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All sources NASA NTRS DOE OSTI

DOE OSTI2014

Modeling and Validation of the Thermal Response of TDI Encapsulating Foam as a function of Initial Density

TDI foams of nominal density from 10 to 45 pound per cubic foot were decomposed within a heated stainless steel container. The pressure in the container and temperatures measured by thermocouples were recorded with each test proceeding to an allowed maximum pressure before venting. Two replicate tests for each of four densities and two orientations in gravity produced very consistent pressure histories. Some thermal responses demonstrate random sudden temperature increases due to decomposition product movement. The pressurization of the container due to the generation of gaseous products is more rapid for denser foams. When heating in the inverted orientation, where gravity is in the opposite direction of the applied heat flux, the liquefied decomposition products move towards the heated plate and the pressure rises more rapidly than in the upright configuration. This effect is present at all the densities tested but becomes more pronounced as density of the foam is decreased. A thermochemical material model implemented in a transient conduction model solved with the finite element method was compared to the test data. The expected uncertainty of the model was estimated using the mean value method and importance factors for the uncertain parameters were estimated. The model that was assessed does not consider the effect of liquefaction or movement of gases. The result of the comparison is that the model uncertainty estimates do not account for the variation in orientation (no gravitational affects are in the model) and therefore the pressure predictions are not distinguishable due to orientation. Temperature predictions were generally in good agreement with the experimental data. Predictions for response locations on the outside of the can benefit from reliable estimates associated with conduction in the metal. For the lighter foams, temperatures measured on the embedded component fall well with the estimated uncertainty intervals indicating the energy transport rate through the decomposed region appears to be accurately estimated. The denser foam tests were terminated at maximum allowed pressure earlier resulting in only small responses at the component. For all densities the following statements are valid: The temperature response of the embedded component in the container depends on the effective conductivity of the foam which attempts to model energy transport through the decomposed foam and on the stainless steel specific heat. The pressure response depends on the activation energy of the reactions and the density of the foam and the foam specific heat and effective conductivity. The temperature responses of other container locations depend heavily on the boundary conditions and the stainless steel conductivity and specific heat.

36 MATERIALS SCIENCE↗

NASA NTRS2014

Full System Modeling and Validation of the Carbon Dioxide Removal Assembly

The Atmosphere Revitalization Recovery and Environmental Monitoring (ARREM) project was initiated in September of 2011 as part of the Advanced Exploration Systems (AES) program. Under the ARREM project, testing of sub-scale and full-scale systems has been combined with multiphysics computer simulations for evaluation and optimization of subsystem approaches. In particular, this paper describes the testing and modeling of various subsystems of the carbon dioxide removal assembly (CDRA). The goal is a full system predictive model of CDRA to guide system optimization and development. The development of the CO2 removal and associated air-drying subsystem hardware under the ARREM project is discussed in a companion paper.

Coker, Robert↗

DOE OSTI2024

A framework for strategic discovery of credible neural network surrogate models under uncertainty

The widespread integration of deep neural networks in developing data-driven surrogate models for high-fidelity simulations of complex physical systems highlights the critical necessity for robust uncertainty quantification techniques and credibility assessment methodologies, ensuring the reliable deployment of surrogate models in consequential decision-making. Here, this study presents the Occam Plausibility Algorithm for surrogate models (OPAL-surrogate), providing a systematic framework to uncover predictive neural network-based surrogate models within the large space of potential models, including various neural network classes and choices of architecture and hyperparameters. The framework is grounded in hierarchical Bayesian inferences and employs model validation tests to evaluate the credibility and prediction reliability of the surrogate models under uncertainty. Leveraging these principles, OPAL-surrogate introduces a systematic and efficient strategy for balancing the trade-off between model complexity, accuracy, and prediction uncertainty. The effectiveness of OPAL-surrogate is demonstrated through two modeling problems, including the deformation of porous materials for building insulation and turbulent combustion flow for ablation of solid fuels within hybrid rocket motors.

