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DOE OSTI2023

Reman Co-Design: A Combined Design and Remanufacturing Optimization Framework for the Sustainable Design of High-Value Components

Remanufacturing is a process that returns end-of-life equipment to as-new conditions and offers numerous environmental and economic benefits. To fully capitalize on remanufacturing, its synergistic interactions with design must be fully realized and addressed during the design stage. Although this fact is widely recognized in the literature, most of the current studies focus primarily either on the design or remanufacturing aspects of design for remanufacturing (DfRem). In an effort to offer a more integrated DfRem approach than those reported in the literature, we propose a new combined design and remanufacturing optimization (reman co-design) framework that takes a holistic approach by leveraging the intricate interplay between design and remanufacturing. Here, the aim of this formulation is to identify the optimal decisions that maximize the benefits of remanufacturing throughout the entire lifespan of a product. To showcase the utility of the new formulation, we are using a case study of a hydraulic manifold, (re)manufactured by John Deere. Using this industry example, we compare the results of reman co-design to the ones from a decoupled remanufacturing design approach. Results reveal that remanufacturing benefits are better realized and improved upon when using the developed reman co-design approach.

design for X↗

DOE OSTI2024

Direct quantification of ion composition and mobility in organic mixed ionic-electronic conductors

Ion transport in organic mixed ionic-electronic conductors (OMIECs) is crucial due to its direct impact on device response time and operating mechanisms but is often assessed indirectly or necessitates extra assumptions. Operando x-ray fluorescence (XRF) is a powerful, direct probe for elemental characterization of bulk OMIECs and was used to directly quantify ion composition and mobility in a model OMIEC, poly(3,4-ethylenedioxythiophene)-poly(styrene sulfonate) (PEDOT:PSS), during device operation. The first cycle revealed slow electrowetting and cation-proton exchange. Subsequent cycles showed rapid response with minor cation fluctuation (~5%). Comparison with optical-tracked electrochromic fronts revealed mesoscale structure–dependent proton transport. The calculated effective ion mobility demonstrated thickness-dependent behavior, emphasizing an interfacial ion transport pathway with a higher mobile ion density. The decoupling of interfacial effects on bulk ion mobility and the decoupling of cation and proton migration elucidate ion transport in conventional and emerging OMIEC-based devices and has broader implications for other ionic conductors writ large.

42 ENGINEERING↗

DOE OSTI2020

A Scalable Multigrid Reduction Framework for Multiphase Poromechanics of Heterogeneous Media

Simulation of multiphase poromechanics involves solving a multiphysics problem in which multiphase flow and transport are tightly coupled with the porous medium deformation. To capture this dynamic interplay, fully implicit methods, also known as monolithic approaches, are usually preferred. The main bottleneck of a monolithic approach is that it requires solution of large linear systems that result from the discretization and linearization of the governing balance equations. Because such systems are nonsymmetric, indefinite, and highly ill-conditioned, preconditioning is critical for fast convergence. Recently, most efforts in designing efficient preconditioners for multiphase poromechanics have been dominated by physics-based strategies. Current state-of-the-art “black-box” solvers such as algebraic multigrid (AMG) are ineffective because they cannot effectively capture the strong coupling between the mechanics and the flow subproblems, as well as the coupling inherent in the multiphase flow and transport process. In this work, we develop an algebraic framework based on multigrid reduction (MGR) that is suited for tightly coupled systems of PDEs. Using this framework, the decoupling between the equations is done algebraically through defining appropriate interpolation and restriction operators. One can then employ existing solvers for each of the decoupled blocks or design a new solver based on knowledge of the physics. We demonstrate the applicability of our framework when used as a “black-box” solver for multiphase poromechanics. Here, we show that the framework is flexible to accommodate a wide range of scenarios, as well as efficient and scalable for large problems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Multi-Fluid and Kinetic Models of Partially Ionized Magnetic Reconnection

Magnetic reconnection in partially ionized plasmas is a ubiquitous and important phenomena in both laboratory and astrophysical systems. Here, simulations of partially ionized magnetic reconnection with well-matched initial conditions are performed using both multi-fluid and fully-kinetic approaches. Despite similar initial conditions, the time-dependent evolution differs between the two models. In multi-fluid models, the reconnection rate locally obeys either a decoupled Sweet-Parker scaling, where neutrals are unimportant, or a fully coupled Sweet-Parker scaling, where neutrals and ions are strongly coupled, depending on the resistivity. In contrast, kinetic models show a faster reconnection rate that is proportional to the fully-coupled, bulk Alfv\'en speed, $v_A^\star$. These differences are interpreted as the result of operating in different collisional regimes. Multi-fluid simulations are found to maintain $\nu_{ni}L/v_A^\star \gtrsim 1$, where $\nu_{ni}$ is the neutral-ion collision frequency and $L$ is the time-dependent current sheet half-length. This strongly couples neutrals to the reconnection outflow, while kinetic simulations evolve to allow $\nu_{ni}L/v_A^\star < 1$, decoupling neutrals from the reconnection outflow. Differences in the way reconnection is triggered may explain these discrepancies.

