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DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

42 ENGINEERING↗

DOE OSTI2022

Tracer-field cross-correlations with k -nearest neighbour distributions

ABSTRACT In astronomy and cosmology significant effort is devoted to characterizing and understanding spatial cross-correlations between points – e.g galaxy positions, high energy neutrino arrival directions, X-ray and AGN sources, and continuous fields – e.g. weak lensing meiand Cosmic Microwave Background maps. Recently, we introduced the k-nearest neighbour (kNN) formalism to better characterize the clustering of discrete (point) data sets. Here, we extend it to the point – field cross-correlations analysis. It combines kNN measurements of the point data set with measurements of the field smoothed at many scales. The resulting statistics are sensitive to all orders in the joint clustering of the points and the field. We demonstrate that this approach, unlike the 2-pt cross-correlation, can measure the statistical dependence of two data sets even when there are no linear (Gaussian) correlations between them. We further demonstrate that this framework is far more effective than the two point function in detecting cross-correlations when the continuous field is contaminated by high levels of noise. For a particularly high level of noise, the cross-correlation between haloes and the underlying matter field in a cosmological simulation, between 10 h−1 Mpc and 30 h−1 Mpc, is detected at >5σ significance using the technique presented here, when the two-point cross-correlation significance is ∼1σ. Finally, we show that kNN cross-correlations of haloes and the matter field can be well modelled on quasi-linear scales using the Hybrid Effective Field Theory (HEFT) framework, with the same set of bias parameters as are used for 2-pt cross-correlations. The substantial improvement in the statistical power of detecting cross-correlations using this method makes it a promising tool for various cosmological applications.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Efficient Contingency Analysis in Power Systems via Network Trigger Nodes

Modeling failure dynamics within a power system is a complex and challenging process due to multiple inter-dependencies and convoluted inter-domain relationships. Subject matter experts (SMEs) are interested in understanding these failure dynamics for reducing the impact from future disasters (i.e., losses or failures of power system components, such as transmission lines). Contingency analysis (CA) tools enable such ’what-if’ scenario analyses to evaluate the impacts on the power system. Analyzing all possible contingencies among N system components can be computationally expensive. An important step for performing CA is identifying a set of k ‘trigger’ components, which when failed initially can significantly impact the overall system by causing multiple failures. Currently SMEs focus on identifying these trigger components by running expensive simulations on all possible subsets, which quickly becomes infeasible. Hence finding a relevant set of trigger components (contingencies) rapidly to enable efficient and useful CA is crucial.In a collaboration between computer scientists and power system experts, we propose an efficient method for performing CA by exploiting network inter-dependencies in power system components. First, we construct a network with multiple electric grid infrastructure components and dependencies as connections among them. We reformulate the problem of finding a set of trigger components as a problem of identifying critical nodes in the network, which can cascade power failures through connected nodes and cause significant damage to the network. To guide the practical CA tools, we develop a network-based model with a probabilistic edge-weights setup using intricate domain rules. Then we conduct an empirical study on real power system data in the US for both regional and national levels. Firstly, we use power system datasets for the US to create a national-scale domain-driven model. Secondly, we demonstrate that network-based model outperforms the outputs from a real CA tool and show on average 25 × improved selection of contingencies, thereby showcasing practical benefits to the power experts.

Tabassum, Anika↗

DOE OSTI2023

An Overview of the Risk Assessment Information System

This technical memorandum (TM) presents an overview of the Risk Assessment Information System (RAIS), a collection of web-based tools designed to assist with the environmental risk assessment process. The objective of the RAIS is to be a single resource for the risk assessment process, providing guidance when planning and performing the steps: data assessment, exposure assessment, toxicity assessment, and risk characterization. The RAIS evolved as a result of the initial remediation efforts at various United States (U.S.) Department of Energy (DOE) facilities. The goal was to increase the efficiency and transparency of the human health and ecological assessments being performed by DOE’s Office of Environmental Management, Oak Ridge Operations (ORO) office by providing a repository for toxicity information, physicochemical data, risk assessment procedures, standardized risk calculation methods, and web-based tools. Since the initial launch in 1996, the RAIS has expanded its user base outside of the federal government and now has users from over 100 countries, universities, states, and local governments. What sets the RAIS apart from other risk assessment sites are the publicly available, searchable toxicity and physicochemical databases and the wide range of chemical and radionuclide risk calculation tools. The purpose of this TM is to present the RAIS tools in order of the website menus and explain how they fit in the risk assessment process. In addition, this TM describes differences between the chemical and radionuclide tools of the RAIS. Screening level equations, chronic daily intake equations, and default exposure factors used in the chemical and radionuclide calculators are included in the appendices of this TM. This TM is not intended to be a detailed guide to risk assessment or the RAIS tools. The tools on the RAIS can be used to comply with procedures from multiple agencies, including but not limited to DOE, U.S. Environmental Protection Agency (EPA), U.S. Department of Defense (DoD), and many state governments. Further information on the RAIS tools can be found in the user guides and tutorials available on the webpage.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2021