42 ENGINEERING↗

NASA NTRS1996

Stratospheric Heterogeneous Chemistry and Microphysics: Model Development, Validation and Applications

The objectives of this project are to: define the chemical and physical processes leading to stratospheric ozone change that involve polar stratospheric clouds (PSCS) and the reactions occurring on the surfaces of PSC particles; study the formation processes, and the physical and chemical properties of PSCS, that are relevant to atmospheric chemistry and to the interpretation of field measurements taken during polar stratosphere missions; develop quantitative models describing PSC microphysics and heterogeneous chemical processes; assimilate laboratory and field data into these models; and calculate the extent of chemical processing on PSCs and the impact of specific microphysical processes on polar composition and ozone depletion. During the course of the project, a new coupled microphysics/physical-chemistry/ photochemistry model for stratospheric sulfate aerosols and nitric acid and ice PSCs was developed and applied to analyze data collected during NASA's Arctic Airborne Stratospheric Expedition-II (AASE-II) and other missions. In this model, detailed treatments of multicomponent sulfate aerosol physical chemistry, sulfate aerosol microphysics, polar stratospheric cloud microphysics, PSC ice surface chemistry, as well as homogeneous gas-phase chemistry were included for the first time. In recent studies focusing on AASE measurements, the PSC model was used to analyze specific measurements from an aircraft deployment of an aerosol impactor, FSSP, and NO(y) detector. The calculated results are in excellent agreement with observations for particle volumes as well as NO(y) concentrations, thus confirming the importance of supercooled sulfate/nitrate droplets in PSC formation. The same model has been applied to perform a statistical study of PSC properties in the Northern Hemisphere using several hundred high-latitude air parcel trajectories obtained from Goddard. The rates of ozone depletion along trajectories with different meteorological histories are presently being systematically evaluated to identify the principal relationships between ozone loss and aerosol state. Under this project, we formulated a detailed quantitative model that predicts the multicomponent composition of sulfate aerosols under stratospheric conditions, including sulfuric, nitric, hydrochloric, hydrofluoric and hydrobromic acids. This work defined for the first time the behavior of liquid ternary-system type-1b PSCS. The model also allows the compositions and reactivities of sulfate aerosols to be calculated over the entire range of environmental conditions encountered in the stratosphere (and has been incorporated into a trajectory/microphysics model-see above). Important conclusions that derived from this work over the last few years include the following: the HNO3 content of liquid-state aerosols dominate PSCs below about 195 K; the freezing of nitric acid ice from sulfate aerosol solutions is likely to occur within a few degrees K of the water vapor frost point; the uptake and reactions of HCl in liquid aerosols is a critical component of PSC heterogeneous chemistry. In a related application of this work, the inefficiency of chlorine injection into the stratosphere during major volcanic eruptions was explained on the basis of nucleation of sulfuric acid aerosols in rising volcanic plumes leading to the formation of supercooled water droplets on these aerosols, which efficiently scavenges HCl via precipitation.

Turco, Richard P.↗

NASA NTRS1998

Wavelet Filtering to Reduce Conservatism in Aeroservoelastic Robust Stability Margins

Wavelet analysis for filtering and system identification was used to improve the estimation of aeroservoelastic stability margins. The conservatism of the robust stability margins was reduced with parametric and nonparametric time-frequency analysis of flight data in the model validation process. Nonparametric wavelet processing of data was used to reduce the effects of external desirableness and unmodeled dynamics. Parametric estimates of modal stability were also extracted using the wavelet transform. Computation of robust stability margins for stability boundary prediction depends on uncertainty descriptions derived from the data for model validation. F-18 high Alpha Research Vehicle aeroservoelastic flight test data demonstrated improved robust stability prediction by extension of the stability boundary beyond the flight regime.

Brenner, Marty↗

NASA NTRS1998

On-Line Robust Modal Stability Prediction using Wavelet Processing

Wavelet analysis for filtering and system identification has been used to improve the estimation of aeroservoelastic stability margins. The conservatism of the robust stability margins is reduced with parametric and nonparametric time- frequency analysis of flight data in the model validation process. Nonparametric wavelet processing of data is used to reduce the effects of external disturbances and unmodeled dynamics. Parametric estimates of modal stability are also extracted using the wavelet transform. Computation of robust stability margins for stability boundary prediction depends on uncertainty descriptions derived from the data for model validation. The F-18 High Alpha Research Vehicle aeroservoelastic flight test data demonstrates improved robust stability prediction by extension of the stability boundary beyond the flight regime. Guidelines and computation times are presented to show the efficiency and practical aspects of these procedures for on-line implementation. Feasibility of the method is shown for processing flight data from time- varying nonstationary test points.

