Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Process settings”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Inferring the scrape-off layer heat flux width in a divertor with a low degree of axisymmetry

Plasma facing components (PFCs) in the next generation of tokamak devices will operate in challenging environments, with heat loads predicted to exceed 10 MWm -2 . The magnitude of these heat loads is set by the width of the channel, the ‘scrape-off layer’ (SOL), into which heat is exhausted, and can be characterised by an e-folding length scale for the decay of heat flux across the channel. It is expected this channel will narrow as tokamaks move towards reactor relevant conditions. Understanding the processes involved in setting the SOL heat flux width is imperative to be able to predict the heat loads PFCs must handle in future devices. Measurements of the SOL width are performed on the high-field spherical tokamak, ST40, using a newly commissioned infrared thermography system. With its high on-axis toroidal magnetic field (≥1.5 T) ST40 is uniquely positioned to investigate the influence of toroidal field on the heat flux width in spherical tokamaks, whilst also extending measurements of the SOL width in spherical tokamaks to increased poloidal field (≥0.3 T). Due to the divertor on ST40 having a low degree of axisymmetry, it is necessary for a set of radial measurements of the heat flux to be taken across the divertor, made possible using an automated toolchain that fully incorporates its 3D geometry. These radial profiles are combined with the magnetic geometry of the plasma to infer the width of the SOL, with both Eich and double exponential profiles of heat flux observed. A reduction in the heat flux is observed toroidally across part of the divertor, along with increased heat loads observed locally around the edges of the tiles. Future work in characterising the impact of tile misalignment and uncertainties in the reconstructed divertor magnetic geometry is required in order to further understand the observed heat flux patterns, as are additional investigations into the role potentially being played by an inhomogeneous sheath electric field.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Understanding structure-processing relationships in metal additive manufacturing via featurization of microstructural images

Understanding and predicting accurate property-structure-processing relationships for additively manufactured components is important for both forward and inverse design of robust, reliable parts and assemblies. While direct mapping of process parameters to properties is sometimes plausible, it is often rendered difficult due to poor microstructural control. Exploring the direct relationship between processing conditions and microstructural features can thus provide significant physical insights and aid the overall design process. Here, in this study, we develop an automated high-throughput framework to simulate an uncertainty-aware additive manufacturing (AM) process, characterize microstructural images, and extract meaningful features/descriptors. A kinetic Monte Carlo (KMC) based model of the AM process is used to simulate microstructural evolution for a diverse set of experimentally relevant processing conditions. We perform a parametric study to explore the relationship between microstructural features and processing conditions. Our results indicate that a many-to-one mapping can exist between processing conditions and typical descriptors; therefore, multiple descriptors are thus necessary to unambiguously represent microstructural images. Our work provides crucial quantitative and qualitative in-formation that would aid in the selection of features for microstructural images. Featurized microstructures could then be utilized to build data-driven models for predictive control of microstructures and thereby properties of additively manufactured components.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Scoping Study of Machine Learning Techniques for Visualization and Analysis of Multi-source Data in Nuclear Safeguards

In implementation of nuclear safeguards, many different techniques are being used to monitor operation of nuclear facilities and safeguard nuclear materials, ranging from radiation detectors, flow monitors, video surveillance, satellite imagers, digital seals to open source search and reports of onsite inspections/verifications. Each technique measures one or more unique properties related to nuclear materials or operation processes. Because these data sets have no or loose correlations, it could be beneficial to analyze the data sets together to improve the effectiveness and efficiency of safeguards processes. Advanced visualization techniques and machine-learning based multi-modality analysis could be effective tools in such integrated analysis. In this project, we will conduct a survey of existing visualization and analysis techniques for multi-source data and assess their potential values in nuclear safeguards.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Toward 2035: Forging a High-Ambition U.S. Climate Pathway

This analysis takes an integrated, innovative approach to develop plausible, high-ambition pathways through 2035 to inform the third U.S. NDC target setting. This approach combines: (1) an extensive consultation and engagement process with a broad set of federal and subnational stakeholders to build a robust U.S. policy platform; and (2) an open-source, field-leading integrated assessment model focused on the U.S. containing subnational details. The modeling tool assesses existing and possible new policies from both federal and subnational levels to assess the overall emissions reduction potential and the policy pathways to deliver the ambition needed for 2035 and leading on to 2050. In addition, we highlight how different actors can contribute to the needed transition in each sector and showcase successful implementation stories by various subnational actors.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

