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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Automated Strain Construction for Biosynthetic Pathway Screening in Yeast

Automation accelerates the Design-Build-Test-Learn (DBTL) cycle for synthetic biology; however, most strain construction pipelines lack robotic integration. Here, in this study, we present the workflow design and source code for a modular, integrated protocol that automates the Build step in Saccharomyces cerevisiae. We programmed the Hamilton Microlab VANTAGE to integrate off-deck hardware via its central robotic arm, enabling automated steps that increased throughput to 2,000 transformations per week. We developed a user interface with the Hamilton VENUS software to support on-demand parameter customization. As a proof of concept, we screened a gene library in an engineered yeast strain producing verazine, a key intermediate in the biosynthesis of steroidal alkaloids. Our pipeline rapidly identified pathway bottlenecks and genes that enhanced verazine production by 2.0- to 5-fold. This technical note provides resources for synthetic biologists designing yeast workflows for biofoundries to screen libraries for pathway discovery/optimization, combinatorial biosynthesis, and protein engineering.

automation↗
DOE OSTI2014

MO-G-BRE-03: Automated Continuous Monitoring of Patient Setup with Second-Check Independent Image Registration

Purpose: To create a non-supervised quality assurance program to monitor image-based patient setup. The system acts a secondary check by independently computing shifts and rotations and interfaces with Varian's database to verify therapist's work and warn against sub-optimal setups. Methods: Temporary digitally-reconstructed radiographs (DRRs) and OBI radiographic image files created by Varian's treatment console during patient setup are intercepted and used as input in an independent registration module customized for accuracy that determines the optimal rotations and shifts. To deal with the poor quality of OBI images, a histogram equalization of the live images to the DDR counterparts is performed as a pre-processing step. A search for the most sensitive metric was performed by plotting search spaces subject to various translations and convergence analysis was applied to ensure the optimizer finds the global minima. Final system configuration uses the NCC metric with 150 histogram bins and a one plus one optimizer running for 2000 iterations with customized scales for translations and rotations in a multi-stage optimization setup that first corrects and translations and subsequently rotations. Results: The system was installed clinically to monitor and provide almost real-time feedback on patient positioning. On a 2 month-basis uncorrected pitch values were of a mean 0.016° with standard deviation of 1.692°, and couch rotations of − 0.090°± 1.547°. The couch shifts were −0.157°±0.466° cm for the vertical, 0.045°±0.286 laterally and 0.084°± 0.501° longitudinally. Uncorrected pitch angles were the most common source of discrepancies. Large variations in the pitch angles were correlated with patient motion inside the mask. Conclusion: A system for automated quality assurance of therapist's registration was designed and tested in clinical practice. The approach complements the clinical software's automated registration in terms of algorithm configuration and performance and constitutes a practical approach to implement safe and cost-effective radiotherapy.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Application-level regression testing framework using Jenkins

Monitoring and testing for regression of large-scale systems such as the NCSA's Blue Waters supercomputer are challenging tasks. In this paper, we describe the solution we came up with to perform those tasks. The goal was to find an automated solution for running user-level regression tests to evaluate system usability and performance. Jenkins, an automation server software, was chosen for its versatility, large user base, and multitude of plugins including collecting data and plotting test results over time. We also describe our Jenkins deployment to launch and monitor jobs on remote HPC system, perform authentication with one-time password, and integrate with our LDAP server for its authorization. We show some use cases and describe our best practices for successfully using Jenkins as a user-level system-wide regression testing and monitoring framework for large supercomputer systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2013

Recent results of the investigation of a micro-fluidic sampling chip and sampling system for hot cell aqueous processing streams