Brenner, Martin J.↗

NASA NTRS2012

SOFIA: Flying the Telescope

The primary focus of this paper is how the flight test team for the Stratospheric Observatory For Infrared Astronomy (SOFIA) re-cast an extensive developmental test program to meet key milestones while simultaneously ensuring safe certification of the airframe and delivery of an operationally relevant platform, ultimately saving the overall program from financial demise. Following a brief introduction to the observatory and what it is designed to do, SOFIAs planned developmental test program is summarized, including analysis and design philosophy, envelope expansion, model validation and airframe certification. How NASA used lessons learned from other aircraft that employed open cavities in flight is explained as well as how and why the chosen design was selected. The approach to aerodynamic analysis, including bare airframe testing, wind tunnel testing, computational fluid dynamics and finite element modeling proved absolutely critical. Despite a solid analytical foundation, many unknowns remained. History provides several examples of disastrous effects on both systems and flight safety if cavity design is not approached properly. For these reasons, an extensive test plan was developed to ensure a safe and thorough build-up for envelope expansion, airframe certification and early science missions. Unfortunately, as is often the case, because of chronic delays in overall program execution, severe schedule and funding pressures were present. If critical milestones were not met, domestic as well as international funding was in serious jeopardy, and the demise of the entire program loomed large. Concentrating on rigorous model validation, the test team challenged certification requirements, increased test efficiency and streamlined engineering analysis. This resulted in the safe reduction of test point count by 72%, meeting all program milestones and a platform that soundly satisfied all operational science requirements. Results from early science missions are shown and a proof of concept mission for which SOFIA was opportunely positioned is showcased. Success on this time-critical mission to observe a rare astronomical event proved the usefulness of an airborne observatory and the value in waiting for the capability provided by SOFIA. Finally, lessons learned in the test program are presented with emphasis on how lessons from previous aircraft and successful test programs were applied to SOFIA. Effective application of these lessons was crucial to the success of the SOFIA flight test program. SOFIA is an international cooperative program between NASA and the German Space Agency, DLR. It is a 2.5 meter (100-inch) telescope mounted in a Boeing 747SP aircraft used for astronomical observations at altitudes above 35,000 feet. SOFIA will accommodate a host of scientific instruments from the international science community and has a planned operational lifespan of more than 20 years.

Asher, Troy A.↗

DOE OSTI2026

DEM Modeling and Validation of Pebble Bed Packing Using Chrono::GPU

Accurate prediction of pebble packing structure is important for pebble bed reactors because the spatial distribution of void fraction directly affects coolant flow, pressure drop, heat transfer, and neutronic behavior. However, experimentally validated DEM studies that directly evaluate local void-fraction structure in reactor-relevant pebble beds remain limited. In this work, the pebble bed experiment conducted at Missouri University of Science and Technology is simulated using the graphics processing unit (GPU)-based discrete element method (DEM) code Chrono::GPU. The study focuses on evaluating the ability of Chrono::GPU to reproduce the packing arrangement and void-fraction distribution of a randomly packed spherical pebble bed. The DEM results are first verified against established radial void-fraction correlations, including the Mueller and Vortmeyer-Schuster models, to assess the predicted bulk porosity, near-wall behavior, and oscillatory packing structure. The simulation is then verified against reference DEM data and validated against gamma-ray computed tomography (CT) experimental data at three axial locations. The Chrono::GPU results reproduce the main features of the experimental packing, including the high void fraction near the wall, the first near-wall trough, and the damped oscillatory radial profile caused by wall-induced ordering. Quantitative comparison with DEM data and the CT-based radial profiles shows good agreement, with mean absolute errors on the order of 0.07 and root-mean-square errors below 0.09 for the averaged profiles. These results demonstrate that Chrono::GPU can accurately capture the void-fraction structure of spherical pebble beds and provides a reliable DEM framework for future pebble bed reactor packing, recycling, and thermal-hydraulic studies.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Experimentally Validated Numerical Models of Non-Isothermal Turbulent Mixing in High Temperature Reactors

