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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.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Highly Efficient Training, Refinement, and Validation of a Knowledge-based Planning Quality-Control System for Radiation Therapy Clinical Trials

Purpose: To demonstrate an efficient method for training and validation of a knowledge-based planning (KBP) system as a radiation therapy clinical trial plan quality-control system. Methods and Materials: We analyzed 86 patients with stage IB through IVA cervical cancer treated with intensity modulated radiation therapy at 2 institutions according to the standards of the INTERTECC (International Evaluation of Radiotherapy Technology Effectiveness in Cervical Cancer, National Clinical Trials Network identifier: 01554397) protocol. The protocol used a planning target volume and 2 primary organs at risk: pelvic bone marrow (PBM) and bowel. Secondary organs at risk were rectum and bladder. Initial unfiltered dose-volume histogram (DVH) estimation models were trained using all 86 plans. Refined training sets were created by removing sub-optimal plans from the unfiltered sample, and DVH estimation models… and DVH estimation models were constructed by identifying 30 of 86 plans emphasizing PBM sparing (comparing protocol-specified dosimetric cutpoints V{sub 10} (percentage volume of PBM receiving at least 10 Gy dose) and V{sub 20} (percentage volume of PBM receiving at least 20 Gy dose) with unfiltered predictions) and another 30 of 86 plans emphasizing bowel sparing (comparing V{sub 40} (absolute volume of bowel receiving at least 40 Gy dose) and V{sub 45} (absolute volume of bowel receiving at least 45 Gy dose), 9 in common with the PBM set). To obtain deliverable KBP plans, refined models must inform patient-specific optimization objectives and/or priorities (an auto-planning “routine”). Four candidate routines emphasizing different tradeoffs were composed, and a script was developed to automatically re-plan multiple patients with each routine. After selection of the routine that best met protocol objectives in the 51-patient training sample (KBP{sub FINAL}), protocol-specific DVH metrics and normal tissue complication probability were compared for original versus KBP{sub FINAL} plans across the 35-patient validation set. Paired t tests were used to test differences between planning sets. Results: KBP{sub FINAL} plans outperformed manual planning across the validation set in all protocol-specific DVH cutpoints. The mean normal tissue complication probability for gastrointestinal toxicity was lower for KBP{sub FINAL} versus validation-set plans (48.7% vs 53.8%, P<.001). Similarly, the estimated mean white blood cell count nadir was higher (2.77 vs 2.49 k/mL, P<.001) with KBP{sub FINAL} plans, indicating lowered probability of hematologic toxicity. Conclusions: This work demonstrates that a KBP system can be efficiently trained and refined for use in radiation therapy clinical trials with minimal effort. This patient-specific plan quality control resulted in improvements on protocol-specific dosimetric endpoints.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2018

Data-Driven Pricing Strategy for Demand-Side Resource Aggregators

We consider a utility who seeks to coordinate the energy consumption of multiple demand-side flexible resource aggregators. For the purpose of privacy protection, the utility has no access to the detailed information of loads of resource aggregators. Instead, we assume that the utility can directly observe each aggregator's aggregate energy consumption outcomes. Furthermore, the utility can leverage resource aggregator energy consumption via time-varying electricity price profiles. Based on inverse optimization technique, we propose an estimation method for the utility to infer the energy requirement information of aggregators. Subsequently, we design a data-driven pricing scheme to help the utility achieve system-level control objectives (e.g., minimizing peak demand) by combining hybrid particle swarm optimizer with mutation algorithm and an iterative algorithm. Case studies have demonstrated the effectiveness of the proposed approach against two benchmark pricing strategies-a flat-rate scheme and a time-of-use scheme.

data-driven optimization↗
DOE OSTI2017

Evaluating Transactive Controls of Integrated Transmission and Distribution Systems using the Framework for Network Co-Simulation

