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DOE OSTI2025

Noncollinear ground states of solids with a source-free exchange correlation functional

In this paper, we expand upon the source-free (SF) exchange correlation (XC) functional developed by Sangeeta Sharma and coworkers to plane-wave density functional theory (DFT) based on the projector augmented wave (PAW) method. This constraint is implemented by the current authors within the VASP source code, using a fast Poisson solver that capitalizes on the parallel three-dimensional fast Fourier transforms (FFTs) implemented in VASP. Using this modified XC functional, we explore the improved convergence behavior that results from applying this constraint to the GGA-PBE+U+J functional. In the process, we compare the noncollinear magnetic ground state computed by each functional and their SF counterpart for a select number of magnetic materials in order to provide a metric for comparing with experimentally determined magnetic orderings. We observe significantly improved agreement with experimentally measured magnetic ground-state structures after applying the source-free constraint. Furthermore, we explore the importance of considering probability current densities in spin-polarized systems, even under no applied field. We analyze the XC torque as well, in order to provide theoretical and computational analyses of the net XC magnetic torque induced by the source-free constraint. Along these lines, we highlight the importance of properly considering the real-space integral of the source-free local magnetic XC field. Our analyses on probability currents, net torque, and constant terms draw additional links to the rich body of previous research on spin-current density functional theory (SCDFT), and pave the way for future extensions and corrections to the SF corrected XC functional.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Motion Control of Hydraulic Actuators In the Presence of Discrete Pressure Rail Switching

Conventional off-highway mobile machines are hydraulically actuated and have poor energy efficiencies. The goal to increase system efficiency and to reap the benefits of electrification have led to the creation of a novel Hybrid Hydraulic-Electric Architecture (HHEA) which could significantly increase efficiency, decrease the sizes and cost of electrical components, and maintain control performance. The key concept is to utilize a set of common pressure rails to provide the majority of power via the power dense hydraulics and to modulate that power by small electric components, which are less power dense, for precise control. The paper presents the motion control strategy for this architecture. The architecture presents a distinct challenge in that as the energy minimization algorithm selects different pressure rails, the system could experience large discrete jumps in pressures that impact control performance, especially when the electric components are torque limited. To meet this challenge, a passivity based back-stepping controller is used as the nominal controller between pressure rail switching events and a separate transition controller is used to deal with the pressure rail switching events. Two transition controllers are proposed, one uses the electric motor torque as the input, and the other also uses valve timing as a second input. For both transition controllers, a least norm control approach is used to steer the system states to the exact desired states at the end of the short transition period (~ 40 ms). The transition controllers are able to reduce the tracking error and the required electric motor torque, and hence achieve better control performance even with smaller electric components.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

A Multi-Stack Variable Stiffness Magnetic Torsion Spring for a Wave Energy Converter

This paper presents the design of a multi-stack high torque adjustable stiffness torsional magnetic spring for use in a wave energy converter. The torsional magnetic spring has a ±45 degrees linear stroke length with peak torque of 823 N⋅m. A 3-D magnetostatic finite element analysis parameter sizing sweeping analysis was performed and the peak energy density for the selected torsion spring was computed to be 12.6 J/kg. The required torque was increased by using a unique seven-stage multi-stacking design. The stiffness of magnetic torsion spring is adjusted through the axial translation of the inner rotor. The presented design is shown to be capable of providing both positive and negative stiffness with equal characteristics and has a very high degree of linearity. The experimental prototype assembly and test-setup used to verify the torsional spring performance is presented.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

