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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Modeling and Harmonic Stability of MMC-HVDC With Passive Circulating Current Filters

A modular multilevel converter (MMC) is an emerging converter technology widely used in wind power applications using high-voltage direct current (HVDC) transmission, and it has been largely investigated in medium-voltage solar harvesting as well as electric motor drives. Different from studies dealing with active circulating current control loops, this paper focuses on impedance modeling and harmonic stability studies for MMCs with passive circulating current filters (PCCFs). A power stage circuit including a PCCF is transformed and remodeled to obtain small-signal formulations. This transformation leads to additional high-order matrix computing complexity due to the added impedance subnetwork matrix from the PCCF as well as relevant crossed-frequency impacts. To simplify the computational burden, the proposed model aims to solve one arm equation instead of all six MMC arm equations. To achieve this result, additional challenges occur when the MMC is connected to a renewable energy source instead of the grid voltage, where low-level zero-sequence components might exist in the neutral point of three phases, especially in the case of no integrated advanced modular voltage balancing control, which prevents computational simplification. To overcome this challenge, further impedance matrix adjustments are conducted in this paper to theoretically suppress the impact of zero-sequence harmonics when obtaining small-signal impedance, taking into account the frequency coupling effect. Finally, simulations are carried out to validate the developed impedance model under different operating scenarios. Harmonic stability case studies of MMCs with PCCFs connected to renewable energy current sources are also presented, where frequency-domain stability analyses based on Bode diagrams are compared to time-domain simulation waveforms and FFTs, which validate the effectiveness of the proposed impedance model.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Optimal Control of the Energy-Saving Hybrid Hydraulic-Electric Architecture (HHEA) for Off-Highway Mobile Machines

Most off-highway constructions and agriculture equipment use hydraulics, which has unmatched power density, for power transmission and throttling as a means for control. A novel hybrid hydraulic-electric architecture (HHEA) has recently been proposed to improve efficiency for high-power machines that would have been cost-prohibitive to electrify directly. HHEA uses a set of common pressure rails (CPRs) to transmit the majority of power hydraulically and small electric motor drives to modulate that power and to achieve precise control. This article proposes a computationally efficient Lagrange multiplier method (LMM) for computing the optimal sequence of pressure rail selections to minimize energy use. This is needed to evaluate HHEA's energy-saving potential and for iterative architecture design and sizing. An interesting complication is that the cost function is not fully defined until the candidate control sequence is fully specified. This issue is dealt with by decomposing the original problem into a set of sub-problems with additional constraints that can be solved efficiently. Computational effort can be further reduced if actuators are optimized individually instead of together. However, additional steps are required to prevent the constraint functions from becoming discontinuous with respect to the Lagrange multipliers, which is necessary for meeting the constraints. Lastly, a case study of a construction machine demonstrates the efficacy of the method and shows that the HHEA reduces energy consumption by 68%-73% compared to the baseline load-sensing architecture.

Lagrange multiplier↗

DOE OSTI2022

Automated Production of Optimization-Based Control Logics for Dynamic Facade Systems, with Experimental Application to Two-Zone External Venetian Blinds

The primary goal of this research is to devise a system that produces controllers for complex fenestration systems that perform nearly as well as Model Predictive Control but at a level of cost and implementation complexity that rivals simple heuristic controls. To this end, a cloud-based automated controller production system has been set up for a motorized external Venetian blind device, with a simple web interface that can be used by non-experts. The computation cost per controller is in the range of a few dollars, and the control logic is simple enough to be implemented on small and cheap distributed controllers. The web interface allows the user to specify some details of their particular building and window configuration, including orientation, latitude, interior geometries, and lighting and HVAC system parameters. Upon submittal, a cloud-based system configures the necessary files and commands, and then runs thousands of optimizations with them. Once the calculations are finished, the system produces a lookup table and interpolation-based controller scripts that can be used on a simple and cheap distributed controller. This paper describes the underlying models and optimization processes. It also describes the resulting control logics for two cases tested at Lawrence Berkeley National Laboratory’s Advanced Windows Testbed Facility: illuminance maximization subject to glare constraints; and lighting + HVAC energy minimization. The performance of the model-based controllers produced by the automated web-based system are compared to a heuristic ‘block beam’ controller in physical experiments at the Testbed. The experimental results are supplemented by simulation experiments with the same configuration as the Testbed. The results show the illuminance maximizing controller significantly outperforms the heuristic controller in terms of glare avoidance, and also outperforms it in terms of hours of daylight autonomy. The energy minimizing controller also outperforms the heuristic controller. This paper also discusses how the web-based system may be extended to consider other configurations, such as electrochromic windows and thermally massive HVAC systems. Potential roles for this type of system within the building design and construction industry are discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Design and Characterization of Hybrid Multilayer Structures: Layer-by-Layer Growth of Polymer and Graphene Oxide Assemblies and Their Utility in Fuel Cell Applications

