightweight wrapper around HTCondor. For automated job submissions a managed tokens service was created to reduce duplication of effort and knowledge of how to securely keep tokens active. The existing Fermilab file transfer tool ifdh was updated to work seamlessly with tokens, as well as the Fermilab POMS (Production Operations Management System) which is used to manage automatic job submission and the RCDS (Rapid Code Distribution System) which is used to distribute analysis code via the CernVM FileSystem. The dCache storage system was reconfigured to accept tokens for authentication in place of X.509 proxy certificates. As some services and sites have not yet implemented token support, proxy certificates are still sent with jobs for backwards compatibility but some experiments are beginning to transition to stop using them. There have been some glitches and learning curve issues but in general the system has been performing well and is being improved as operational problems are addressed.

Dykstra, David↗

DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗

DOE OSTI2020

TIC 278956474: Two Close Binaries in One Young Quadruple System Identified by TESS

We have identified a quadruple system with two close eclipsing binaries in Transiting Exoplanet Survey Satellite (TESS) data. The object is unresolved in Gaia and appears as a single source at parallax 1.08 ± 0.01 mas. Both binaries have observable primary and secondary eclipses and were monitored throughout TESS Cycle 1 (sectors 1–13), falling within the TESS Continuous Viewing Zone. In one eclipsing binary (P = 5.488 days), the smaller star is completely occluded by the larger star during the secondary eclipse; in the other (P = 5.674 days) both eclipses are grazing. Using these data, spectroscopy, speckle photometry, spectral energy distribution analysis, and evolutionary stellar tracks, we have constrained the masses and radii of the four stars in the two eclipsing binaries. The Li i equivalent width indicates an age of 10–50 Myr and, with an outer period of 858{sub −5}{sup +7} days, our analysis indicates this is one of the most compact young 2 + 2 quadruple systems known.

79 ASTRONOMY AND ASTROPHYSICS↗