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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

Although ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM. Test artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C. Deviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters. To the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A functional modeling approach for quality assurance in metal additive manufacturing

Purpose: Due to the complexity of and variations in additive manufacturing (AM) processes, there is a level of uncertainty that creates critical issues in quality assurance (QA), which must be addressed by time-consuming and cost-intensive tasks. This deteriorates the process repeatability, reliability and part reproducibility. So far, many AM efforts have been performed in an isolated and scattered way over several decades. Here, a systematically integrated holistic view is proposed to achieve QA for AM. Design/methodology/approach: A systematically integrated view is presented to ensure the predefined part properties before/during/after the AM process. It consists of four stages, namely, QA plan, prospective validation, concurrent validation and retrospective validation. As a foundation for QA planning, a functional workflow and the required information flows are proposed by using functional design models: Icam DEFinition for Function Modeling. Findings: The functional design model of the QA plan provides the systematically integrated view that can be the basis for inspection of AM processes for the repeatability and qualification of AM parts for reproducibility. Research limitations/implications: A powder bed fusion process was used to validate the feasibility of this QA plan. Feasibility was demonstrated under many assumptions; real validation is not included in this study. Social implications: This study provides an innovative and transformative methodology that can lead to greater productivity and improved quality of AM parts across industries. Furthermore, the QA guidelines and functional design models provide the foundation for the development of a QA architecture and management system. Originality/value: This systematically integrated view and the corresponding QA plan can pose fundamental questions to the AM community and initiate new research efforts in the in-situ digital inspection of AM processes and parts.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Step-Down Test Procedure for Wavelet Shrinkage Using Bootstrapping

Wavelet thresholding (or shrinkage) attempts to remove the noises existing in the signals while preserving inherent pattern characteristics in the reconstruction of true signals. For data-denoising purpose, we present a new wavelet thresholding procedure which employs the step-down testing idea of identifying active contrasts in unreplicated fractional factorial experiments. The proposed method employs bootstrapping methods to a step-down test for thresholding wavelet coefficients. By introducing the concept of a false discovery error rate in testing wavelet coefficients, we shrink the wavelet coefficients with p -values higher than the error rate. The error rate controls the expected proportion of wrongly accepted coefficients among chosen wavelet coefficients. Bootstrap samples are used to approximate the p -value for computational efficiency. We also present some guidelines for selecting the values of hyper-parameters which affect the performance in the step-down thresholding procedure. Based on some common testing signals and an air-conditioner sounds example, the comparison of our proposed procedure with other thresholding methods in the literature is performed. The analytical results show that the proposed procedure has a potential in data-denoising and data-reduction in a variety of signal reconstruction applications.

42 ENGINEERING↗
DOE OSTI2025

Enhancing the Survivability of Power Systems With Grid-Edge DERs Against DoS Attacks

Power system survivability, defined as the ability of a system to maintain steady-state functionality under varying operational conditions, reflects its resilience against disturbances. While existing research primarily focuses on physical-layer disturbances, the increasing prevalence of grid-edge DERs, which are primarily used for integrating renewable energy, has significantly expanded the cyber attack surface. As a result, operational disruptions caused by cyber threats are posing significant challenges to system survivability and cannot be overlooked. To fill this gap, we redefine system survivability to incorporate the cyber layer’s status and propose a Distributionally Robust Optimization (DRO) approach to enhance power system survivability against potential cyber-physical threats. In this paper, we first analyze the operational guidelines of systems with a high penetration of DERs under various cyber network conditions and redefine survivability in this context. Next, we focus on the most common cyber threat, Denial-of-Service (DoS) attacks, and develop a corresponding attack model. This model allows for the creation of a kernel-based ambiguity set that captures attack uncertainties using historical data. Finally, we transform the proposed DRO model as a tractable optimization problem, with its solution providing an optimal cyber redundancy plan to enhance system survivability in DoS attack scenarios. Simulation results on the IEEE 13-node and 123-node test feeders demonstrate the effectiveness of our proposed model in improving system survivability. This model can also be expanded to include other types of common attacks and serve as a comprehensive planning tool to improve overall cyber physical survival of the system.

cybersecurity↗
DOE OSTI2025

A Secondary Control Framework for Microgrid Interoperability With Vendor-Agnostic Grid-Forming Units: Design, Implementation, and Demonstration via Large-Scale Hardware Setup