With an ever-evolving power grid, concerns regarding how to maintain system stability, efficiency, and reliability remain constant because of increasing uncertainties and decreasing rotating inertia. To alleviate some of these concerns, demand response represents a viable solution and is virtually an untapped resource in the current power grid. This work describes a hierarchical control framework that allows coordination between distributed energy resources and demand response. This control framework is composed of two control layers: a coordination layer that ensures aggregations of resources are coordinated to achieve system objectives and a device layer that controls individual resources to assure the predetermined power profile is tracked in real time. Large-scale simulations are executed to study the hierarchical control, requiring advancements in simulation capabilities. Technical advancements necessary to investigate and answer control interaction questions, including the Framework for Network Co-Simulation platform and Arion modeling capability, are detailed. Insights into the interdependencies of controls across a complex system and how they must be tuned, as well as validation of the effectiveness of the proposed control framework, are yielded using a large-scale integrated transmission system model coupled with multiple distribution systems.

demand response↗
DOE OSTI2021

Development and Evaluation of Velocity Predictive Optimal Energy Management Strategies in Intelligent and Connected Hybrid Electric Vehicles

In this study, a thorough and definitive evaluation of Predictive Optimal Energy Management Strategy (POEMS) applications in connected vehicles using 10 to 20 s predicted velocity is conducted for a Hybrid Electric Vehicle (HEV). The presented methodology includes synchronous datasets gathered in Fort Collins, Colorado using a test vehicle equipped with sensors to measure ego vehicle position and motion and that of surrounding objects as well as receive Infrastructure to Vehicle (I2V) information. These datasets are utilized to compare the effect of different signal categories on prediction fidelity for different prediction horizons within a POEMS framework. Multiple artificial intelligence (AI) and machine learning (ML) algorithms use the collected data to output future vehicle velocity prediction models. The effects of different combinations of signals and different models on prediction fidelity in various prediction windows are explored. All of these combinations are ultimately addressed where the rubber meets the road: fuel economy (FE) enabled from POEMS. FE optimization is performed using Model Predictive Control (MPC) with a Dynamic Programming (DP) optimizer. FE improvements from MPC control at various prediction time horizons are compared to that of full-cycle DP. All FE results are determined using high-fidelity simulations of an Autonomie 2010 Toyota Prius model. The full-cycle DP POEMS provides the theoretical upper limit on fuel economy (FE) improvement achievable with POEMS but is not currently practical for real-world implementation. Perfect prediction MPC (PP-MPC) represents the upper limit of FE improvement practically achievable with POEMS. Real-Prediction MPC (RP-MPC) can provide nearly equivalent FE improvement when used with high-fidelity predictions. Constant-Velocity MPC (CV-MPC) uses a constant speed prediction and serves as a “null” POEMS. Results showed that RP-MPC, enabled by high-fidelity ego future speed prediction, led to significant FE improvement over baseline nearly matching that of PP-MPC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

A Two-Level Model Predictive Control-Based Approach for Building Energy Management including Photovoltaics, Energy Storage, Solar Forecasting and Building Loads

This paper uses a two-level model predictive control-based approach for the coordinated control and energy management of an integrated system that includes photovoltaic (PV) generation, energy storage, and building loads. Novel features of the proposed local controller include (1) the ability to simultaneously manage building loads and energy storage to achieve different operational objectives such as energy efficiency, economic cost efficiency, demand response and grid optimization through the design of specific power trajectory tracking performance functionals, (2) an energy trim function that minimizes the impact of solar forecasting errors on system performance, and (3) the design of a state of charge controller that uses day-ahead forecast of solar power and building loads to intialize energy storage at the start of each day. The local controller is tested in simulation using an exemplary system with PV generation, energy storage and dispatchable building loads. Two sample days with different PV forecasts and multiple case scenarios are considered, and the performance of the algorithm in managing the real and reactive net building load trajectories and the ramp rate of PV injections into the utility network are evaluated. The simulations are based on actual forecasted and measured PV data, and the results show that the local controller meets the tracking requirements for real and reactive power within the operating constraints of the building.

