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Thermal Mechanical Finite Element Simulation of Additive Manufacturing; Process Modeling of the LENS Process.
Abstract not provided.
Dehalogenation of electrochemical processing salt simulants with ammonium phosphates and immobilization of salt cations in an iron phosphate glass waste form
This study demonstrates the conversion of simulated pyroprocessing salt wastes [i.e., ER(SF) and ERV2] into chemically durable iron phosphate glass waste forms through reactions with ammonium hydrogen phosphate precursors [i.e., NH4H2PO4 and (NH4)2HPO4] and added Fe2O3. The reaction of the salt simulants with the phosphate precursors resulted in dehalogenation of the salt through the production of NH4Cl and NH4I (along with water), of which the NH4Cl can be used to produce UCl3 oxidant for use in the electrorefiner during pyroprocessing. These iron phosphate glasses contain a notably higher waste loading than the baseline glass-bonded sodalite ceramic waste form, which requires about 70 vol% sodalite to accommodate Cl from the salt, because they are dehalogenated prior to vitrification. The high waste loadings coupled with higher bulk densities (~3×103 kg/m3) than glass-bonded sodalite (~2.3×103 kg/m3) mean that these glasses have a higher storage volume, i.e., the volume required to immobilize a given mass of waste. The iron phosphate glass waste forms were characterized using a variety of techniques including physical property measurements and chemical durability testing. Following initial testing, a proof-of-concept demonstration was conducted to show that the NH4Cl generated from this process could be used to produce UCl3 using depleted uranium dendrites as a feedstock.
Structural analyses of NudT16-ADP-ribose complexes direct rational design of mutants with improved processing of poly(ADP-ribosyl)ated proteins
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A modular reactor design for in situ synchrotron x-ray investigation of atomic layer deposition processes
Synchrotron characterization techniques provide some of the most powerful tools for the study of film structure and chemistry. The brilliance and tunability of the Advanced Photon Source allow access to scattering and spectroscopic techniques unavailable with in-house laboratory setups and provide the opportunity to probe various atomic layer deposition (ALD) processes in situ starting at the very first deposition cycle. Here, we present the design and implementation of a portable ALD instrument which possesses a modular reactor scheme that enables simple experimental switchover between various beamlines and characterization techniques. As first examples, we present in situ results for (1) X-ray surface scattering and reflectivity measurements of epitaxial ZnO ALD on sapphire, (2) grazing-incidence small angle scattering of MnO nucleation on silicon, and (3) grazing-incidence X-ray absorption spectroscopy of nucleation-regime Er{sub 2}O{sub 3} ALD on amorphous ALD alumina and single crystalline sapphire.
Processable High Electron Mobility {pi}-Copolymers via Mesoscale Backbone Conformational Ordering
The synthesis and experimental/theoretical characterization of a new series of electron-transporting copolymers based on the naphthalene bis(4,8-diamino-1,5-dicarboxyl)amide (NBA) building block are reported. Comonomers are designed to test the emergent effects of manipulating backbone torsional characteristics, and density functional theory (DFT) analysis reveals the key role of backbone conformation in optimizing electronic delocalization and transport. The NBA copolymer conformational and electronic properties are characterized using a broad array of molecular/macromolecular, thermal, optical, electrochemical, and charge transport techniques. All NBA copolymers exhibit strongly aggregated morphologies with significant nanoscale order. Copolymer charge transport properties are investigated in thin-film transistors and exhibit excellent electron mobilities ranging from 0.4 to 4.5 cm(2) V-1 s(-1). Importantly, the electron transport efficiency correlates with the film mesoscale order, which emerges from comonomer-dependent backbone planarity and extension. These results illuminate the key NBA building block structure-morphology-bulk property design relationships essential for processable, electronics-applicable high-performance polymeric semiconductors.
Description of the Fission Process: Nuclear Models for Fission Dynamics
Nuclear fission is the splitting of a heavy nucleus into two or more fragments, a process that releases a substantial amount of energy. It is ubiquitous in modern applications, critical for national security, energy generation and reactor safeguards. Fission also plays an important role in understanding the astrophysical formation of elements in the universe. Eighty years after the discovery of the fission process, its theoretical understanding from first principles remains a great challenge. In this paper, we present promising new approaches to make more accurate predictions of fission observables.
Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)
The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.
A new multi-model absolute difference-based sensitivity (MMADS) analysis method to screen non-influential processes under process model and parametric uncertainty
Process-based models have been widely used for hydrologic modeling, and it is a common practice to use sensitivity analysis methods for excluding non-influential hydrologic processes from further investigation and/or model improvement. This study develops a new method called multi-model absolute difference-based sensitivity (MMADS) analysis method to screen non-influential system processes and parameters. MMADS is conceptually similar to the Morris method for addressing parametric uncertainty, but has a unique feature to address both process model uncertainty (i.e., a process may be represented by multiple process models) and process model parameter uncertainty (i.e., parameters associated with a process model are random). MMADS first evaluates absolute differences of a quantity of interest (i.e., a system model output) by varying process models and/or process model parameter values, and then calculates the mean and variance of the differences for investigating process influence. The mean measures overall influence of the process on the quantity of interest, and the variance estimates influence of nonlinear effects of the process and/or its interactions with other processes. MMADS is an extension of the Morris method from a parameter space to a joint parameter-model space for explicitly addressing both process model uncertainty and model parameter uncertainty. The performance of MMADS is evaluated by using two numerical experiments. One experiment is based on Sobol’s G*-function with ten product elements, and has analytical solutions of the MMADS mean and variance of absolute differences. The other experiment is for groundwater flow modeling which considers three processes (i.e., recharge, geology, and snowmelt) that interact with each other. Finally, results indicate that MMADS is computationally efficient and can identify non-influential processes of complex hydrological systems.
Water Governance Process Assessment: Evaluating the Link between Decision Making Processes and Outcomes in the Columbia River Basin
Academics and practitioners agree that in water governance, the quality of a decision making process should influence the quality of the outcome and the degree to which it is accepted by interested parties. However, finding a feasible way to evaluate and then improve the quality of a decision making process has proven elusive. Systematically collecting evidence of a link between process and outcome is also challenging. In my dissertation, I developed a synthesis framework for evaluating and improving water governance decision making to address these two challenges. The synthesis framework, which I call the Water Governance Process Assessment (Water GPA), draws upon 22 existing frameworks rooted in resilience, adaptive governance, and good governance. From these frameworks, I identified and provided a way to evaluate four characteristics critical to good water governance decision making processes: 1) accountability, 2) inclusivity, and 3) information, and 4) context. I applied the Water GPA framework to the recent reviews of the Columbia River Treaty by the United States and Canada. I collected data for the case studies through semi-structured interviews and surveys of process participants from the federal agencies, Tribal and First Nations, state/provincial governments, local governments, stakeholder interests, and citizens. I coded and analyzed the interviews using the qualitative analysis software QSR NVivo and the characteristics identified in the Water GPA framework. I used the two case study applications to demonstrate how to use the framework. I identified what aspects of the four process categories served as barriers and building blocks for good water governance in each water governance process. I also gleaned lessons learned and recommendations including some for determining process leadership, ensuring meaningful engagement and inclusivity, addressing sovereignty issues, setting decision criteria, sharing decision authority, allocating resources in future processes in the US and BC portions of the Columbia River Basin and similar basins. In my case studies, I also investigated which characteristics of the water governance decision making process influenced the direct outcomes of those processes (the decisions) as well as other non-target outcomes (such as trust, co-produced science, new coalitions, etc.). All four characteristics outlined in the Water Governance Process Assessment (Water GPA), played some role in the development of the content and/or support of the two case study decision documents (US Regional Recommendation and BC Provincial Decision). Generally, when the characteristic of the process was done well, it improved the legitimacy and acceptance of the decision. At the same time performing poorly in one area did not necessarily torpedo the process or decision. In both case studies, it appears that the interplay between the process characteristics (that is where two or more characteristics converge) had a greater influence over the decision. Further work is needed to clearly identify what characteristics of a process are most influential in different situations. The Water GPA is one useful tool for this effort.