A Fuel Cycle Research and Development project has investigated an innovative sampling method that could evolve into the next generation sampling and analysis system for metallic elements present in aqueous processing streams. Initially sampling technologies were evaluated and micro-fluidic sampling chip technology was selected and tested. A conceptual design for a fully automated microcapillary-based system was completed and a robotic automated sampling system was fabricated. The mechanical and sampling operation of the completed sampling system was investigated. Different sampling volumes have been tested. It appears that the 10 μl volume has produced data that had much smaller relative standard deviations than the 2 μl volume. In addition, the production of a less expensive, mass produced sampling chip was investigated to avoid chip reuse thus increasing sampling reproducibility/accuracy. The micro-fluidic-based robotic sampling system's mechanical elements were tested to ensure analytical reproducibility and the optimum robotic handling of micro-fluidic sampling chips. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

A Heterogeneous System for Eagle Detection, Deterrent, and Wildlife Collision Detection for Wind Turbines (Final Technical Report)

This report summarizes the design, implementation, and test of an integrated system for automated detection and deterrence of eagles, with included wind turbine blade strike detection and imaging functionality. A machine learning approach was used in conjunction with a 360° camera system for automated detection and classification of golden eagles. This was developed using footage obtained from trained golden eagles and other raptors, in collaboration with wildlife biologists and professional bird handlers. Oregon State University developed a visual deterrent system, which uses inflatable anthropomorphic sculptures with random, kinetic motion to deter eagles, and conducted limited field testing on live eagles; the deterrent can be triggered by the visual detection of eagles using the vision system. Finally, a multi-sensor module was developed that is mounted at the turbine blade root. This module measures vibration and other motions to detect blade strikes, and an integrated on-blade camera captures an image of any impacting objects. Long-term, this blade strike detection system is intended to support an automatic monitoring and certification system for the eagle detection and deterent system. Independent field testing of each system component is described. Testing of the integrated system on an operational wind turbine was conducted across three separate field tests. This includes multi-day fields tests on a General Electric 1.5MW wind turbine at the National Renewable Energy Laboratory (NREL) National Wind Technology Center (NWTC) in Boulder, CO in October 2018 and July 2019; installation procedures, test procedures, and a summary of collected data are presented. A third multi-day on-turbine field test is also presented, which was performed using a General Electric 1.5MW wind turbine at the North American Wind Research and Training Center (NAWRTC) at Mesalands Community College, Tucumcari, NM in April 2019. Across these field tests, the vision system was demonstrated using unmanned aerial vehicles (UAV), and the eagle classification algorithm was not tested; the visual deterrent system was demonstrated, including automatic, remote deployment following surrogate visual detections; and, multi-sensor on-blade data was recorded across multiple wind turbine operational conditions and through more than 100 surrogate blade strikes using soft projectiles, including the successful demonstration of automatic image capture of striking objects. This data set was also used for offline development and validation of enhanced collision detection algorithms. As summarized in this report, the development and field validation of an integrated detection, deterrent, and blade collision detection system represents a critical proof of concept for future technology development of related detection and deterrent technologies, where both deterrent as well as collision detection recording devices are needed for future siting, monitoring, and operation of wind turbine installations, both onshore and offshore.

17 WIND ENERGY↗
DOE OSTI2024

Moving toward automated µFTIR spectra matching for microplastic identification: addressing false identifications and improving accuracy

