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At least 649 records · Page 36

Processes for fabricating composite reinforced material

A family of materials wherein nanostructures and/or nanotubes are incorporated into a multi-component material arrangement, such as a metallic or ceramic alloy or composite/aggregate, producing a new material or metallic/ceramic alloy. The new material has significantly increased strength, up to several thousands of times normal and perhaps substantially more, as well as significantly decreased weight. The new materials may be manufactured into a component where the nanostructure or nanostructure reinforcement is incorporated into the bulk and/or matrix material, or as a coating where the nanostructure or nanostructure reinforcement is incorporated into the coating or surface of a "normal" substrate material. The nanostructures are incorporated into the material structure either randomly or aligned, within grains, or along or across grain boundaries.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Joining and reinforcing a composite bumper beam and a composite crush can for a vehicle

A front bumper beam and crush can (FBCC) system is provided for a vehicle. A bumper beam has an interior surface with a plurality of ribs extending therefrom. The ribs and the interior surface are made of a chopped fiber composite and cooperate to engage a crush can. The chopped fiber composite reinforces the engaging surfaces of the crush can and the interior surface of the bumper beam. The crush can has a tubular body made of a continuous fiber composite. The crush can has outwardly-extending flanges at an end spaced away from the bumper beam. The flanges are at least partially provided with a layer of chopped fiber composite to reinforce a joint between the outwardly-extending flange and the vehicle frame.

33 ADVANCED PROPULSION SYSTEMS↗

Thin-walled reinforcement lattice structure for hollow CMC buckets

A hollow ceramic matrix composite (CMC) turbine bucket with an internal reinforcement lattice structure has improved vibration properties and stiffness. The lattice structure is formed of thin-walled plies made of CMC. The wall structures are arranged and located according to high stress areas within the hollow bucket. After the melt infiltration process, the mandrels melt away, leaving the wall structure to become the internal lattice reinforcement structure of the bucket.

47 OTHER INSTRUMENTATION↗

Rheological Characteristics of Fiber Reinforced Poly(Ether Ketone Ketone) (PEKK) for Melt Extrusion Additive Manufacturing

Several grades of unreinforced and short fiber reinforced poly(ether ketone ketone) (PEKK) copolymers are analyzed for their potential use as feedstock materials in melt extrusion-based additive manufacturing (AM) systems. Rheological characterization has been performed to study the effect of extrusion processing parameters such as time, temperature, environment, and shear rate for the selected materials. The effect of reinforcing filler content on the melt processing conditions of PEKK composites are also reported, and processing conditions for successful extrusion of these materials on AM systems are determined.

Kishore, Vidya↗

Optimizing thermodynamic trajectories using evolutionary reinforcement learning

Using a model heat engine we show that neural network-based reinforcement learning can identify thermodynamic trajectories of maximal efficiency. We use an evolutionary learning algorithm to evolve a population of neural networks, subject to a directive to maximize the efficiency of a trajectory composed of a set of elementary thermodynamic processes; the resulting networks learn to carry out the maximally-efficient Carnot, Stirling, or Otto cycles. Given additional irreversible processes this evolutionary scheme learns a hitherto unknown thermodynamic cycle. Our results show how the reinforcement learning strategies developed for game playing can be applied to solve physical problems conditioned upon path-extensive order parameters.

97 MATHEMATICS AND COMPUTING↗

The Influence of Rheology on Melt Processing Conditions of Carbon Fiber Reinforced Polyetherimide for Big Area Additive Manufacturing

An approach is presented for determining the melt processing conditions of high temperature amorphous thermoplastics, specifically carbon fiber reinforced polyetherimide (PEI), for Big Area Additive Manufacturing (BAAM). PEI is a high performance thermoplastic that is attractive for various high temperature applications in the automotive and aircraft industry. For PEI to be processed successfully with BAAM, it must be stable over a range of temperatures and print conditions to ensure the final part possesses the desired strength and modulus. Under this approach, thermal properties are first analyzed to identify the lower and upper operating limits for the polymer and then extensive rheological characterization is carried out at selected temperatures within these bounds. This study investigates the effect of temperature, fiber loading, and processing environment on rheology in order to identify suitable process parameters for extruding carbon-fiber reinforced PEI on BAAM.

Ajinjeru, Christine↗

Reinforcement-based Program Induction in a Neural Virtual Machine

We present a neural virtual machine that can be trained to perform algorithmic tasks. Rather than combining a neural controller with non-neural memory storage as has been done in the past, this architecture is purely neural and emulates tape-based memory via fast associative weights (onestep learning). Here we formally define the architecture, and then extend the system to learn programs using recurrent policy gradient reinforcement learning based on examples of program inputs labeled with corresponding output targets, which are compared against actual output to generate a sparse reward signal. We describe the policy gradient training procedure used, and report its empirical performance on a number of smallscale list processing tasks, such as finding the maximum list element, filtering out certain elements, and reversing the order of the elements. These results show that program induction via reinforcement learning is possible using sparse rewards and solely neural computations.