Magnetic reconnection↗

DOE OSTI2020

Summertime Post-Cold-Frontal Marine Stratocumulus Transition Processes over the Eastern North Atlantic

Abstract Marine boundary layer (MBL) cloud morphology associated with two summertime cold fronts over the eastern North Atlantic (ENA) is investigated using high-resolution simulations from the Weather Research and Forecasting (WRF) Model and observations from the Atmospheric Radiation Measurement (ARM) ENA Climate Research Facility. Lagrangian trajectories are used to study the evolution of post-cold-frontal MBL clouds from solid stratocumulus to broken cumulus. Clouds within specified domains in the vicinity of transitions are classified according to their degree of decoupling, and cloud-base and cloud-top breakup processes are evaluated. The Lagrangian derivative of the surface latent heat flux is found to be strongly correlated with that of the cloud fraction at cloud base in the simulations. Cloud-top entrainment instability (CTEI) is shown to operate only in the decoupled MBL. A new indicator of inversion strength at cloud top that employs the vertical gradients of equivalent potential temperature and saturation equivalent potential temperature, which can be computed directly from soundings, is proposed as an alternative to CTEI. Overall, results suggest that the deepening–warming hypothesis suggested by Bretherton and Wyant explains many of the characteristics of the summertime postfrontal MBL evolution of cloud structure over the ENA, thereby widening the phase space over which the hypothesis may be applied. A subset of the deepening–warming hypothesis involving warming initially dominating over moistening is proposed. It is postulated that changes in climate change–induced modifications in cold-frontal structure over the ENA may be accompanied by coincident changes in the location and timing of MBL cloud transitions in the post-cold-frontal environment.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Quantifying the Impacts of Land Surface Modeling on Hub-Height Wind Speed under Different Soil Conditions

We investigate the impact of three land surface models (LSMs) on hub-height wind speed under three different soil regimes (dry, wet, and frozen) to understand and improve the physics of wind energy forecasts using the Weather Research and Forecasting (WRF) model. A six-day representative period is selected for each soil condition. The simulated wind speed, surface energy budget and soil properties are compared with the observations collected from the second Wind Forecast Improvement Project (WFIP2). For the selected cases, our simulation results suggest that, the impact of LSMs on hub-height wind speed are sensitive to the soil states but not so much to the choice of LSM. The simulated hub-height wind speed is in much better agreement with the observations for the dry soil case than the wet and frozen soil cases. Over the dry soil, there is a strong physical connection between the land surface and hub-height wind speed through near-surface turbulent mixing. Over the wet soil, the simulated hub-height wind speed is less impacted by land surface due to weaker surface fluxes and more dominated by large-scale synoptic disturbances. Over the frozen soil, the land surface model seems to have limited impact on hub-height wind speed variability due to the decoupling of the land surface with the overlying atmosphere. Two main sources of modeling uncertainties are proposed. The first are the insufficient model physics representing the surface energy budget, especially the ground heat flux, and the second are the inaccurate initial soil states such as soil temperature and soil moisture.

Xia, Geng↗

DOE OSTI2022

Optimizing the fuel efficiency of an opposed piston engine for electric power generation

This paper investigates the optimal crankshaft motion for an opposed piston (OP) engine in a novel hybrid architecture to maximize fuel efficiency. The OP engine was selected for this work due to its inherent thermodynamic benefits and the balanced nature of the engine which can achieve downsizing through reducing the number of cylinders rather than the individual cylinder volume. The typical geartrain required on an OP engine was exchanged for two electric motors, reducing friction loss and decoupling the crankshafts. Using the motors to control the crankshaft motion profiles, this architecture introduces capabilities to dynamically vary compression ratio, combustion volume, and scavenging dynamics. To leverage these opportunities, an optimization scheme was developed utilizing nonlinear optimization of a 0-D model to compute the crankshaft motion profile that maximizes the work generated by the system. This optimization was then iteratively coupled with a high fidelity model which supplies the cylinder flow boundary conditions. This iterative approach reduces the model complexity used in the optimal control problem (OCP) while capturing the gas exchange dynamics critical to the 2-stroke cycle of the OP engine. By using the rate of change of motor torque as the input to the OCP, the torque fluctuation in a single cycle can be limited to ensure tracking feasibility. The results show crankshaft velocity slows during the compression stroke and conversely accelerates during the expansion stroke, reducing the peak motor torque required for control and thus reducing the motor losses. The extended residence time at top dead center, however, leads to an increase in heat transfer, illustrating the trade-off between the work extraction efficiency and the indicated engine efficiency.

