Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “design challenges”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Extended Rice–Thomson analysis and atomistic simulations revealing grain boundary effects on fracture in refractory high-entropy alloys

Significance This work serves to extend the fundamental ductile vs. brittle fracture theory, specifically the Rice–Thomson criterion, by introducing a grain boundary ahead of an initiating crack which propagates at an oblique angle to impinge the boundary. Atomistic fracture simulations on two refractory complex concentrated alloys, the brittle NbMoTaW and the ductile Nb 45 Ta 25 Ti 15 Hf 15 , demonstrate qualitative correspondence with the extended Rice–Thomson criterion and experimental observations. Abstract Understanding how grain boundaries mediate fracture remains a critical challenge in designing ductile, high-performance refractory alloys. Here, we extend the Rice–Thomson criterion to account for the angle between cracks and the impinging grain boundaries (GBs), capturing the competition between intergranular fracture and dislocation-mediated plasticity. Using machine learning interatomic potentials, we performed molecular statics simulations to probe fracture mechanisms in nanocrystalline NbMoTaW and Nb 45 Ta 25 Ti 15 Hf 15 , each with two different grain sizes, revealing trends consistent with experimental observations and the extended Rice model. Comparison with averaged R-curves for bulk samples demonstrates that GBs enhance ductility in Nb 45 Ta 25 Ti 15 Hf 15 in both grain sizes investigated. In contrast, GBs only locally improve fracture resistance in NbMoTaW when cracks are temporarily pinned at GBs inclined at high angles from the crack, but generally promote brittle intergranular fracture. These contrasting behaviors are attributed to differences in GB cohesion, reflecting clear alloying trends that align with ab-initio calculations and trends observed experimentally. Our results bridge classical fracture theory, atomistic simulations, and experimental observations, providing a comprehensive understanding of the fracture mechanisms in nanocrystalline refractory complex concentrated alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design and optimization of the RF input-coupler for a low-frequency, split-coaxial RFQ

The Isotope Decay-At-Rest experiment (IsoDAR) is a proposed underground experiment which is expected to be a definitive search for sterile neutrinos. In order to be decisive within 5 years, high rates of neutrinos must be produced, by impinging a 10 mA continuous wave proton beam at 60 MeV on a high power target. Due to space restrictions, a compact cyclotron was chosen as an accelerator to produce this driver beam. To overcome space charge limitations during injection, H 2 + ions are accelerated and later stripped into protons by means of a carbon foil. IsoDAR uses an especially designed low-frequency (32.8 MHz) split-coaxial Radio-Frequency Quadrupole (RFQ) to effectively bunch H 2 + ions before injecting them into this cyclotron. The RFQ will be embedded vertically in the cyclotron yoke, facilitating a very compact design. This puts stringent limits on RFQ size, type, and accessibility. Here, we present the design and optimization of the low-frequency (32.8 MHz) RF input-coupler for the IsoDAR RFQ. The design is challenging due to the necessarily small diameter of the RFQ (28 cm) and the split-coaxial type, as well as limited access to the RFQ. We have determined the optimal position and shape for the coupler, leading to a low power consumption of < 6 kW for an inter-vane voltage of 22 kV. Finally, the highest calculated fields are safely below the Kilpatrick limit for this structure.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

A butterfly-shaped acceptor with rigid skeleton and unique assembly enables both efficient organic photovoltaics and high-speed organic photodetectors

ABSTRACT It remains challenging to design efficient bifunctional semiconductor materials in organic photovoltaic and photodetector devices. Here, we report a butterfly-shaped molecule, named WD-6, which exhibits low energy disorder and small reorganization energy due to its enhanced molecular rigidity and unique assembly with strong intermolecular interaction. The binary photovoltaic device based on PM6:WD-6 achieved an efficiency of 18.41%. Notably, an efficiency of 19.42% was achieved for the ternary device based on PM6:BTP-eC9:WD-6. Moreover, the photodetection device based on WD-6 demonstrated an ultrafast response speed (205 ns response time at λ of 820 nm) and a high cutoff frequency of −3 dB (2.45 MHz), surpassing the values of most commercial Si photodiodes. Based on these findings, we showcased an application of the WD-6-based photodetection device in high-speed optical communication. These results offer valuable insights into the design of organic semiconductor materials capable of simultaneously exhibiting high photovoltaic and photodetective performance.