Katz, Garrett E.↗

Fiber Orientation Evaluation in Reinforced Composites using Digital Image Correlation

This paper presents an innovative nondestructive evaluation (NDE) approach to evaluate fiber orientation in fiber reinforced composites utilizing digital image correlation (DIC). Fiber orientation is a crucial factor that influences the mechanical and thermal properties of the composite. Conventional methods for fiber orientation evaluation and measurement are either destructive, which are typically laborious. NDE methods such as micro computed tomography are expensive and limited in sample size. In this work, we evaluate two methods of excitation of the composite, namely-quasistatic mechanical loading and thermal cycling. Digital Image Correlation (DIC) has been employed in conjunction for fiber orientation measurements. The DIC system is able to measure the fiber orientation by capturing 19x higher strain in the transverse direction of the reinforced fiber axis during excitation. The larger strain occurs in the transverse direction due to larger elongation in the surrounding polymer matrix than the fiber which resists elongation. This innovative method is within the preliminary stage and has been developed to fill the gap/limitations of other NDE methods.

Spencer, Ryan↗

Silicon carbide reinforced zirconium based cladding

A method for making an improved nuclear fuel cladding tube includes reinforcing a Zr alloy tube by first winding or braiding ceramic yarn directly around the tube to form a ceramic covering, then physically bonding the ceramic covering to the tube by applying a first coating selected from the group consisting of Nb, Nb alloy, Nb oxide, Cr, Cr oxide, Cr alloy, or combinations thereof, by one of a thermal deposition process or a physical deposition process to provide structural support member for the Zr tube, and optionally applying a second coating and optionally applying a third coating by one of a thermal deposition process or a physical deposition process. If the tube softens at 800° C.-1000° C., the structural support tube will reinforce the Zr alloy tube against ballooning and bursting, thereby preventing the release of fission products to the reactor coolant.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Mold and method for molding a reinforced preform

A mold for molding a reinforced preform having at least two apertures therein includes first and second mold halves, first and second emitters disposed in the mold halves and configured to emit light therefrom, first and second receivers disposed in the mold halves and configured to receive light from the respective first and second emitters, and first and second moving members having couplings for connection with side portions of the reinforced preform and actuators for moving the couplings between respective first and second positions. A controller determines an alignment condition based on signals received from the receivers. If the alignment condition fails to meet predetermined criteria, then at least one of the actuators is caused to move its coupling from its respective first position to a respective adjusted position that is different from the respective second position.

Rodgers, William R.↗

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades: Preprint

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their tidal turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. Instead, it was infused with a novel, infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermos-mechanical characterization, and evaluation of material performance in marine environments, to understand the key differences between the fiberglass reinforced epoxy and Elium composites used for the respective rotors. Matrix burnoff tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period, however, it was determined that the Elium laminates had higher diffusion coefficients, so initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while taking periodic mass measurements. The datasets were extrapolated out to assume a full 20 year operational life span and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades

In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three deployed rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system (Elium from Arkema). Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.

composite manufacturing↗

CDRL: Certification-Driven Reinforcement Learning for Neutrino Flavor Model Discovery

Many scientific discovery problems require searching combinatorial hypothesis spaces under complex domain constraints. Reinforcement learning (RL) offers a promising approach, but existing methods rely on scalar rewards that provide limited information about why candidate solutions fail, leading agents to repeatedly explore invalid regions. We introduce Certification-Driven Reinforcement Learning (CDRL), a framework that leverages structured feedback from symbolic reasoning tools. When a candidate violates domain constraints, these tools produce certificates identifying the actions responsible for failure. CDRL converts these certificates into reusable constraints that eliminate classes of invalid solutions and guide exploration toward valid regions. We evaluate CDRL on neutrino flavor model discovery in theoretical particle physics, where the hypothesis space exceeds $10^{26}$ possible models, and compare it with the state-of-the-art RL approach previously used for this task. Across three theory spaces, CDRL achieves up to 1.95$\times$ higher valid model rates and up to 6.33$\times$ higher neutrino model rates while evaluating up to 4$\times$ fewer candidates. We further extract 40 interpretable rules from search trajectories using a post-hoc decision-tree framework and show that reusing them as soft constraints yields gains of up to 2$\times$ in valid model rates and 3$\times$ in neutrino model discovery across all three theory spaces. These results suggest that CDRL uncovers reusable structure in combinatorial search spaces and provides a general framework for scientific model discovery.

Jha, Piyush [Georgia Tech., Atlanta; Georgia Tech]↗

A Physics-Informed Reinforcement Learning Framework for Economic-Thermal Co-Optimization of Crypto Mining Data Centers: Preprint