In the Very High Temperature Reactor (VHTR), the non-uniform heat generation and flow maldistribution of coolant in the core generates conditions leading into the lower plenum with many jets at different temperatures and velocities. The hope is that the combined flow becomes fully mixed in a short distance so that the fluctuating temperatures in the mixing region do not cause unwanted thermal stresses in the supporting structures. These cyclic thermal stresses can cause degradation of the wall microstructure including crack initiation and growth, ultimately leading to the fatigue failure in the lower plenum, and can be accelerated by the high temperature environment in the VHTR. The focus of this project was to provide experimental data for future validation of computational efforts aimed at capturing the turbulent mixing in the lower plenum. Computational fluid dynamics (CFD) is also used as part of this effort to assess the requirements to model fundamental flows with application to the lower plenum as well at the applied flow conditions that mimic the experimental facilities. These efforts will lay the groundwork for future incorporation of stress analysis as well as fatigue and failure studies for multiple VHTR components. An additional emphasis is placed on reduced order models (ROM) using canonical flows, which will help to balance computational expense and accuracy and enable future work in uncertainty quantification. The flow in the lower plenum is extremely complex with hundreds of cooling jets entering and then being forced to change directions by 90° while navigating through an array of cylindrical support posts. Generating experimental data for such a complicated flow is difficult, not to mention that the computational requirements to generate an adequate temporal and spatial sampling is extremely expensive and time consuming. Therefore, the ultimate focus of this research is a “unit cell” which consists of six jets in the presence of a crossflow, and seven cylindrical support posts. It is scaled to achieve similar ranges of key dimensionless numbers. This serves to mimic flow conditions in different regions of the lower plenum by adjusting velocities, temperatures, and orientations, and represents a compromise between the complexity inside the full-scale application and the ideal conditions of a more fundamental study. In addition to the unit cell experiments and simulations, the complex flows in the VHTR lower plenum are broken down into a number of simplified (in some cases even fundamental) flows, two of which are turbulent jets and flow past cylinders. Each of these are studied, computationally and experimentally for isothermal and non-isothermal conditions. Flows where trusted experimental data is available in the literature (e.g., turbulent free jet), additional experiments are not needed. The result of these efforts is a database of experimental data and multiple computational studies, which provide an outlook to the requirements, needed to capture turbulent mixing flow physics The ROM results provide assessments for appropriate resource-light models that balance accuracy with reduced computational burdens.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2014

Using Micro-Synchrophasor Data for Advanced Distribution Grid Planning and Operations Analysis

This report reviews the potential for distribution-grid phase-angle data that will be available from new micro-synchrophasors (µPMUs) to be utilized in existing distribution-grid planning and operations analysis. This data could augment the current diagnostic capabilities of grid analysis software, used in both planning and operations for applications such as fault location, and provide data for more accurate modeling of the distribution system. µPMUs are new distribution-grid sensors that will advance measurement and diagnostic capabilities and provide improved visibility of the distribution grid, enabling analysis of the grid’s increasingly complex loads that include features such as large volumes of distributed generation. Large volumes of DG leads to concerns on continued reliable operation of the grid, due to changing power flow characteristics and active generation, with its own protection and control capabilities. Using µPMU data on change in voltage phase angle between two points in conjunction with new and existing distribution-grid planning and operational tools is expected to enable model validation, state estimation, fault location, and renewable resource/load characterization. Our findings include: data measurement is outstripping the processing capabilities of planning and operational tools; not every tool can visualize a voltage phase-angle measurement to the degree of accuracy measured by advanced sensors, and the degree of accuracy in measurement required for the distribution grid is not defined; solving methods cannot handle the high volumes of data generated by modern sensors, so new models and solving methods (such as graph trace analysis) are needed; standardization of sensor-data communications platforms in planning and applications tools would allow integration of different vendors’ sensors and advanced measurement devices. In addition, data from advanced sources such as µPMUs could be used to validate models to improve/ensure accuracy, providing information on normally estimated values such as underground conductor impedance, and characterization of complex loads. Although the input of high-fidelity data to existing tools will be challenging, µPMU data on phase angle (as well as other data from advanced sensors) will be useful for basic operational decisions that are based on a trend of changing data.