Science & Technology - Other Topics↗
DOE OSTI2024

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates

Abstract The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure–property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Eswarappa Prameela, Suhas (ORCID:0000000334530184)↗
DOE OSTI2021

Elastic distributed training with fast convergence and efficient resource utilization

Distributed learning is now routinely conducted on cloud as well as dedicated clusters. Training with elastic resources brings new challenges and design choices. Prior studies focus on runtime performance and assume a static algorithmic behavior. In this work, by analyzing the impact of of resource scaling on convergence, we introduce schedules for synchronous stochastic gradient descent that proactively adapt the number of learners to reduce training time and improve convergence. Our approach no longer assumes a constant number of processors throughout training. In our experiment, distributed stochastic gradient descent with dynamic schedules and reduction momentum achieves better convergence and significant speedups over prior static ones. Numerous distributed training jobs running on cloud may benefit from our approach.

Cong, Guojing↗
DOE OSTI2022

Surrogate Modeling of Nonlinear Dynamic Systems: A Comparative Study

Surrogate models play a vital role in overcoming the computational challenge in designing and analyzing nonlinear dynamic systems, especially in the presence of uncertainty. This paper presents a comparative study of different surrogate modeling techniques for nonlinear dynamic systems. Four surrogate modeling methods, namely, Gaussian process (GP) regression, a long short-term memory (LSTM) network, a convolutional neural network (CNN) with LSTM (CNN-LSTM), and a CNN with bidirectional LSTM (CNN-BLSTM), are studied and compared. All these model types can predict the future behavior of dynamic systems over long periods based on training data from relatively short periods. The multi-dimensional inputs of surrogate models are organized in a nonlinear autoregressive exogenous model (NARX) scheme to enable recursive prediction over long periods, where current predictions replace inputs from the previous time window. Three numerical examples, including one mathematical example and two nonlinear engineering analysis models, are used to compare the performance of the four surrogate modeling techniques. The results show that the GP-NARX surrogate model tends to have more stable performance than the other three deep learning (DL)-based methods for the three particular examples studied. The tuning effort of GP-NARX is also much lower than its deep learning-based counterparts.

42 ENGINEERING↗
DOE OSTI2024

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗
DOE OSTI2021

Integrating Systems and Synthetic Biology to Understand and Engineer Microbiomes

Microbiomes are complex and ubiquitous networks of microorganisms whose seemingly limitless chemical transformations could be harnessed to benefit agriculture, medicine, and biotechnology. Here, the spatial and temporal changes in microbiome composition and function are influenced by a multitude of molecular and ecological factors. This complexity yields both versatility and challenges in designing synthetic microbiomes and perturbing natural microbiomes in controlled, predictable ways. In this review, we describe factors that give rise to emergent spatial and temporal microbiome properties and the meta-omics and computational modeling tools that can be used to understand microbiomes at the cellular and system levels. We also describe strategies for designing and engineering microbiomes to enhance or build novel functions. Throughout the review,we discuss key knowledge and technology gaps for elucidating the networks and deciphering key control points for microbiome engineering, and highlight examples where multiple omics and modeling approaches can be integrated to address these gaps.

42 ENGINEERING↗
DOE OSTI2025

PETSc/TAO developments for GPU-based early exascale systems

The Portable Extensible Toolkit for Scientific Computation (PETSc) library provides scalable solvers for nonlinear time-dependent differential and algebraic equations and for numerical optimization via the Toolkit for Advanced Optimization (TAO). PETSc is used in dozens of scientific fields and is an important building block for many simulation codes. During the U.S. Department of Energy’s Exascale Computing Project, the PETSc team has made substantial efforts to enable efficient utilization of the massive fine-grain parallelism present within exascale compute nodes and to enable performance portability across exascale architectures. We recap some of the challenges that designers of numerical libraries face in such an endeavor, and then discuss the many developments we have made, which include the addition of new GPU backends, features supporting efficient on-device matrix assembly, better support for asynchronicity and GPU kernel concurrency, and new communication infrastructure. In conclusion, we evaluate the performance of these developments on some pre-exascale systems as well as the early exascale systems Frontier and Aurora, using compute kernel, communication layer, solver, and mini-application benchmark studies, and then close with a few observations drawn from our experiences on the tension between portable performance and other goals of numerical libraries.