Engineering↗

DOE OSTI2023

PKA regulatory subunit Bcy1 couples growth, lipid metabolism, and fermentation during anaerobic xylose growth in Saccharomyces cerevisiae

Organisms have evolved elaborate physiological pathways that regulate growth, proliferation, metabolism, and stress response. These pathways must be properly coordinated to elicit the appropriate response to an ever-changing environment. While individual pathways have been well studied in a variety of model systems, there remains much to uncover about how pathways are integrated to produce systemic changes in a cell, especially in dynamic conditions. We previously showed that deletion of Protein Kinase A (PKA) regulatory subunit BCY1 can decouple growth and metabolism in Saccharomyces cerevisiae engineered for anaerobic xylose fermentation, allowing for robust fermentation in the absence of division. This provides an opportunity to understand how PKA signaling normally coordinates these processes. Here, we integrated transcriptomic, lipidomic, and phospho-proteomic responses upon a glucose to xylose shift across a series of strains with different genetic mutations promoting either coupled or decoupled xylose-dependent growth and metabolism. Together, results suggested that defects in lipid homeostasis limit growth in the bcy1Δ strain despite robust metabolism. To further understand this mechanism, we performed adaptive laboratory evolutions to re-evolve coupled growth and metabolism in the bcy1Δ parental strain. The evolved strain harbored mutations in PKA subunit TPK1 and lipid regulator OPI1 , among other genes, and evolved changes in lipid profiles and gene expression. Deletion of the evolved opi1 gene partially reverted the strain’s phenotype to the bcy1Δ parent, with reduced growth and robust xylose fermentation. We suggest several models for how cells coordinate growth, metabolism, and other responses in budding yeast and how restructuring these processes enables anaerobic xylose utilization.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Tethered balloon measurements reveal enhanced aerosol occurrence aloft interacting with Arctic low-level clouds

Low-level clouds in the Arctic affect the surface energy budget and vertical transport of heat and moisture. The limited availability of cloud-droplet-forming aerosol particles strongly impacts cloud properties and lifetime. Vertical particle distributions are required to study aerosol–cloud interaction over sea ice comprehensively. This article presents vertically resolved measurements of aerosol particle number concentrations and sizes using tethered balloons. The data were collected during the Multidisciplinary drifting Observatory for the Study of Arctic Climate expedition in the summer of 2020. Thirty-four profiles of aerosol particle number concentration were observed in 2 particle size ranges: 12–150 nm (N 12−150 ) and above 150 nm (N >150 ). Concurrent balloon-borne meteorological measurements provided context for the continuous profiles through the cloudy atmospheric boundary layer. Radiosoundings, cloud remote sensing data, and 5-day back trajectories supplemented the analysis. The majority of aerosol profiles showed more particles above the lowest temperature inversion, on average, double the number concentration compared to below. Increased N 12−150 up to 3,000 cm −3 were observed in the free troposphere above low-level clouds related to secondary particle formation. Long-range transport of pollution increased N >150 to 310 cm −3 in a warm, moist air mass. Droplet activation inside clouds caused reductions of N >150 by up to 100%, while the decrease in N 12−150 was less than 50%. When low-level clouds were thermodynamically coupled with the surface, profiles showed 5 times higher values of N 12−150 in the free troposphere than below the cloud-capping temperature inversion. Enhanced N 12−150 and N >150 interacting with clouds were advected above the lowest inversion from beyond the sea ice edge when clouds were decoupled from the surface. Vertically discontinuous aerosol profiles below decoupled clouds suggest that particles emitted at the surface are not transported to clouds in these conditions. It is concluded that the cloud-surface coupling state and free tropospheric particle abundance are crucial when assessing the aerosol budget for Arctic low-level clouds over sea ice.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Technical report: Design of the accessor