New method for analysis of X-ray computed tomography scans of TRISO fuel forms

X-ray computed tomography (XCT) is a powerful characterization tool that has been used for examination of both tristructural-isotropic (TRISO) coated particles and fuel forms. Rapid, nondestructive imaging of complete specimens by XCT provides significant characterization advantages in both speed and comprehensiveness over traditional materialographic methods. This paper discusses a method that has been developed to analyze XCT images of pebble fuel forms containing ~18,000 TRISO particles each. The XCT images are three-dimensional with contrast based on relative x-ray transparency. In the case of TRISO fuel forms, XCT image intensity distinguishes between the high-density kernel, the medium-density SiC, and the low-density matrix and carbon layers. Image analysis software has been developed to process XCT data sets to extract spatial distribution information, including particle nearest-neighbor distances, local packing fraction, and fuel-free zone thickness in TRISO fuel forms. Finally, although this type of high-resolution XCT analysis is likely not feasible as a quality control measurement for commercial TRISO fuel, it is highly useful in generating feedback for the development of fuel form fabrication processes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Simulating organic aerosol in Delhi with WRF-Chem using the volatility-basis-set approach: exploring model uncertainty with a Gaussian process emulator

The nature and origin of organic aerosol in the atmosphere remain unclear. The gas–particle partitioning of semi-volatile organic compounds (SVOCs) that constitute primary organic aerosols (POAs) and the multigenerational chemical aging of SVOCs are particularly poorly understood. The volatility basis set (VBS) approach, implemented in air quality models such as WRF-Chem (Weather Research and Forecasting model with Chemistry), can be a useful tool to describe emissions of POA and its chemical evolution. However, the evaluation of model uncertainty and the optimal model parameterization may be expensive to probe using only WRF-Chem simulations. Gaussian process emulators, trained on simulations from relatively few WRF-Chem simulations, are capable of reproducing model results and estimating the sources of model uncertainty within a defined range of model parameters. In this study, a WRF-Chem VBS parameterization is proposed; we then generate a perturbed parameter ensemble of 111 model runs, perturbing 10 parameters of the WRF-Chem model relating to organic aerosol emissions and the VBS oxidation reactions. This allowed us to cover the model's uncertainty space and to compare outputs from each run to aerosol mass spectrometer observations of organic aerosol concentrations and O:C ratios measured in New Delhi, India. The simulations spanned the organic aerosol concentrations measured with the aerosol mass spectrometer (AMS). However, they also highlighted potential structural errors in the model that may be related to unsuitable diurnal cycles in the emissions and/or failure to adequately represent the dynamics of the planetary boundary layer. While the structural errors prevented us from clearly identifying an optimized VBS approach in WRF-Chem, we were able to apply the emulator in the following two periods: the full period (1–29 May) and a subperiod period of 14:00–16:00 h LT (local time) on 1–29 May. The combination of emulator analysis and model evaluation metrics allowed us to identify plausible parameter combinations for the analyzed periods. We demonstrate that the methodology presented in this study can be used to determine the model uncertainty and to identify the appropriate parameter combination for the VBS approach and hence to provide valuable information to improve our understanding of OA production.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

In-depth analysis on parallel processing patterns for high-performance Dataframes

The Data Science domain has expanded monumentally in both research and industry communities during the past decade, predominantly owing to the Big Data revolution. Artificial Intelligence (AI) and Machine Learning (ML) are bringing more complexities to data engineering applications, which are now integrated into data processing pipelines to process terabytes of data. Typically, a significant amount of time is spent on data preprocessing in these pipelines, and hence improving its efficiency directly impacts the overall pipeline performance. The community has recently embraced the concept of Dataframes as the de-facto data structure for data representation and manipulation. However, the most widely used serial Dataframes today (R, pandas) experience performance limitations while working on even moderately large data sets. We believe that there is plenty of room for improvement by taking a look at this problem from a high-performance computing point of view. In a prior publication, we presented a set of parallel processing patterns for distributed dataframe operators and the reference runtime implementation, Cylon. In this paper, we are expanding on the initial concept by introducing a cost model for evaluating the said patterns. Furthermore, we evaluate the performance of Cylon on the ORNL Summit supercomputer.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Techno-Economic Analysis of Magnesium Extraction from Seawater via a Catalyzed Organo-Metathetical Process