25 ENERGY STORAGE↗

DOE OSTI2020

Structural modeling and validation of laminated stacks in magnetic gearing applications

Laminated structures are commonly employed in magnetic gears based on their ability to direct magnetic flux, while inhibiting eddy currents. Unfortunately, the stiffness of the laminated structure is much lower than a solid part, which can lead to unacceptable deflections, given the large magnetic forces and small air gaps in magnetic gears. Finite element analysis of laminations to accurately predict these deflections can be computationally expensive due to the small elements needed to model the thin lamination dimensions. These analyses also have some uncertainty due to the assignment of bonding stiffness. This paper presents a means of accurately modelling the deflection of a laminated stack with reduced complexity and computational time, which is compared to experimental results. Here, the resulting methods are then used to assess the magnetic and mechanical advantages of different designs for the modulating pieces of a magnetic gear.

42 ENGINEERING↗

DOE OSTI2015

Verification and Validation of the PLTEMP/ANL Code for Thermal-Hydraulic Analysis of Experimental and Test Reactors

The document compiles in a single volume several verification and validation works done for the PLTEMP/ANL code during the years of its development and improvement. Some works that are available in the open literature are simply referenced at the outset, and are not included in the document. PLTEMP has been used in conversion safety analysis reports of several US and foreign research reactors that have been licensed and converted. A list of such reactors is given. Each chapter of the document deals with the verification or validation of a specific model. The model verification is usually done by comparing the code with hand calculation, Microsoft spreadsheet calculation, or Mathematica calculation. The model validation is done by comparing the code with experimental data or a more validated code like the RELAP5 code.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Model and Validation of Single-Axis Tracking with Bifacial PV

Single-axis tracking is a cost-effective deployment strategy for large-scale ground-mount photovoltaic systems in regions with high direct-normal irradiance. Bifacial modules in 1-axis-tracking systems boost energy yield by 4%-15% depending on module type and ground albedo, with a global average of 9%. This benefit is in addition to the 15%-25% energy gain already afforded by single-axis tracking relative to fixed-tilt deployments. Here, we compare model results against field performance data for two side-by-side bifacial/monofacial tracked systems - one in Albuquerque, NM, USA, and one in eastern Oregon. The Albuquerque system shows monthly rear irradiance gain of 10%-14.9%, and the Oregon bifacial system has an average performance ratio 9.4% higher than the monofacial system. Both results match bifacial irradiance model results within uncertainty. Simulations show that smart tracking algorithms can offer more than 1% improvement on annual energy yield by adjusting tilt angle under cloudy conditions. Finally, ray-tracing simulations investigated edge brightening, suggesting a 15%-25% increase in rear irradiance at the ends of tracker rows, but up to 20% loss from center-mounted torque tubes, creating multiple shadows.

14 SOLAR ENERGY↗

DOE OSTI2019

Estimation of inflow uncertainties in laminar hypersonic double-cone experiments

We propose herein a probabilistic framework for assessing the consistency of an experimental dataset, i.e., whether the stated experimental conditions are consistent with the measurements provided. In case the dataset is inconsistent, our framework allows one to hypothesize and test sources of inconsistencies. This is crucial in model validation efforts. The framework relies on Bayesian inference to estimate experimental settings deemed uncertain, from measurements deemed accurate. The quality of the inferred variables is gauged by its ability to reproduce held-out experimental measurements. We test the correctness of the framework on three double-cone experiments conducted in the CUBRC Inc.'s LENS-I shock tunnel, which have also been numerically simulated successfully. Thereafter, we use the framework to investigate two double-cone experiments (executed in the LENS-XX shock tunnel) which have encountered difficulties when used in model validation exercises. We detect an inconsistency with one of the LENS-XX experiments. In addition, we hypothesize two causes for our inability to simulate LEXS-XX experiments accurately and test them using our framework. We find that there is no single cause that explains all the discrepancies between model predictions and experimental data, but different causes explain different discrepancies, to larger or smaller extent. We end by proposing that uncertainty quantification methods be used more widely to understand experiments and characterize facilities, and we cite three different methods to do so, the third of which we present in this paper.