The rapid expansion of cryptocurrency mining has created a new class of high-density data centers characterized by extreme thermal flux and high sensitivity to volatile economic markets. Traditional thermal management strategies, typically reliant on rule-based control, maintain static setpoints that fail to account for fluctuating electricity prices and cryptocurrency values - factors critical to mining profitability. To address this, we present a physics-informed reinforcement learning (PIRL) framework for economic-thermal co-optimization in crypto mining data centers. This framework consists of a proximal policy optimization (PPO) agent, a virtual testbed powered by high-fidelity physics-based models, and an interactive frontend dashboard. The PPO agent is trained using the virtual testbed and strict hardware safety limits. This physics-informed approach allows the agent to learn a stochastic policy that dynamically balances mining revenue against operational costs by co-optimizing HVAC cooling setpoints and IT computational hashrate. The simulation results demonstrate that the integrated framework achieved an 8.62% increase in net operational profit compared to traditional baseline strategies while strictly adhering to safety-critical temperature constraints (coolant supply temperature < 32 degrees C). This work provides a scalable template for the deployment of reinforcement learning in mission critical facilities where economic volatility and physical safety must be managed simultaneously.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Build optimization of fiber-reinforced additively manufactured components

Additive manufacturing (AM) is enabling the fabrication of artifacts with unprecedented geometric and material complexity. The focus of this paper is on the build the optimization of short fiber reinforced polymers (SFRP) AM components. Specifically, we consider optimization of the build direction, topology, and fiber orientation of SFRP components. All three factors have a significant impact on the functional performance of the printed part. While significant progress has been made on optimizing these independently, the objective of this paper is to consider all three factors simultaneously and explore their interdependency, within the context of thermal applications. Towards this end, the underlying design parameters are identified, appropriate sensitivity equations are derived, and a formal optimization problem is posed as an extension to the popular Solid Isotropic Material with Penalization (SIMP). Results from several numerical experiments are presented, highlighting the impact of build direction, topology, and fiber orientation on the performance of SFRP components.

42 ENGINEERING↗

Nuclear microreactor transient and load-following control with deep reinforcement learning

The economic feasibility of nuclear microreactors will depend on minimizing operating costs through advancements in autonomous control, especially when these microreactors are operating alongside other types of energy systems (e.g., renewable energy). This study explores the application of deep reinforcement learning (RL) for real-time drum control in microreactors, exploring performance in regard to load-following scenarios. By leveraging a point kinetics model with thermal and xenon feedback, we first establish a baseline using a single-output RL agent, then compare it against a traditional proportional–integral–derivative (PID) controller. This study demonstrates that RL controllers, including both single- and multi-agent RL (MARL) frameworks, can achieve similar or even superior load-following performance as traditional PID control across a range of load-following scenarios. In short transients, the RL agent was able to reduce the tracking error rate in comparison to PID by one half to one third. Over extended 300-minute load-following scenarios in which xenon feedback becomes a dominant factor, PID maintained better accuracy, but RL still remained within a 1% error margin despite being trained only on short-duration scenarios. This highlights RL’s strong ability to generalize and extrapolate to longer, more complex transients, affording substantial reductions in training costs and reduced overfitting. Furthermore, when control was extended to multiple drums, MARL enabled independent drum control as well as maintained reactor symmetry constraints without sacrificing performance---an objective that standard single-agent RL could not learn. We also found that, as increasing levels of Gaussian noise were added to the power measurements, the RL controllers were able to maintain lower error rates than PID, and to do so with at least 10% and upwards of 150% less control effort. These findings illustrate RL's potential for autonomous nuclear reactor control, laying the groundwork for future integration into high-fidelity simulations and experimental validation efforts.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Reinforcement Learning-Guided Long-Timescale Simulation of Hydrogen Transport in Metals

Diffusion in alloys is an important class of atomic processes. However, atomistic simulations of diffusion in chemically complex solids are confronted with the timescale problem: the accessible simulation time is usually far shorter than that of experimental interest. In this work, long-timescale simulation methods are developed using reinforcement learning (RL) that extends simulation capability to match the duration of experimental interest. Two special limits, RL transition kinetics simulator (TKS) and RL low-energy states sampler (LSS), are implemented and explained in detail, while the meaning of general RL are also discussed. As a testbed, hydrogen diffusivity is computed using RL TKS in pure metals and a medium entropy alloy, CrCoNi, and compared with experiments. The algorithm can produce counter-intuitive hydrogen-vacancy cooperative motion. We also demonstrate that RL LSS can accelerate the sampling of low-energy configurations compared to the Metropolis–Hastings algorithm, using hydrogen migration to copper (111) surface as an example.

36 MATERIALS SCIENCE↗

Correlation between failure and local material property in chopped carbon fiber chip-reinforced sheet molding compound composites under tensile load

To develop further understanding towards the role of a heterogeneous microstructure on tensile crack initiation and failure behavior in chopped carbon fiber chip-reinforced composites, uni-axial tensile tests are performed on coupons cut from compression molded plaque with varying directions. Our experimental results indicate that failure initiation is relevant to the strain localization, and a new criterion with the nominal modulus to predict the failure location is proposed based on the strain analysis. Furthermore, optical microscopic images show that the nominal modulus is determined by the chip orientation distribution. At the area with low nominal modulus, it is found that chips are mostly aligning along directions transverse to loading direction and/or less concentrated, while at the area with high nominal modulus, more chips are aligning to tensile direction. On the basis of failure mechanism analysis, it is concluded that transversely-oriented chips or resin-rich regions are easier for damage initiation, while longitudinally-oriented chips postpone the fracture. Good agreement is found among failure mechanism, strain localization and chip orientation distribution.

36 MATERIALS SCIENCE↗