Magnesium (Mg) has many useful applications especially in various Mg alloys which can decrease weight while increasing strength. To increase the affordability and minimize environment consequence, a novel catalyzed organo-metathetical (COMET) process was proposed to extract Mg from seawater aiming to achieve significant reduction in total energy and production cost comparing with the melting salt electrolysis method currently adopted by US Mg LLC. A process flowsheet for a reference COMET process was set-up using Aspen Plus which included five key steps, anhydrous MgCl2 production, transmetallation, dibutyl Mg decomposition, n-BuLi regeneration, and LiCL electrolysis. The energy and production cost and CO2 emission were estimated based on the Aspen modeling using Aspen economic analyzer. Our results showed that it is possible to produce Mg from seawater with a production cost of $2.0/kg-Mg while consuming about 35.3 kWh/kg-Mg and releasing 7.0 kg CO2/kg-Mg. A simplified US Mg manufacturing process was also generated using Aspen and the cost and emission results were estimated for comparison purpose. Under our simulation conditions, the reference COMET process maintain a comparable CO2 emission rate and can save about 40% in production cost and save about 15% energy compared to the simplified US Mg process.

Liu, Jian (ORCID:0000000153297408)↗
DOE OSTI2020

Extended Finite Element Based Approach in Additive Manufacturing Modeling for Optimizing Highly Complex Manifold in Protonic Ceramic Electrochemical Cells

The objective of this project is to develop a novel numerical approach based on the extended finite element method (XFEM) for modeling moving boundaries of material deposited in additive manufacturing (AM) process with improved accuracy and reduced computational cost. One of the major challenges in simulating AM processes is that the boundaries of the computational domain need to change as material is deposited. Previous approaches have achieved this by activating new finite elements, but this requires a high level of mesh refinement to capture small movement of the boundary. XFEM allows the solution boundary to move independently of the mesh, permitting smooth representation of the evolution of the boundary as material is deposited. As a result, this new method will significantly improve the simulation accuracy while reducing the computational cost compared with existing approaches. Furthermore, this project will bring significant improvements for the design and AM process optimization in an iterative fashion among numerical simuation, parameter optimization, and experimental validation. Specifically, this project will support the protonic ceramic electrochemical cells (PCEC) stack development at INL by providing insights into the density, residual stress, thermal and mechanical properties of the PCEC manifold and interconnect, which is critical in enhancing the system lifetime and reducing the overall cost. Upon the success of proposed development and validation of the proposed approach, simulation will be applied to determine an optimal set of AM process parameters for the PCEC manifold production. This project will consolidate Idaho National Laboratory (INL)’s simulation capabilities provided by the MOOSE framework and the Valhalla AM simulation application, with encouraging expansion to emerging PCEC applications and AM technologies at INL and beyond.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Influence of Water, Vacuum, and Temperature on Surface Conditions of a Zeolite‐based Molecular Sieve

Molecular sieves such as zeolite-based materials are ubiquitous in industrial separation processes. However, there is a significant gap in understanding the surface properties and adsorption mechanisms for commercial zeolites, as most research focuses on pure zeolite powders rather than industrially relevant forms. Here, this work addresses this gap in understanding by employing advanced characterization techniques, including positron annihilation spectroscopy, X-ray diffraction, scanning electron microscopy, X-ray fluorescence spectroscopy, X-ray photoelectron spectroscopy, liquid nitrogen sorption, and Fourier-transform infrared spectroscopy, to investigate the adsorption and desorption behavior of water in commercial zeolite 13X. Our research reveals insights into the pore-filling mechanisms, the impact of material binders on adsorption properties, and the dynamics of hydration and drying processes for zeolites. Monitoring changes on a minute scale allowed the distinction between fast and slow processes leading to sample drying. The identification of positronium bound to Na + ions indicated that water molecules remain in the vicinity of Na + ions after air-drying zeolite 13X. These findings highlight the importance of various environmental conditions in restoring zeolite properties to baseline after hydration, with significant implications for optimizing industrial processes. This work sets the direction for further research aimed at developing more efficient and robust separation techniques.