Abstract Infrared spectroscopy is a widely used tool for studying microplastics and identifying microparticles. Researchers rely on spectral libraries to differentiate between synthetic and natural materials. Unfortunately, spectral library matching is not perfect, and best practices require researchers to use time consuming, manual peak matching to assess spectral matches. Moving toward automated matching requires increased confidence in the matching process. Using spectra matching software may increase the efficiency of particle identification, however some matching strategies may confuse natural materials such as cotton, silk, and plant matter with common classes of synthetics such as polyesters and polyamides. In this experiment, we prepared 22 pristine sample materials from natural and synthetic sources and measured micro-Fourier transform infrared (µFTIR) spectra in transmission mode for each sample using a Thermo Nicolet iN10 MX instrument. The collected spectra were then input into two spectral library matching systems (Omnic Picta and Open Specy), using a total of five identification routines. Next, we placed a subset of four pristine microplastic materials in a biologically active river system for two weeks to simulate environmental samples. These simulated environmental samples were processed using 10% hydrogen peroxide for 24 h to remove organic contamination and then identified using the strongest performing library. We found that libraries with fewer sample spectra produced lower correlation matches and that using derivative correction greatly reduced the number of inaccuracies in identifying materials as either natural or synthetic. We also found that environmental fouling reduced the correlation value of library matches when compared to pristine particles, however the effect was not consistent across the four materials tested. Overall, we found that the accuracy of automated library matching in the tested systems and processing routines varied from 64.1 to 98.0% for distinguishing between natural and synthetic materials, and that a high Hit Quality Index (HQI) did not always correlate with accuracy. These results are important for the microplastic field, demonstrating a need to rigorously test spectral libraries and processing routines with known materials to ensure identification accuracy.

Kozloski, Rachel↗
DOE OSTI2015

WE-AB-BRA-07: Quantitative Evaluation of 2D-2D and 2D-3D Image Guided Radiation Therapy for Clinical Trial Credentialing, NRG Oncology/RTOG

Purpose: 2D-2D kV image guided radiation therapy (IGRT) credentialing evaluation for clinical trial qualification was historically qualitative through submitting screen captures of the fusion process. However, as quantitative DICOM 2D-2D and 2D-3D image registration tools are implemented in clinical practice for better precision, especially in centers that treat patients with protons, better IGRT credentialing techniques are needed. The aim of this work is to establish methodologies for quantitatively reviewing IGRT submissions based on DICOM 2D-2D and 2D-3D image registration and to test the methodologies in reviewing 2D-2D and 2D-3D IGRT submissions for RTOG/NRG Oncology clinical trials qualifications. Methods: DICOM 2D-2D and 2D-3D automated and manual image registration have been tested using the Harmony tool in MIM software. 2D kV orthogonal portal images are fused with the reference digital reconstructed radiographs (DRR) in the 2D-2D registration while the 2D portal images are fused with DICOM planning CT image in the 2D-3D registration. The Harmony tool allows alignment of the two images used in the registration process and also calculates the required shifts. Shifts calculated using MIM are compared with those submitted by institutions for IGRT credentialing. Reported shifts are considered to be acceptable if differences are less than 3mm. Results: Several tests have been performed on the 2D-2D and 2D-3D registration. The results indicated good agreement between submitted and calculated shifts. A workflow for reviewing these IGRT submissions has been developed and will eventually be used to review IGRT submissions. Conclusion: The IROC Philadelphia RTQA center has developed and tested a new workflow for reviewing DICOM 2D-2D and 2D-3D IGRT credentialing submissions made by different cancer clinical centers, especially proton centers. NRG Center for Innovation in Radiation Oncology (CIRO) and IROC RTQA center continue their collaborative efforts to enhance quality assurance services and to be consistently adaptive to the new advances in radiation therapy. This project was supported by NCI grants U10CA180868, U10CA180822, U24CA180803, U24CA12014 and PA CURE Grant.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

High Performance Building Mockup in FLEXLAB

Genentech has ambitious energy and indoor environmental quality performance goals for Building 35 (B35) being constructed by Webcor at the South San Francisco campus. Genentech and Webcor contracted with the Lawrence Berkeley National Laboratory (LBNL) to test building systems including lighting, lighting controls, shade fabric, and automated shading controls in LBNL’s new FLEXLAB facility. The goal of the testing is to ensure that the systems installed in the new office building will function in a way that reduces energy consumption and provides a comfortable work environment for employees.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Silicon Carbide Temperature Monitor Processing Improvements. Status Report

