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At least 469 records · Page 26

Virtual Collaborative Simulation Environment for Integrated Product and Process Development

Deneb Robotics is a leader in the development of commercially available, leading edge three- dimensional simulation software tools for virtual prototyping,, simulation-based design, manufacturing process simulation, and factory floor simulation and training applications. Deneb has developed and commercially released a preliminary Virtual Collaborative Engineering (VCE) capability for Integrated Product and Process Development (IPPD). This capability allows distributed, real-time visualization and evaluation of design concepts, manufacturing processes, and total factory and enterprises in one seamless simulation environment.

Gulli, Michael A.↗

Thermal Systems Modeling for Integration of Industrial Processes with Advanced Nuclear

Applying combined heat and power concepts to advanced nuclear reactors can enable increased nuclear utilization in the future clean economy, as well as provide safe and reliable clean energy to industrial systems. Analyses have been performed to evaluate the integration of nuclear energy with industrial processes for both clean electricity production and providing process heat for direct use to reduce emissions in the production of chemical commodities. The key research question that needs to be answered is: "What are the prospective approaches for integrating nuclear-generated heat energy into non-electric applications that can facilitate combined heat and power operations by advanced nuclear reactor systems?" This presentation will highlight several case studies showing conceptual designs for thermal delivery systems to integrate small modular reactor (SMR) process steam and electricity with industrial processes including oil refining, hydrogen production, and methanol production.

hydrogen↗

CoRE MOF DB: A curated experimental metal-organic framework database with machine-learned properties for integrated material-process screening

Here, we present an updated version of the Computation-Ready, Experimental (CoRE) Metal-Organic Framework (MOF) database, which includes a curated set of computation-ready MOF crystal structures designed for high-throughput computational materials discovery. Data collection and curation procedures were improved from the previous version to enable more frequent updates in the future. Machine-learning-predicted properties, such as stability metrics and heat capacities, are included in the dataset to streamline screening activities. An updated version of MOFid was developed to provide detailed information on metal nodes, organic linkers, and topologies of an MOF structure. DDEC6 partial atomic charges of MOFs were assigned based on a machine-learning model. Gibbs ensemble Monte Carlo simulations were used to classify the hydrophobicity of MOFs. The finalized dataset was subsequently used to perform integrated material-process screening for various carbon-capture conditions using high-fidelity temperature-swing adsorption (TSA) simulations. Our workflow identified multiple MOF candidates that are predicted to outperform CALF-20 for these applications.

CoRE MOF database↗

Integrated parameter and process learning for hydrologic and biogeochemical modules in Earth System Models

Focus area: Primary focal area #2; secondary focal area #3: Learning about parameters and processes of land surface hydrologic and biogeochemical models in Earth System models by integrating machine learning, physics, and big data. Science challenges: How do we maximally leverage big-data observations to improve hydrobiogeochemical process description and parameterization so that such modules more realistically capture hydrologic and vegetation responses and feedbacks under the future climate? For example, how can we leverage physics, limited observations of vegetation and streamflow to better estimate evapotranspiration, and, relatedly, net primary productivity, especially for drought areas? Vegetation plays a critical role in regional and global water cycles; however, existing vegetation models have failed to predict vegetation response to droughts (McDowell & Xu, 2017) , arctic greening (Keenan & Riley, 2018) , and critical transitions between forest and savanna (Hirota et al., 2011) . These studies suggest that when we build process-based models (PBM) parameterized from regional and global plant traits, we tend to poorly describe plant adaptation and local-scale competition processes. The models and their associated parameters assigned for different regions in the world are not capturing essential heterogeneity in vegetation responses at finer spatial scales. Many parameters of the land surface models control hydrology and vegetation dynamics at the same time. The heterogeneity in vegetation response is a function of (i) plant type, (ii) plant size, (iii) competition and succession, (iv) environmental controls, and (v) local variations due to the unique ecological community that are very difficult to describe (e.g., the size of gaps resulting from fire that facilitated the coexistence of pioneering species). In the demographic models, only factors (i) and (iv) were captured, and plant types were generally described only by leaf phenology and climate zones. With current demographic models, we generally consider more traits to define plant types (i) and calibrate these traits to consider factors (ii), (iii) and (iv); however, it is substantially challenging to scale to regional and global simulations due to trait variations across space (Ali et al., 2016). Moreover, it has been noted that hillslope processes, including ridge-to-valley flow and sunny vs. shady slopes are primary organizers of water, energy, and vegetation (Clark et al., 2015; Fan et al., 2019) . Although gradual improvements in the hydrologic model component in earth system models may reduce this error (at a remarkably slow pace), the long-term, gradual impact of hydrology on plant traits are not well captured. Recent work showed that the hydrologic controls exerted by groundwater and lateral flow are primary regulators of rooting depth (Fan et al., 2017) . Such hydrologic controls have seldom been reflected in vegetation model parameterizations.

