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At least 451 records · Page 25

Quasi-static to Dynamic Response and Microstructure Development of Tantalum-Tungsten Alloys

Lawrence Livermore National Laboratory (LLNL) has a need to understand the quasi-static to dynamic mechanical response and microstructure evolution of tantalum-tungsten (Ta-W) alloys made by conventional wrought processing and additive manufacturing (AM). This two-year work scope will be performed at the Colorado School of Mines (Mines) and will include quasi-static (e.g., 10 -3 s -1 ) mechanical testing in tension and compression, along with high strain rate (Kolsky) pressure bar testing in tension and compression (e.g., 10 3 s -1 ), without and with temperature variations. Gas gun experiments at higher strain rates (e.g., over 10 3 s -1 ) will also be pursued. Complementary microstructure characterization will be performed on undeformed and deformed samples to fundamentally understand the role of processing on the microstructure characteristics and resulting deformation mechanisms that dictate the mechanical response of these alloys with variations in strain rate, temperature, and strain state. Alloys of interest will be Ta-based, containing up to 10 wt.% W. LLNL will supply initial wrought-processed material for sample machining. LLNL will also supply samples built by AM during the project for testing. Arc melting and casting may also be performed at Mines to produce small quantities of different alloys for machining and exploratory testing on an as-needed basis. This project will support multiple postdocs and graduate students at Mines, training them with the knowledge, skills, and abilities needed to study materials under extreme conditions of interest to the National Nuclear Security Agency.

36 MATERIALS SCIENCE↗

Indoor Occupant Counting by RF Backscattering

Building HVAC (heating, ventilation and air conditioning) consumes approximately 13% of all energy consumption in USA. Motion detectors, cameras and user programmable thermostats have been shown to be ineffective for HVAC controls to save energy, mostly due to the user concerns of comfort, reliability and privacy. A new HVAC control system based on real-time occupant counting that is fully automated, highly accurate, economically sensible and preserving privacy and aesthetics can thus bring forth a disruptive impact to this large energy sector. Our indoor occupant monitoring technology is based on the radio-frequency identification system (RFID), deployed in the room, not on the occupants. One reader with four antennas can be deployed on the ceiling or behind the ceiling panels for every thousand square feet in home, office and assisted living, with or without room partitions. The sticker-like passive tag, 10 cents each and maintenance-free, are profusely hidden on the wall or inside the furniture at arbitrary position, preserving privacy and aesthetics. The large number of tags can realize diverse observation points to accommodate arbitrary room layouts, which is impractical by other active units of camera, infrared, radar or lidar. With 20 tags, the system can reliably detect the number of occupants. For 100 tags, occupant posture and location can be known. The technology has been verified in the research labs and test buildings with very high accuracy. When the real-time occupant number can be accurately known without assuming devices on occupants or occupant motion, the building HVAC system can be automated to achieve building energy saving without sacrificing occupant comfort. According to our limited testing in a few types of building models and the simplified cost calculation, the RFID system has low overall cost in production, deployment, operation and maintenance. The signal processing algorithm based on machine learning requires very small number of training cases as most learning is transferrable for various layouts, and very low computational needs during operation, according to our testing in four different room sizes and layouts. In our preliminary estimate from HVAC saving alone, the RFID system can potentially pay for itself within 1.5 years, in addition to the other enhancement in building automation systems (BAS). Our commercialization strategy and business pitch deck focus on venturing this Cornell occupant monitoring technology into BAS and energy management markets. We have identified three broad BAS market segments of senior living, residential buildings, and office buildings. We have put together the minimum viable product characteristics for these identified segments, including analyses on total cost and competing technologies, as well as the fit and technical gaps for these market segments. We intend to bring the technology to market by licensing or partnering with existing BAS vendors. A list of potential collaborators and licensing partner candidates was assembled for different aspects of integrating our technology into a potential product that can be used with BAS.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing

Computer vision and deep learning tools that advance the ability to establish processing-structure-property-performance (PSPP) relations are presented. The Bayesian binning method for image segmentation enables quantitative analysis of microstructural features in an automated way, while the analysis of shapes and relative orientation of these features reveals local deformation maps indicative of both, material flow and residual stresses due to materials processing. The deep learning method leads to the previous knowledge agnostic mapping of empirically observed microstructural zones in friction stir welding (FSW) process and synthetic microstructure generation capability that is statistically equivalent to experimentally collected data.