Silicon carbide (SiC) temperature monitors are used as temperature sensors in Advanced Test Reactor (ATR) irradiations at the Idaho National Laboratory (INL). Although thermocouples are typically used to provide real-time temperature indication in instrumented lead tests, other indicators, such as melt wires, are also often included in such tests as an independent technique of detecting peak temperatures incurred during irradiation. In addition, less expensive static capsule tests, which have no leads attached for real-time data transmission, often rely on melt wires as a post-irradiation technique for peak temperature indication. Melt wires are limited in that they can only detect whether a single temperature is or is not exceeded. SiC monitors are advantageous because a single monitor can be used to detect for a range of temperatures that occurred during irradiation. As part of the process initiated to make SiC temperature monitors available at the ATR, post-irradiation evaluations of these monitors have been previously completed at the High Temperature Test Laboratory (HTTL). INL selected the resistance measurement approach for determining irradiation temperature from SiC temperature monitors because it is considered to be the most accurate measurement. The current process involves the repeated annealing of the SiC monitors at incrementally increasing temperature, with resistivity measurements made between annealing steps. The process is time consuming and requires the nearly constant attention of a trained staff member. In addition to the expensive and lengthy post analysis required, the current process adds many potential sources of error in the measurement, as the sensor must be repeatedly moved from furnace to test fixture. This time-consuming post irradiation analysis is a significant portion of the total cost of using these otherwise inexpensive sensors. An additional consideration of this research is that, if the SiC post processing can be automated, it could be performed in an MFC hot cell, further reducing the time and expense of lengthy decontaminations prior to processing. Sections of this report provide a general description of resistivity techniques currently used to infer peak irradiation temperature from silicon carbide temperature monitors along with some representative data, the proposed concepts to improve the process of analyzing irradiated SiC temperature monitors, the completed efforts to prove the proposed concepts, and future activities. The efforts detailed here succeeded in designing and developing a real-time automated SiC resistivity measurement system, and performed two initial test runs. Activities carried out include the assembly and integration of the system hardware; the design and development of a preliminary monitor fixture; the design of a technique to automate the data analysis and processing; the development of the communication, coordination, and user software; and the execution and troubleshooting of test run experiments using the box furnace. Although the automation system performed as required, the designed fixture did not succeed in establishing the needed electrical contacts with the SiC monitor.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Will the Measurement Robots Take Our Jobs? An Update on the State of Automated M&V for Energy Efficiency Programs

Trustworthy savings calculations are critical to convincing regulators of both the cost-effectiveness of energy efficiency program investments and their ability to defer supply-side capital investments. Today’s methods for measurement and verification (M&V) of energy savings constitute a significant portion of the total costs of energy efficiency programs. They also require time-consuming data acquisition. A spectrum of savings calculation approaches is used, with some relying more heavily on measured data and others relying more heavily on estimated, modeled, or stipulated data. The rising availability of “smart” meters and devices that report near-real time data, combined with new analytical approaches to quantifying savings, offers potential to conduct M&V more quickly and at lower cost, with comparable or improved accuracy. Commercial energy management and information systems (EMIS) technologies are beginning to offer M&V capabilities, and program administrators want to understand how they might assist programs in quickly and accurately measuring energy savings. This paper presents the results of recent testing of the ability to use automation to streamline some parts of M&V. Here in this paper, we detail metrics to assess the performance of these new M&V approaches, and a framework to compute the metrics. We also discuss the accuracy, cost, and time trade-offs between more traditional M&V, and these emerging streamlined methods that use high-resolution energy data and automated computational intelligence. Finally we discuss the potential evolution of M&V and early results of pilots currently underway to incorporate M&V automation into ratepayer-funded programs and professional implementation and evaluation practice.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