We report the layer-by-layer growth of poly- (ethylenimine) (PEI) that has been modified with sulfamate functionalities (S-PEI) using Zr 4+ -complexation interlayer linking chemistry. We have also deposited adlayers of graphene oxide (GO) that have been modified to possess sulfate functionalities (SGO), onto the S-PEI layers. The multilayer assemblies are formed with sulfamate/sulfate and sulfate/sulfate (S-PEI + S-GO) interlayer linking chemistry. In all cases the adlayer thickness is consistent with predictions based on van der Waals volume and/or molecular mechanics calculations. X-ray photoelectron spectroscopy (XPS) is used to characterize the Zr/S stoichiometry in the multilayer assembly. The utility of these hybrid multilayer structures is demonstrated in a Proton Exchange Membrane (PEM) fuel cell, where they are shown to reduce H 2 gas crossover by 15% with only a 12 nm thick layer.

fuel cell↗

DOE OSTI2024

Next Generation High Efficiency Boosted Engine Concept

This report summarizes a collaborative research project between Ford Motor Company, FEV North America, and Oak Ridge National Laboratory to develop a next-generation, high-efficiency, boosted spark-ignited engine. The goal was to achieve a 23% improvement in fuel economy and a 15% reduction in engine weight compared to a 2016 Ford F150. The team utilized advanced technologies including a high compression ratio, cooled exhaust gas recirculation (EGR), early intake valve closing, and a novel active pre-chamber ignition system. The final engine prototype met the fuel economy goal and demonstrated a 4.3% weight reduction, with further opportunities identified to reach the full 15% target.

Fuel economy↗

DOE OSTI2022

The Strange Case of Ground-Coupled Airwaves on Seismoacoustic Stations at Local to Near-Regional Scales

Here we investigate the application of ground-coupled airwaves observed by seismoacoustic stations at local to near-regional scales to detect signals of interest and determine back-azimuth information. Ground-coupled airwaves are created from incident pressure waves traveling through the atmosphere that couple to the earth and transmit as a seismic wave with retrograde elliptical motion. Previous studies at sub-local scales (<10 km from a source of interest) found the back-azimuth to the source could be accurately determined from seismoacoustic signals recorded by acoustic and 3-component seismic sensors spatially separated on the order of 10 to 150 m. The potential back-azimuth directions are estimated from the coherent signals between the acoustic and vertical seismic data, via a propagation-induced phase shift of the seismoacoustic signal. A unique solution is then informed by the particle motion of the 3-component seismic station, which was previously found to be less accurate than the seismoacoustic-sensor method. We investigate the applicability of this technique to greater source-receiver distances, from 50-100 km and up to 400 km, which contains pressure waves with tropospheric and stratospheric ray paths, respectively. Specifically, we analyze seismoacoustic sources with ground truth from rocket motor fuel elimination events at the Utah Test and Training Range (UTTR) as well as a 2020 rocket launch in Southern California. From these sources we observe evidence that while coherent signals can be seen from both sources on multiple seismoacoustic station pairs, the determined ground-coupled airwave back-azimuths are more complicated than results at more local scales. Our findings suggest more complex factors including incidence angle, coupling location, subsurface material, and atmospheric propagation effects need to be fully investigated before the ground-coupled airwave back-azimuth determination method can be applied or assessed at these further distances.