Electronic Structure Theory Calculations Using Modern Architectures: KNL vs Haswell

The time to solution and parallel efficiency of several commonly used electronic structure methods (Hartree–Fock, density functional theory, second order perturbation theory, resolution of the identity second order perturbation theory, coupled cluster) are evaluated on both the Intel Xeon Haswell and the Intel Xeon Phi Knights Landing (KNL) architectures. The Haswell completes the benchmark calculations with a faster time to solution than the KNL for all molecules and methods tested. While the Haswell exhibits an average speedup of at least 3.5 relative to the KNL for all nonthreaded computations, the KNL has a better parallel efficiency than the Haswell with increasing core counts. The architectures are further tested using a more computationally costly coupled cluster method on a transition state reaction. The Haswell appears to be the best choice to minimize the time to solution, though for very large systems and high levels of theory that require memory intensive processes the superior memory hierarchy and larger on node memory of the KNL can make it a better choice. These results are used to showcase aspects of novel architectures that will increase efficiency for quantum chemistry applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Multilevel graph embedding

The goal of the present paper is the design of embeddings of a general sparse graph into a set of points in $\mathbb{R}^d$ for appropriate d ≥ 2. The embeddings that we are looking at here aim to keep vertices that are grouped in communities together and keep the rest apart. To achieve this property, we utilize coarsening that respects possible community structures of the given graph. We employ a hierarchical multilevel coarsening approach that identifies communities (strongly connected groups of vertices) at every level. The multilevel strategy allows any given (presumably expensive) graph embedding algorithm to be made into a more scalable (and faster) algorithm. We demonstrate the presented approach on a number of given embedding algorithms and large-scale graphs and achieve speed-up over the methods in a recent paper.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Mass generation in an Abelian gauge theory with multiple scalar fields and no tree-level dimensionful couplings

We study the Abelian Higgs model with multiple scalar fields, but without mass terms. Solving the model nonperturbatively order-by-order in the number of scalar fields, we find that radiative corrections generate masses for the scalar and gauge boson, without spontaneous symmetry breaking. The mass scales are set by the Λ -parameter of the electroweak running coupling, thereby naturally avoiding the hierarchy problem. No part of our calculation employs a weak-coupling expansion, and we find that the perturbative vacuum is metastable, and hence must decay to the stable nonperturbative vacuum of the theory, which we identify. Although the field content of our Lagrangian is standard, our results predict the existence of two heavy scalar resonances in addition to the Higgs. We believe that these predicted resonances will ultimately allow experimentalists to discriminate between our method and standard solutions of the Higgs model. Published by the American Physical Society 2024

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Coherency-Constrained Spectral Clustering for Power Network Reduction

This paper presents a methodology for reducing the complexity of large-scale power network models using spectral clustering, aggregation of electrical components, and cost function approximation. Two approaches are explored using unconstrained and constrained spectral clustering to determine areas for effective system reduction. Once the system areas are determined, both loads and generators by type are aggregated, and their new cost function is approximated through polynomial curve-fitting or statistical methods. The performance of reduced networks is evaluated in terms of their ability to follow the true daily cost of the original system over a 24-hour period considering a set of several days. Two test systems are taken as test beds. Application of the methodology to a modified version of the IEEE 39-bus system reduces it from 17 generators to a 4-bus system and 9 generators with about 93% of accuracy. Similarly, the IEEE 118-bus system is reduced from 19 generators to a 3-bus system with three aggregated units achieving over 99% of accuracy. These findings address scalability challenges and enhance accuracy for high and mid-loading level conditions, and by aggregating thermal units with similar cost functions.