The reliable operation of islanded microgrids increasingly depends on secondary controls that restore voltage and frequency to nominal values and ensure accurate active and reactive power sharing. Centralized secondary control architectures achieve high accuracy through global coordination at the cost of single-point failures and limited scalability compared with decentralized/distributed approaches. But a critical gap remains in addressing the interoperability and vendor-agnostic operation of secondary controls in real-world microgrids where heterogeneous diesel generator(s) and grid-forming (GFM) inverter(s) from multiple manufacturers always coexist. Practical and vendor-agnostic interoperability guidelines for the secondary control architecture of microgrids with multiple GFM units have not yet been developed; therefore, this paper proposes an interoperable and vendor-agnostic secondary control framework that operates seamlessly across GFM units from different vendors without relying on proprietary controls and protocols, hardware, or lock-ins. The framework leverages existing communication infrastructures (e.g., Modbus TCP/IP) to enable cost-effective deployment while addressing practical challenges, such as packet loss and quantization errors. Mitigation strategies-including data averaging, situational event-triggered control, and finite-iteration execution-are introduced to enhance reliability under real-world conditions. A generalized modeling and design framework is also presented, supported by robustness analysis to demonstrate independence from vendor-specific implementations. The proposed framework is validated through a large-scale hardware demonstration using a 3-$\phi$, 480-V, 60-Hz, 713-kVA laboratory hardware microgrid involving a heterogeneous diesel generator and multiple GFM inverters, showcasing its effectiveness in achieving stable voltage and frequency restoration and accurate power sharing under practical constraints. The results highlight the framework's potential as a scalable and practical solution for next-generation microgrids requiring openness, standard framework, and interoperability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Phase Drifts and Signal Dispersion in Coaxial Cables

Phase reference distribution is a critical challenge in modern linear particle accelerators, such as European Spallation Source (ESS), European X-ray Free Electron Laser (E-XFEL), or Proton Improvement Plan II (PIP-II). Similar issues may also arise in other RF systems that need to synchronize many independent circuits. Achieving low phase drift of the reference signal requires careful selection of cables and their environmental operating conditions. Due to the limited data provided by cable manufacturers, it is necessary to characterize the cable performance. This article investigates the phase drifts in coaxial cables and presents a dedicated measurement methodology. The dispersion characteristics of the cables are also examined. The measurement results of various coaxial cables are presented, along with conclusions and practical guidelines for designers of phase reference distribution lines.

coaxial cables↗
DOE OSTI2023

Medium Voltage Solid State Transformer for Extreme Fast Charging Applications

A modular and scalable solid state transformer (SST) with direct medium voltage (MV) AC connectivity is proposed to enable DC extreme fast charging (XFC) of electric vehicles. Single-phase-modules (SPMs), each consisting of an active-front-end (AFE) stage and an isolated DC-DC stage, are connected in input-series-output-parallel (ISOP) configuration. The modular hardware is co-designed with decentralized control of the DC-DC stages where voltage and power balancing are achieved by each SPM using only its local sensor feedback; a centralized controller (CC) regulates the low voltage (LV) DC bus through the AFE stages without any sensor feedback form the SPMs. The controller architecture contrasts sharply with the prior art for MV AC to LV DC SSTs where high-speed bidirectional communication among SPMs and a CC are required for module-level voltage and power balancing, which severely limits the scalability and practical realization of higher voltage and higher power units. Detailed small-signal analysis and controller design guidelines are developed. Furthermore, a soft start-up strategy is presented. The proposed converter and control structure are validated through simulation and experimental results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

DaYu: Optimizing Distributed Scientific Workflows by Decoding Dataflow Semantics and Dynamics

The combination of ever-growing scientific datasets and distributed workflow complexity creates I/O performance bottlenecks due to data volume, velocity, and variety. Although the increasing use of descriptive data formats (e.g., HDF5, netCDF) helps organize these datasets, it also creates obscure bottlenecks due to the need to translate high level operations into file addresses and then into low-level I/O operations. To address this challenge, we introduce DaYu, a method and toolset for analyzing (a) semantic relationships between logical datasets and file addresses, (b) how dataset operations translate into I/O, and (c) the combination across entire workflows. DaYu's analysis and visualization enables identification of critical bottlenecks and reasoning about remediation. We describe our methodology and propose optimization guidelines. Evaluation on scientific workflows demonstrates up to 3.7x performance improvements in I/O time for obscure bottlenecks. The time and storage overhead for DaYu's time-ordered data is typically under 0.2% of runtime and 0.25% of data volume, respectively.

Tang, Meng↗
DOE OSTI2021

Comparison of Simulation of Dual-Active Bridge in Different Simulators and Using Different Simulation Methods

The accuracy of states measured from simulation of a dual-active bridge (DAB) converter with an open-loop controller has been used for comparing simulation software and algorithms. The accuracy of the measured states is sensitive to simulation settings and parameters chosen. In this paper, the simulation of the DAB converter with open-loop control is run in the MATLAB/Simscape Electrical, PLECS, and PSCAD software environments, with various simulation settings. The simulation results are also compared with a new simulation algorithm proposed for DAB simulations. Different simulation settings are evaluated, including different solver types, operating conditions, and the on-state resistance values of the MOSFET switches. The simulation results are compared with the theoretical calculations. It is shown that unexpected divergence and DC offset may occur in some cases. This paper provides guidelines to simulate the DAB converter with open-loop control.

Yin, Shiyuan↗
DOE OSTI2020

A Sensorless Coil Detection Scheme based on Dead-Time Effect in Dynamic Wireless Power Transfer Systems

The detection of electric vehicles in dynamic wireless power transfer (DWPT) systems is important to reduce the standby losses and comply with the electromagnetic-field emission guidelines recommended by the International Commission for Non-Ionizing Radiation Protection. This paper discusses a novel sensorless coil detection scheme, which exploits the phenomenon of voltage-polarity reversal/notches caused by the dead-time effect in the full-bridge inverter. The variations in the system impedance and dead-time effects are collectively exploited to detect the receiver coil in the DWPT system. The proposed coil detection scheme is accomplished at low excitation voltage, which reduces the inverter standby losses. The theoretical analysis of the notch occurrence and open-loop simulation results are presented using a DWPT model developed in the piecewise linear electrical circuit simulation software.