58 GEOSCIENCES↗

DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

Concentrating Solar Power (CSP) plants with Thermal Energy Storage (TES), require compressors capable of circulating supercritical carbon dioxide (sCO2) heat transfer fluids (HTFs) at temperatures from 500 to 700+°C and pressures from 8 to 25 MPa (80 to 250 Bar or 1160 to 3626 psia) in order to achieve thermal-to-electric efficiencies >50%. A review of papers relating to SCO2 compressors reveals that in almost every case the conditions being considered either allow for cooling of the SCO2 working fluid or are considering operating conditions close to the critical point at a temperature and pressure of approximately 31°C and 1070 psi). While the technology reported in these papers is relevant to most turbomachinery, the current CSP gas pathway circulator operating pressures are well above the CO2 critical point and do not allow for cooling of the main HTF flow. The purpose of this paper was to describe the key system issues affecting the design of a HTF circulator that could be scaled from a small size research and proof of concept circulator compressor to sizes supporting power plants producint upwards of 100 to 300 Mega Watts of electrical power. Due to the high temperatures and pressures the research scale HTF circulator was designed to be hermetically sealed to prevent leakage of the super critical carbon dioxide to the environment. In order to achieve hermetic sealing the drive motor and centrifugal impeller were fully integrated in a single shaft system configuration. From a preliminary assessment of compression power as a function of operating speed and impeller diameter it was determined that a smaller, higher speed impeller would result in a more efficient circulator. However, due to the high pressure and corresponding density of the sCO2 coupled with high operating speeds, large windage losses (i.e., viscous drag on the high speed rotating shaft) would occur which could result in a substantial reduction in efficiency of the system. Therefore tradoff studies were complerted to identify the operating speeds and system component sizes to achieve high efficiency. Based on the trade studies, the final design was a 55 mm diamter compressor impeller operating at speeds to 85,000 rpm. The unit will be built and tested in the future. Key Words: Super Critical Carbon Dioxide, Heat Transfer Fluid, Turbomachinery, Compressor, Circulator, Critical Point, Concentrating Solar Power, Solar Energy

Super Critical Carbon Dioxide, Heat Transfer Fluid↗

DOE OSTI2021

Mitigating Phase Unbalance for Distribution Systems with High Penetrations of Solar PV (Final Technical Report)

Distribution system operators have traditionally limited unbalance among phases by maintaining similar loadings on each phase. High penetrations of distributed solar PV continually change the net loading on each phase, resulting in time-varying phase unbalances that can damage three-phase devices such as three-phase motors, violate grid codes, and increase technical losses. This project has developed several control strategies for the reactive power outputs of solar PV inverters in order to mitigate power quality issues related to phase unbalance. These control strategies include a decentralized approach that is solely based on local measurements, distributed and grouped approaches that consider subsets of loads and PV generators, and a centralized approach that leverages measurements from a variety of locations in order to compute optimal reactive power setpoints for each inverter. Variants of the controllers handle challenges relevant to practical implementations, including noisy measurements, delayed communications, and reactive power limits. Moreover, the project developed theory that provides convergence guarantees for systems with multiple interacting controllers as well as “balanceability” certificates that ensure satisfaction of phase unbalance requirements with variable loading. The controllers were integrated with NRECA’s Open Modeling Framework (omf.coop) and evaluated using actual distribution system models obtained from several NRECA member utilities. Application of the controllers results in significant improvements to phase unbalance in these test cases with decreases from base case levels of over 3% to under 0.5%, which is within the 2% IEC phase unbalance standard.

14 SOLAR ENERGY↗

DOE OSTI2021

Transition to Online Cable Insulation Condition Monitoring

Nuclear power plant cables were originally qualified for 40 year life and generally have not required specific test verification to assure service availability through the initial plant qualification period. However, license renewals to 60 and 80 years of operation require a cable aging management program that depends on some form of test and verification to assure fitness for service. Environmental stress (temperature, radiation, chemicals, water, and mechanical) varies dramatically within a nuclear power plant and, in some cases, cables have degraded and required repair or replacement before their qualified end-of-life period. In other cases, cable conditions have been mild and dependable cable performance confirmed to extend well beyond the initial qualified life. Most offline performance-based testing requires cables to be de-coupled and de-energized for specially trained technicians to perform testing. These offline tests constitute an expensive operational burden that limits the economic viability of nuclear power plants. Although initial investment may be higher, new online test practices are emerging as options or complements to offline testing that avoid or minimize the regularly scheduled offline test burden. These online methods include electrical and fiber-optic partial discharge measurement, spread spectrum time or frequency domain reflectometry, distributed temperature profile measurements, and local interdigital capacitance measurement of insulation characteristics. Introduction of these methods must be supported by research to confirm efficacy plus either publicly financed or market driven investment to support the start-up expense of cost-effective instrumentation to monitor cable condition and assure reliable operation. This work summarizes various online cable assessment technologies plus introduces a new cable motor test bed to assess some of these technologies in a controlled test environment.