REGULATORY TESTING AND POSTTEST ANALYSIS OF THE DPP-3 TYPE B SHIPPING CONTAINER FOR NCT AND HAC TESTS

The safe transportation of radioactive material using appropriately designed and certified transportation packages is important to protect the public and environment. Therefore, a comprehensive and rigorous system of packaging requirements are required. The purpose of this test protocol is to determine the effects of drop testing on package performance in a Type B shipping package (DPP-3). Required physical tests for the DPP-3 package include normal conditions of transport and hypothetical accident conditions test requirements. The preparation, regulatory testing, and post-test evaluation of a Type B shipping package tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. Six packages were tested and the responses when subjected to the HAC sequence of free drop, puncture, and thermal tests according to 10 CFR 71.73 were measured. The posttest helium leak test showed a leak rate less than 1 × 10-7 He-cc/sec which means that the containment boundary was maintained after the regulatory testing, therefore maintaining a leak tight environment. To determine the amount of change in the package performance measurements, statistical analyses were conducted using SPSS version 26. The null hypothesis of the testing was that there would not be a change in the measurements from pre to post-testing large enough to find statistical significance. Therefore, a finding of statistical significance indicated too much variability in the package design and was deemed an unfavorable finding. A repeated measures t-test was used to analyze the drum lids and CV torques. A one-way ANOVA was used to analyze height and diameter packages. Results of the repeated measures t-test indicated that all six containment vessel lid torques were statistically significant. However only three out of the six drum lid torques were statistically significant. Therefore, design of the lids caused more variability than necessary when subjected to the following drop tests: 1.) horizontal and cold; 2.) vertical lid down; and 3.) corner with lid up. Results of the one-way ANOVA analysis on height indicated that four out of the six CTUs were statistically significant. Thus, design of the CTUs caused more variability then necessary when subjected to the following drop tests: 1.) horizontal hot; 2.) horizontal cold; 3.) corner lid up; and 4.) corner lid down. Results of the one-way ANOVA analysis on diameter indicated that all six CTUs were statistically significant. Thus, design of the CTUs caused more variability then necessary when subjected to all of the tests. The DPP-3 design has been shown to be an acceptable design for the transport of radioactive materials. However, results of the statistical analysis reveal a possible improvement in package and test design to reduce variability in package performance measurement before and after testing.

Martinez, Oscar↗

DOE OSTI2020

The paradox of the tight spiral pass in American football: A simple resolution

An American football is a rotationally symmetric object, which, when well-thrown, spins rapidly around its symmetry axis. In the absence of aerodynamic effects, the football would be a torque-free gyroscope and the symmetry/spin axis would remain pointing in a fixed direction in space as the football moved on its parabolic path. When a pass is well-thrown through the atmosphere, however, the symmetry axis remains—at least approximately—tangent to the path of motion. The rotation of the symmetry axis must be due to aerodynamic torque; yet, that torque, at first glance, would seem to have precisely the opposite effect. In this work, we explain the action of aerodynamics on the ball's orientation at second glance.

42 ENGINEERING↗

DOE OSTI2022

Efficient, Compact, and Smooth Variable Propulsion Motor (Final Report)

In this project, a new architecture of highly efficient hydraulic motor was developed for the propulsion of off-highway vehicles. The motor uses an adjustable linkage driving a cam to vary the displacement of the piston, resulting in a Variable Displacement Linkage Motor (VDLM). The motor uses low friction rolling element bearings to significantly reduce mechanical friction, especially in the demanding low-speed high-torque conditions experienced by off-highway vehicles. The VDLM has high torque capabilities for its size due to the radial piston packaging and use of a multi-lobe cam. A VDLM is very smooth due to the ability to tune the torque ripple through the design of the cam profile. The project was divided into three periods. During the first period, a dynamic model was constructed of the motor to predict the performance of the motor and the vehicle. During the second period, a single-cylinder learning prototype was designed, built, and tested to validate the models constructed in the first period. In the third period, a multi-cylinder prototype motor was optimized, designed, fabricated, and tested. The motor demonstrated excellent mechanical efficiency (above 92.5% across the range of displacements), but the experimentally measure volumetric efficiency was lower than expected due to higher leakage rates created by the poor tolerance control on the prototype. To validate the dynamic models developed in the first period and better understand design trade-offs. In the third period a multi-cylinder concept demonstration prototype will be designed, fabricated, and tested. The final prototype will be tested on a motor dynamometer and will be utilized in hardware-in-the-loop testing to demonstrate its efficiency and performance impacts on the overall drive train. The experimental results were used in a drive train simulation of a compact track loader operating through a drive cycle. Using the VDLM in a hydrostatic circuit yielded 17.1% reduction in fuel consumption and 36.5% reduction in a series hybrid transmission.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Downhole Sensing and Event-Driven Sensor Fusion for Depth-of-Cut Based Autonomous Fault Response and Drilling Optimization

