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DOE OSTI2024

Emittance Measurements with Wire Scanners in the Fermilab Side-coupled Linac

The Fermilab Side-Coupled Linac accelerates H-beam from 116 MeV to 400 MeV through seven 805 MHz modules. Twelve wire scanners are present in the Side Coupled Linac and four are present in the transfer line between the Linac and the Booster synchrotron ring. These wire scanners act as important diagnostic instruments to directly collect information on the beam's transverse distribution. The manipulation of the conditions of wire scanner data collection enables further characterization of the beamline, such as calculating emittance and the Twiss parameters of the beam at select regions, which we present here.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Data Driven Fault Detection of Premixer Centerbody Degradation in a Swirl Combustor

This paper introduces a data-driven framework for combustor-focused, performance-based condition monitoring of gas turbines. Commercial condition monitoring systems typically generate huge amounts of data that make efficient onboard monitoring challenging. This paper focuses on quantifying combustor component degradation, using premixer centerbody degradation in a swirl stabilized combustor as a case study. The input for these analyses is acoustic pressure measurements acquired at various locations on the combustor. The diagnosis methodology is based on a classification framework and consists of 3 steps: 1) Data curation, 2) Feature Engineering, and 3) Diagnosis. Data curation ensures good quality of the data that is passed through the algorithm. Feature engineering deals with the extraction of the most informative features, from the most informative sensors, that can accurately capture the introduced fault. To perform diagnosis, the classification model is trained using experimentally acquired data and is then tested on a separate data set. The framework was able to achieve high classification accuracy (>99%) for training size as low as 30% of the total recorded observations. The low number of features required to achieve this accuracy suggests high potential for integration into existing onboard condition monitoring systems.

data driven methods, fault detection, swirl flames↗

DOE OSTI2020

Injury severity analysis of truck-involved crashes under different weather conditions

This paper investigates truck-involved crashes to determine the statistically significant factors that contribute to injury severity under different weather conditions. The analysis uses crash data from the state of Ohio between 2011 and 2015 available from the Highway Safety Information System. To determine if weather conditions should be considered separately for truck safety analyses, parameter transferability tests are conducted; the results suggest that weather conditions should be modeled separately with a high level of statistical confidence. To this end, three separate mixed logit models are estimated for three different weather conditions: normal, rain and snow. The estimated models identify a variety of statistically significant factors influencing the injury severity. Different weather conditions are found to have different contributing effects on injury severity in truck-involved crashes. Rural, rear-end and sideswipe crash parameters were found to have significantly different levels of impact on injury severity. Based on the findings of this study, several countermeasures are suggested: 1) safety and enforcement programs should focus on female truck drivers, 2) a variable speed limit sign should be used to lower speeds of trucks during rainy condition, and 3) trucks should be restricted or prohibited on non-interstates during rainy and snowy conditions. These countermeasures could reduce the number and severity of truck-involved crashes under different weather conditions.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

System and method for wave prediction

A method and system for prediction of wave properties include collecting time-series data streams from one or more wave measurement devices and processing the data to identify data parameters to establish boundary conditions of a numerical model. The numerical model may be used to compute a predicted wave field of time-series data for a variety of wave properties at a target location.

Previsic, Mirko↗

DOE OSTI2024

Physical discovery in representation learning via conditioning on prior knowledge

Recent advances in electron, scanning probe, optical, and chemical imaging and spectroscopy yield bespoke data sets containing the information of structure and functionality of complex systems. In many cases, the resulting data sets are underpinned by low-dimensional simple representations encoding the factors of variability within the data. The representation learning methods seek to discover these factors of variability, ideally further connecting them with relevant physical mechanisms. However, generally, the task of identifying the latent variables corresponding to actual physical mechanisms is extremely complex. Here, we present an empirical study of an approach based on conditioning the data on the known (continuous) physical parameters and systematically compare it with the previously introduced approach based on the invariant variational autoencoders. The conditional variational autoencoder (cVAE) approach does not rely on the existence of the invariant transforms and hence allows for much greater flexibility and applicability. Interestingly, cVAE allows for limited extrapolation outside of the original domain of the conditional variable. However, this extrapolation is limited compared to the cases when true physical mechanisms are known, and the physical factor of variability can be disentangled in full. We further show that introducing the known conditioning results in the simplification of the latent distribution if the conditioning vector is correlated with the factor of variability in the data, thus allowing us to separate relevant physical factors. We initially demonstrate this approach using 1D and 2D examples on a synthetic data set and then extend it to the analysis of experimental data on ferroelectric domain dynamics visualized via piezoresponse force microscopy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Improving Additive Manufactured Component Performance through Multi-Scale Microstructure Simulation and Process Optimization