Glass, Samuel W.↗

DOE OSTI2024

The 2023 Gold Run in the Injectors

RHIC Run 23 used Gold beam from Tandem with an AGS extraction energy of 9.8 GeV. The same basic setup, 8 single bunch transfers from the Booster and a 12-6 merge in the AGS to provide 4 bunches at extraction, had been used before to deliver Tandem Au to RHIC. But in those cases, it was used for low energy runs (3.85 GeV in 2021 and 5.75 GeV in 2020) where extraction was below transition energy (7.9 GeV). Tandem beam was used for this run because the intensity and stability of EBIS Au did not meet the requirements for RHIC. Physics was first declared in RHIC on May 22 nd and on August 1 st the run was cut short by about 2 months due to a major failure in RHIC. Prior to the advent of EBIS as the preinjector in 2012, 9.8 GeV Tandem Au was regularly delivered to RHIC but the setup in the Booster and AGS was quite different: Four Booster transfers of 6 bunches each were merged into 4 bunches using a 24-12-4 merge scheme. The supercycle length was 6.0 sec before June 29 th when it was extended to 6.6 sec to accommodate EBIS commissioning. The Tandem, Booster, and AGS were on user 1 for the 9.8 GeV setup. Some work with EBIS Au 32+ took place on EBIS, Booster, and AGS user 5 using the standard 9.8 GeV injector setup with a 4 to 1 merge in Booster and a 6-3-1 type merge in AGS. The Siemens motor generator was used for the entire run. An intensity limit of 8.0e9 Au 77+ ions in the AGS was in effect during the run to protect the J7 plunging stripping foil and the Copper absorber of the AGS beam dump. This corresponds to a merged bunch intensity limit of 2.0e9 Au 77+ ions for 4 equal intensity bunches. The per bunch intensity limit can be increased to 2.67e9 by reducing the number of BtA transfers from 8 to 6. There was also a Booster Late intensity limit of 16e9 Au ions in effect to protect the BtA stripping foil from damage due to overheating. Lowering the number of transfers also makes this limit less of a constraint. BtA foil 5, which was installed in 2020 and had not been used regularly prior to this run was used all run and showed no obvious signs of deterioration. In May, a Tandem Au 3.85 GeV setup from 2021 was also re-established on AGS user 2. It was used for APEX on May 24 and July 26. Initial work with 3.85 GeV beam was on May 19. Proton beam was also set up during the run and extracted to W dump on July 10. It was used for APEX on July 12. Although the OPPIS source was used the AGS setup was without snakes.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Assessment of an E10 gasoline surrogate: Qualitative and quantitative comparisons of in-cylinder spray morphology

A minimum-component gasoline fuel surrogate that captures both chemical and physical behaviors of a full-distillate fuel is needed for high-fidelity CFD simulations. This study evaluates gasoline spray characteristics in a direct-injection spark-ignition engine under motored operation. Two fuels are compared; PACE-20, which is a 9-component surrogate formulation of RD5-87, is compared with its target fuel RD5-87, which is a full-boiling range research grade E10 gasoline. The spray morphologies of both fuels are recorded for a centrally-located direct-injection 8-hole spray subject to intake air cross-flow during the early part of the intake stroke. High-speed imaging recorded scattered light of the side and axial projections of the liquid spray. Quantitative metrics were developed and employed to facilitate comparison of spray morphologies as well as to identify the transition in spray morphology due to flash boiling. This paper builds on a previous study of RD5-87 where coolant temperature (20°C–100°C), in-cylinder pressure (40–110 kPa), engine speed (650–1950 rpm), and injection pressure (60–180 bar) were systematically changed to span operating conditions with and without flash boiling. Images of the PACE-20 morphology are selected for a sub-set of operating conditions from the previous study where distinctive morphology changes occurred. Visual inspection of the images and quantitative metrics demonstrate that the PACE-20 spray morphology is equivalent to that of the RD5-87 in most cases. The exception was for changes in the ambient-gas pressure where the flash-boiling transition occurred at ∼5 kPa higher in-cylinder pressure for PACE-20. Three empirical metrics, Merging Index, Asymmetry, and Flash Index are proposed here and they were found to be useful both as quantitative comparisons of the fuel morphologies, and for identifying the transition in spray morphology due to flash boiling.