As we have seen the arithmetic power of hardware architectures growing much faster than the memory bandwidth, there is an urgent need to rethink the way we operate, communicate, and store data. A promising strategy for overcoming the “memory wall” is the decoupling of memory precision from arithmetic precision as proposed in Anzt et al. Such a decoupling of memory precision and arithmetic precision requires an “accessor” that handles the conversion between formats (resp. compression of the data) on the fly in registers. Such an accessor has to be general in the sense that it can handle a wide range of floating point formats and compression strategies, and still allows for further extension. At the same time, is important that the use of the accessor is not a burden for the developer. Therefore, it is important to abstract all implementation details from the user, hide the underlying storage format from the user, and make the accessor cross-platform portable. In this document we present the design of an accessor that aims at fulfilling all these requirements.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Technical Report: Accessor Realization

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Using Artificial Microstructures to Understand Microstructure Property Relationship-Toughening Mechanisms in Metallic Glass (Final Report)

Metallic glasses are a new class of structural materials which exhibit exciting mechanical properties including high strength and elasticity. In terms of fracture toughness, the material class of metallic glasses spans a wide range; Some metallic glasses are extremely brittle and exhibit near ideal brittle behavior whereas others can be exceptional tough with values comparable to the toughest metals out there. Such large range of observed fracture toughness within the material class of metallic glasses is surprising as they have seemingly a very similar atomic structure. Therefore, we developed “artificial microstructures” which allows to decouple the various contribution of sample geometry, imperfection and structure. Specifically, we decouple variations in the alloys’ chemical composition and the atomic structure and quantified the resulting fracture toughness. Atomic structure of a metallic glass can be modified by the fictive temperature. The fictive temperature of a glass is the temperature at which the liquid metallic glass falls out of equilibrium upon colling and forms a glass. Upon further cooling the structure is maintained only thermal oscillations decrease due to a lower absolute temperature. We found that the effect of fictive temperature (same chemistry, different structural stages of the glass) is comparable to the variations of fracture toughness when the chemistry is varied. Hence, it appears that the subtle differences in the glass structure are responsible for the large range of fracture toughness’s observed. Our results reveal that fracture toughness within the material class of metallic glasses varies significantly and we found some example alloys with exceptional high resistance to fracture and others that are almost ideally brittle. Significant influences on the fracture toughness have the structure of the glass, its chemistry, and some imperfections in the structure.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A multi-Physics Experiment for Low-Yield Nuclear Explosion Monitoring

A series of multi-physics experiments, referred to as Physics Experiment 1 (PE1) is underway at the United States’ Nevada National Security Site (NNSS). The PE1 series includes detonations of three underground chemical explosions in P-tunnel, with fully coupled (PE1 A), partially decoupled (PE1 D L ), and fully decoupled (PE1 B) emplacements. Canisters with gas tracers are imbedded in the explosives, and the tracers are released when the canister is destroyed by the detonation. A dedicated electromagnetic (EM) experiment (EMX) generates well-characterized EM signals at an underground location near the chemical explosive experiments. A series of atmospheric experiments (METEX, REACT, and METREX) release smoke and radioactive tracers around Aqueduct Mesa to test gas transport in complex topography. Each of the chemical explosive experiments includes a network of sensors to record seismic, acoustic, and electromagnetic waves, measurement of atmospheric conditions, and air sample collection for measurement of tracer concentration. EMX records EM signals underground and on the surface of Aqueduct Mesa. METEX, REACT, and METREX include measurement of atmospheric condition, as well as tracking smoke releases. REACT and METREX add low-level radioactive gas tracers to the atmospheric releases.

58 GEOSCIENCES↗

DOE OSTI2026

Spectral Flux Measurements on SNS Direct Geometry Spectrometers at IRP-2 End-of-Life

The Inner Reflector Plug (IRP) of the Spallation Neutron Source (SNS) was replaced during the SNS shutdown period beginning 25 November 2025. This IRP, IRP-2, was first placed in service in May 2018, and was in use for 42.5 GW-hrs of operation, somewhat longer than its original design life of 30 GW-hrs, or even a refined estimate of 33 GW-hrs for the water moderator poison plate and 39 GW-hrs on the decoupled-poisoned hydrogen moderator decoupler (Gallmeier, Lu, and Iverson 2018). The time-integrated power history for IRP-2 is tracked in Figure 1.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Low-Temperature Plasma Assisted Kinetics Study of Ethanol

