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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗
DOE OSTI2022

The Branes Behind Generalized Symmetry Operators

The modern approach to m-form global symmetries in a d-dimensional quantum field theory (QFT) entails specifying dimension d–m–1 topological generalized symmetry operators which non-trivially link with m-dimensional defect operators. In QFTs engineered via string constructions on a non-compact geometry X, these defects descend from branes wrapped on non-compact cycles which extend from a localized source / singularity to the boundary ∂X. The generalized symmetry operators which link with these defects arise from magnetic dual branes wrapped on cycles in ∂X. This provides a systematic way to read off various properties of such topological operators, including their worldvolume topological field theories, and the resulting fusion rules. We illustrate these general features in the context of 6D superconformal field theories, where we use the F-theory realization of these theories to read off the worldvolume theory on the generalized symmetry operators. Defects of dimension 3 which are charged under a suitable 3-form symmetry detect a non-invertible fusion rule for these operators. We also sketch how similar considerations hold for related systems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Process optimization of complex geometries using feed forward control for laser powder bed fusion additive manufacturing

Additive manufacturing (AM) enables the fabrication of complex designs that are difficult to create by other means. Metal parts manufactured by laser powder bed fusion (LPBF) can incorporate intricate design features and demonstrate desirable mechanical properties. However, printing a part that is qualified for its intended application often involves reprinting and discarding many parts to eliminate defects, improve dimensional accuracy, and increase repeatability. The process of iteratively converging on the appropriate build parameters increases the time and cost of creating functional LPBF manufactured parts. This work describes a fast, scalable method for part-scale process optimization of arbitrary geometries. Additionally, the computational approach uses feature extraction to identify scan vectors in need of parameter adaptation and applies results from simulation-based feed forward control models. This method provides a framework to quickly optimize complex parts through the targeted application of models with a range of fidelity and by automating the transfer of optimization strategies to new part designs. The computational approach and algorithmic framework are described, a software package is implemented, the method is applied to parts with complex features, and parts are printed on a customized open architecture LPBF machine.

3D printing↗
DOE OSTI2022

Feature extraction for subtle anomaly detection using semi-supervised learning

The demand for automated and effective monitoring techniques has soared with the increased digitization of industrial monitoring systems. State-of-the-art machine learning methods are effectively detecting abrupt changes in system states. However, these methods lack comparable maturity in detecting subtle changes that may be signs of incipient faults. This manuscript argues that the current anomaly detection methods can be enhanced by exploring weak patterns to enable subtle variation detection. Specifically, the concept of semi-supervised learning is employed, with labels representing knowledge about some anomalous conditions of a system. The basic idea is to extract a candidate set of weak patterns discarded by state-of-the-art baselining algorithms. With few labeled anomalous data, the algorithm selects the weak patterns and allows for their possible fusion using the highest sensitivity to the labeled anomalies. Here, the method’s applicability is demonstrated using a representative pressurized water reactor (PWR) model simulated by Dymola.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Experimental platforms for investigating feature-driven jets for HED mix model validation

High-energy-density (HED) systems, such as inertial confinement fusion (ICF), are susceptible to hydrodynamic instabilities that can significantly affect both experimental results and modeling predictions. Isolated features, such as fill tubes or divots in the capsule, can cause material to jet as a result of the compressive shock exciting the Richtmyer–Meshkov instability, and serve as one of the primary degradation mechanisms in ICF yield. Simulations of feature-driven jets and how they mix require extensive experimental validation, particularly for understanding to what degree the initial size and shape of a feature influence jet dynamics, and how much instability feeds through downstream layers. A better understanding of feature-driven jetting can improve our mix modeling capabilities and increase hydrodynamic simulation accuracy. This manuscript describes a series of experimental platforms fielded by Los Alamos National Laboratory as a part of the Mshock Omega 60 and ModCons Omega EP campaigns to explore feature-driven jetting. These platforms are designed to benchmark jet evolution and growth as a function of initial feature size and shape, investigate jet-layer interactions leading to instability feedthrough, and will be used to characterize jet-jet interactions resulting from clusters of features. In conclusion, preliminary results for both platforms are shown. The ModCons experiments are on-going, and a discussion of future work directions is included.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Delineating the mechanism of anti-Lassa virus GPC-A neutralizing antibodies