Kim, Namho↗

DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Net Zero Energy Model for Wastewater Treatment Plants

The primary objective of this study is to achieve net-zero energy (NZE) wastewater treatment plants (WWTPs) by utilizing energy efficiency opportunities (EEO), combined heat and power (CHP) systems, and other renewable energy (RE) sources, e.g., solar, water, and wind powers. Herein, this study discusses an innovative energy solution for WWTPs in the United States, and one of the WWTPs with a flow capacity of 1.5 million gallons per day (MGD) was selected as a case study. An optimization tool, Hybrid Optimization of Multiple Energy Resources (HOMER) software, is used in this study to find the best energy system configuration to run the system. An energy audit for one WWTP was conducted in early 2020 and the report is used to do this study. The proposed EEOs were able to reduce WWTP energy consumption by about 11%. The excess anaerobic digester gas was utilized in a CHP system to cover about 42% of the facility’s consumption. Also, 3% of the utility energy consumption can be claimed by microturbines in the aeration tanks. Another two renewable energy systems, solar photovoltaic (PV) with 29% and water turbines with 15%, contribute to covering 100% of the WWTP energy consumption and achieving an NZE WWTP.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Mild hybridisation of turboprop engine with high-power-density integrated electric drives

Here this paper shares with the aerospace community a case study of turboprop mild hybridisation using a recently developed integrated drive system in the University of Nottingham, UK, within the ACHIEVE project under EU H2020 CleanSky 2 program (project No. 737814). The developed drive system enables green taxiing of a turboprop aircraft while on the ground with its engine off, and as an electrical generator when the turboprop is in the air. The entire system is designed to be able to integrate within the power auxiliary gear box (PAGB) of a turboprop aircraft. Some of the key features of the developed system include a high-speed permanent magnet machine (up to 14,200rpm) with dual three-phase design, SiC-based high power density (11.8kW/L for the power converter, 35.3kW/L and 7.2kW/kg for the machine active parts), integrated cooling design for high-temperature operation (>130°C ambient temperature), fault tolerance consideration with dual channel operation capabilities and sensorless control for entire operational conditions. This paper is giving an overview of the design process of the electrical machine, power converters, and its cooling of the entire drive. Numerical analysis (FEM and CFD) and some experimental results are presented to demonstrate the effectiveness and the desired performance of the developed integrated drive system.