97 MATHEMATICS AND COMPUTING↗

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗

Region-Based Convolutional Neural Network for Wind Turbine Wake Characterization in Complex Terrain

We present a proof of concept of wind turbine wake identification and characterization using a region-based convolutional neural network (CNN) applied to lidar arc scan images taken at a wind farm in complex terrain. We show that the CNN successfully identifies and characterizes wakes in scans with varying resolutions and geometries, and can capture wake characteristics in spatially heterogeneous fields resulting from data quality control procedures and complex background flow fields. The geometry, spatial extent and locations of wakes and wake fragments exhibit close accord with results from visual inspection. The model exhibits a 95% success rate in identifying wakes when they are present in scans and characterizing their shape. To test model robustness to varying image quality, we reduced the scan density to half the original resolution through down-sampling range gates. This causes a reduction in skill, yet 92% of wakes are still successfully identified. When grouping scans by meteorological conditions and utilizing the CNN for wake characterization under full and half resolution, wake characteristics are consistent with a priori expectations for wake behavior in different inflow and stability conditions.

17 WIND ENERGY↗

The suitability of differentiable, physics-informed machine learning hydrologic models for ungauged regions and climate change impact assessment

As a genre of physics-informed machine learning, differentiable process-based hydrologic models (abbreviated as δ or delta models) with regionalized deep-network-based parameterization pipelines were recently shown to provide daily streamflow prediction performance closely approaching that of state-of-the-art long short-term memory (LSTM) deep networks. Meanwhile, δ models provide a full suite of diagnostic physical variables and guaranteed mass conservation. Here, we ran experiments to test (1) their ability to extrapolate to regions far from streamflow gauges and (2) their ability to make credible predictions of long-term (decadal-scale) change trends. We evaluated the models based on daily hydrograph metrics (Nash–Sutcliffe model efficiency coefficient, etc.) and predicted decadal streamflow trends. For prediction in ungauged basins (PUB; randomly sampled ungauged basins representing spatial interpolation), δ models either approached or surpassed the performance of LSTM in daily hydrograph metrics, depending on the meteorological forcing data used. They presented a comparable trend performance to LSTM for annual mean flow and high flow but worse trends for low flow. For prediction in ungauged regions (PUR; regional holdout test representing spatial extrapolation in a highly data-sparse scenario), δ models surpassed LSTM in daily hydrograph metrics, and their advantages in mean and high flow trends became prominent. In addition, an untrained variable, evapotranspiration, retained good seasonality even for extrapolated cases. The δ models' deep-network-based parameterization pipeline produced parameter fields that maintain remarkably stable spatial patterns even in highly data-scarce scenarios, which explains their robustness. Combined with their interpretability and ability to assimilate multi-source observations, the δ models are strong candidates for regional and global-scale hydrologic simulations and climate change impact assessment.

54 ENVIRONMENTAL SCIENCES↗

AI-Science for Performance Optimization and Diagnosis of Science Instrument Federations

Next generation of science workflows are expected to be executed over complex federations composed of supercomputers, science instruments, storage systems and networks, with new additions of the edge and cloud systems and services. The sheer complexity of these multi-domain federations makes it hard to manage them and optimize their performance, as small impedance mismatches (that can dynamically develop between systems) could drastically degrade the entire federation performance. Recent proliferation of Software Defined Everything (SDX) technologies combined with containerization frameworks provide custom instruments that can monitor and collect critical measurements at various levels to support diagnoses and performance optimization; but their data too enormous for human operators and analysts to process and generate decisions. Machine Learning (ML) methods that extract critical parameters, relationships and trends from the data offer general solutions. Artificial Intelligence (AI) and ML methods must be custom-developed for these problems based on solid, rigorous foundations, since black-box approaches are often ineffective and unsound.We propose to develop comprehensive AI-Science for the performance of science federations to (i) monitor and control storage, networks, experiments, and computing systems across multiple domains via softwarization layers, at speeds and scales orders of magnitude superior to current practice, (ii) optimally realize and orchestrate complex workflows with high performance by using dynamic state and performance estimation methods, and (iii) aggregate measurements across sites and time to develop infrastructure-level profiles, optimizations and diagnoses using AI-Science based on foundational principles from ML, game theory, and information fusion areas.