Lightweight Software Process Improvement Using Productivity and Sustainability Improvement Planning (PSIP)
Productivity and Sustainability Improvement Planning (PSIP) is a lightweight, iterative workflow that allows software development teams to identify development bottlenecks and track progress to overcome them. In this paper, we present an overview of PSIP and how it compares to other software process improvement (SPI) methodologies, and provide two case studies that describe how the use of PSIP led to successful improvements in team effectiveness and efficiency.
Fiber-fed time-resolved photoluminescence for reduced process feedback time on thin-film photovoltaics
Not Available
Photovoltaic Inverter Momentary Cessation: Recovery Process is Key
Momentary cessation refers to an inverter control mode. When the inverter terminal voltage falls below (or exceeds) a certain level, the inverter ceases to output any current, but attempts to maintain (or quickly regain) phase-locked loop synchronization to allow for quick reinjection of current when the voltage recovers to a certain point. This paper presents a photovoltaic (PV) momentary cessation model developed in PSS/E. Simulations are presented for a high voltage transmission line fault contingency in the Hawaiian island of Oahu power system on a validated PSS/E model, modified to include a custom distributed PV inverter model, and different near-future distributed PV penetration levels. Simulations for the island power system include different penetration levels of PV, and different recovery times (ramp rates and delays) after momentary cessation. The results indicate that during low voltage events, such as faults, momentary cessation can produce severe under frequency events, causing significant load shed and shortly thereafter, in some cases, over frequency events that cause generation to trip offline. The problem is exacerbated with higher penetration levels of PV. If momentary cessation is used (as is typically the case for distribution-connected resources), the recovery process after momentary cessation should be carefully considered to minimize impacts to bulk power system stability.
Development of Statistical Process Control Methodology for an Environmentally Compliant Surface Cleaning Process in a Bonding Laboratory
Bonding labs at both MSFC and the northern Utah production plant prepare bond test specimens which simulate or witness the production of NASA's Reusable Solid Rocket Motor (RSRM). The current process for preparing the bonding surfaces employs 1,1,1-trichloroethane vapor degreasing, which simulates the current RSRM process. Government regulations (e.g., the 1990 Amendments to the Clean Air Act) have mandated a production phase-out of a number of ozone depleting compounds (ODC) including 1,1,1-trichloroethane. In order to comply with these regulations, the RSRM Program is qualifying a spray-in-air (SIA) precision cleaning process using Brulin 1990, an aqueous blend of surfactants. Accordingly, surface preparation prior to bonding process simulation test specimens must reflect the new production cleaning process. The Bonding Lab Statistical Process Control (SPC) program monitors the progress of the lab and its capabilities, as well as certifies the bonding technicians, by periodically preparing D6AC steel tensile adhesion panels with EA-91 3NA epoxy adhesive using a standardized process. SPC methods are then used to ensure the process is statistically in control, thus producing reliable data for bonding studies, and identify any problems which might develop. Since the specimen cleaning process is being changed, new SPC limits must be established. This report summarizes side-by-side testing of D6AC steel tensile adhesion witness panels and tapered double cantilevered beams (TDCBs) using both the current baseline vapor degreasing process and a lab-scale spray-in-air process. A Proceco 26 inches Typhoon dishwasher cleaned both tensile adhesion witness panels and TDCBs in a process which simulates the new production process. The tests were performed six times during 1995, subsequent statistical analysis of the data established new upper control limits (UCL) and lower control limits (LCL). The data also demonstrated that the new process was equivalent to the vapor degreasing process.