42 ENGINEERING↗

DOE OSTI2023

2023 Critical Materials Strategy

The global effort to curb carbon emissions is accelerating demand for clean energy technologies and the materials they rely on. Demand for these materials will only continue to grow, especially as some nations aim to achieve net zero emissions by 2050. While some major materials like steel, copper, and aluminum are already powering the fossil fuel economy, others are more minor materials with potential supply risks. These risks could jeopardize the ability to reduce greenhouse gas emissions within the desirable timeframe to avoid significant climate change. In some cases, it may be necessary to take action to improve the resilience of material supply chains and mitigate supply risks. Understanding the importance of individual materials to clean energy and the supply risks associated with them is necessary to identify which materials may serve as potential roadblocks to a clean energy future. The U.S. Department of Energy (DOE) issued a series of 13 supply chain deep dive assessment reports on various energy technologies in 2022 in response to President Biden’s Executive Order on America’s Supply Chains (E.O. 14017). These reports emphasized that supply chain bottlenecks can occur at any stage of the value chain from mining and refining to component and even sub-system manufacturing. The bottlenecks are a combination of factors such as material availability, equipment availability, work force availability and quality, logistics, regulatory framework, and market conditions. These bottlenecks were worsened during the global Covid-19 pandemic. Its lingering impacts have hindered capacity expansion for material supply chains and prevented product lead-time recovery. One approach to reduce supply chain risks for the United States is to have a strong domestic manufacturing sector with a diverse set of producers. Boosting responsible domestic production would require leveraging the latest science not only in material extraction but also in developing substitutes, recycling, reuse, and remanufacturing. This report is an updated analysis of previous Critical Materials Strategy (CMS) reports published by the DOE in 2010, 2011, and 2019 based on national and global priorities, technology advancement, and technology adoption trends. Like the CMS reports, this analysis presents the results of a formal material criticality assessment to identify which materials are critical to the continued deployment of clean energy technologies globally. The analysis in this report leveraged the DOE supply chain deep dive assessments to develop the initial list of materials to evaluate. This DOE Critical Materials Assessment (CMA) is conducted independently of criticality assessments performed by other U.S. government agencies, such as that conducted by the U.S. Geological Survey (USGS). This analysis complements the USGS critical minerals determination in three aspects. First, the DOE assessment is performed from a global perspective, while the USGS analysis focusses on the importance of minerals to the U.S. economy. Second, this report focuses on the importance of materials to clean energy technologies, rather than to the economy in general. Lastly, this study is forward looking to 2035 based on clean energy deployment scenarios, whereas the USGS assessment is retrospective. Materials evaluated in this report that do not appear in the USGS Critical Minerals List include copper, uranium, electrical steel, and SiC. A draft version of this report received ~80 public comments related to supporting data and methodological improvement. Those comments have been incorporated as much as possible where appropriate. Highlights of findings from this 2023 CMA include: Rare earth materials (neodymium, praseodymium, dysprosium, and terbium) used in magnets in electric vehicle (EV) motors and wind turbine generators continue to be critical. While dysprosium (Dy) and terbium (Tb) are both heavy rare earth elements that serve the same function in magnets, the criticality of Tb is slightly lower than that for Dy in the short term due to the widespread use of Dy in high-grade magnets and Tb’s present role as a substitute. Similarly, praseodymium (Pr) is critical in the medium term but only near critical in the short term because it is more substitutable in magnets than neodymium (Nd); Materials used in batteries for EVs and stationary storage are now considered to be critical. While cobalt (Co) was found to be critical in this and previous reports, lithium (Li) becomes critical in the medium term due to its broader use in various battery chemistries and the rampant growth of the EV industry. Natural graphite is a new addition in this assessment and is also found to be critical; Platinum group metals used in hydrogen electrolyzers, such as platinum (Pr) and iridium (Ir), are critical due to an increased focus on hydrogen technologies to achieve net zero carbon emissions, while those used in catalytic converters, such as rhodium (Rh) and palladium (Pd), were screened out due to the decreased importance of catalytic converters in the medium term; Gallium (Ga) continues to be critical due to its use in light-emitting diodes (LEDs). In addition, the use of Ga has increased in magnet manufacturing and in semiconductor in forms such as gallium arsenide (GaAs) or gallium nitride (GaN); Major materials like Aluminum (Al), copper (Cu), nickel (Ni), and silicon (Si) move from noncritical in the short term to near critical in the medium term due to their importance in electrification; Electrical steel is near critical due to its use in transformers for the grid and electric motors in EVs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Data Summary Report for Soil and Slab Sampling at Former Building 175