Achieving robust and efficient drilling is a critical part of reducing the cost of geothermal energy exploration and extraction. Drilling performance is often evaluated using one or more of three key metrics: depth of cut (DOC), rate of penetration (ROP), and mechanical specific energy (MSE). All three of these quantities are related to each other. DOC refers to the depth a bit penetrates into rock during drilling. This is an important quantity for estimating bit behavior. ROP is the simply the DOC multiplied by the rotational rate, and represents how quickly the drill bit is advancing through the ground. ROP is often the parameter used for drilling control and optimization. Finally, MSE provides insight into drilling efficiency and rock type. MSE calculations rely on ROP, drilling force, and drilling torque. Surface-based sensors at the top of the drill are often used to measure all these quantities. However, top-hole measurements can deviate substantially from the behavior at the bit due to lag, vibrations, and friction. Therefore, relying only on top-hole information can lead to suboptimal drilling control. In this work, we describe recent progress towards estimating ROP, DOC, and MSE using down-hole sensing. We assume down-hole measurements of torque, weight-on-bit (WOB). Our hypothesis is that these measurements can provide more rapid and accurate measures of drilling performance. We show how a multi-layer perceptron (MLP) machine learning algorithm can provide rapid and accurate performance when evaluated on experimental data taken from Sandia’s Hard Rock Drilling Facility. In addition, we implement our algorithms on an embedded system intended to emulate a bottom-hole-assembly for sensing and estimation. Our experimental results show that DOC can be estimated accurately and in real-time. These estimates when combined with measurements for rotary speed, torque, and force can provide improved estimates for ROP and MSE. These results have the potential to enable better drilling assessment, improved control, and extended component lifetimes.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Nonsteady Load Responses of Wind Turbines to Atmospheric and Mountain-Generated Turbulence Eddies, With Impacts on the Main Bearing: A Validation Study

Previous computational and field experiments identify three characteristic time scales in the aerodynamic responses of utility-scale wind turbine loads to atmospheric boundary layer (ABL) turbulence: a 30-90 second time scale for the passage of high/low speed "streaks" through the rotor plane, the blade and rotor rotation time scales (approximately 1 to 5 seconds), and a sub-second time scale created by blade rotation through gradients within eddy coherent structure. In the current study we compare aerodynamic load responses from daytime ABL turbulence quantified with large-eddy simulation and a actuator line model of the NREL 5 MW wind turbine with analysis of field data from the NREL/GE 1.5 MW wind turbine 5 kilometers east of the Rocky Mountain Front Range in Colorado. In addition, we contrast the responses to the passage of the mountain-generated eddies embedded within the westerly winds with the ABL eddies embedded within northerly/southerly winds. These analyses are in context with the nonsteady forcing of the main bearing by the aerodynamic generation of nontorque bending moments on the main shaft. Potentially relevant to main bearing failure mechanisms, both computational and field data show that the magnitudes of turbulence-generated nontorque bending moments, that we show generate nonsteady force on the main bearing, are of order, and often larger than, torque (which underlies power). However, the temporal variations in these two responses are uncorrelated, implying that the aerodynamic mechanisms that drive power and main bearing response are fundamentally different. We find this to be the case in the field with both mountain-generated eddies (westerly winds) and ABL-generated eddies (northerly/southerly winds). Whereas the time and length scales are comparable, the mountain eddies were somewhat more energetic than the northerly/southerly ABL eddies. Interestingly, however, the fluctuations in nontorque bending moment that force the main bearing were found to be stronger when forced by the ABL eddies than the mountain eddies. The field studies validate the key results from the computational study and show even stronger response in the nontorque bending moment than in the computer simulations. In all cases, the torque and nontorque bending moments are temporally uncorrelated, torque and power are driven by time variations in rotor-averaged horizontal wind velocity and nontorque bending moments are driven by time changes in the degree of nonuniformity in the distribution of velocity over the rotor plane. Thus the results generalize the mechanisms underlying nonsteady aerodynamic forcing to classes of turbulence eddy types with strength of order or stronger than ABL eddies with transverse scale of order the wind turbine rotor. These include atmospheric turbulence eddies, topography-generated turbulence eddies and, by extension, impacts of turbine-wake-scale turbulence eddies on downstream wind turbine rotors.

17 WIND ENERGY↗

DOE OSTI2024

Acoustic-based monitoring and machine learning of component status for microreactor applications