14 SOLAR ENERGY↗
DOE OSTI2021

Targeted metabolomic analysis identifies increased serum levels of GABA and branched chain amino acids in canine diabetes

Introduction Dogs with naturally occurring diabetes mellitus represent a potential model for human type 1 diabetes, yet signifcant knowledge voids exist in terms of the pathogenic mechanisms underlying the canine disorder. Untargeted metabolomic studies from a limited number of diabetic dogs identifed similarities to humans with the disease. Objective To expand and validate earlier metabolomic studies, identify metabolites that difer consistently between diabetic and healthy dogs, and address whether certain metabolites might serve as disease biomarkers. Methods Untargeted metabolomic analysis via liquid chromatography-mass spectrometry was performed on serum from diabetic (n=15) and control (n=15) dogs. Results were combined with those of our previously published studies using identical methods (12 diabetic and 12 control dogs) to identify metabolites consistently diferent between the groups in all 54 dogs. Thirty-two candidate biomarkers were quantifed using targeted metabolomics. Biomarker concentrations were compared between the groups using multiple linear regression (corrected P<0.0051 considered signifcant). Results Untargeted metabolomics identifed multiple persistent diferences in serum metabolites in diabetic dogs compared with previous studies. Therefore, targeted metabolomics showed increases in gamma amino butyric acid, valine, leucine, isoleucine, citramalate, and 2-hydroxyisobutyric acid in diabetic versus control dogs while indoxyl sulfate, N-acetyl-L-aspartic acid, kynurenine, anthranilic acid, tyrosine, glutamine, and tauroursodeoxycholic acid were decreased. Conclusion Several of these fndings parallel metabolomic studies in both human diabetes and other animal models of this disease. Given recent studies on the role of GABA and branched chain amino acids in human diabetes, the increase in serum concentrations in canine diabetes warrants further study of these metabolites as potential biomarkers, and to identify similarity in mechanisms underlying this disease in humans and dogs.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Robot-based Additive Manufacturing of Lego-type Modular Molds for Wind Blades

The objective of this project is to reduce the cost and lead time of horizontal wind turbine blade mold tooling and blade transportation, while maintaining the highest standards of blade quality. The solution involves a smart-design family of modular molds that are easily transportable to fabrication sites near the place of service. Key innovations include the use of additive manufacturing (AM) to integrate conformal thermal management channels, offering enhanced control over the thermal profiles tailored to specific blade materials. This approach enables in-situ quality assurance during mold fabrication, significantly improves mold life, and allows for reuse across multiple production cycles. Ultimately, the solution aims to optimize both tooling and transportation costs, contributing to the scalability of wind turbine blade production. A significant barrier to scaling up the production of large wind turbine blades lies in the high costs associated with tooling and the transportation of blades. Traditional molds are expensive, bulky, and difficult to transport, adding considerable lead time and cost to the overall manufacturing process. Additionally, transporting blades to distant locations for final assembly further exacerbates these challenges. The project aims to address these inefficiencies by demonstrating a modularized, additive-manufactured mold that meets all necessary blade specification requirements, specifically for blade lengths between 120m and 150m.

17 WIND ENERGY↗
NASA NTRS2018

Automated Collision Avoidance (ACA) and Automated Return to Course (ARTC) Requirement and Guidance Review: Final

This report's objectives were to review regulatory and guidance documents to identify requirements and considerations for the design and operation of automated systems that perform the functions of automated collision avoidance (ACA) and/or automated return to course (ARTC). The importance of this work is twofold: 1) to help focus efforts addressing new automated collision avoidance and return to course systems requirements and considerations, and 2) in pulling together available requirements from multiple sources, generate a master resource for these automated system requirements and considerations. Reviewed documents include regulations, industry standards and research papers that specifically address ACA and ARTC systems, other automatedl control and guidance systems, ICAO (International Civil Aviation Organization) and Eurocontrol documents.