Beads Binder↗
DOE OSTI2018

Status Report on the Component Models Developed in the Modelica Framework: Reverse Osmosis Desalination Plant & Thermal Energy Storage

This report has been prepared as part of an effort to design and build a Modeling and Simulation (M&S) framework to assess the economic viability of a Nuclear-Renewable Hybrid Energy System (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories and universities have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In Fiscal Years (FYs) 2015, Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water Reverse Osmosis (RO) desalination plants as industrial processes. In FYs 2016–2017, INL developed two additional subsystems in the Modelica framework: (1) a high-temperature steam electrolysis plant as a high priority industrial plant to be integrated with a light water reactor within an N-R HES and (2) a gas turbine power plant as a secondary energy supply. In FY 2018, the RO desalination system model developed in FY 2015 has been updated such that the model is compatible with the most recent version of the ThermoPower library. Special attention has been given to the controller settings based on process models, aiming to improve process dynamics and controllability. A dynamic performance analysis of the updated RO desalination plant was carried out to evaluate the technical feasibility (load-following capability) of such a system operating under highly variable conditions requiring flexible output. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the variable electrical load and RO feed pressure) within desired limits under various plant operating conditions. The results also indicate that the proposed RO plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES. For a small-scale energy storage system, a sensible Thermal Energy Storage (TES) model has been developed in the Modelica Framework in FY 2018.

25 ENERGY STORAGE↗
DOE OSTI2017

SPRUCE Large-Collar In Situ CO2 and CH4 Flux Data for the SPRUCE Experimental Plots: Whole-Ecosystem-Warming

This data set reports community-level CO2 and CH4 flux measurements for the SPRUCE experimental study plots located in the S1-Bog. Surface flux measurements of CO2 and CH4 were made using open-path analyzers over an area of 1.13 m2 within each of 16 plots. A custom-designed chamber encloses the hummock-hollow topography and allows point in time measurements of the shrub, forb, Sphagnum spp. and the complex microbial community. These observations were made with ambient light and imposed dark conditions to allow estimates of community daytime and night respiratory processes. This data set is all inclusive – beginning in 2011 and continuing through the Whole-Ecosystem-Warming (WEW) phase of the experiment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Iterative Method to Obtain Raman Spectra of Organic Dyes by Their Chaotic Generation in Multiple-Scattering Media

An iterative method is developed to obtain vibrational spectra of laser organic dyes from their secondary radiation spectra in multiple-scattering media, which manifests as a result of coupled process of chaotic generation (CG) and stimulated Raman scattering (SRS). The developed method increases significantly the capability to detect weak Raman lines by using batch processing of a set of experimental SRS-CG spectra, which makes it possible to optimize the deconvolution of these spectra and to average vibrational spectra obtained from the set of experimental SRS-CG spectra. The method is tested on spectra of the SRS-CG laser dye pyrromethene 597 in a vesicular film. The obtained results agree well with Raman spectra calculated by the Hartree–Fock method.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Physics-Dynamics Coupling in Weather, Climate, and Earth System Models: Challenges and Recent Progress

Geophysical models of the atmosphere and ocean invariably involve parameterizations. These represent two distinct areas: a) Subgrid processes which the model cannot (yet) resolve, due to its discrete resolution, and b) sources in the equation, due to radiation for example. Hence coupling between these physics parameterizations and the resolved fluid dynamics and also between the dynamics of the different fluids in the system (air and water) is necessary. This coupling is an important aspect of geophysical models. However, often model development is strictly segregated into either physics or dynamics. Hence, this area has many more unanswered questions than in-depth understanding. Furthermore, recent developments in the design of dynamical cores (significant increase of resolution, move to non-hydrostatic equation sets etc), extended process physics (prognostic micro physics, 3D turbulence, non-vertical radiation etc) and predicted future changes of the computational infrastructure (Exascale with its need for task parallelism, data locality and asynchronous time stepping for example) is adding even more complexity and new questions.

Gross, Markus↗
DOE OSTI2017

Status Report on the High-Temperature Steam Electrolysis Plant Model Developed in the Modelica Framework (FY17)