Lawrence Livermore National Security (LLNS) and the U.S. Department of Energy (DOE) are in the process of returning the area where Building 175 existed to beneficial use for future site development. The completed assessment will help LLNS and DOE to outline project scope and costs associated with the removal, characterization, and disposal of materials generated when the concrete slab for the former building and any associated remaining subsurface structures are demolished. Slab removal under the Transition & Disposition process requires full screening for potential site contamination to determine appropriate future land use. Borehole locations and depths were designed to correctly assess DOE’s future liability for characterizing residual vadose zone contamination. If a residual source area is identified at depth, DOE will need to evaluate the additional cost of future subsurface cleanup (with limited access) due to planned development. This is necessary to leave the location in a “ready-to-build” status. As a result, Phase II sampling requirements may in some cases extend beyond the construction zone required for slab removal to ensure the necessary due diligence. To avoid the potential spread of contamination and/or the creation of an environmental release by impacting the integrity of known contamination areas (e.g., pit within room 102 and the east to west boundary seam), these locations were not sampled for this project. During demolition of the slab, these locations and their underlying soils should be further evaluated. The assessment was conducted in accord with the May 2022 Lawrence Livermore National Laboratory Former Building 175 Assessment Soil Sampling and Analysis Plan / Quality Assurance Plan. Thirty-six, direct-push borings were advanced, along with collecting concrete (where present) and soil samples for laboratory analyses. Thirty-two of the borings were advanced to a depth of 25 feet below ground (bgs), and four borings were advanced to a depth of 55 feet bgs. The concrete slab for former Building 175 ranged from approximately 8 inches to over two feet in thickness. Soils encountered during the investigation consisted primarily of clayey silt, with interbeds of sandy gravel and silty sand to the total depth explored of 55 feet bgs. Field photoionization detector readings – checking for volatile organic compound (VOC) vapors in soils, ranged from zero (0) to a peak of 33 parts per million at 25 feet bgs in boring PC-B175- 028. The cause for the peak reading is unknown, however, no visually discolored or odorous soils were encountered during the assessment and all VOC results were below Lawrence Livermore National Laboratory’s (LLNL’s) Soil Screening and Management Plan (SSMP) soil screening levels (SSL). Groundwater was not encountered during the assessment and is expected to occur at roughly 65 feet bgs in the project area. No metals were detected at concentrations of concern in the concrete core samples collected and analyzed. Low gross alpha and beta activity concentrations were detected in the concrete core samples collected and analyzed. The detected activity concentrations would appear to be from naturally occurring radioactive isotopes, i.e., potassium 40, present in the raw materials used to make concrete and not artificially added. Tritium was not detected above the testing laboratory's Method Detection Limit (MDL) in any of the concrete core samples collected and analyzed. The radioactive isotopes - actinium 228, bismuth 214, lead 212, lead 214, potassium 40, radium 226, radium 228, and thallium 208, were detected at low activity concentrations in the concrete core samples analyzed. Based on the detected activity concentrations, the isotopes would appear to be naturally occurring in the raw materials used to make concrete and not artificially added. Acetone – a common laboratory contaminant, was detected in nine of the soil samples collected and analyzed. Concentrations of two other volatile organic compounds (benzene and tetrachloroethene) were detected in five of the soil samples analyzed. All concentrations were below SSLs. Total petroleum hydrocarbons as diesel range organics were detected at 43.9 milligrams per kilogram (mg/kg) in the 20-foot bgs duplicate sample from boring PC-B175-007. Total petroleum hydrocarbons as motor oil were detected at 7.20 mg/kg in the 15-foot bgs routine sample from boring PC-B175-001, and at 20.7 mg/kg in the 20-foot bgs duplicate sample from boring PC-B175-007. The SSL for diesel-range TPHs is 260 mg/kg. LLNL does not have an SSL for motor oil range TPHs. No indications of a release, e.g., visibly stained, or odorous soil, were present at the boring locations. No samples collected contained polychlorinated biphenyls (PCBs) in concentrations above the laboratory reporting limit. Arsenic was detected above its SSL of 8.51 mg/kg in the 25-foot bgs routine sample collected from boring PC-B175-023. Nickel was detected above its SSL of 86.0 mg/kg in the 10-foot bgs routine sample from boing PC-B175-005, the 20-foot bgs routine sample from boring PC-B175-025, and the 25-foot bgs routine sample from boring PC-B175-034. The detected concentrations, however, were well below ten times (10x) their respective STLCs. Gross alpha and/or gross beta were detected above their respective SSL activity concentrations in three routine soil samples. Retesting (two per sample) of the samples showed that the initial reported activity concentrations were anomalous. Tritium was not detected in any of the routine or duplicate soil samples collected and analyzed during the investigation. The radioactive isotopes - actinium 228, bismuth 212 and 214, lead 212 and 214, potassium 40, radium 224, 226 and 228, thallium 208, thorium 234 and uranium, were detected at low activity concentrations in the soil samples analyzed for radioactive constituents. The detected isotopes and their associated activity concentrations are typical of those naturally occurring in the marine-type sedimentary deposits underlying the Livermore Valley. No radiological controls are necessary for the soil evaluated.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