Exascale Computing Project (ECP)↗
DOE OSTI2020

Critical Unresolved Region Integral Experiment Execution

Integral Experiments are a key aspect of validating nuclear data behavior and simulation capabilities. Further, integral experiments are the earliest form of validation of equations and codes. They have been used extensively since the 1940s. Today, simulation and predictive capabilities have improved greatly from 75 years ago, but nonetheless, integral experiments are still needed. As simulation capabilities improve, their uncertainties get much smaller. The current focus of many new experiments is understanding the intermediate energy range. The intermediate energy range does not have a wide application space and it can be challenging to design experiments that are sensitive to neutron energies in this region. The Zeus experiments evaluated highly enriched uranium (HEU) in the intermediate energy region. Building on the success and knowledge gained from the Zeus experiments, the Critical Unresolved Region Integral Experiment (CURIE) experiments were designed to evaluate HEU in the narrower unresolved resonance region (URR). These experiments were executed during June and July 2020 at the National Criticality Experiments Research Center (NCERC). The National Criticality Experiments Research Center (NCERC), operated by Los Alamos National Laboratory, is the only general purpose critical experiments facility in the United States of America. NCERC regularly designs and executes critical experiments and other measurements useful to a wide variety of fields including nuclear criticality safety, commercial nuclear energy, nonproliferation, and nuclear data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Perfect absorption in GaAs metasurfaces near the bandgap edge

Perfect optical absorption occurs in a metasurface that supports two degenerate and critically-coupled modes of opposite symmetry. The challenge in designing a perfectly absorbing metasurface for a desired wavelength and material stems from the fact that satisfying these conditions requires multi-dimensional optimization often with parameters affecting optical resonances in non-trivial ways. This problem comes to the fore in semiconductor metasurfaces operating near the bandgap wavelength, where intrinsic material absorption varies significantly. Here we devise and demonstrate a systematic process by which one can achieve perfect absorption in GaAs metasurfaces for a desired wavelength at different levels of intrinsic material absorption, eliminating the need for trial and error in the design process. Using this method, we show that perfect absorption can be achieved not only at wavelengths where GaAs exhibits high absorption, but also at wavelengths near the bandgap edge. In this region, absorption is enhanced by over one order of magnitude compared a layer of unstructured GaAs of the same thickness.

Hale, L. L. (ORCID:0000000176544272)↗
DOE OSTI2023

Cavity and Cryomodule Developements for EIC

The EIC is a major new project under construction at BNL in partnership with JLab. It relies upon a number of new SRF cavities at 197 MHz, 394 MHz, 591 MHz and 1773 MHz to pre-bunch, accelerate, cool and crab the stored beams. R&D is focusing on the 591 MHz elliptical cavity and 197 MHz crab cavity first as these are the most challenging. Preliminary designs of these cavities are presented along with an R&D status report. To avoid developing multiple different cryostats a modular approach is adopted using a high degree of commonality of parts and systems. This approach may be easily adapted to other frequencies and applications.