This report has been prepared as part of an effort to design and build a modeling and simulation (M&S) framework to assess the economic viability of a nuclear-renewable hybrid energy system (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In fiscal year 2015 (FY15), Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water reverse osmosis desalination plants as industrial processes. In FY16, INL developed two additional subsystems in the Modelica framework: (1) a high-temperature steam electrolysis (HTSE) plant as a high priority industrial plant to be integrated with a light water reactor (LWR) within an N-R HES and (2) a gas turbine power plant as a secondary energy supply. In FY17, five new components (i.e., a feedwater pump, a multi-stage compression system, a sweep-gas turbine, flow control valves, and pressure control valves) have been incorporated into the HTSE system proposed in FY16, aiming to better realistically characterize all key components of concern. Special attention has been given to the controller settings based on process models (i.e., direct synthesis method), aiming to improve process dynamics and controllability. A dynamic performance analysis of the improved LWR/HTSE integration case was carried out to evaluate the technical feasibility (load-following capability) and safety of such a system operating under highly variable conditions requiring flexible output. The analysis (evaluated in terms of the step response) clearly shows that the FY17 model resulted in superior output responses with much smaller settling times and less oscillatory behavior in response to disturbances in the electric load than those observed with the FY16 model. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the steam utilization factor, cathode stream inlet composition, and temperatures and pressures of the process streams at various locations) within desired limits under various plant operating conditions. The results also indicate that the proposed HTSE plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES.

08 HYDROGEN↗
DOE OSTI2023

The environmental controls on efficiency of enhanced rock weathering in soils

Abstract Enhanced rock weathering (ERW) in soils is a promising carbon removal technology, but the realistically achievable efficiency, controlled primarily by in situ weathering rates of the applied rocks, is highly uncertain. Here we explored the impacts of coupled biogeochemical and transport processes and a set of primary environmental and operational controls, using forsterite as a proxy mineral in soils and a multiphase multi-component reactive transport model considering microbe-mediated reactions. For a onetime forsterite application of ~ 16 kg/m 2 , complete weathering within five years can be achieved, giving an equivalent carbon removal rate of ~ 2.3 kgCO 2 /m 2 /yr. However, the rate is highly variable based on site-specific conditions. We showed that the in situ weathering rate can be enhanced by conditions and operations that maintain high CO 2 availability via effective transport of atmospheric CO 2 (e.g. in well-drained soils) and/or sufficient biogenic CO 2 supply (e.g. stimulated plant–microbe processes). Our results further highlight that the effect of increasing surface area on weathering rate can be significant—so that the energy penalty of reducing the grain size may be justified—only when CO 2 supply is nonlimiting. Therefore, for ERW practices to be effective, siting and engineering design (e.g. optimal grain size) need to be co-optimized.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

A High-Throughput Method to Define Additive Manufacturing Process Parameters: Application to Haynes 282

This paper demonstrates how an analytical and experimental method can be used to rapidly define the 45 additive manufacturing settings for a new alloy where the process parameters were previously unknown. A nickel-based superalloy, Haynes 282, was chosen for the analysis. An experimental matrix of focused processing parameters was predicted with a dimensionless number and 100 samples were printed using the Selective Laser Melting technique. High-throughput measurements validated the predicted process conditions needed to achieve desired density and hardness. The whole process was completed in 16 hours. The new technique was confirmed with analytical processing maps adopted by the metal additive manufacturing community. With the predicted set of process parameters, microstructural characterizations and tensile testing were used to confirm the predictions. The resultant as-fabricated microstructures have refined length scales of both microsegregation and secondary phase distributions. As a result, the mechanical properties were comparable within the predicted processing window and exhibited high strength and high ductility.

Laser Material Processing↗
DOE OSTI2018

Simulations of Van Allen Probes Plasmaspheric Electron Density Observations

Here we simulate equatorial plasmaspheric electron densities using a physics-based model (Cold PLasma, CPL; used in the ring current-atmosphere interactions model) of the source and loss processes of refilling and erosion driven by empirical inputs. The performance of CPL is evaluated against in situ measurements by the Van Allen Probes (Radiation Belt Storm Probes) for two events: the 31 May to 5 June and 15 to 20 January 2013 geomagnetic storms observed in the premidnight and postmidnight magnetic local time (MLT) sectors, respectively. Overall, CPL reproduces the radial extent of the plasmasphere to within a mean absolute difference of |ΔL avg |=0.5 ± 0.1 L. The model electric field responsible for E × B convection and the parameterization of geomagnetic conditions (under the Kp-index and solar wind properties) implemented by CPL did not account for localized enhancements in the duskward electric field during increased activity. Rather, it was found to be largely dependent on the measure of the quiet time background. Finally, this property indicates that the agreement between these simulations and observations does not account for the complete set of physical processes during extreme (strong or weak) geomagnetic conditions impacting the plasmasphere. Nevertheless, at the presented resolution of the model CPL does provide good agreement in reproducing Radiation Belt Storm Probes observations of plasmaspheric density and plasmapause location.

79 ASTRONOMY AND ASTROPHYSICS↗