Automation↗
DOE OSTI2022

‘Flux+Mutability’: a conditional generative approach to one-class classification and anomaly detection

Abstract Anomaly Detection is becoming increasingly popular within the experimental physics community. At experiments such as the Large Hadron Collider, anomaly detection is growing in interest for finding new physics beyond the Standard Model. This paper details the implementation of a novel Machine Learning architecture, called Flux+Mutability, which combines cutting-edge conditional generative models with clustering algorithms. In the ‘flux’ stage we learn the distribution of a reference class. The ‘mutability’ stage at inference addresses if data significantly deviates from the reference class. We demonstrate the validity of our approach and its connection to multiple problems spanning from one-class classification to anomaly detection. In particular, we apply our method to the isolation of neutral showers in an electromagnetic calorimeter and show its performance in detecting anomalous dijets events from standard QCD background. This approach limits assumptions on the reference sample and remains agnostic to the complementary class of objects of a given problem. We describe the possibility of dynamically generating a reference population and defining selection criteria via quantile cuts. Remarkably this flexible architecture can be deployed for a wide range of problems, and applications like multi-class classification or data quality control are left for further exploration.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1994

Algorithm For Control Of Underactuated Manipulators

Algorithm for improved control of underactuated multiple-link robotic manipulators developed via spatial-algebra-operator approach. Aspects of this approach described in several previous articles in NASA Tech Briefs-most recently "Robot Control Based on Spatial-Operator Algebra" (NPO-17918). Underactuated manipulator has fewer actuators than it has degrees of freedom. Complexity of underactuated systems managed by unified analysis. It has implications for fault-tolerant control, and many practical manipulators underactuated. Examples include manipulators with flexible joints and/or flexible links; space/underwater robots; manipulators that operate with some actuators that turned off because of failure or because of need to conserve energy; manipulators that grasp objects loosely, and manipulators that grasp objects with internal degrees of freedom (e.g., plungers, rollers).

Jain, Abhinandan↗
NASA NTRS2001

Learning Sequences of Actions in Collectives of Autonomous Agents

In this paper we focus on the problem of designing a collective of autonomous agents that individually learn sequences of actions such that the resultant sequence of joint actions achieves a predetermined global objective. We are particularly interested in instances of this problem where centralized control is either impossible or impractical. For single agent systems in similar domains, machine learning methods (e.g., reinforcement learners) have been successfully used. However, applying such solutions directly to multi-agent systems often proves problematic, as agents may work at cross-purposes, or have difficulty in evaluating their contribution to achievement of the global objective, or both. Accordingly, the crucial design step in multiagent systems centers on determining the private objectives of each agent so that as the agents strive for those objectives, the system reaches a good global solution. In this work we consider a version of this problem involving multiple autonomous agents in a grid world. We use concepts from collective intelligence to design goals for the agents that are 'aligned' with the global goal, and are 'learnable' in that agents can readily see how their behavior affects their utility. We show that reinforcement learning agents using those goals outperform both 'natural' extensions of single agent algorithms and global reinforcement, learning solutions based on 'team games'.

Turner, Kagan↗
DOE OSTI2020

Robust Assessment of Real-World Adversarial Examples

We explore rigorous, systematic, and controlled experimental evaluation of adversarial examples in the real world and propose a testing regimen for evaluation of real world adversarial objects. We show that for small scene/ environmental perturbations, large adversarial performance differences exist. Current state of adversarial reporting exists largely as a frequency count over a dynamic collections of scenes. Our work underscores the need for either a more complete report or a score that incorporates scene changes and baseline performance for models and environments tested by adversarial developers. We put forth a score that attempts to address the above issues in a straight-forward exemplar application for multiple generated adversary examples. We contribute the following: 1. a testbed for adversarial assessment, 2. a score for adversarial examples, and 3. a collection of additional evaluations on testbed data.