Non-equilibrium plasma assisted kinetics of ethanol at 0.5 atm over a temperature range of 523-1203 K were studied at stoichiometric conditions by using a plasma flow reactor (PFR). The effects of plasma chemistry on fuel and its influence on neutral chemistry is decoupled with both experimental and modelling efforts. Enhanced reactivity was observed experimentally in both plasma-assisted oxidation and pyrolysis cases with fuel consumption beginning at temperatures as low as 523 K. Absolute fuel consumption was observed at temperatures nearly 200 K earlier than pure thermal reactions highlighting the effectiveness of non-equilibrium plasma to promote reactivity. Furthermore, modelling results illustrated the effect of electron impact reactions towards accelerating fuel consumption and promoting low temperature chemistry by generating excited state N2 and reactive O and OH radicals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Measurements and Prediction of Ash Deposition in a Cyclone-Fired Boiler Operating under Variable Load Conditions

Measurements of ash deposition rates were made between the secondary superheater and reheater sections of a 450 MW cyclone-fired lignite boiler as the operational load varied from 33 to 100%. Significant reductions in deposition rates with a decrease in operational load were observed. To uncover the causative mechanisms behind these observations, operational data from the power plant were used to carry out computational fluid dynamic (CFD) simulations of the boiler. After ascertaining that the gas temperatures and velocities at various sections within the boiler were being represented adequately, decoupled simulations of the ash deposition process on the deposit probe were carried out using a finely resolved boundary layer mesh. Fly ash particle size distribution (PSD) and its concentration for the decoupled calculations were determined from stand-alone cyclone barrel simulations. The ash partitioning (mass %) between the fly ash and slag was found to be ~50:50, which was in line with previous field observations, and it did not vary significantly across different cyclone loads. The predicted PSD of the deposit ash was concentrated in the size range 10–30 microns, which was in agreement with cross-sectional images of the deposit obtained from the measurements. At lower loads, sharp variations in the deposition rates were predicted in the gas temperature range 950–1150 K. The particle kinetic energy—particle viscosity-based capture methodology utilized in this study in conjunction with appropriate ash compositions, ash viscosity models and gas temperature estimates can help estimate slagging propensities at different loads reasonably well in these systems.

Krishnamoorthy, Gautham (ORCID:0000000255205092)↗

DOE OSTI2024

Near-Complete Sampling of Forest Structure from High-Density Drone Lidar Demonstrated by Ray Tracing

Drone lidar has the potential to provide detailed measurements of vertical forest structure throughout large areas, but a systematic evaluation of unsampled forest structure in comparison to independent reference data has not been performed. Here, we used ray tracing on a high-resolution voxel grid to quantify sampling variation in a temperate mountain forest in the southwest Czech Republic. We decoupled the impact of pulse density and scan-angle range on the likelihood of generating a return using spatially and temporally coincident TLS data. We show three ways that a return can fail to be generated in the presence of vegetation: first, voxels could be searched without producing a return, even when vegetation is present; second, voxels could be shadowed (occluded) by other material in the beam path, preventing a pulse from searching a given voxel; and third, some voxels were unsearched because no pulse was fired in that direction. We found that all three types existed, and that the proportion of each of them varied with pulse density and scan-angle range throughout the canopy height profile. Across the entire data set, 98.1% of voxels known to contain vegetation from a combination of coincident drone lidar and TLS data were searched by high-density drone lidar, and 81.8% of voxels that were occupied by vegetation generated at least one return. By decoupling the impacts of pulse density and scan angle range, we found that sampling completeness was more sensitive to pulse density than to scan-angle range. There are important differences in the causes of sampling variation that change with pulse density, scan-angle range, and canopy height. Our findings demonstrate the value of ray tracing to quantifying sampling completeness in drone lidar.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

On the Injection Scale of the Turbulence in the Partially Ionized Very Local Interstellar Medium

The cascade of magnetohydrodynamic (MHD) turbulence is subject to ion–neutral collisional damping and neutral viscous damping in the partially ionized interstellar medium. By examining the damping effects in the warm and partially ionized local interstellar medium, we find that the interstellar turbulence is damped by neutral viscosity at ~261 au and cannot account for the turbulent magnetic fluctuations detected by Voyager 1 and 2. The MHD turbulence measured by Voyager in the very local interstellar medium (VLISM) should be locally injected in the regime where ions are decoupled from neutrals for its cascade to survive the damping effects. With the imposed ion–neutral decoupling condition and the strong turbulence condition for the observed Kolmogorov magnetic energy spectrum, we find that the turbulence in the VLISM is sub-Alfvénic, and its largest possible injection scale is ~194 au.

79 ASTRONOMY AND ASTROPHYSICS↗