Rimmer, R.A.↗
DOE OSTI2020

OpenSNAPI: Toward a Unified API for SmartNICs

The end of Moore’s Law and Dennard Scaling has produced a renaissance in the field of computer architecture. Unable to continue leveraging silicon-level processor improvements to further enhance performance and scalability, system architects have been forced to explore other options. In this new era of heterogeneous architectures and hardware/software codesign, a new class of devices known as “accelerators” has emerged. Independently designed for optimized execution of distinct workloads, these devices have proven critical to the continued advancement of application performance. SmartNICs, accelerator devices integrated with a network controller, have conventionally been utilized to offload low-level networking functionality. However, newer SmartNIC variants, which incorporate a system-on-chip (SoC) with traditional designs, are challenging this precedent. Leveraging significantly augmented resources, these new devices offer increased versatility and the potential to more effectively complement a given architecture’s CPU. In this talk, we introduce the motivation underlying acceleration, explore the fundamentals of SmartNICs, and discuss traditional use cases. We also detail our initial efforts to investigate the feasibility and benefits of SmartNICs as general-purpose accelerators. We present the OpenSNAPI project created to define a uniform application programming interface (API) for this emerging class of devices. Finally, we provide a brief tutorial regarding development of SmartNIC-accelerated applications on Los Alamos National Laboratory’s SmartNIC-enabled platforms.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

A Path Toward Understanding the Performance Capabilities of SmartNIC Devices [Slides]

SmartNICs, accelerator devices integrated with a network, have conventionally been utilized to offload low-level networking functionality. However, newer SmartNIC variants, which incorporate a system-on-chip (SoC) with traditional designs, are challenging this precedent. Leveraging significantly augmented resources, these new devices offer increased versatility and the potential to more effectively complement a given architecture’s CPU. Naturally, there is performance overhead associated with offloading tasks from a host CPU to a SmartNIC. As SmartNICs become more versatile and are used for a wider range of computational tasks, it is critical to understand how well the SmartNICs perform those respective tasks in order to determine whether the cost of offloading is worthwhile. In this work, we lay out a path to understand the important question of when and when not to offload to SmartNIC devices by way of a series of microbenchmarks.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Beam Induced Heating Analysis Update for the EIC Vacuum Chamber Components

One of the challenges of designing the Electron-Ion Col lider (EIC) is to mitigate beam-induced heating due to the intense electron and hadron beams. Heating of the ESR vac uum chamber components is mainly due to beam-induced resistive wall (RW) losses and synchrotron radiation. For the HSR heating is mainly due to large radial offsets and heat conduction from room temperature to cryogenic tem perature for cryo-components. In this paper, we provide an update on the beam-induced heating and thermal analysis of some critical ESR vacuum chamber components, such as the ESR Large Angle Bremhustraulung Monitor (LABM). We also provide a similar update for critical HSR vacuum com ponents, including the cryo-cooled BPM button assembly, beam screen, abort kicker, and polarimeter. To perform the thermal analyses, the resistive wall loss on individual compo nents is calculated with CST and the synchrotron radiation (if exists) is evaluated using SynRad. These losses, along with realistic boundary conditions are then fed to ANSYS to determine the temperature distribution.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Particles scattering in a HVDC gun

The Electron Ion Collider (EIC) hadron cooling electron source will utilize a high average current, high voltage DC gun ,aiming to generate 1nC, 100 mA average current, and 1mm-mrad normalized emittance[1]. One of the challenges in designing and operating the HVDC gun is the occurrence of undesired "ghost" particles that disrupt the gun's operation. In other words, the high voltage power supply (HVPS) trips more frequently when pushing to higher current.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Fabrication of a Liner Assembly for the MARVEL Microreactor

A liner assembly for an intermediate heat exchanger within the MARVEL microreactor at Idaho National Laboratory has been fabricated using laser-based additive manufacturing. The liner design includes challenging features such as long thin walls, overhangs, and tight geometric tolerances. Two versions of the liner assembly, one full length and the other shortened, were printed from several materials (316L SS, Inconel 625, and Inconel 718) using four powder-based laser printers (AddUp BeAM Modulo 400 DED, EOS 290M LPBF, GE Concept M2, and GE Concept Xline 2000R LPBF) located at the Manufacturing Demonstration Facility of Oak Ridge National Laboratory. Dimensional accuracy, print time, and powder utilization have been evaluated to help assess the feasibility of these AM approaches to liner fabrication. Based on this assessment, a potentially cost-effective pathway for fabrication has been proposed.

36 MATERIALS SCIENCE↗