The purpose of this project was to utilize computational tools to understand the relationships between processing, microstructure, and properties for additively manufactured (AM) aluminum alloys for automotive applications, and to provide an engineering solution for helping to optimize process conditions. The project leverages ORNL developments in computational modeling, including AM process modeling, phase-field based microstructure evolution predictions, and data analytics techniques for mapping process conditions to material outcomes. The project utilized an Al-Cu-Mn-Zr alloy as a model material for studying formation of defects and microstructural features in response to variations in process conditions. Based on both pre-existing experimental data and simulation results, statistical process maps were constructed to identify regions of process space with minimal defect formation and advantageous microstructures and properties. The software tools used for this purpose were successful disseminated to GM, who were able to successful compile the relevant HPC codes within their own computing ecosystem and perform initial calculations to reproduce ORNL results.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Organizing Large Data Sets for Efficient Analyses on HPC Systems

Upcoming exascale applications could introduce significant data management challenges due to their large sizes, dynamic work distribution, and involvement of accelerators such as graphical processing units, GPUs. In this work, we explore the performance of reading and writing operations involving one such scientific application on two different supercomputers. Our tests showed that the Adaptable Input and Output System, ADIOS, was able to achieve speeds over 1TB/s, a significant fraction of the peak I/O performance on Summit. We also demonstrated the querying functionality in ADIOS could effectively support common selective data analysis operations, such as conditional histograms. In tests, this query mechanism was able to reduce the execution time by a factor of five. More importantly, ADIOS data management framework allows us to achieve these performance improvements with only a minimal amount of coding effort.

Gu, Junmin↗

DOE OSTI2025

Open data sets for assessing photovoltaic system reliability

Photovoltaic (PV) systems have become a cornerstone of renewable energy strategies, particularly due to the significant reduction in solar power costs over the past decade. However, the long-term reliability of PV installations presents a persistent challenge, requiring the development of advanced monitoring and predictive maintenance strategies. A wide range of data types is used to evaluate the health of PV systems, including environmental conditions, electrical performance, and inspection imagery. These data enable methodologies such as machine learning (ML) models for lifetime prediction and computer vision techniques for defect detection. However, the acquisition of high-quality and comprehensive data is difficult, particularly in terms of long-term consistency and data variety. Publicly available data sets serve as valuable resources for addressing these challenges, but they often suffer from fragmentation and are difficult to access. This paper presents a comprehensive review of existing open-source data sets related to PV degradation, analyzing their features, functionalities, and potential applications. We categorize these data sets based on the specific aspects of PV system information they cover, such as environmental conditions, operational monitoring, image inspection and module materials, and propose relevant tools and ML models for processing them. In addition, we propose practices for future data collection and usage, while also discussing potential directions in data-driven research. Our aim is to enhance data utilization and publication among researchers and industry professionals, promoting a deeper understanding of the role of data in enhancing the performance and durability of PV systems.

14 SOLAR ENERGY↗

DOE OSTI2021

Daily grass reference evapotranspiration with Meteosat Second Generation shortwave radiation and reference ET products