42 ENGINEERING↗

DOE OSTI2021

Single-Site Metal Organic Complexes on Oxide Supports for Selective Alkane Functionalization

High levels of reaction selectivity for heterogeneous catalysis are generally difficult to achieve with traditional metal nanoparticle catalysts, due to the variety of metal binding sites available. In this project, we have developed a metal-ligand coordination strategy to form transition metal single-sites on high surface area supports as heterogeneous single-site catalysts. Metal centers can be atomically dispersed in the binding pockets of organic ligands on oxide supports. The systems have to be carefully designed so that tendencies for metal cluster formation or binding to surface defect sites are overcome by the attractive coordination environment provided by the organic ligand. This was confirmed by a comprehensive set of characterization methods, including XAS, XPS, XRD, TEM, and CO adsorption. Design and tuning of metal-support and support-ligand interactions were crucial for high structural uniformity. We demonstrate that supported metal-ligand SSCs are effective, recyclable catalysts for alkene hydrosilylation reactions. Compared with commercial homogeneous catalysts, they exhibit improved yield and selectivity, less metal aggregation and side reactions, and stronger tolerance with functionalized substrates. These results give some preliminary indication that coordination with organic ligands can improve activity and selectivity in metal/oxide heterogeneous catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Underwater Noise Measurements around a Tidal Turbine in a Busy Port Setting

Acoustic emissions from current energy converters remain an environmental concern for regulators because of their potential effects on marine life and uncertainties about their effects stemming from a lack of sufficient observational data. Several recent opportunities to characterize tidal turbine sound emissions have begun to fill knowledge gaps and provide a context for future device deployments. In July 2021, a commercial-off-the-shelf hydrophone was deployed in a free-drifting configuration to measure underwater acoustic emissions and characterize a 25 kW-rated tidal turbine at the University of New Hampshire’s Living Bridge Project in Portsmouth, New Hampshire. Sampling methods and analysis were performed in alignment with the recently published IEC 62600-40 Technical Specification for acoustic characterization of marine energy converters. Results from this study indicate acoustic emissions from the turbine were below ambient sound levels and therefore did not have a significant impact on the underwater noise levels of the project site. As a component of Pacific Northwest National Laboratory’s Triton Field Trials (TFiT) described in this Special Issue, this effort provides a valuable use case for the IEC 62600-40 Technical Specification framework and further recommendations for cost-effective technologies and methods for measuring underwater noise at future current energy converter project sites.

tidal turbine↗

DOE OSTI2023

Unbalanced Nested Random Effects Estimation of Variance Components

To investigate the contributing factors of variance in the measurement of an iodine 127 (127I) sample, we implement a nested random effects analysis of variance (ANOVA). Historically, the reported uncertainty on a measurement of 127I has been obtained by methods of forward uncertainty propagation because there is typically only one replicate of a given sample for which to estimate the uncertainty. When samples are processed there are several types of quality control (QC) standards analyzed along-side the unknown samples with two to five replicates for each. Assuming the variance observed in these replicate QC standards is representative of that of the unknown samples, we use these data in a nested random effects ANOVA to estimate the total uncertainty of a measurement. We demonstrate this approach with two sets of measurements from Idaho National Laboratory and compare the results with the forward uncertainty propagation approach. Variance component estimates for the coarsest level of the nesting structure were most imprecise because replicates were most limited at these levels. We find that the results largely agree between forward propagation and ANOVA, and the greatest contributors of variance are due to instrument variation and chemical processing, with human processing being among the smallest contributors. This analysis provides reassurance that the reported uncertainties using forward propagation are reasonable and the process is well controlled. We propose a future designed experiment to increase replicates at the coarsest level of the hierarchy to improve estimates of these variance components.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Scalable line and plane relaxation in a parallel structured multigrid solver

The efficient solution of sparse, linear systems that arise through the discretization of partial differential equations remains a key challenge for a range of high performance scientific simulations. One approach for reducing data movement and improving performance is by exposing and exploiting structure in a problem through the use of robust structured multilevel solvers. By choosing coarsening that preserves the structure of the problem, these methods maintain efficient structured computation and communication throughout the multigrid hierarchy. However, when coarsening is not permitted to be dependent on the operator, anisotropy must be addressed by the smoother — producing error compatible for coarse-grid correction with structured coarsening. Here, the components required in a scalable parallel structured solver are described with a focus on memory and communication efficiency of robust smoothers. While the implementation of communication and memory reduction techniques in smoothers integrated in a complete 3D solver present a significant engineering challenge, a novel approach is proposed that addresses these challenges systematically through a change to the solver’s execution model. Enabled by user-level threading paired with a set of data and communication abstractions, this approach permits seamless aggregation of communication in plane smoothers — directly reusing code for a 2D distributed multilevel cycle. Results show an effective reduction in communication costs for coarse-grid problems, and result in a speedup of 8.7x in smoothing routines shown in Fig. 12 using this approach. This produces a significant improvement to strong scalability while maintaining favorable weak scaling behavior. Finally, a parallel scaling study using a series of refined meshes is included that demonstrates the effectiveness of this approach in an application of interest.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