This report provides a description and assessment of recent efforts to couple acoustic-based experimental measurements and characterization with machine learning models in order to enhance structural health monitoring capabilities for nuclear microreactors. With resilient embedded sensors in development by others supported by programs funded by the US Department of Energy’s Office of Nuclear Energy, the work described herein builds upon ongoing efforts to improve non-destructive testing technology that relates measured acoustic signatures to component stresses and/or structural defects, using a combination of new experimental measurements and machine learning architectures. The experimental procedure remained similar to that developed for the previous year’s demonstration of damage detection by the authors, with the same damaged sample tested under similar applied stress conditions. Notably, a new mounting fixture was designed and implemented to improve measurement consistency and a more sophisticated laser Doppler vibrometer was employed to make high-fidelity vibration measurements. Two nominally identical sets of training data were collected for each experimental setup to better understand the repeatability of the experiment and to better test the generality of trained neural network models. Additionally, we obtained new high-quality 3D mode shapes of the damaged test article at various stress and excitation levels, providing greater insights into the physical response of the sample during testing. Previously, we demonstrated that a machine learning model based on a convolutional neural network can predict structural details of an artificially introduced interface (intact, rough cut, smooth cut), and the applied torque level. In this study, we have transitioned to graph-based neural network architectures to better develop and test a flexible framework that is more suitable to being transferred away from controlled benchtop experiments and into more applied settings where less-structured data inputs may be expected. In general, performance testing of a graph neural network on frequency-domain representations of the data indicates strong and consistent identification of test conditions for datasets recorded on damaged components. With goals of predicting damage location and other changing experimental conditions using limited datasets, predictive models using a graph neural network architecture correctly predicted the applied torque level with an accuracy of 85% using only a single measurement point and predicted within one torque level in 95% of test windows. Predictions of damage location had limited success due to the symmetry and minimal number of the damage scenarios presented during model training. Results were ambiguous as to whether the model could detect the location of the artificial damage, or if it was instead learning the location of a given measurement point on the part and subsequently detecting which points were closest to the location of the damage. This finding will be factored into upcoming planned work on damaged graphite components, where new experimental tests with a larger number and variety of damage scenarios are expected to provide improved validation of recent developments in monitoring methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Main Shaft Bending Moment Analysis for a Gamesa G97 2-MW Wind Turbine

In a collaborative project between Siemens Gamesa Renewable Energy and the National Renewable Energy Laboratory (NREL), a cost-effective method to measure dynamic main shaft torque and the influence of non-torque loads was applied to the gearbox of the Gamesa G97 2-megawatt (MW) wind turbine at the NREL Flatirons Campus and verified through a field test campaign that took place in 2023. The method involved the installation of fiber-optic sensors on the ring gear of the gearbox. Additionally, traditional strain gauges and a rotary encoder were installed on the main shaft to measure mechanical torque and orthogonal bending moments. We compare the measured total main shaft bending moments from the field test campaign to those predicted by an updated OpenFAST model of the G97 wind turbine for similar environmental conditions. We also assessed the sensitivity of the predicted bending moment to varying levels of turbulence intensity, shear exponent, and yaw error.

17 WIND ENERGY↗

DOE OSTI2022

Verification and Validation of Model-Scale Turbine Performance and Control Strategies for the IEA Wind 15 MW Reference Wind Turbine

To enable the fast growth of the floating offshore wind industry, simulation models must be validated with experimental data. Floating wind model-scale experiments in wind–wave facilities have been performed over the last two decades with varying levels of fidelity and limitations. However, the turbine controls in these experiments have considered only limited control strategies and implementations. To allow for control co-design, this research focuses on implementing and experimentally validating more advanced turbine control actions and strategies in a wind–wave basin for a 1:70-scale model of the International Energy Agency’s wind 15 MW reference wind turbine. The control strategies analyzed include torque control, collective pitch control, and transition region control (setpoint smoothing). Our experimental and numerical results include the effects of varying rotor speeds, blade pitches, and wind environments on the turbine thrust and torque. Numerical models from three different software tools are presented and compared to the experimental results. Their ability to effectively represent the aero-dynamic response of the wind turbine to the control actions is successfully validated. Finally, turbine controller tuning parameters based on the derivatives of thrust and torque are derived to allow for improved offshore wind turbine dynamics and to validate the ability of modeling tools to model the dynamics of floating offshore wind turbines with control co-design.

17 WIND ENERGY↗

DOE OSTI2024

The Dynamics of Debris Disk Creation in Neutron Star Mergers

Abstract The detection of GW170817/AT2017gfo inaugurated an era of multimessenger astrophysics, in which gravitational-wave and multiwavelength photon observations complement one another to provide unique insight into astrophysical systems. A broad theoretical consensus exists, in which the photon phenomenology of neutron star mergers largely rests upon the evolution of the small amount of matter left on bound orbits around the black hole or massive neutron star remaining after the merger. Because this accretion disk is far from inflow equilibrium, its subsequent evolution depends very strongly on its initial state, yet very little is known about how this state is determined. Using both snapshot and tracer particle data from a numerical relativity/MHD simulation of an equal-mass neutron star merger that collapses to a black hole, we show how gravitational forces arising in a nonaxisymmetric, dynamical spacetime supplement hydrodynamical effects in shaping the initial structure of the bound debris disk. The work done by hydrodynamical forces is ∼10 times greater than that due to time-dependent gravity. Although gravitational torques prior to remnant relaxation are an order of magnitude larger than hydrodynamical torques, their intrinsic sign symmetry leads to strong cancellation; as a result, hydrodynamical and gravitational torques have a comparable effect. We also show that the debris disk’s initial specific angular momentum distribution is sharply peaked at roughly the specific angular momentum of the merged neutron star’s outer layers, a fewr g c, and identify the regulating mechanism.