Here we assess the accuracy of estimating daily grass reference evapotranspiration (PM-ET o ) using daily shortwave radiation (R s ) and reference evapotranspiration (ET REF ) products provided by the Meteosat Second Generation (MSG) geostationary satellite delivered by the Satellite Applications Facility on Land Surface Analysis (LSA-SAF) framework. The accuracy of using reanalysis ERA5 shortwave radiation data (R s ERA5 ) provided by the European Center for Medium-Range Weather Forecasts (ECMWF) is also evaluated. The assessments were performed using observed weather variables at 37 weather stations distributed across continental Portugal, where climate conditions range from semi-arid to humid, and 12 weather stations located in Azores islands, characterized by humid, windy and often cloudy conditions. This study's use of data from a variety of climate conditions contributed to a unique and innovative assessment of the usability of LSA-SAF and ERA5 products for ET o estimation. The first assessment focused on comparing LSA-SAF estimates of R s (R s LSA-SAF ) against ground stations (R s ground ). The results showed a good matching between the two R s data sets for continental Portugal but a tendency for R s LSA-SAF to under-estimate R s ground in the cloudy islands of Azores. ET o values computed using R s LSA-SAF data and observed temperature, humidity and wind speed (ET o LSA-SAF ) were then compared with PM-ET o estimates with ground-based data, which were used as benchmark; input data of temperature and humidity needed for PM-ET o were quality checked for surface aridity effects. It was observed that ET o LSA-SAF is strongly correlated with PM-ET o (R 2 > 0.97) for most locations in continental Portugal, with regression coefficient of a linear regression forced to the origin ranging between 0.95 and 1.05, mean root mean square error (RMSE) of 0.13 mm d –1 , and Nash and Sutcliff efficiency of modeling (EF) above 0.95. For most Azores locations, ET o LSA-SAF over-estimated PM-ET o . This is likely a consequence of the high spatio-temporal heterogeneity of weather conditions that occur in these oceanic islands together with the different footprints of satellite (averaged over the pixel) and station observations. Reanalysis ERA5 shortwave radiation data presented similar behavior to the LSA-SAF products, however with slightly lower accuracy. The daily LSA-SAF ET REF product (ET REF LSA-SAF ) was assessed and results have shown a good accuracy of this product, with acceptable RMSE and high EF values, for continental Portugal but a low accuracy for the Azores islands. A simplified bias correction approach was shown to improve both ET o derived from the LSA-SAF products, namely for Azores stations, which seem to be representative of smaller areas. The use of the FAO-PM temperature approach (PMT) was also assessed using the R s LSA-SAF and R s ERA5 data, which showed a superiority of the LSA-SAF product for ET o estimations (ET o PMT LSA-SAF ). No significant differences (p < 0.05) were observed in terms of the median value of the RMSE when adopting ET o PMT and ET REF LSA-SAF . Differently, results showed that using the R s LSA-SAF in the PMT approach (ET o PMT LSA-SAF ) produces significantly better RMSE results than ET o PMT and ET REF LSA-SAF . Overall, the performed assessment allows concluding that the use of R s LSA-SAF, and to a lesser extent the use of the R s ERA5 , highly improves the accuracy of computation of ET o when R s observations are not available, including when only temperature data are accessible. The use of the ET REF LSA-SAF product is a good alternative when observed weather data are not available.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Data-based filtered dissipation rate modelling for multi-modal turbulent combustion: evaluating a priori model generalizability

Manifold-based models offer a computationally efficient alternative to directly transporting the thermochemical state in computational simulations of turbulent reacting flows, projecting the high-dimensional thermochemical state-space onto a low-dimensional manifold. Recent efforts have yielded a manifold-based model applicable to multi-modal combustion, enabling reconstruction of the thermochemical state from solutions to two-dimensional manifold equations in mixture fraction and generalized progress variable that are parameterised by three scalar dissipation rates. In coarse-grained simulations such as Large Eddy Simulation (LES), closure of the multi-modal manifold equations and subfilter variances/covariance requires closure of three filtered scalar dissipation rates. Here, the present work adopts a data-based approach, providing closure for the three filtered scalar dissipation rates via deep neural networks (DNNs). High-fidelity datasets corresponding to an autoigniting n-dodecane jet flame and a bluff body swirl-stabilized confined lifted spray flame of two aviation fuels (Jet-A and C1) with different ignition propensities are leveraged to generate training data that spans a diverse range of thermodynamic conditions and combustion modes, including low- and high-temperature ignition regimes in addition to premixed and nonpremixed behaviour. A final DNN model is trained to enforce inherent physical constraints by learning nonlinear functional transformations of the three filtered scalar dissipation rates. The generalizability of this constrained DNN model is demonstrated a priori via conditional statistics evaluated on the lifted spray flame with C1–a configuration that had not been included in the training data. Excellent DNN agreement with conditional DNS statistics is observed, and integrated gradients are computed to identify the most sensitive input variables. The similarity of the marginal PDFs of the most informative input variables and outputs across configurations are quantified via the Wasserstein metric, demonstrating that data-based models may successfully generalize to unseen parametric conditions so long as the most informative input variables share similar distributions across training and testing datasets.

