Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “test approach”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Probing the role of solids loading and mix procedure on the properties of acoustically mixed materials for additive manufacturing

We report resonant acoustic mixing has been of particular interest for use in additive manufacturing since viscous, solids-loaded materials can be difficult to mix and inhomogeneity has adverse effects on print quality. In this study, we detail a method to iterate through different formulations and mix procedures and assess mixture quality. The approach utilizes a constant pressure-driven flow test to collect statistics on flow rate through a standard geometry. This test is first applied to well mixed formulations containing particulate solids and find that the results are sensitive to viscosity produced by solids content. We then consider the formulations at various stages of mixing and find that the spread in the volume measurements is indicative of the mixing quality; poorly mixed material yields measurements with wide distributions. We believe this testing approach can be useful when screening new formulations, developing mixing processes, or for quality control.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Enhanced climate reproducibility testing with false discovery rate correction

Simulating the Earth's climate is an important and complex problem, thus climate models are similarly complex, comprised of millions of lines of code. In order to appropriately utilize the latest computational and software infrastructure advancements in Earth system models running on modern hybrid computing architectures to improve their performance, precision, accuracy, or all three; it is important to ensure that model simulations are repeatable and robust. This introduces the need for establishing statistical or non-bit-for-bit reproducibility, since bit-for-bit reproducibility may not always be achievable. Here, we propose a short-simulation ensemble-based test for an atmosphere model to evaluate the null hypothesis that modified model results are statistically equivalent to that of the original model. We implement this test in version 2 of the US Department of Energy's Energy Exascale Earth System Model (E3SM). The test evaluates a standard set of output variables across the two simulation ensembles and uses a false discovery rate correction to account for multiple testing. The false positive rates of the test are examined using re-sampling techniques on large simulation ensembles and are found to be lower than the currently implemented bootstrapping-based testing approach in E3SM. We also evaluate the statistical power of the test using perturbed simulation ensemble suites, each with a progressively larger magnitude of change to a tuning parameter. The new test is generally found to exhibit more statistical power than the current approach, being able to detect smaller changes in parameter values with higher confidence.

Kelleher, Michael E. [Oak Ridge National Laborator↗
DOE OSTI2020

EVOLUTION OF SPACE REACTOR QUALIFICATION METHODS AND A PATH FORWARD FOR NEW SPACE REACTORS UNDER CONSIDERATION

These slides outline the evolution of space reactor system qualifications and provide a potential framework for qualification of current space reactor concepts. Qualification approaches for SNAP 10A, SP-100, TOPAZ II, and Prometheus reactor systems will be discussed. Several qualification approaches from past reactors will be reviewed including: a component qualification approach demonstrated in the SNAP reactor program, a system level approach in the SP-100 program, adding additional features to an existing design in the TOPAZ program, and a combination of a computational and basic testing approach for the Prometheus reactor. Past and present test facilities will also be discussed and the impact of test facility availability (or existence) is discussed. A suggested approach that complies with the updated Presidential Directive (NSPM-20, August 2019) that is derived from previous program approaches will be discussed for qualification of future space reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of an integrated platform for hardware-in-the-loop evaluation of microgrids prior to site commissioning

This paper presents an integrated hardware-in-the-loop (HIL) platform for testing the operation and control of a real-world microgrid system prior to site commissioning. The proposed testing approach shows the value of setting up an integrated HIL platform to test multiple hardware devices (including the system-level controller, device controllers, and field devices). A test bed developed for the Borrego Springs community microgrid is used as an example to demonstrate the feasibility of the integrated platform. Comprehensive tests are carried out using the Borrego Springs test bed to validate the platform, meet the test objectives, and gain valuable insight prior to site commissioning. The selected test scenarios, initial conditions, events, test metrics, etc., are similar to those defined in IEEE P2030.8. The test objectives are to evaluate the microgrid controller and the operation of the microgrid. The HIL platform presented in this paper shows good value for microgrid testing in terms of its flexibility and scalability for testing various microgrids; its accuracy in its representation of the field; the comprehensiveness of the testing capability; and the efficiency of testing, which can reduce risks prior to field deployment.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Experimental and statistical study on the effect of process parameters on the quality of continuous fiber composites made via additive manufacturing

Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. Here, in this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Tabletop Testing for EV Charging Ecosystem PKI (Project T34PKI Final Report)

To test the communications and cybersecurity functionality, Electric Vehicle and charging station vendors have had to ship their products to in-person testing events. This is cumbersome, expensive, inefficient, and an impediment to rapid time-to-deployment. In this project Sandia used COTS hardware and Open-Source Software to develop and demonstrate a more agile, productive approach: testing low-voltage controllers independently from high-voltage power delivery sub-systems. This approach allows communications controllers to be transported easily (e.g. shipped at low cost, checked as airline baggage); set up on a table-top (“bench testing”); and use ordinary 120 VAC outlets to conduct agile testing. Table-top platforms become end nodes that can connect to laboratory and cloud-based servers to test communications and cybersecurity, specifically Public Key Infrastructure (PKI) functionality and interoperability, separately from EV battery charging (power/energy transfer) functionality.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Leveraging Additive Manufacturing and Coatings for Turbine Thermal Management

This presentation provides an update to the University Turbine Systems Research meeting on research performed at NETL in areas of sCO2 heat transfer for direct cycle power generation and aerothermal research to improve the efficiency and reduce emissions of small gas turbines. Specific topics include a novel test approach to measure the performance of a thermal barrier coating in-situ and fabrication of advanced, additively manufactured airfoils for testing in a high speed cascade.

Searle, Matthew↗
DOE OSTI2020

Aquifer Hydraulic Testing and Characterization Plan for the Ringold Formation Unit A in the Hanford 200-ZP-1 Groundwater Operable Unit and Vicinity

This document presents a plan for testing and characterizing the hydraulic properties of the Ringold Formation, member of Wooded Island – unit A (Rwia) in the 200-ZP groundwater operable unit. The testing approach includes multiple field methods and associated analyses designed to investigate and understand aquifer hydraulic properties over a range of scales. Testing was designed to achieve specific testing objectives identified previously in the 200 ZP-1 Groundwater Operable Unit Ringold Formation Unit A Characterization Sampling and Analysis Plan (Ringold A SAP). The test plan provides necessary technical and operational detail for writing subsequent field test instruction documents specific to each testing location. Hydraulic characterization activities will proceed in a phased manner focusing on areas identified to have knowledge gaps and also critical for remedy modifications and/or selection. These activities are designed to minimize impact to pump-and-treat (P&T) operations and to use existing P&T injection and extraction wells as stress wells, and include use of the new Rwia monitoring wells installed for Ringold A SAP activities. ZP-1 hydraulic testing will include slug testing in new Rwia wells, shutdown-recovery tests in multiple Rwia and composite Ringold Formation member of Wooded Island – unit E (Rwie)-Rwia aquifer test locations, installation of new Automated Water Level Network stations in Rwia monitoring wells, characterization of P&T and barometric responses, identifying the vertical distribution of hydraulic conductivity in the Rwia and Rwie units using electromagnetic borehole flowmeter tests, and single-well tracer testing in select Rwia monitoring wells. Slug testing to be conducted during drilling is described under the Ringold A SAP. The remaining testing activities are to be conducted after well drilling and completion and are described in this test plan.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Low responsiveness of machine learning models to critical or deteriorating health conditions

Machine learning (ML) based mortality prediction models can be immensely useful in intensive care units. Such a model should generate warnings to alert physicians when a patient’s condition rapidly deteriorates, or their vitals are in highly abnormal ranges. Before clinical deployment, it is important to comprehensively assess a model’s ability to recognize critical patient conditions. We develop multiple medical ML testing approaches, including a gradient ascent method and neural activation map. We systematically assess these machine learning models’ ability to respond to serious medical conditions using additional test cases, some of which are time series. Guided by medical doctors, our evaluation involves multiple machine learning models, resampling techniques, and four datasets for two clinical prediction tasks. We identify serious deficiencies in the models’ responsiveness, with the models being unable to recognize severely impaired medical conditions or rapidly deteriorating health. For in-hospital mortality prediction, the models tested using our synthesized cases fail to recognize 66% of the injuries. In some instances, the models fail to generate adequate mortality risk scores for all test cases. Our study identifies similar kinds of deficiencies in the responsiveness of 5-year breast and lung cancer prediction models. Using generated test cases, we find that statistical machine-learning models trained solely from patient data are grossly insufficient and have many dangerous blind spots. Most of the ML models tested fail to respond adequately to critically ill patients. How to incorporate medical knowledge into clinical machine learning models is an important future research direction.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