Rao, Nageswara↗

Machine Learning Algorithms for Automated NIF Capsule Mandrel Selection

Small shells, approximately 2 mm in diameter, made from Poly(α-methylstyrene) (PAMS) are used as mandrels in the production of glow discharge polymer capsules located at the center of inertial confinement fusion experiments. The visual inspection process of microscope images of these shell mandrels, including detection of micron-sized defects on the shell surface as well as the handling and sorting, is a very labor-intensive, repetitive, and highly subjective process that stands to benefit greatly from automation. As part of an effort to decrease the number of labor hours spent in capsule handling, inspection, and metrology, the development of robotic systems was presented in a paper by Carlson et al., “Automation in Target Fabrication” [Fusion Sci. Technol., Vol. 70, p. 274 (2016)]. The current work expands the automated image acquisition systems developed previously and adds the use of convolutional neural networks to select capsules best suited for use in the downstream production process. Through the use of these machine learning algorithms, the selection process becomes robust, repeatable, and operator independent. Finally, as an added benefit the system developed as part of this work is able to provide defect statistics on entire shell batches and feed this information upstream to the production team.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Integrated Risk-Informed Condition Based Maintenance Capability and Automated Platform: Technical Report 3

This project is a collaborative research effort between PKMJ Technical Services LLC, Idaho National Laboratory, and Public Service Enterprise Group (PSEG) Nuclear, LLC. The collaboration, led by PKMJ Technical Services LLC, is part of the industry Funding Opportunity Announcement (FOA) award under Advanced Nuclear Technology Development FOA #DE-FOA-0001817. The pilot demonstration focuses on the Circulating Water System (CWS), an important non-safety-related system that impacts the power generation capability of the plant site. Achieving riskinformed condition-based Predictive Maintenance (PdM) on the CWS will result in significant economic benefits, and the developed methodologies can also be applied to other plant systems. This approach supports an industry goal of ensuring that nuclear power generation remains a viable, economically competitive option in the energy market. Operation and Maintenance (O&M) costs include labor-intensive Preventive Maintenance (PM) programs that involve manually performed inspection, calibration, testing, and maintenance of plant assets at periodic frequencies as well as time-based replacement of assets, irrespective of condition. This project offers an alternative by focusing on riskinformed condition-based maintenance to reduce O&M costs while still maintaining plant health and safety. This report summarizes the progress made toward achieving a risk-informed condition-based maintenance approach. The research and development (R&D) activities presented in this report are associated with development of a nuclear digital platform application, integration of fault signature models, and automated work management processes. The fault signatures and Machine Learning (ML) models are key components in predictive analytics and are heavily leveraged to improve the insights received by existing plant process data sources. Availability of the analysis results within a centralized digital platform enhances efficiency by enabling automation of activities otherwise performed manually. Personnel are presented with enhanced information that can be used to evaluate plant status and risks. Utilizing the enhancements to data analytics supports automated responses, (i.e. issuance of work orders) to address developing equipment faults and thus preventing forced, unplanned shutdowns of components or systems. The R&D activities described within this report lay the foundation for developing and demonstrating a digital automated platform to centralize the implementation of condition monitoring and response to equipment faults. The digital automated platform is cloud-based and designed to enable improved efficiency of plant processes. The digital platform includes content related to maintenance optimization, fault signature analysis, and plant records, which can all be used to support efficiencies when located within a centralized digital platform. These efficiencies could be further enhanced when deployed through industry-wide deployment of the technology to improve insights and processes based upon economies of scale.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Investigation of Machinability of Additively Manufactured Ti-6Al-4V

Additively manufactured metals differ from their conventionally produced counterparts due to the inherent material inhomogeneity, porosity, and thermal stress induced by the process. These differences make the machining of additively manufactured metals more difficult and cause premature tool failure or unexpected surface finish at certain conditions. This study takes the first step to investigate and identify the causes of these issues, particularly for Ti-6Al-4V. Printed and wrought samples, as well as heat treatment effect, are compared in a dry cutting condition at a cutting speed of 90 m/min in terms of cutting power, vibration, temperature, and produced surface finish. The results show a lower cutting power and more vibration for as-printed Ti samples, indicating a less ductile microstructure and inclusion of pores. Heat treatment can eliminate these phenomena. There is no significant difference found in the produced surface finish at the current cutting condition.