54 ENVIRONMENTAL SCIENCES↗

Earth and Planetary Surface Processes Perspectives on Integrated, Coordinated, Open, Networked (ICON) Science

This article provides a commentary about the state of integrated, coordinated, open, and networked (ICON) principles in Earth and Planetary Surface Processes and discussion on the opportunities and challenges of adopting them. Further, this commentary focuses on the challenges with current inclusive, equitable, and accessible science and highlights how research undertaken in the earth and planetary surface processes community currently benefit from and would be able to grow as a discipline with more directed implementation of ICON principles.

42 ENGINEERING↗

Creep performance and microstructure of grade 91 steel weldments with integrated welding and thermal processing

Ferritic-Martensitic steel welds typically require post weld heat treatment (PWHT) to restore toughness and high temperature performance. This off-line thermal process reduces disparities between weld and base metal, but can cause distortion, cracking, or simply be impractical due to assembly size and joint non-uniformity. Here we show integrated welding and thermal processing applied to modified 9Cr-1Mo (Grade 91) steel, favored for advanced power generation applications, performed in real time through the addition of a secondary heat source near the primary weld head. Optimal integrated processing reduces weld fusion and heat affected zone hardness by 125 HV, approaching performance of conventional 730 °C, 60 min PWHT processing. Microstructures and mechanical performance are compared for mechanized GTAW welds, with equivalent lifetimes noted in cross-weld creep rupture tests up to 234 MPa at 550 °C, and up to 104 MPa at 650 °C. The integrated process was validated on a Grade 91 pressure vessel with multipass cold wire feed GTAW. After 550 °C, 71.4 bar thermomechanical cyclic testing, the maximum weld hardness is <350 HV.

36 MATERIALS SCIENCE↗

An Open Computing Infrastructure that Facilitates Integrated Product and Process Development from a Decision-Based Perspective

Computer applications for design have evolved rapidly over the past several decades, and significant payoffs are being achieved by organizations through reductions in design cycle times. These applications are overwhelmed by the requirements imposed during complex, open engineering systems design. Organizations are faced with a number of different methodologies, numerous legacy disciplinary tools, and a very large amount of data. Yet they are also faced with few interdisciplinary tools for design collaboration or methods for achieving the revolutionary product designs required to maintain a competitive advantage in the future. These organizations are looking for a software infrastructure that integrates current corporate design practices with newer simulation and solution techniques. Such an infrastructure must be robust to changes in both corporate needs and enabling technologies. In addition, this infrastructure must be user-friendly, modular and scalable. This need is the motivation for the research described in this dissertation. The research is focused on the development of an open computing infrastructure that facilitates product and process design. In addition, this research explicitly deals with human interactions during design through a model that focuses on the role of a designer as that of decision-maker. The research perspective here is taken from that of design as a discipline with a focus on Decision-Based Design, Theory of Languages, Information Science, and Integration Technology. Given this background, a Model of IPPD is developed and implemented along the lines of a traditional experimental procedure: with the steps of establishing context, formalizing a theory, building an apparatus, conducting an experiment, reviewing results, and providing recommendations. Based on this Model, Design Processes and Specification can be explored in a structured and implementable architecture. An architecture for exploring design called DREAMS (Developing Robust Engineering Analysis Models and Specifications) has been developed which supports the activities of both meta-design and actual design execution. This is accomplished through a systematic process which is comprised of the stages of Formulation, Translation, and Evaluation. During this process, elements from a Design Specification are integrated into Design Processes. In addition, a software infrastructure was developed and is called IMAGE (Intelligent Multidisciplinary Aircraft Generation Environment). This represents a virtual apparatus in the Design Experiment conducted in this research. IMAGE is an innovative architecture because it explicitly supports design-related activities. This is accomplished through a GUI driven and Agent-based implementation of DREAMS. A HSCT design has been adopted from the Framework for Interdisciplinary Design Optimization (FIDO) and is implemented in IMAGE. This problem shows how Design Processes and Specification interact in a design system. In addition, the problem utilizes two different solution models concurrently: optimal and satisfying. The satisfying model allows for more design flexibility and allows a designer to maintain design freedom. As a result of following this experimental procedure, this infrastructure is an open system that it is robust to changes in both corporate needs and computer technologies. The development of this infrastructure leads to a number of significant intellectual contributions: 1) A new approach to implementing IPPD with the aid of a computer; 2) A formal Design Experiment; 3) A combined Process and Specification architecture that is language-based; 4) An infrastructure for exploring design; 5) An integration strategy for implementing computer resources; and 6) A seamless modeling language. The need for these contributions is emphasized by the demand by industry and government agencies for the development of these technologies.