Astronomy & Astrophysics↗

DOE OSTI2020

Fluid-powered linear motor with rotary pistons and motion rectifier

A fluid-powered linear motor with rotary pistons is disclosed. An application is for a downhole motor but it could be used in other applications. Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long (generally up to a maximum length of 30 ft.), a high-torque motor can be produced using this method. A pressurized fluid is used to drive the piston assemblies to produce bit shaft power. This concept employs rotary pistons and a mechanical rectifier to convert the rotational reciprocation produced by a reciprocating rotational piston into continuous rotary motion.

42 ENGINEERING↗

DOE OSTI2022

Fluid-powered linear motor with rotary pistons and motion rectifier and synthetic diamond bearing assemblies

Raymond, David W.↗

DOE OSTI2024

Systems and methods that use harmonic drives for converting reciprocating axial motion to continuous rotary motion, helical drives for converting reciprocating rotary motion to reciprocating axial motion and combinations thereof for converting reciprocating rotary motion to continuous rotary motion

A harmonic drive assembly and fluid-powered linear motors with both axial pistons are rotary piston arrangements incorporating the harmonic drive assembly are disclosed. The motors may be used in downhole drilling applications, but the drive assembly and/or motors may be used in other applications. The assembly, motors and methods use advanced harmonic drives, advanced helical drives, and combinations thereof with 1) motors with axial pistons and reciprocating linear rings to convert reciprocative axial motion to continuous rotary motion, and 2) motors with rotary pistons and reciprocating linear rings to rectify reciprocative rotary motion to continual rotary motion to improve performance over prior configurations. Axial pistons provide a robust simple solution for generating rotation; Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long, a high-torque motor can be produced using this method.

Raymond, David W.↗

DOE OSTI2021

Rare-Earth Permanent Magnet SmCo 5 for Chiral Interfacial Spin-Orbitronics

Interfacially asymmetric magnetic multilayers made of heavy metal/ferromagnet have attracted considerable attention in the spintronics community for accommodating spin-orbit torques (SOTs) and meanwhile for hosting chiral spin textures. In these multilayers, the accompanied interfacial Dzyaloshinskii–Moriya interaction (iDMI) permits the formation of Néel-type spin textures. While significant progresses have been made in Co, CoFeB, Co 2 FeAl, CoFeGd based multilayers, it would be intriguing to identify new magnetic multilayers that could enable spin-torque controllability and meanwhile host nanoscale skyrmions. In this report, first, thin films made of permanent magnet SmCo 5 with perpendicular magnetic anisotropy are synthesized, in which the deterministic SOT switching, enabled by the spin Hall effect, in Pt/SmCo 5 /Ta trilayer is demonstrated. Further, the stabilization of room-temperature skyrmions with diameters ≈100 nm in [Pt/SmCo 5 /Ta] 15 , together with a skyrmionium-like spin texture in [Pt/SmCo 5 /Ir] 15 multilayers is shown. Based on the material specific parameters, micromagnetic simulations are also carried out. The results confirm the presence of chiral spin textures in this new material family. Through interfacial engineering, the results thus demonstrate that rare earth permanent magnets could be a new platform for studying interfacial chiral spintronics.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Room-Temperature, Current-Induced Magnetization Self-Switching in A Van Der Waals Ferromagnet

2D layered materials with broken inversion symmetry are being extensively pursued as spin source layers to realize high-efficiency magnetic switching. Such low-symmetry layered systems are, however, scarce. In addition, most layered magnets with perpendicular magnetic anisotropy show a low Curie temperature. Here, in this study, the experimental observation of spin–orbit torque magnetization self-switching at room temperature in a layered polar ferromagnetic metal, Fe 2.5 Co 2.5 GeTe 2 is reported. The spin–orbit torque is generated from the broken inversion symmetry along the c-axis of the crystal. These results provide a direct pathway toward applicable 2D spintronic devices.

36 MATERIALS SCIENCE↗