A Technology Roadmap for Advanced Geothermal Well Construction

Recent analysis has shown that by 2050, geothermal energy can supply up to 90 GW of power to the U.S. electrical grid. Reducing the lifecycle cost of geothermal wells is critical to achieving this level of adoption. While time-related costs of drilling remain an important issue, there is also a need to focus on the costs associated with casing and cementing of geothermal wells. This report provides a roadmap of R&D activities needed to reduce the life cycle cost of casing and cementing while improving life-of-well performance. The purpose of the roadmap is to develop priorities for R&D in the areas of (1) high-performance and cost-effective materials for target geothermal well conditions, (2) well construction methods and techniques to reduce construction costs, and (3) methods and techniques to decrease to decrease long-term operating costs. The roadmap sets targets for the next 10-year period and purposely excludes R&D efforts into improved rock reduction. The roadmap was developed by a joint working group of experts from Oak Ridge National Laboratory, Brookhaven National Laboratory, and Sandia National Laboratories as well as 35 experts from industry and academia. Input from a series of information gathering sessions was used to inform and guide the development of the roadmap.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

A Load Switching Group based Feeder-level Microgrid Energy Management Algorithm for Service Restoration in Power Distribution System

This paper presents a load switching group based energy management system (LSG-EMS) for operating microgrids on a distribution feeder powered by one or multiple grid-forming distributed energy resources. Loads on a distribution feeder are divided into load switching groups that can be remotely switched on and off. The LSG-EMS algorithm, formulated as a mixed-integer linear programming (MILP) problem, has an objective function of maximizing the served loads while minimizing the total number of switching actions. A new set of topology constraints are developed for allowing multiple microgrids to be formed on the feeder and selecting the optimal supply path. Customer comfort is accounted for by maximizing the supply duration in the customer preferred service period and enforcing a minimum service duration. The proposed method is demonstrated on a modified IEEE 33-bus system using actual customer data. Simulation results show that the LSG-EMS successfully coordinates multiple grid-forming sources by selecting an optimal supply topology that maximizes the supply period of both the critical and noncritical loads while minimizing customer service interruptions in the service restoration process.

Hu, Rongxing↗

DOE OSTI2022

Disentangling long and short distances in momentum-space TMDs

The extraction of nonperturbative TMD physics is made challenging by prescriptions that shield the Landau pole, which entangle long- and short-distance contributions in momentum space. The use of different prescriptions then makes the comparison of fit results for underlying nonperturbative contributions not meaningful on their own. We propose a model-independent method to restrict momentum-space observables to the perturbative domain. This method is based on a set of integral functionals that act linearly on terms in the conventional position-space operator product expansion (OPE). Artifacts from the truncation of the integral can be systematically pushed to higher powers in Λ QCD /k T . We demonstrate that this method can be used to compute the cumulative integral of TMD PDFs over k T ≤ k$^{cut}_{T}$ in terms of collinear PDFs, accounting for both radiative corrections and evolution effects. This yields a systematic way of correcting the naive picture where the TMD PDF integrates to a collinear PDF, and for unpolarized quark distributions we find that when renormalization scales are chosen near k$^{cut}_{T}$, such corrections are a percent-level effect. We also show that, when supplemented with experimental data and improved perturbative inputs, our integral functionals will enable model-independent limits to be put on the non-perturbative OPE contributions to the Collins-Soper kernel and intrinsic TMD distributions.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

CarbStor: Development, Analysis and Modification of Carbon Storing Model Soil Communities