guideline36_conformance_test 0.1

The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) has established a set of standardized high performance sequences of operation for Heating, Ventilation and Air Conditioning (HVAC) systems in buildings through their "Guideline 36". In order to achieve the intended performance, these sequences must be translated and programmed accurately in the Building Automation System (BAS) controllers. Standardizing these sequences will allow for a more efficient product delivery mechanism where the sequences are programmed and tested centrally by each manufacturer, and then distributed to their dealers/engineering contractors. This approach would minimize the need for each installer to re-interpret and program the sequences, reduces risk of errors, and reduces the time required for commissioning in the field. To achieve this goal, a performance validation method is needed to provide independent confirmation that each manufacturer has programmed the Guideline 36 sequences accurately. A standardized method of test would also avoid the need for manual interpretation (and the associated human variability) that is required with typical functional testing approaches by automating the inputs and the range of expected responses. This software "guideline36_conformance_test" has been developed to conduct standardized, repeatable and manufacturer independent tests to validate that a BAS controller has been programmed in conformance with Guideline 36. Manufacturers would provide the controller (or the control program) and the software would run a suite of tests by setting a set of inputs to the controller and verifying the output signals from the controller matches the expected output as set by Guideline 36.

Pritoni, Marco↗
DOE OSTI2015

TU-AB-303-03: CBCT-Based On-Site Simulation, Planning, and Delivery (OSPD) for Whole Brain Radiotherapy

Purpose: To demonstrate the feasibility of a CBCT-based on-site simulation, planning, and delivery (OSPD) for whole brain radiotherapy, in which all steps from imaging, planning to treatment delivery are performed at the treatment unit in one appointment time slot. This work serves as the proof of concept for future OSPD single fraction radiation therapy. Methods: An integrated on-site imaging, planning and delivery workflow was developed and tested for whole brain radiotherapy. An automated two-opposed-oblique-beam plan is created by utilizing the treatment planning system scripting and simple field-in-field IMRT. The IMRT plan is designed with maximum 8 control points to cover the target volume consisting of the brain to C1/C2 of the spinal cord, with dose homogeneity criteria from −5% to +7% of the prescription dose. Due to inaccuracy of reconstructed Hounsfield unit numbers in CBCT images, the dose distribution is calculated with non-heterogeneity correction introducing only clinically insignificant dose discrepancy. A coherent and synchronized workflow was designed for a team of attending physician, physicist, therapists, and dosimetrist to work closely with the ability to quickly modify, approve, and implement the treatment. Results: Thirty-one patients have been treated with this OSPD treatment, without compromising the plan quality compared to our regular clinically used parallel apposed 2D plans. The average time for these procedures are 48.02 ±11.55 minutes from the time patient entered the treatment room until s/he exited, and 35.09 ±10.35 minutes from starting CBCT until last beam delivered. This time duration is comparable to the net time when individual tasks are summed up during our regular CT- based whole brain planning and delivery. Conclusions: The OSPD whole brain treatment has been tested to be clinically feasible. The next step is to further improve the efficiency and to streamline the workflow. Other disease sites will be also tested with this new technology.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Discrete and Continuum Plane-Hopper Flow Simulations with Experimental Validation Using X-Ray Imaging, Arch Profilometry and Wall Pressure Measurements

The flow of spherical glass beads, approximately cubic wood crumbles®, and wood microchips are investigated using a combination of discrete element modeling (DEM), finite element analysis (FEA), and physical experiments using a custom plane-flow hopper in which the flow is characterized using x-ray imaging, profilometry to measure arching geometry and pressure measurements at the wall. The purpose of this study is to investigate fundamental flow behavior, and for this purpose the simulations and physical tests are specially designed. During the physical tests and simulations, the hopper geometry begins as a V shape with the two opposing side walls touching at the bottom of the V. Basic tests are performed by first filling the hopper with material, and then rotating the opposing side walls inward about their common intersection axis to cause an approximately uniform stress condition throughout most of the hopper. The side walls then slide upward to effectively increase the size of the opening at the bottom of the hopper until the arch of material in the hopper breaks, and all of the material falls out of the hopper. More advanced tests are also performed in which the initial rotation of the walls is slightly reversed to decrease the pressure in the hopper, corresponding to “preshear” and “shear” conditions in standard shear tests. Shear tests of the materials are also performed using a Schulze automated ring shear tester with a standard size M shear cell, and the shear tests of the glass beads and wood crumbles® are also simulated using DEM to calibrate the DEM with the FEA. Reasonable agreement between predicted and measured flow behavior is obtained indicating that this type of physical tests and modeling shows promise for characterizing and predicting the flow behavior of compressible and anisotropic materials.