Hale, Mark A.↗

Integrated optical signal processing with magnetostatic waves

Magneto-optical devices based on Bragg diffraction of light by magnetostatic waves (MSW's) offer the potential of large time-bandwidth optical signal processing at microwave frequencies of 1 to 20 GHz and higher. A thin-film integrated-optical configuration, with the interacting MSW and guided-optical wave both propagating in a common ferrite layer, is necessary to avoid shape-factor demagnetization effects. The underlying theory of the MSW-optical interaction is outlined, including the development of expressions for optical diffraction efficiency as a function of MSW power and other relevant parameters. Bradd diffraction of guided-optical waves by transversely-propagating magnetostatic waves and collinear TE/TM mode conversion included by MSW's have been demonstrated in yttrium iron garnet (YIG) thin films. Diffraction levels as large as 4% (7 mm interaction length) and a modulation dynamic range of approx 30 dB have been observed. Advantages of these MSW-based devices over the analogous acousto-optical devices include: much greater operating frequencies, tunability of the MSW dispersion relation by varying either the RF frequency or the applied bias magnetic field, simple broad-band MSW transducer structures (e.g., a single stripline), and the potential for very high diffraction efficiencies.

Fisher, A. D.↗

Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report

The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

An Integrated Risk Assessment Process of Safety-Related Digital I&C Systems in Nuclear Power Plants

Upgrading the existing analog instrumentation and control (I&C) systems to state-of-the-art digital I&C (DI&C) systems will greatly benefit existing light water reactors. However, the issue of software common cause failure (CCF) remains an obstacle in terms of qualification for digital technologies. Existing analyses of CCFs in I&C systems mainly focus on hardware failures. With the application and upgrading of new DI&C systems, design flaws could cause software CCFs to become a potential threat to plant safety, considering that most redundancy designs use similar digital platforms or software in their operating and application systems. With complex multilayer redundancy designs to meet the single failure criterion, these I&C safety systems are of particular concern in U.S. Nuclear Regulatory Commission licensing procedures. In Fiscal Year 2019, the Risk-Informed Systems Analysis (RISA) Pathway of the U.S. Department of Energy’s Light Water Reactor Sustainability Program initiated a project to develop a risk assessment strategy for delivering a strong technical basis to support effective, licensable, and secure DI&C technologies for digital upgrades and designs. An integrated risk assessment for the DI&C process was proposed for this strategy to identify potential key digital-induced failures, implement reliability analyses of related digital safety I&C systems, and evaluate the unanalyzed sequences introduced by these failures (particularly software CCFs) at the plant level. Here this paper summarizes these RISA efforts in the risk analysis of safety-related DI&C systems at Idaho National Laboratory.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗

Implementing the LSST Software Stack for DESGW processing and the Integration of Convolutional Neural Networks into the DESGW Pipeline

The Dark Energy Survey Gravitational Wave (DESGW) group strives to understand thelargescale structure of the universe and galaxies by looking for electromagnetic signatures intelescope images following gravitational wave detections. The DESGW group uses a processing pipeline to perform difference imaging to look for potential candidates. In order to perform these searches more effectively, we first explored using an alternative processing pipeline, the LSST Software Stack to analyze the telescope images. Because the LSST software stack is currently transitioning between its generation 2 and generation 3 system, we decided that while the software will be usable in the future once generation 3 is complete, at the moment its incompleteness makes it impractical to use. We then decided to work on improving the current pipeline by developing a module that integrates a Convolutional Neural Network (CNN) to test difference imaging products for bad subtractions due to misalignment.

Navarro, Alexander↗