deep learning, adversarial machine learning, machi↗
NASA NTRS2003

Collectives for Multiple Resource Job Scheduling Across Heterogeneous Servers

Efficient management of large-scale, distributed data storage and processing systems is a major challenge for many computational applications. Many of these systems are characterized by multi-resource tasks processed across a heterogeneous network. Conventional approaches, such as load balancing, work well for centralized, single resource problems, but breakdown in the more general case. In addition, most approaches are often based on heuristics which do not directly attempt to optimize the world utility. In this paper, we propose an agent based control system using the theory of collectives. We configure the servers of our network with agents who make local job scheduling decisions. These decisions are based on local goals which are constructed to be aligned with the objective of optimizing the overall efficiency of the system. We demonstrate that multi-agent systems in which all the agents attempt to optimize the same global utility function (team game) only marginally outperform conventional load balancing. On the other hand, agents configured using collectives outperform both team games and load balancing (by up to four times for the latter), despite their distributed nature and their limited access to information.

Tumer, K.↗
DOE OSTI2019

High Energy Storage Capacity Low Cost Iron Flow Battery

A new flow battery was proposed that utilizes low cost materials: iron as the only active element, cheap aqueous electrolytes, and inexpensive separators. During charging, ferrous iron (Fe 2+ ) is oxidized to ferric iron (Fe 3+ ) at the positive electrode while it (Fe 2+ ) is reduced to form iron metal (Fe 0 ) at the negative electrode. Because iron is plated at the negative electrode during charging, conventional electrode structures couple the energy storage capacity and the power rating of the battery. In order to decouple the energy and power ratings and regain the economic advantages of a flow battery, a slurry electrode design was proposed for use as the negative electrode. The slurry electrode is made by flowing electrically conductive particles in an electrolyte containing the dissolved iron species. On charging, iron is plated onto the particles. The particles can then carry the iron metal out of the cell to be stored in external reservoirs. This project looked to develop a slurry for the negative electrode of the all-iron flow battery that can operate at 200 mA/cm 2 with <100 mV overpotential, be pumped with parasitic energy costs < 10%, and promote plating on the particles. A scalable and stackable cell design of 1100 cm 2 was developed. The project was initially under contract in mid-January 2013. The project was converted from a one-year proof of concept seedling to an additional two-year program, then extended with an 18-month plus-up, and finally with an additional 6-month approved cost-overrun. During the seeding project, the concept of plating on carbon particles in a slurry was demonstrated. However, this was accomplished with high-cost multi-walled carbon nanotubes as the slurry material. The following two-year program discovered several low-cost carbon blacks that could also be used in this application. These findings were supported by an analysis that demonstrated the effectiveness of the carbon that takes into account not just the effective electronic conductivity of the slurry, but also the surface area per volume of the slurry. It was demonstrated that stable, flowable slurries could be created with these carbons, even when the carbons where fully loaded with iron during charging. During the two-year program, laboratory-scale 50 cm 2 single-cells demonstrated charge-discharge cycling at current densities of 150 mA/cm 2 and energy efficiencies of >50%. Meanwhile, cost modeling continued to show promise for this energy storage approach. Following the conversion period, the overall objective of the nominally 18-month plus up period was to close the technical gap of a 25X scale-up and reduce risk to enable commercial investment required to develop a slurry iron flow battery product. A specific objective was to demonstrate 150 cycles of performance exceeding 70% energy efficiency with a 10-cell stack of 1156 cm 2 cells operating at 100 mA/cm 2 . The 10-cell short stack was designed to have a power delivery rating of approximately 1 kW, which represents a size commensurate with the requirements of our commercialization partner at that time. A complete battery support system for the full-size cell was designed, fabricated, and tested. This includes pumps (multiple types were considered, and constant volume hose pumps were found to be acceptable for performance and cost), electrolyte rebalance reactor, and sensors and control systems. The support system proved to be well-behaved and worked well. A new low-cost membrane was developed for this system based on a microporous polymer support with a layer of hydrogel polymer. The membrane had low resistivity, and significantly reduced pressure driven fluid flow across the membrane (as compared to the un-coated microporous support). This membrane approach was scaled-up in conjunction with a commercial toll coating company, and a large amount of membrane was manufactured to support large cell and stack testing. A new concept for an electrolyte rebalance reactor to react hydrogen gas from the negative electrolyte (from plating inefficiency) with excess ferric ion in the positive electrolyte was developed. This design was very simple, low cost, and effective. The full scale 1156 cm 2 single-cell was designed, modeled, fabricated and tested. Modeling showed that uniform flow-distribution should be obtained with the designed flow distributor. The design took into consideration the need to stack the cells, and components were fabricated for a ten-cell stack. Testing of the cell for charge and discharge demonstrated current densities of 50 mA/cm 2 with efficiencies of 50%. However, optimization and long cycling could not be accomplished because the slurry electrode would plug within the cell and block the flow. This would shut down the cell after several charge-discharge cycles. Various approaches were pursued to address this problem with some progress. However, there was not adequate time to find solutions to the problem although several promising approaches were identified for future work. The final deliverable for this proposed 18-month effort was to be a 1 kW, 6 kWh slurry flow battery, with complete balance of plant, ready for testing at an ARPA-E ‘Charges’ site with an estimated capital cost less than $\$ $45/kWh for a six-hour system (excluding power electronics). The deliverable milestone was not achieved for reasons mentioned above related to the slurry plugging. At the completion of this project, it was determined that the cost targets are achievable. The cost estimate for a 1 MW system with a one-hour capacity was estimated at $\$ $140/kWh (including power electronics) and for a six-hour system was estimated at $\$ $40/kWh (including power electronics). These costs include the battery, the balance of plant, the power conditioning and a concrete pad. This program resulted in three patents including the slurry-based iron flow battery, the rebalance reactor, and the membrane separator. At the time of this report, slurry-based iron flow battery patents have been issued in the US, China, Japan, Korea, and Europe. The other patent applications were under various stages of examination. A licensee was identified and the company initiated a scale-up and development program to take this technology to the marketplace, and CWRU staff have transferred their know-how and knowledge base to the company. This technology will enhance the economic and energy security of the United States by enabling the use of intermittent renewable energy technology, such as wind and solar power, as dispatchable resources. This report summarizes the results of this research and development program.