Data-based modelling↗

DOE OSTI2024

Development and Characterization of Densified Biomass-plastic Blend for Entrained Flow Gasification (Final Technical Report)

Supported by the U.S. DOE NETL Award DE-FE0032043, this project was a collaborative effort. Project participants included the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA), Biosystems and Agricultural Engineering department (UK BAE), and Wabash Valley Resources, LLC. The goal of this final technical project report is to comprehensively summarize the work conducted on project DE-FE0032043. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky (UK) (Project Prime Recipient) has developed and studied a biomass/plastic fuel with a hydrophobic surface area less than 10 m 2 /m 3 that is suitable for oxygen-blown entrained flow gasification with slurry feed. The project involved the utilization of an existing thermogravimetric analysis (TGA)-mass spectrometer (MS), 1.5” drop tube furnace, 1 ton per day (TPD) coal gasifier, and high-pressure extruder operated at UK. The pilot-scale production of blended material was done at the Polymers Technology Center in Charlotte, North Carolina. Parametric testing and solid fuel blend slurry performance validation was completed using the UK entrained flow gasifier with multiple opposed burners to narrow the major near-term technical gaps that impede gasification of biomass and carbonaceous mixed wastes such as plastics in order to achieve net-negative CO 2 emissions. Project results validated the UK approach to address the major technical challenges on the biomass/plastic pretreatment and gasification. Previously, this has been limited in application to fluidized-type or moving bed-type gasifiers due to the high-water uptake of porous biomass containing hydroxyl groups during the conventional slurry preparation, resulting in a highly viscous, un-pumpable slurry. The biomass pretreatment with plastic developed for this project demonstrates advantages in cost and flexibility, which include: 1) the development of a blended solid fuel slurry with 55-60 wt% solids and comparable heating value to 100% coal-based water slurry; 2) the collection of gasification kinetic data and identification of preliminary operating conditions by performing thermogravimetric analysis, gasification experiments by using a 1.5” drop tube furnace; and finally 3) the demonstrated gasification of the blended solid fuel in the UK entrained flow gasifier with a long-lasting stable solid fuel blend slurry, dataset detailing operating conditions, and characterization of slag phase formation and solidification. The lab-scale data and experience obtained during this project encourages the development of technologies and commercial approaches to enable a hydrogen-based energy economy while achieving net-negative CO 2 emissions through gasification of coal, biomass, and carbonaceous mixed wastes such as plastics.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Data-driven prediction of geometry- and toolpath sequence-dependent intra-layer process conditions variations in laser powder bed fusion

Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.

42 ENGINEERING↗

DOE OSTI2022

Observations on the deformation of metal microspheres in shock-driven polymer flows

We report that solid particles can be fragmented by a fast-moving fluid if their velocity difference is great enough, such as during the atmospheric entry of meteoroids or the shock compression of engineered particulate composites. The extent of particle deformation and breakup in such systems is poorly understood because the necessary extreme conditions make observation difficult and data scarce. To meet this need, experiments combining ultrafast synchrotron-based radiography with plate impact loading were performed at the dynamic compression sector at the advanced photon source. Metal microspheres of several densities and strengths (Au, Ta, and W) were placed inside a polymer matrix. A planar shock wave was then produced in the polymer by the impact of a gun-launched flyer plate. X-ray images of the resulting flow were collected at ~150ns intervals. These images document the progression of particle deformation across a range of flow conditions and particle materials. They show that the extent of deformation is sensitive to the ratio of drag stress to particle strength. The deforming particle's shape is determined by the initial shock–particle interaction, fluid stagnation pressure, and vorticity, each acting on its own timescale. A set of scaling relationships is presented to capture these observations and enable comparison with prior hydrodynamic data. The result is a framework for predicting the conditions under which strong particles are severely deformed by a shock-driven flow.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Modeling of Vertical Motor-driven Pump for Simulation of a Fault Signature \\ for Condition Monitoring

As part of the ongoing effort to transition from preventive maintenance strategies to condition-based maintenance strategies in nuclear power plants, there is significant reliance on using machine learning techniques. To develop a robust machine learning model that can diagnose all the fault modes of a vertical motor-driven pump, data capturing the unique signature of each fault mode is required. In practice, it is difficult to collect or capture data that captures all the fault modes from a single plant site. So to address this situation, a computational model of a vertical motor-driven pump is developed using the multipurpose finite element software COMSOL Multiphysics. The developed model is used to generate simulated data under normal operation and is compared with the vibration data collected using vibration sensors. Once the simulation model is verified under normal operating condition, simulated data for the fault mode for which minimal or no evidence is available in historical plant process data is developed. This simulated data is used to develop fault signatures to achieve robust predictive models. This paper presents modeling details and verification of the model that can used to generate data for fault modes that are not available at a plant site for condition monitoring purpose.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2023

Modeling of Vertical Motor-driven Pump for Simulation of a Fault Signature \\ for Condition Monitoring