ON THE EFFECTIVENESS OF LLMS IN UNIT TEST GENERATION FOR STRUCTURED TEXT PROGRAMS

The reliability of industrial automation systems heavily depends on the correctness of Programmable Logic Controller (PLC) programs, which are often written in Structured Text (ST). While Large Language Models (LLMs) have shown promise in automating test generation for mainstream programming languages, their effectiveness for the syntactically strict ST language remains underexplored. This thesis presents a systematic empirical evaluation of three state-of-the-art LLMs—GPT-4o, Gemini 2.5 Pro, and Claude Sonnet 4.5—for generating ST unit tests. We examine three prompting strategies: Natural Language (NL), Code Language (CL), and Chain-of-Thought (CoT), across a curated set of 11 ST function blocks. The quality of the generated tests is assessed using Compilation Success Rate (CSR), Statement Coverage (SC), and Branch Coverage (BC). In the zero-shot setting, Claude Sonnet 4.5 achieves the highest CSR, while Gemini 2.5 Pro consistently delivers the best statement and branch coverage, particularly under CL prompts. By incorporating a one-shot CL prompt, all models exhibit substantial improvements—most notably GPT-4o, whose CSR increases from 45.45% to 90.91%, with substantial gains in both SC and BC. To further contextualize these findings, we compare GPT-4o’s one-shot results with PLCAutoTester, a state-ofthe- art ST unit test generation tool, on an additional benchmark dataset. While LLMgenerated tests approach competitive coverage levels, PLCAutoTester maintains significantly higher and more stable coverage across programs. This study provides the first comprehensive benchmark of modern LLMs for ST unit testing, highlighting their strengths, limitations, and improvements through one-shot prompting, and positioning their performance relative to specialized automated testing tools in industrial automation.

42 ENGINEERING↗
DOE OSTI2022

Development of a Laser Ultrasonics-based Approach for Rapid Screening of High Entropy Alloys

This project utilized a laser ultrasonic technique to systematically study temperature-induced evolution of material properties in a set of interrelated binary alloys and a high entropy alloy (HEA) fabricated using arc-melting and spark plasma sintering processes. This technique involved the use of a nanosecond duration, high-intensity pulsed laser to thermo-elastically generate ultrasonic waves that propagate in the bulk of the metal alloy. Sub-nanometer-scale displacements associated with the propagating bulk ultrasonic waves were detected along the epicenter on the opposite surface of the sample using a 1 GHz bandwidth photorefractive interferometer. Phase transformations and microstructural changes were inferred from the temperature-dependent trends in the bulk acoustic velocities and features in the ultrasonic epicentral waveforms measured in the binary alloys. These inferences were then correlated with electron/optical microscopy observations and predictions using calculations of phase diagrams (CALPHAD). The results showed that the laser-generated ultrasonic pulses were strongly influenced by changes in material microstructure and could accurately track thermally driven phase transformations and detect the presence of microscale heterogeneities (grain boundaries, dendritic structures, etc.) in the set of binary alloy samples. The measurement approach was then applied to a quinary HEA sample for estimating phase transition temperature and determining microstructural heterogeneity. The rapid, non-contact and non-destructive ultrasonic testing approach demonstrated here is amenable to high throughput combinatorial investigations that can be applied to graded composition HEAs produced using advanced manufacturing methods. When paired with atomistic simulations and CALPHAD modeling, this approach can overcome the bottlenecks faced by current material characterization methods in efficiently screening the vast discovery space of HEAs that spans over a hundred million unique quinary alloy compositions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