Soil microbial communities carry out a number of key processes including plant growth promotion, bioremediation and cycling of nutrients. Carbon cycling is among the most important of these nutrients that are metabolized and processed by the soil microbial community. Many of the carbon inputs are converted to alternative organic forms of carbon that can be used by plants or act as biomass for microbial growth. However, inorganic forms of carbon can also be produced by soil microbial communities including calcium carbonate (CaCO 3 ). Production of calcium carbonate is beneficial for the ecosystem in several ways: it can stabilize soils and improve soil health, especially denser soils with high clay content, it can act as a method of bioremediation, it can serve as an alternative carbon source for plants and it can be a way to store carbon in soil in a stable, inorganic manner for the long term. While the chemistry surrounding individual species carrying out this process is well known what is lacking is an understanding of how species interact in a community to drive carbonate production. As all microbial species in soil exist in a community setting gaining this knowledge is critical to our predicting and controlling this microbial phenotype to greatly improve soil health. The CarbStor project is focused on developing, analyzing and modifying defined microbial soil consortia that express phenotypes at both the species and community level to convert carbon into recalcitrant stable sources such as precipitated carbonate or microbial necromass. To take full advantage of the soil community for this process we will need to fill several key knowledge gaps (KG), three of which are the focus of CarbStor. KG1: Whether and to what degree microbial communities can be developed that produce precipitated carbon via microbial metabolism. KG2: What interspecies interactions drive the individual member phenotypes in defined communities that lead to carbon precipitation. KG3: How can these interactions be modified to enhance carbon sequestration beyond what native communities are capable of. We hypothesize that in a carbon sequestering community only a subset of species will express phenotypes related to carbon storage processes. We also hypothesize that these phenotypes are expressed as a result of interactions with other species in the community that are not involved in carbon storage processes and that these interactions can be harnessed to enhance community carbon sequestration.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

A theoretical investigation of the hydrolysis of uranium hexafluoride: the initiation mechanism and vibrational spectroscopy

Depleted uranium hexafluoride (UF 6 ), a stockpiled byproduct of the nuclear fuel cycle, reacts readily with atmospheric humidity, but the mechanism is poorly understood. Here we compare several potential initiation steps at a consistent level of theory, generating underlying structures and vibrational modes using hybrid density functional theory (DFT) and computing relative energies of stationary points with double-hybrid (DH) DFT. A benchmark comparison is performed to assess the quality of DH-DFT data using reference energy differences obtained using a complete-basis-limit coupled-cluster (CC) composite method. The associated large-basis CC computations were enabled by a new general-purpose pseudopotential capability implemented as part of this work. Dispersion-corrected parameter-free DH-DFT methods, namely PBE0-DH-D3(BJ) and PBE-QIDH-D3(BJ), provided mean unsigned errors within chemical accuracy (1 kcal mol -1 ) for a set of barrier heights corresponding to the most energetically favorable initiation steps. The hydrolysis mechanism is found to proceed via intermolecular hydrogen transfer within van der Waals complexes involving UF 6 , UF 5 OH, and UOF 4 , in agreement with previous studies, followed by the formation of a previously unappreciated dihydroxide intermediate, UF 4 (OH) 2 . The dihydroxide is predicted to form under both kinetic and thermodynamic control, and, unlike the alternate pathway leading to the UO 2 F 2 monomer, its reaction energy is exothermic, in agreement with observation. Finally, harmonic and anharmonic vibrational simulations are performed to reinterpret literature infrared spectroscopy in light of this newly identified species.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Multivariate analysis: An essential for studying complex glasses

Understanding the impact of individual compositional components on the devitrification of complex multicomponent glasses, for example, 10–50+ oxides, typically requires numerous studies to examine each component's impact. Here we apply exploratory data analysis (EDA) to a heterogeneous data set of silicate glasses to determine the cations’ individual and interacting effects on the crystallization of nepheline (nominally NaAlSiO 4 ). Our data consisted of 795 simulated high-level nuclear waste glasses composed of, on average, 50 oxide components. We determine the interactions in the heterogeneous data that cause deviations from the behavior found in simplified composition studies. Using both univariate and bivariate EDA techniques, we demonstrate the importance of including calculated structural glass parameters on nepheline's devitrification, including field strength, cation-to-anion radius ratio, and single-bond strength. Here, we also show that studies with simplified glass compositions may fall short in generating knowledge directly transferrable to complex glass compositions. The method used in this study has the potential to inform experimental design for simplified compositions (~6+ oxides) that can generate knowledge directly transferrable to complex, multivariable compositions. The observations reported here have broad implications for any study attempting to map the physical properties of a complex glass containing numerous cations.

36 MATERIALS SCIENCE↗