09 BIOMASS FUELS↗
DOE OSTI2022

Use of vision and sound to classify feller-buncher operational state

Productivity measures in logging involve simultaneous recognition and classification of event occurrence and timing, and the volume of stems being handled. In full-tree felling systems these measurements are difficult to implement in an autonomous manner because of the unfavorable working environment and the abundance of confounding extraneous events. This paper proposed a vision method that used a lowcost camera to recognize feller-buncher operational events including tree cutting and piling. It used a fine K-nearest neighbors (fKNN) algorithm as the final classifier based on both audio and video features derived from short video segments as inputs. The classifier’s calibration accuracy exceeds 94%. The trained model was tested on videos recorded under various conditions. The overall accurate rates for short segments were greater than 89%. Comparisons were made between the human- and algorithm derived event detection rates, events’ durations, and inter-event timing using continuously recorded videos taken during feller operation. Video results between the fKNN model and manual observation were similar. Statistical comparison using the Kolmogorov–Smirnov test to evaluate measured parameters’ distributions (manual versus automated event duration and inter-event timing) did not show significant differences with the lowest P-value among all Kolmogorov–Smirnov tests equal to 0.12. Here the result indicated the feasibility and potential of using the method for the automatic time study of drive-to-tree feller bunchers.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Cooperative Automated Cohort Driving on Connected Infrastructure, Arterial Roadways, and Highways: Final Project Demonstration and System-of-Systems Model Correlation

This project seeks to synergize vehicle automated driving and connectivity data to improve mobility and energy efficiency of groups of mixed vehicles operating in close proximity (vehicle cohort) on various infrastructure. A custom cellular communication network links vehicles operating as a cohort with infrastructure to a centralized system-of-systems digital twin with an AI-based optimal behavior planner. The data contained in this set are from final testing and technology demonstrations to U.S. Department of Energy staff at the American Center for Mobility. The data contain single-lane, single-light scenarios; multi-lane, multi-light arterial scenarios; and limited-access highway scenarios. All test cases were derived from simulations and replicated on the test track. The project employed two and four light-duty vehicles with connectivity and drive automation for the testing. The baseline scenario without connectivity was run under the control of the system-of-systems centralized planner but operating each vehicle with an intelligent driver model controlling the velocity, lane utilization, and vehicle gap. This was to ensure the highest compatibility with the simulation in terms of dynamic behavior. The connected cohort case utilized AI optimization to perform coordinated and cooperative control for energy, as well as safe, comfortable behavior for the cohort. The dataset is appropriately named with unconnected and connected designations, with comparisons sharing the same run index number. The included PowerPoint and PDF files describe the test setup and provide an overview of results from the project. ![image](de-EE0009209_March_2023_Data_Arterial_Scenario_Results.png)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Enterprise: a reduced-scale, flexible fuel, single-cylinder crosshead marine diesel research engine