Thermophysics↗

DOE OSTI2020

Multiple Environmental Influences on the Lightning of Cold-Based Continental Cumulonimbus Clouds. Part I: Description and Validation of Model

In this two-part paper, influences from environmental factors on lightning in a convective storm are assessed with a model. In Part I, an electrical component is described and applied in the Aerosol–Cloud model (AC). AC treats many types of secondary (e.g., breakup in ice–ice collisions, raindrop-freezing fragmentation, rime splintering) and primary (heterogeneous, homogeneous freezing) ice initiation. AC represents lightning flashes with a statistical treatment of branching from a fractal law constrained by video imagery. The storm simulated is from the Severe Thunderstorm Electrification and Precipitation Study (STEPS; 19/20 June 2000). The simulation was validated microphysically [e.g., ice/droplet concentrations and mean sizes, liquid water content (LWC), reflectivity, surface precipitation] and dynamically (e.g., ascent) in our 2017 paper. Predicted ice concentrations (~10 L -1 ) agreed—to within a factor of about 2—with aircraft data at flight levels (-10° to -15°C). Here, electrical statistics of the same simulation are compared with observations. Flash rates (to within a factor of 2), triggering altitudes and polarity of flashes, and electric fields, all agree with the coincident STEPS observations. The “normal” tripole of charge structure observed during an electrical balloon sounding is reproduced by AC. It is related to reversal of polarity of noninductive charging in ice–ice collisions seen in laboratory experiments when temperature or LWC are varied. Positively charged graupel and negatively charged snow at most midlevels, charged away from the fastest updrafts, is predicted to cause the normal tripole. Total charge separated in the simulated storm is dominated by collisions involving secondary ice from fragmentation in graupel–snow collisions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

Model and Validation of Single-Axis Tracking with Bifacial Photovoltaics: Preprint

Single-axis tracking is a cost effective deployment strategy for large-scale ground-mount photovoltaic (PV) systems in regions with high direct-normal irradiance (DNI). Bifacial modules in 1-axis tracking systems boost energy yield by 4% - 15% depending on module type and ground albedo, with a global average of 9%. This benefit is in addition to the 15%-25% energy gain already afforded by single-axis tracking relative to fixed-tilt deployments. Here we compare model results against field performance data for two side-by-side bifacial / monofacial tracked systems - one in Albuquerque NM, and one in eastern Oregon. The Albuquerque system shows monthly rear irradiance gain of 10-14.9%, and the Oregon bifacial system has an average performance ratio 9.4% higher than the monofacial system. Both results match bifacial irradiance model results within uncertainty. Simulations show that smart tracking algorithms can offer more than 1% improvement on annual energy yield by adjusting tilt angle under cloudy conditions. Finally, ray-tracing simulations investigated edge brightening, suggesting 15%-25% increase in rear irradiance at the ends of tracker rows, but up to 20% loss from center-mounted torque tubes, creating multiple shadows.

14 SOLAR ENERGY↗

DOE OSTI2012

Spreader-Bar Radiation Detection System Enhancements: A Modeling and Simulation Study