Raval, Jay↗

Accelerating data acquisition with FPGA-based edge machine learning: a case study with LCLS-II

New scientific experiments and instruments generate vast amounts of data that need to be transferred for storage or further processing, often overwhelming traditional systems. Edge machine learning (EdgeML) addresses this challenge by integrating machine learning (ML) algorithms with edge computing, enabling real-time data processing directly at the point of data generation. EdgeML is particularly beneficial for environments where immediate decisions are required, or where bandwidth and storage are limited. In this paper, we demonstrate a high-speed configurable ML model in a fully customizable EdgeML system using a field programmable gate array (FPGA). Our demonstration focuses on an angular array of electron spectrometers, referred to as the ‘CookieBox,’ developed for the Linac Coherent Light Source II project. The EdgeML system captures 51.2 Gbps from a 6.4 GS s −1 analog to digital converter and is designed to integrate data pre-processing and ML inside an FPGA. Our implementation achieves an inference latency of 0.2 µs for the ML model, and a total latency of 0.4 µs for the complete EdgeML system, which includes pre-processing, data transmission, digitization, and ML inference. The modular design of the system allows it to be adapted for other instrumentation applications requiring low-latency data processing.

97 MATHEMATICS AND COMPUTING↗

Machine Learning Enabled Atomistic Study of the Micro-Cold Spray Process [Poster]

Micro-cold spray is typically conducted by impacting 200-2000 nm particles at velocities of ~500 m/s. Molecular dynamics simulations have been used to study micro cold spray, but the particles that can be simulated using conventional potentials are much smaller than those used experimentally. The viewgraphs taken from molecular dynamics simulations and shown below are cross-sections of a 50 nm Ta particle with a 3 nm oxide layer impacting at 500 m/s using a machine learning enabled DeePMD potential. Using more expensive reactive interatomic potentials, the previous largest particle size for a metal/oxide impact simulation was 12 nm.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Preliminary Study on Machining of Additively Manufactured Ti-6Al-4V

We report additively manufactured metals differ from their conventionally produced counterparts due to the inherent material inhomogeneity, porosity, and thermal stress induced by the process. These differences make the machining of additively manufactured metals more difficult and cause premature tool failure or unexpected surface finish at certain conditions. This study takes the first step to investigate and identify the causes of these issues, particularly for Ti-6Al-4V. Printed and wrought samples, as well as heat treatment effect, are compared in a dry cutting condition at a cutting speed of 90 m/min in terms of cutting power, vibration, temperature, and produced surface finish. The results show a lower cutting power and more vibration for as-printed Ti samples, indicating a less ductile microstructure and inclusion of pores. Heat treatment can eliminate these phenomena. There is no significant difference found in the produced surface finish at the current cutting condition.

36 MATERIALS SCIENCE↗

Operation of Grid Forming Converters as Self Excited Induction Generators Under Non-Ideal Loading Conditions

Self-excited induction generators offer a robust solution for power production for standalone as well as grid-connected systems. In general, self-excited induction generators require excitation capacitors which make use of the machine magnetization characteristics for voltage build up process as well as operation at a specific frequency. In this paper, a self-excited induction machine is modeled with both the electrical and mechanical dynamics. This modeled virtual machine's dynamics are utilized for voltage build up process for a standalone photovoltaic converter connected to a local load for a microgrid application. The modeled machine's parameters are used from the name plate rating from the manufacturer. However, in a microgrid the accommodation of unbalanced and/or nonlinear harmonic rich load is a necessity, therefore, in this work the virtual self-excitation capacitors of the modeled machine are varied based on the machine characteristics. With the objective of ensuring harmonic free point of common coupling voltage, the modeled virtual self-excitation capacitors are varied to accomplish change in terminal frequency and the virtual load torque is varied to obtain voltage magnitude change. To verify the efficacy, the overall system is modeled in MATLAB/Simulink and PLECS domain and most important case studies are presented.

grid forming converters (GFM)↗

Processed Lab Data for Neural Network-Based Shear Stress Level Prediction

Machine learning can be used to predict fault properties such as shear stress, friction, and time to failure using continuous records of fault zone acoustic emissions. The files are extracted features and labels from lab data (experiment p4679). The features are extracted with a non-overlapping window from the original acoustic data. The first column is the time of the window. The second and third columns are the mean and the variance of the acoustic data in this window, respectively. The 4th-11th column is the the power spectrum density ranging from low to high frequency. And the last column is the corresponding label (shear stress level). The name of the file means which driving velocity the sequence is generated from. Data were generated from laboratory friction experiments conducted with a biaxial shear apparatus. Experiments were conducted in the double direct shear configuration in which two fault zones are sheared between three rigid forcing blocks. Our samples consisted of two 5-mm-thick layers of simulated fault gouge with a nominal contact area of 10 by 10 cm^2. Gouge material consisted of soda-lime glass beads with initial particle size between 105 and 149 micrometers. Prior to shearing, we impose a constant fault normal stress of 2 MPa using a servo-controlled load-feedback mechanism and allow the sample to compact. Once the sample has reached a constant layer thickness, the central block is driven down at constant rate of 10 micrometers per second. In tandem, we collect an AE signal continuously at 4 MHz from a piezoceramic sensor embedded in a steel forcing block about 22 mm from the gouge layer The data from this experiment can be used with the deep learning algorithm to train it for future fault property prediction.