A custom-built 1/10 scale, flexible-fuel, single-cylinder crosshead marine diesel research engine, dubbed the Enterprise, was designed and built as a platform for conducting marine lubricant research. The engine design was focused on maintaining lubricant boundary conditions similar those of full-scale engines. The Enterprise has a rated speed of 625 rpm to match the linear mean piston speed of full-scale marine engines with the reduced stroke and is capable of 18 bar brake mean effective pressure (BMEP). A high-swirl, uniflow-scavenged, two-stroke combustion system was designed to operate on either distillate diesel or heavy fuel oil (HFO). A hydraulic electronic unit injector (HEUI) fuel injection system with two injectors having customized three-hole nozzles provides fueling and is driven by the MAHLE Flexible ECU (MFE). Intake air boost is provided using a variable speed industrial air compressor along with closed-loop electronically controlled pressure regulation. Exhaust backpressure is also controlled electronically using an electro-pneumatic butterfly valve. A customized, miniaturized Hans Jensen Lubetronic cylinder lubrication system, which is capable of delivering 0.88 mg of cylinder oil per lubricator per injection to the ring pack at up to the maximum engine overspeed rating of 656 rpm, was commissioned for the Enterprise. Four independently temperature-controlled cooling zones are used to provide control of the liner temperature profile. The four coolant zones as well as the system oil and cylinder oil supplies are all controlled within 1°C for consistent thermal boundary conditions. The engine is instrumented with an in-cylinder pressure transducer as well as an inline torque transducer and numerous process temperature and pressure measurements to allow for detailed thermodynamic efficiency analysis, and experimental facilities allow for precise measurement of liner wear and characterization of deposits on the piston and rings. A radio telemetry system from IR Telemetrics is used to measure piston crown temperatures during engine operation. Engine design considerations and experimental facilities are described in detail, along with the results of a study investigating the impact of both system oil and cylinder oil viscosity on friction and efficiency. A test matrix was designed to compare base stock chemistries and viscosities for both system and cylinder oils. Experiments were completed using a fuel economy test protocol that was defined, consisting of repeating six speed/load operating conditions. An automated dynamometer control system was implemented to ensure repeatability of the test procedure. Preliminary testing indicated that the coolant, oil, and exhaust temperatures reach a steady state within 5 minutes of changing operating conditions. The system oil viscosity was found to have a significant impact on friction, with a reduction in viscosity from SAE 30 to SAE 20 resulting in over 6% reduction in friction mean effective pressure (FMEP) and over a 2% reduction in brake-specific fuel consumption (BSFC). Chemistry effects were also evident in the system and cylinder oils. Repeatability comparisons between the individual repetitions of each operating condition were used to ensure that results are statistically valid. For the initial cylinder oil viscosity experiments, observed changes were within the established/normal repeatability; ongoing experiments will determine whether improvements in boundary condition control will enable cylinder friction changes of this magnitude to be measured on this engine platform.

Kaul, Brian↗
DOE OSTI2022

Residual Stress Measurements in Extreme Environments for Hazardous, Layered Specimens

In nuclear fuel plates of low-enriched U-10Mo (LEU) clad with aluminum by hot isostatic pressing (HIP), post-irradiation stresses arising during reactor shutdown are a major concern for safe reactor operations. Measurement of those residual stresses has not previously been possible because the high radioactivity of the plates requires handling only by remote manipulation in a hot cell. The incremental slitting method for measuring through-thickness stress profiles was modified, and a system for automated, remote operation was built and tested. Experimental modifications consisted of replacing electric-discharge machining (EDM) with a small end mill and strain-gauge measurements with cantilever displacement measurements. The inverse method used to calculate stresses was the pulse-regularization method modified to allow discontinuities across material interfaces. The new system was validated by comparing with conventional slitting on a depleted U-10Mo (DU) fuel plate. The new system was applied to two measurements each on six as-fabricated (pre-irradiation) LEU miniature fuel plates. Variations between the measurements at two locations in the same plate were strongly correlated with measured geometrical heterogeneity in the plate—a tilt in the fuel foil. Compressive stresses in the U-10Mo were shown to increase from 20 to 250 MPa as the ratio of aluminum thickness to U-10Mo thickness increased causing increased constraint during cooling. Faster cooling rates during processing also increased stress magnitudes. The measurements trends agreed with data in the literature from similar plates made with DU, which further validates the method. Because other methods are impractical in a hot cell, the modified slitting method is now poised for the first measurements of post-irradiation stresses.

36 MATERIALS SCIENCE↗