Lassa virus (LASV) is the etiologic agent of Lassa Fever, a hemorrhagic disease that is endemic to West Africa. During LASV infection, LASV glycoprotein (GP) engages with multiple host receptors for cell entry. Neutralizing antibodies against GP are rare and principally target quaternary epitopes displayed only on the metastable, pre-fusion conformation of GP. Currently, the structural features of the neutralizing GPC-A antibody competition group are understudied. Structures of two GPC-A antibodies presented here demonstrate that they bind the side of the pre-fusion GP trimer, bridging the GP1 and GP2 subunits. Complementary biochemical analyses indicate that antibody 25.10C, which is broadly specific, neutralizes by inhibiting binding of the endosomal receptor LAMP1 and also by blocking membrane fusion. The other GPC-A antibody, 36.1F, which is lineage-specific, prevents LAMP1 association only. These data illuminate a site of vulnerability on LASV GP and will guide efforts to elicit broadly reactive therapeutics and vaccines.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Sub-millisecond keyhole pore detection in laser powder bed fusion using sound and light sensors and machine learning

Laser powder bed fusion is a mainstream additive manufacturing technology widely used to manufacture complex parts in prominent sectors, including aerospace, biomedical, and automotive industries. However, during the printing process, the presence of an unstable vapor depression can lead to a type of defect called keyhole porosity, which is detrimental to the part quality. In this study, we developed an effective approach to locally detect the generation of keyhole pores during the printing process by leveraging machine learning and a suite of optical and acoustic sensors. Simultaneous synchrotron x-ray imaging allows the direct visualization of pore generation events inside the sample, offering high-fidelity ground truth. A neural network model adopting SqueezeNet architecture using single-sensor data was developed to evaluate the fidelity of each sensor for capturing keyhole pore generation events. Our comparative study shows that the near infrared images gave the highest prediction accuracy, followed by 100 kHz and 20 kHz microphones, and the photodiode sensitive to processing laser wavelength had the lowest accuracy. Using a single sensor, over 90% prediction accuracy can be achieved with a temporal resolution as short as 0.1 ms. A data fusion scheme was also developed with features extracted using SqueezeNet neural network architecture and classification using different machine learning algorithms. Our work demonstrates the correlation between the characteristic optical and acoustic emissions and the keyhole oscillation behavior, and thereby provides strong physics support for the machine learning approach.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Complementary Measurements of Residual Stresses Before and After Base Plate Removal in an Intricate Additively-Manufactured Stainless-Steel Valve Housing

Residual stress measurements using neutron diffraction and the contour method were performed on a valve housing made from 316 L stainless steel powder with intricate three-dimensional internal features using laser powder-bed fusion additive manufacturing. The measurements captured the evolution of the residual stress fields from a state where the valve housing was attached to the base plate to a state where the housing was cut free from the base plate. Making use of this cut, thus making it a non-destructive measurement in this application, the contour method mapped the residual stress component normal to the cut plane (this stress field is completely relieved by cutting) over the whole cut plane, as well as the change in all stresses in the entire housing due to the cut. The non-destructive nature of the neutron diffraction measurements enabled measurements of residual stress at various points in the build prior to cutting and again after cutting. Good agreement was observed between the two measurement techniques, which showed large, tensile build-direction residual stresses in the outer regions of the housing. The contour results showed large changes in multiple stress components upon removal of the build from the base plate in two distinct regions: near the plane where the build was cut free from the base plate and near the internal features that act as stress concentrators. These observations should be useful in understanding the driving mechanisms for builds cracking near the base plate and to identify regions of concern for structural integrity. Neutron diffraction measurements were also used to show the shear stresses near the base plate were significantly lower than normal stresses, an important assumption for the contour method because of the asymmetric cut.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Reactor Power Level Estimation by Fusing Multi-Modal Sensor Measurements