The R -Process Alliance: Exploring the cosmic scatter among ten r -process sites with stellar abundances
Context. The astrophysical origin of the rapid neutron-capture process (r-process), responsible for producing roughly half of the elements heavier than iron, remains uncertain. Detailed chemical signatures from the oldest, most metal-poor stars, which act as fossil records of the earliest nucleosynthesis events, can be used to identify the dominant r-process sites. Aims. We present a homogeneous chemical abundance analysis of ten r-process element-enhanced stars. These old and metal-poor stars are strongly enriched in r-process elements with minimal contamination from other nucleosynthetic sources. By focusing on this chemically pure sample, we aim to investigate intrinsic variations in the r-process abundance patterns and explore their implications for the nature and potential diversity of r-process sites. Methods. We performed a detailed chemical abundance analysis of high-resolution, high-signal-to-noise spectra. For each star, we inspected over 1400 individual absorption lines using a combination of equivalent width measurements and spectral synthesis. The analysis was conducted under the assumption of 1D local thermodynamic equilibrium and employing the MOOG radiative transfer code. Results. We derived abundances for 54 chemical species, including 29 neutron-capture (n-capture) elements, covering the full mass range of the r-process abundance pattern. A kinematic analysis reveals that stars likely originated from ten kinematically distinct systems. Based on this assumption, we used the sample to probe the maximum variation expected from ten independent r-process nucleosynthesis events and computed the intrinsic dispersion of each element relative to Zr and Eu for the light and heavy r-process elements, respectively. This exercise resulted in a remarkably low cosmic scatter across the ten r-process sites enriching these stars; for the rare earth and third peak elements, for example, we find σ [La/Eu] = 0.08 and σ [Os/Eu] = 0.11 dex, while the scatter between light and heavy elements, σ [Zr/Eu] , is slightly higher at 0.18 dex. Conclusions. The elemental abundance patterns across the ten independent r-process sites show remarkably small cosmic dispersions. This minimal dispersion suggests a high degree of uniformity in r-process yields across diverse astrophysical environments.
Data from Impact of Fractionation Process on the Technical and Economic Viability of Corn Dry Grind Ethanol Process
Use of corn fractionation techniques in dry grind process increases the number of coproducts, enhances their quality and value, generates feedstock for cellulosic ethanol production and potentially increases profitability of the dry grind process. The aim of this study is to develop process simulation models for eight different wet and dry corn fractionation techniques recovering germ, pericarp fiber and/or endosperm fiber, and evaluate their techno-economic feasibility at the commercial scale. Ethanol yields for plants processing 1113.11 MT corn/day were 37.2 to 40 million gal for wet fractionation and 37.3 to 31.3 million gal for dry fractionation, compared to 40.2 million gal for conventional dry grind process. Capital costs were higher for wet fractionation processes ($92.85 to $97.38 million) in comparison to conventional ($83.95 million) and dry fractionation ($83.35 to $84.91 million) processes. Due to high value of coproducts, ethanol production costs in most fractionation processes ($1.29 to $1.35/gal) were lower than conventional ($1.36/gal) process. Internal rate of return for most of the wet (6.88 to 8.58%) and dry fractionation (6.45 to 7.04%) processes was higher than the conventional (6.39%) process. Wet fractionation process designed for germ and pericarp fiber recovery was most profitable among the processes.
Single-Step Shear-Based Deformation Processing of Electrical Conductor Wires
Commercial electrical conductor wires are currently produced from aluminum alloys by multi-step deformation processing involving rolling and drawing. These processes typically require 10 to 20 steps of deformation, since the plastic strain or reduction that can be imposed in a single step is limited by material workability and process mechanics. Here, we demonstrate a fundamentally different, single-step approach to produce flat wire aluminum products using machining-based deformation that also ensures adequate material workability in the formed product. Two process routes are proposed: (1) chip formation by free-machining (FM), with a post-machining, light drawing reduction (<20%) to achieve desired finish and (2) constrained chip formation by large strain extrusion machining (LSEM). Using commercially pure aluminum conductor alloys (Al 1100 and EC1350) as representative material systems, we demonstrate key features of the machining-based processing, including (a) single-step processing to achieve flat wire geometries, (b) surface finish (Ra = 0.2 to 1.0 μm) comparable to that of commercial wire products made by drawing/rolling, (c) deformation control independent of wire size, and (d) hardness increases of 50–150% over that of annealed wires, while retaining high electrical conductivity (>56% IACS). Here, the wire microstructure, which can also be varied via the large-strain deformation parameters, is correlated with mechanical and electrical properties. Implications for commercial manufacture of flat wire products are discussed.