An investigation of radiation detectors on crane-mounted platforms was performed to understand the limitations and optimal capability of these types of systems. Crane-mounted systems are primarily focused on crane-mounted radiation detector systems, where the detectors are mounted on a spreader-bar platform. Spreader bars are attached with cables to a crane at seaports to load and unload containers from cargo ships. The bars can spread from 20 feet to 53 feet using hydraulics, allowing a single bar to move a variety of container lengths. Spreader-bars are also used on straddle carriers, which move containers around the laydown yard in the port. Spreader bar radiation detection (SBRD) systems are commercially available from at least two companies. These systems employ a set of spectroscopic sensors placed on the underside of a gantry crane and held near the top of a cargo container for detection. These systems have been previously tested and some issues and limitations observed. Radiation detectors mounted on spreader-bars are single sided systems (observing cargo only from the top) and it is therefore challenging to obtain the same sensitivity as double-sided systems (for example, portal monitors) especially when considering the possible amounts of intervening cargo that could be present. The approximately exponential attenuation of gamma rays in intervening dense cargo presents an inherent limitation to detection. However, SBRD systems hold detectors closer to the container, have a longer dwell time, and may have lower background (over the ship); all of these aspects help mitigate the single-sided issue. In addition, there are operational considerations that make spreader-bar radiation systems attractive. These include scanning for radiation during other operations (loading, unloading or container movement) which minimizes additional time for scanning, incorporating the radiation detection into existing equipment to minimize initial cost, and in the case of ship unloading, scanning the containers before reaching the laydown yard. This study is focused on researching optimized configurations of SBRD systems, including number of detectors, locations, and best use of detector data, to determine a reasonable limit on the capability of these types of systems. The results will help support decisions on where and how these systems might be effectively deployed, and could be used for future specification development for SBRD acquisition. The next phase of this research and investigation into SBRD systems and quantification of the possible improved capability with an enhanced SBRD is the focus of this report. Supporting this investigation, detailed models of an enhanced SBRD system were created using a 3D radiation transport code, and models were run to simulate the data from sources and background for a realistic cargo-loading port environment. The enhanced SBRD had increased detector material (numbers of detectors) compared to the commercial systems, with a distribution providing more uniform coverage. Measurements using small industrial sources were made with an enhanced SBRD system developed by Sandia National Laboratory to support model validation to establish credibility for the simulations of these threat and background scenarios. A significant simulation effort was undertaken to simulate sources of interest within a 40-foot cargo container. In order to estimate the performance of a generalized SBRD system in scenarios including background and cargo, a highly enriched uranium (HEU) test source (with 3x10 -8 232 U by weight) within a wood cargo model was simulated for a 40-foot cargo container. This source was placed at a variety of locations, and the flux from the source was multiplied as necessary to create estimated minimal detectable quantities (MDQ) figures for various quantities of HEU. Simulated data sets were produced corresponding to a complete container offloading scenario for a large number of statistical realizations. Significant work was performed on both the algorithm development and the container cargo distributions entering the US, and the result of this modeling, validation, and simulation effort was a set of estimates of the performance of a variety of radiation detection algorithms in this cargo-screening environment. In the case of algorithms, a variety of contemporary radiation detection and identification approaches were employed, and the optimal approaches to selecting time and location subsets of detector data were explored. In all cases, algorithm performance was compared, and the best approaches were suggested along with the best expected performance from the enhanced SBRD. In general, template-matching schemes employing a limited set of regression parameters tend to provide best results. The improvements of an enhanced SBRD with increased detector material and improved algorithms result in an effective MDQ of 10 kg of HEU in ~50 percent of the imported cargo in 40-foot containers, assuming a random source location. This is approximately two times the capability of the estimated performance of the commercial systems. For an MDQ of the 10 kg HEU source located in the worst location (bottom of the 40-foot container), the volume of cargo scanned drops to 10% for the enhanced SBRD, again a factor of two or more larger than the commercial systems. Enhancing the SBRD systems by adding more detectors, providing a more uniform coverage, and incorporating more advanced algorithms will result in a significant increase in capability. Although this investigation provided some indication of the performance capabilities of an enhanced SBRD system, additional work is needed to estimate the capability for other container configurations, such as the 20 and 45 foot containers. Since the 20-foot container weight limit is similar to the 40-foot, more dense cargo is typically shipped in 20-foot containers. This will result in a smaller percentage of cargo scanned for the 20-foot containers (for a particular source quantity) compared to the 40-foot containers. In addition to other configuration, other source material needs to be investigated to understand the capabilities for the entire threat space, where only HEU is considered in this work.

crane-mounted↗

DOE OSTI2017

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Simunovic, Srdjan↗