15 GEOTHERMAL ENERGY↗

Teaching AI when to care about gender

Natural Language Processing (NLP) is a branch of Artificial Intelligence (AI) concerned with solving language tasks by modeling large amounts of textual data. Some NLP techniques use word embeddings which are semantic models where machine learning (ML) is used to learn to cluster semantically related words by learning about word co-occurrences in the original training text. Unfortunately, these models tend to reflect or even exaggerate biases that are present in the training corpus. Here we describe the Word Embedding Navigator (WEN), which is a tool for exploring word embedding models. We examine a specific potential use case for this tool: interactive discovery and neutralization of gender bias in word embedding models, and compare this human-in-the-loop approach to reducing bias in word embeddings with a debiasing post-processing technique.

97 MATHEMATICS AND COMPUTING↗

Finding Electronic Structure Machine Learning Surrogates without Training

A myriad of phenomena in materials science and chemistry rely on quantum-level simulations of the electronic structure in matter. While moving to larger length and time scales has been a pressing issue for decades, such large-scale electronic structure calculations are still challenging despite modern software approaches and advances in high-performance computing. The silver lining in this regard is the use of machine learning to accelerate electronic structure calculations – this line of research has recently gained growing attention. The grand challenge therein is finding a suitable machine-learning model during a process called hyperparameter optimization. This, however, causes a massive computational overhead in addition to that of data generation. We accelerate the construction of machine-learning surrogate models by roughly two orders of magnitude by circumventing excessive training during the hyperparameter optimization phase. We demonstrate our workflow for Kohn-Sham density functional theory, the most popular computational method in materials science and chemistry.

36 MATERIALS SCIENCE↗

Freeform thermoelectrics in single-step manufacturing: additive manufacturing of bismuth-telluride thermoelectrics

The project succeeded in producing crack-free Bismuth Telluride thermoelectric parts with density exceeding 98% through laser powder bed fusion (LPBF) additive manufacturing (AM). This greatly exceeded the highest previously reported density of 88% and is the highest among all semiconducting materials processed by LPBF. The additively manufactured material shows comparable Seebeck coefficient as conventional form and can be made into complex geometries with reduced material loss. On the other hand, measured properties are dramatically sensitive to the AM process parameters used, such that with identical composition, the Seebeck coefficient can be controllably tuned from +120 µV/K to -207 µV/K, which means the material switches between an n-type to a p-type semiconductor depending on processing. These changes are accompanied by significant differences in the as-processed microstructure due to rapid solidification. A machine learning protocol was developed and greatly reduced the experimental burden of the project, reducing the typical process optimization period of 2 years to 6 months. The project was fully successful in the objective of producing defect-free, complex geometry of bismuth-telluride parts through LPBF, but only partially successful in achieving performance goals. First, cost reduction of manufacturing, as measured by material waste, was successfully reduced by up to 70% compared to conventional manufacturing methods. This exceeded the proposed 30% reduction in materials waste needed to reach the 20% cost reduction goal of the project. On the other hand, the device performance, as measured by Seebeck coefficient, failed to reach the 40% improvement in efficiency. Rather, we observe comparable Seebeck coefficient between AM samples and conventionally processed counterparts. The device-level efficiency improvement does exceed 40% for complex geometry samples due to shape-induced increase in temperature gradients, but this was not the originally proposed metric. The machine learning approach developed in this project greatly accelerated the process optimization and can be adopted for fast development of AM processing parameters for other brittle and otherwise difficult-to-print materials. For the public, we deliver an efficient and widely adoptable process for incorporating waste-heat harvesting thermoelectric devices in both industrial and commercial heat exchangers. The geometric flexibility allows the capturing device to conform to the shape of the heat source to improve the system-level conversion efficiency. The technique can be deployed on any commercial LBPF systems with zero modifications, thus poses minimal adoption barrier for any manufacturer that already employed AM technology. Beyond bismuth-telluride, the machine-learning guided optimization protocol can be used in the future to reduce both the time and cost of process development for AM of other energy conversion and harvesting materials.

36 MATERIALS SCIENCE↗