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2021

TRANSIENT THERMAL MODELING OF THE HIGH BURNUP DEMONSTRATION RESEARCH PROJECT CASK USING STAR-CCM+ AND COBRA-SFS

The Department of Energy in collaboration with the Electric Power Research Institute is in the process of conducting the High Burnup Demonstration Project. Where the objective is to characterize the performance of high-burnup fuel in long term storage. As part of this demonstration, a TN-32B dry storage cask was instrumented and loaded with spent nuclear fuel at North Anna Nuclear Generating Station in November 2017. The project cask provides a unique opportunity to gain information on spent fuel and cask performance from an in-service operational system. The cask was instrumented with thermocouples inside of the fuel assemblies, then loaded and dried using normal procedures. After the drying process a thermal soak period where the cask was left indoors was used to obtain steady temperatures for model comparison along with surface temperatures. This paper details thermal modeling validation work that was done to model both the steady state and transient cases. Two modeling tools were used to predict temperatures in the cask. The general purpose CFD and heat transfer code STAR-CCM+ was used with both a detailed pin-by-pin model was used along with a more efficient k-effective simplification. The other code is COBRA-SFS, a purpose-built detailed thermal modeling tool developed and maintained at PNNL. Results from all the modeling tools were compared blind to the test data. Each model utilized general design information and compared reasonably well to the blind steady state data using convection and surface temperature boundary conditions. Post-test adjustments were later made to better reflect the “as built” conditions of the cask. Based on lessons learned from the steady state analysis the vacuum drying process was modeled in both codes. Utilizing the measured loading conditions the transient models were able to compare very well with the measured data. Overall the project showed an ability to model spent fuel storage conditions very well and future work is planned to generalize the methodology used for vacuum drying.

Thermal Analysis, Spent Fuel, Dry Storage↗

DOE OSTI2021

Development of Real-Time, In-pile Creep Test Rigs for Characterizing the Structural Materials of Nuclear Components

New and improved materials are being considered for supporting both existing and next-generation nuclear reactors. Reactor materials can significantly degrade with time, thus limiting or altering their properties in harsh reactor environments. To accurately understand such material degradation, real-time data obtained under prototypic irradiation conditions are required. In particular, understanding the creep behavior of materials exposed to irradiation and elevated temperatures is essential for safety concern evaluations. To provide these capabilities, Idaho National Laboratory (INL)’s High Temperature Test Laboratory (HTTL) developed several instrumented test rigs for obtaining real-time data from specimens in well-controlled pressurized-water reactor (PWR) coolant conditions at the Materials Test Reactor. This technical report focuses on INL’s efforts to evaluate and enhance the former creep test rig prototype that relied on linear variable differential transformers in laboratory settings. Specifically, the test rig can detect changes in the length of creep specimens, which is useful for measuring thermal expansion and creep deformation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Oceanographic Conditions. 2007 - 2040. North Slope Alaska.

Complete representations of oceanographic conditions require spatial and temporal information about the significant wave height (Hs), peak wave period (Tp), wind speed, wind direction, wave direction, water level, salinity, and temperature. This data develops location-independent typologies to reduce the number of boundary conditions needed to assess nearshore oceanographic environments in both a Historical (2007-2019) and Future (2020-2040) timespan along the Alaskan North Slope. Wave information for both time spans were generated from WaveWatch III, Delft3D-FLOW, and Delft3D-WAVE simulations forced by wind conditions from reanalysis data (e.g., ASRv2 and ERA5) for the historical simulations while projected conditions were obtained from downscaled GFDL-CM3 forced under RCP8.5 conditions. Salinity was generated from GOFS 3.1 for the years between 2008-2015 and skin temperature of the ocean was obtained from ASRv2 reanalysis data for the years between 2007-2016. To identify generalized oceanographic typologies, K-means clustering was applied to the energy-weighted joint-probability distribution of Hs and Tp at six sites along the North Slope of Alaska. Distributions of wave and wind direction, wind speed, and water level associated with locaiton-indepndent centroids were assigned single values to describe a reduced order, typological rendition of offshore oceanographic conditions. These final typologies and their constituent data are provided here and can be used to evaluate the change in ocean energy over the next two decades in response to climate change and provide insight into expected consequences such as coastal erosion and flooding. A full assessment of the findings and techniques developed can be found in: Eymold, W.K., Flanary, C., Erikson, L., Nederhoff, K., Chartrand, C.C., Jones, C., Kasper, J., and Bull, D.L. Typological Representation of the Offshore Oceanographic Environment along the Alaskan North Slope. Continental Shelf Research (2022). 10.1016/j.csr.2022.104795

54 ENVIRONMENTAL SCIENCES↗