25 ENERGY STORAGE↗
NASA NTRS2010

NASA Airborne Science Program: NASA Stratospheric Platforms

The National Aeronautics and Space Administration conducts a wide variety of remote sensing projects using several unique aircraft platforms. These vehicles have been selected and modified to provide capabilities that are particularly important for geophysical research, in particular, routine access to very high altitudes, long range, long endurance, precise trajectory control, and the payload capacity to operate multiple, diverse instruments concurrently. While the NASA program has been in operation for over 30 years, new aircraft and technological advances that will expand the capabilities for airborne observation are continually being assessed and implemented. This presentation will review the current state of NASA's science platforms, recent improvements and new missions concepts as well as provide a survey of emerging technologies unmanned aerial vehicles for long duration observations (Global Hawk and Predator). Applications of information technology that allow more efficient use of flight time and the ability to rapidly reconfigure systems for different mission objectives are addressed.

Curry, Robert E.↗
DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗
DOE OSTI2023

Control oriented model order reduction for the hydraulic system of an autonomous wheel loader

Control design for an autonomous wheel loader requires a high-fidelity and low-order dynamics model. The objective of order reduction is to decrease the number of states in the model while maintaining performance comparable to the original model. Of all the power components in a wheel loader, the model order reduction for steering and working hydraulic systems is most demanding due to its nonlinear and stiff dynamical nature. This paper describes a physics-inspired model order reduction method that can reduce the model order by close to thirty percent. It is achieved by discarding orders with fast dynamics and consolidating multiple states into less new states. Furthermore, this method can also be extended to other types of off-road vehicles such as excavators, bulldozers, etc. Simulation results demonstrate that the reduced-order model exhibits very similar performance to the full-order model under typical operating conditions of wheel loaders, with an output error of less than six percent.

42 ENGINEERING↗
DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