AGR-2 Loose Particle Heating Tests in the Furnace for Irradiated TRISO Testing

A furnace system was developed to thermally expose individual tristructural-isotropic (TRISO) coated particles to expand upon established postirradiation examination (PIE) safety testing that is used to explore particle failures and fission product release from compacts. Two systems were installed in the Irradiated Fuels Examination Facility (IFEL) at Oak Ridge National Laboratory (ORNL). The targeted design was intended to be simple and flexible to allow a range in conditions to be explored. Initial inert atmosphere testing indicated the presence of particle failures, so modifications to the testing approach were implemented to improve the furnace operation. Ultimately, burnback particles were analyzed to provide a direct measurement of fission product release, thus avoiding the complications from integral release that were observed during whole compact testing. Particles were exposed to temperatures ranging 1,150–1,300°C for up to 1,500 h and 1,600°C up to 500 h. No indication of uniform release of fission products such as 106 Ru, 125 Sb, or 154 Eu was observed, however, indication of particle dependent 154 Eu release was suggested for select particles. Exploration of 110m Ag release was limited to 1,150°C and 1,300°C up to 500 h. The analysis indicated that there was nonuniform release of 110m Ag and supports a possible bimodal temperature dependence on silver release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Progress on Advancing the Robotic Air-slot Volumetric Inspection System (RAVIS) for Hanford Under-tank Inspection - 20519

The 27 in-service double-shell tank (DST) systems at Hanford provide interim storage for nearly 56 million gallons of nuclear and hazardous chemical legacy waste. The safe and reliable storage of the waste is critical to the site's extended cleanup mission. While in service, the leak integrity of the DSTs must be demonstrated to satisfy the Washington Administrative Code, inform decisions on tank management, and gauge fitness for continued service beyond originally intended design lives. The carbon steel plates and welds that comprise DST primary tank sidewalls and lower knuckles are routinely 'sampled' for volumetric non-destructive testing using ultrasonic inspection technology to determine whether corrosion pitting, cracking, or general corrosion are occurring that could compromise tank leak integrity. However, the carbon steel plates and welds that comprise the bottoms of primary tanks have not been thoroughly inspected since the DSTs were constructed (i.e., since 1968-1986) due to limited physical access to the exterior tank bottoms. The Robotic Air-slot Volumetric Inspection System, or 'RAVIS,' is being engineered to overcome the challenge of tank bottom in-service inspection. The system will be deployed under primary tanks within the small cooling channels/air-slots in the refractory pads upon which the tanks rest and will use ultrasonic guided wave inspection technology to volumetrically inspect physically inaccessible regions that make up ∼90% of a tank bottom, as well as regions that are physically accessible from the air-slots but comprise only ∼10% of a tank bottom. This paper describes the air-slot sensor and robotic deployment system and focuses on the testing approach and methods that are being applied to support (1) design feedback and performance acceptance (requirement verification) and (2) performance repeatability/reliability assessments (qualification) to ensure the RAVIS is prepared for successful inservice inspections of primary tank bottoms. Test progress made against the test plan, the results of 2019 testing, and the future outlook are included. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Performance of concrete under accelerated physical salt attack and carbonation

Conventional testing of physical salt attack (PSA) on concrete does not consider concomitant factors that may exist in service and alter the mechanisms and kinetics of PSA. This study adopted a combined testing approach where concrete was concurrently investigated under accelerated PSA and carbonation, simulating elements serving in heavy traffic and industrial zones, while implementing ambient conditions similar to that in geographic locations with previous cases of PSA. Based on the tested mixture design parameters [water-to-binder ratio, cement type, and supplementary cementitious materials], potential performance improvement and risks were identified. Thermal, mineralogical, and microscopy analyses elucidated the co-occurrence of complex degradation processes in concrete subjected to accelerated PSA and carbonation, which were distinctive from that induced by the single-factor PSA exposure. The synoptic results from this study may informatively improve guidance on mixture design of concrete when dual exposure to PSA and carbonation is expected in the field.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Introducing the embedded random phase approximation: H 2 dissociative adsorption on Cu(111) as an exemplar