Estimates of the power level of a nuclear reactor based on measurements from an independent monitoring sensor system can help in the compliance verification of its declared operations. We present a three-level fusion method to estimate the power level of a nuclear reactor using features derived from infrared, electromagnetic, and acoustic sensor measurements collected in proximity to the reactor. Based on a simplified analytical model of the secondary coolant system of the reactor, we identify partial regression functions of the power level in terms of the temperature difference between inlet and outlet of coolant pipes, and the activity levels of four fans and four pumps, which are estimated as features from the sensor measurements. The power level estimator employs a combination of aggregate and complementary fusion steps at three levels to incorporate the multi-modal features in a structure that reflects the secondary cooling system and its partial regression functions. Using the measurements from a test campaign at an operational reactor, we show that this estimator achieves 3.47% or lower root mean square error under 5-fold cross validation. More generally, these results illustrate a progressive reduction in estimation error as additional modalities are appropriately incorporated, and that the fuser outperforms single modality features and their sub-combinations.

Rao, Nageswara↗
DOE OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗
DOE OSTI2025

GRinding Automated Classification Engine

This work is an ML-driven framework for automated surface analysis of microscopy images. We create a training dataset by imaging stainless steel samples to benchmark four developed deep neural network architectures. These models, based on a YOLOv8n-cls backend, integrate image features and process metadata using various fusion methods to distinguish between acceptable and unacceptable surface finishes. This code is associated with publication "Classifying Alloy Surface Preparation Quality with Metadata-Infused Machine Learning for Rapid Alloy Discovery" for project APEX LDRD-ER (25-ERD-039)

Gongora, AldairE [Lawrence Livermore National Labo↗
DOE OSTI2020

Detection of Synchrophasor False Data Injection Attack using Feature Interactive Network

The synchrophasor data recorded by Phasor Measurement Units (PMUs) plays an increasingly critical role in the regulation and situational awareness of power systems. However, the widely installed PMUs are vulnerable to multiple malicious attacks from cyber hackers during data transmission and storage. To address this problem, a Modified Ensemble Empirical Mode Decomposition (MEEMD) is proposed first to extract the intrinsic mode functions of each Synchrophasor Data Attacks (SDA). The frequency-based adaptive screening criterion embedded in MEEMD is used to eliminate the false intrinsic mode functions. Next, a Multivariate Convolutional Neural Network (MCNN) is proposed to identify multiple SDA by utilizing the extracted intrinsic mode functions and original SDA as input vectors. A fusion block as the main structure of MCNN is also leveraged to increase the diversity of features and compress the model parameters. Integrating MEEMD and MCNN, a framework with automatic feature extraction and multi-source information fusion capability, referred to as Feature Interactive Network (FIN), is proposed to detect multiple SDA. Based on the proposed FIN framework, six types of SDA are explored for the first time using actual synchrophasor data in FNET/Grideye that was collected from different locations in the U.S. Eastern Interconnection. Finally, a large quantity of experiments with different attack strengths are used to evaluate the adaptability and classification performance of the proposed FIN.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Extension of the energetic particle transport kick model in TRANSP to multiple fast ion species

Abstract Alfvénic instabilities (AEs) are well known to cause enhanced transport of energetic particles (EPs) in fusion devices. Most studies until now have focused on characterizing and understanding AE stability in single-species plasmas heated by neutral beams (NB), where deuterium is typically used as both main plasma species and NB fuel. As the fusion community moves toward fusion reactors that target burning plasma conditions, such as ITER, the single-species picture breaks down. Burning plasmas, which will use a mix of deuterium and tritium (DT) as main fuel, also feature the presence of several supra-thermal fusion products such as alpha particles, protons, helium isotopes and high-energy tritium ions. This work presents the extension of the EP transport kick model implemented in the TRANSP time-dependent tokamak transport code to study the combined effect of multiple EP species on AE stability and, in turn, the response of different EP species to plasma instabilities in terms of their redistribution and losses. Further validation of the enhanced model is planned based on experimental results expected from the JET DT campaign scheduled for 2021, in preparation for ITER plasmas and beyond.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of consideration for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 10 5 – 10 7 K/s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Interpreting experimental measurements of helium bubbles using stochastic cluster dynamics models of heterogeneous nucleation and growth in irradiated ferritic alloys