The random phase approximation (RPA) as a means of treating electron correlation recently has been shown to outperform standard density functional theory (DFT) approximations in a variety of cases. However, the computational cost of the RPA is substantially more than DFT, especially when aiming to study extended surfaces. Properly accounting for sufficient surface ensemble size, Brillouin zone sampling, and vacuum separation of periodic images in standard periodic-planewave-based DFT code raises the cost to achieve converged results. Here, we show that sub-system embedding schemes enable use of the RPA for modeling heterogeneous reactions at reduced computational cost. Further, we explore two different embedded RPA (emb-RPA) approaches, periodic emb-RPA and cluster emb-RPA. We use the (experimentally and theoretically) well-studied H 2 dissociative adsorption on Cu(111) as our exemplar, and first perform full periodic RPA calculations as a benchmark. The full RPA results match well the semi-empirical barrier fit to experimental observables and others derived from high-level computations, e.g., from recent embedded n-electron valence second order perturbation theory [Zhao et al., J. Chem. Theory Comput. 16(11), 7078–7088 (2020)] and quantum Monte Carlo [Doblhoff-Dier et al., J. Chem. Theory Comput. 13(7), 3208–3219 (2017)] simulations. Among the two emb-RPA approaches tested, the cluster emb-RPA accurately reproduces the energy profile (maximum error of 50 meV along the reaction pathway) while reducing the computational cost by approximately two orders of magnitude. We therefore expect that the embedded cluster approach will enable wider RPA implementation in heterogeneous catalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Methods for Delivery and Distribution of Amendments for Subsurface Remediation: A Critical Review

The ability to reliably deliver and widely distribute remedial amendments through the subsurface environment is of paramount importance to achieve clean-up objectives for contaminated sediments and groundwater for protection of sensitive environmental habitats and natural resources. A wide range of amendment types, delivery techniques, and subsurface access methods are available. However, the applicability of these approaches is dependent on a multitude of site-specific factors and conditions. In this review, an overview of amendment types (i.e., liquid, gas, and solids) and access/distribution methods is provided, along with discussion of the maturity level (low, medium, or high), advantages, and limitations that relate to the potential effectiveness of each approach in the context of site-specific factors (subsurface geology, geochemistry, contaminant properties, etc.). Each amendment type and delivery approach are further evaluated for applicability to the following subsurface target zones: saturated, unsaturated, and perched water, with specific focus on high and low permeability variants of each zone. The review highlights a critical need for field-tested approaches targeting unsaturated and perched water zones, as well as low-permeability regions within all subsurface regions. The intent of this review is to provide critical information and insight into how amendments can be delivered, emplaced, and/or distributed effectively in the subsurface environment to effectively manage subsurface contamination.

Muller, Katherine A.↗
DOE OSTI2022

Origin, parameters, and underlying deformation mechanisms of propagating deformation bands in irradiated 316L stainless steel

Lüders-type propagating deformation bands were observed in specimens of irradiated 316L stainless steel samples removed from Spallation Neutron Source target vessels after service. Mechanical testing with digital image correlation (DIC) and in-situ tensile testing with scanning electron microscopy electron backscatter diffraction showed that the observed Lüders-type behavior was not related to the known transformation-induced plasticity or twinning-induced plasticity behavior. Instead, the phenomenon occurs at small local strain values before a significant amount of martensite or deformation twins appear in the microstructure. Microstructural analysis and in-situ mechanical test results suggest Lüders-type band formation and propagation were related to the appearance and evolution of defect-free channels—analogous to slip bands. A modified Swift equation with a Ludwigson-like component was offered to rationalize the phenomenon and model the strain-softening processes at small strain values. Finally, the results indicate complex microstructural processes and deformation mechanisms were active at small strain values and underline the benefits of advanced mechanical test approaches such as DIC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Reveal-CoV Diaagnostic Platform (Final Report)

LLNL designed and built a rapid, RT-LAMP-based molecular diagnostics platform as a potential tool to quickly diagnose COVID-19 in under one hour. This point-of-care testing approach involves an initial high temperature swab sample inactivation step followed by amplification of viral RNA using up to 5 control and pathogen-specific assays. Results are determined based on a discreet reaction color change from red to yellow but can also be determined using fluorescence detection. Testing of this prototype platform was conducted with synthetic viral RNA and dried, stabilized reagents. Buffer systems, swab selection, and assay stabilization formulations were evaluated for performance. Limits of detection were determined using RNA; however, testing was not performed with viable SARS-CoV-2 virus or clinical samples.

59 BASIC BIOLOGICAL SCIENCES↗