Among a number of other advantageous features, ferritic/martensitic steels are being considered as fusion reactor structural materials due to their low intrinsic swelling under irradiation. However, under high-energy neutron irradiation, He produced through (n, α) reactions stabilizes vacancy clusters, which then act as seeds for bubble formation and growth, negating the intrinsic swelling resistance of these alloys. Standard models of irradiation damage accumulation and microstructural evolution consider homogeneous nucleation as the basis for bubble formation and growth. However, this generally does not explain the large bubble densities and sizes observed experimentally under a number of different conditions. Here, we propose a more realistic physical model of bubble nucleation, formation, and growth designed to capture recent experimental measurements of He-bubble formation and evolution during co-implantation of He and Fe ions in model ferritic alloys. We find that experimental results are explained only when the following three features are considered simultaneously: (i) heterogeneous nucleation of He-vacancy bubbles at defect sinks (e.g., dislocations, grain boundaries, and second-phase precipitates), (ii) nucleation and growth of bubbles via the ‘trap mutation’ mechanism (i.e., spontaneous production of Frenkel pairs due to absorption of He atoms), and (iii) transition from a growth-limited, He-stabilized bubble regime to a ‘runaway’ void-type growth scenario. The model is implemented into a stochastic cluster dynamics framework that takes advantage of cluster size grouping methods to accelerate the simulations, allowing us to reach 10 dpa of simulated irradiated dose, and to capture cluster sizes in excess of 20 nm. Further, a careful extrapolation exercise conducted assuming classical nucleation theory leads to excellent agreement with the experimental measurements at 50 dpa of irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Velocity-space compression from Fermi acceleration with Lorentz scattering

The Fermi acceleration model describes how cosmic ray particles accelerate to great speeds by interacting with moving magnetic fields. In this work, we identify a variation of the model where light ions interact with a moving wall while undergoing pitch angle scattering through Coulomb collisions due to the presence of a heavier ionic species. The collisions introduce a stochastic component which adds complexity to the particle acceleration profile and sets it apart from collisionless Fermi acceleration models. The unusual effect captured by this simplified variation of Fermi acceleration is the nonconservation of phase space, with the possibility for a distribution of particles initially monotonically decreasing in energy to exhibit an energy peak upon compression. A peaked energy distribution might have interesting applications, such as to optimize fusion reactivity or to characterize astrophysical phenomena that exhibit nonthermal features.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

On Feature, Classifier and Detector Fusers for 235U Signatures Using Gamma Spectral Counts

Three types of information fusion strategies are studied to assess the performance of classifiers for detecting low-level 235 U radiation sources, using features obtained from gamma spectra of NaI detectors. These three strategies are based on using two spectral region features, fusing eight classifiers of diverse designs, and fusing multiple detectors located at different positions around the source. The inner, middle and outer groups of detectors, within a formation of two concentric circles and a spiral of 21 detectors, are identified based on their distance to the source, which is located at the center. This study provides two main qualitative insights into this classification task. First, the fusion of detectors leads to an overall improved classification performance, least in the inner group, most in the outer group, and in between for the middle group. Second, several classifiers and fusers achieve lower training error which does not translate to lower generalization error, indicating their over-fitting to training data.

Rao, Nageswara↗
DOE OSTI2023

On the role of mode resonances in regulating zonal-flow-moderated plasma microturbulence

Abstract The onset of turbulent heat transport at a higher temperature gradient than the critical gradient of linear instability, known as the Dimits shift, is a recurring feature of nonlinear simulations for magnetically confined fusion plasmas. Resonance in the nonlinear coupling between the modes that dominate energy transfer can lead to suppression of turbulence and transport above the linear critical gradient. As an expression of this resonance, gyrokinetic simulations show a quasi-coherent interaction between streamers and sidebands coupled through the zonal flow within the Dimits regime. This mechanism is further confirmed by use of artificial complex frequencies which break the resonance. By incorporating corresponding saturation physics, the standard quasilinear model for rapid head flux prediction is improved, which can now predict reduced heat flux in the Dimits regime. In particular, the triplet correlation time, the lifetime of the nonlinear interaction, is shown to be well-approximated by combinations of linear eigenvalues, and yields good representations of the heat flux variation both in and above the Dimits regime. Thus, a reduced but predictive model for transport near the critical gradient of zonal-flow saturated turbulence now exists.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