Kavimandan, Utkarsh↗
DOE OSTI2020

Shield Design for 50 kW Three-Phase Wireless Charging System

In this paper, magnetic field emissions (MFE) from a 50 kW bipolar coil-based three-phase wireless charging system (WCS) is investigated. Then, a shield design is proposed to suppress the MFE below the safety limit identified by the International Commission of Non-Ionized Radiation Protection (ICNIRP) guidelines. Bipolar coil-based three-phase (3φ) WCSs provide extremely high power-density; therefore, the 3φ WCSs are highly promising for high-power fast-wireless-charging of the electric vehicles. For the high-power EV application, it is a critical challenge to design a shield to suppress the MFE below the safety limit. The traditional aluminum shield is found ineffective for the bipolar 3φ-WCS. The proposed shield is designed with high-permeability magnetic material, i.e. ferrite, nanocrystalline material, etc. The proposed shield is simulated in finite element analysis (FEA) and the FEA results show that the proposed magnetic shield effectively suppresses the magnetic field emission below the ICNIRP limit. The generalized design of the proposed shield can be used for even higher power bipolar coil based WCSs.

Mohammad, Mostak↗
DOE OSTI2021

Angle Droop Design for Grid-Forming Inverters Considering Impacts of Virtual Impedance Control

Grid-forming inverters (GFMs) based on active power-frequency droop control and reactive power-voltage droop control have been developed in recent years, which can generate voltage and frequency references for islanded power systems or microgrids to improve system-wide synchronization and power-sharing capability. It is known that the control delays in GFMs may cause system harmonic instability. To eliminate this issue, virtual impedance techniques are normally adopted. This paper gives a comprehensive examination of the impacts of virtual impedance control block Z v in GFMs on system stability. It is revealed that although Z v is effective in eliminating system harmonic stability, it may ruin system synchronization stability as a side effect. To compensate for the negative impacts caused by Z v , an active power-angle control block is added into the conventional droop control. Design criteria are also proposed accordingly to ensure system stability over the entire frequency range. Simulations and experimental testing are conducted to validate the analysis and the proposed design guidelines. It can be concluded that the Z v control-caused grid-synchronization instability issues can be eliminated with an appropriate active power-angle droop design.

Kong, Le↗
DOE OSTI2022

A Fast-Response High-Accuracy Overvoltage Protection Circuit for Soft-Switching Current-Source Converters

Although voltage-source converters (VSCs) have been a focus of research for decades and are widely applied in numerous applications, they face great challenges in short-circuit failures, high dv/dt and electromagnetic interference (EMI), especially using wide bandgap devices. Instead, current-source converters (CSCs) are attracting increasing attention in recent years owing to their friendliness to short-circuit faults, improved EMI, etc. For CSCs, overvoltage is the most catastrophic failure since the semiconductor devices can hardly withstand an overvoltage for a short pulse. In this paper, a fast-response high-accuracy overvoltage protection (OVP) circuit is proposed to protect CSCs from overvoltage damage. It also features a small form factor, good noise-immunity, friendly retrofit capability, and no need for active switches. In this paper, the operating principle and design guideline of the proposed OVP circuit is introduced. Its effectiveness is validated in soft-switching solid-state transformer (S4T) at 500 V. In experiments, the voltage detection error of less than 5% and a propagation delay of fewer than 400 ns have been achieved.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Deep Learning-enhanced Block-Diagram Modeling of Solar Power Systems

Data-driven models of power system inverter-based resources are desired to run simulations faster than with detailed electromagnetic transient models, to hide proprietary design details, to support control system design applications, and to aggregate the effects of distributed energy resources. This paper applies a customized Hammerstein Wiener framework to train block diagram models from thousands of electromagnetic transient simulations or experimental test records. The block diagram models integrate with larger grid simulations as voltagecontrolled current sources or current-controlled voltage sources for several simulators. Guidelines for block architecture and training are presented. Three-phase balanced, three-phase unbalanced, and single-phase examples all achieve an acceptable root mean square error of no more than 0.05 per-unit.

Mcdermott, Thomas E. [Private consulting company]↗
DOE OSTI2022

F*** workflows: when parts of FAIR are missing

The FAIR principles for scientific data (Findable, Accessible, Interoperable, Reusable) are also relevant to other digital objects such as research software and scientific workflows that operate on scientific data. The FAIR principles can be applied to the data being handled by a scientific workflow as well as the processes, software, and other infrastructure which are necessary to specify and execute a workflow. The FAIR principles were designed as guidelines, rather than rules, that would allow for differences in standards for different communities and for different degrees of compliance. There are many practical considerations which impact the level of FAIR-ness that can actually be achieved, including policies, traditions, and technologies. Because of these considerations, obstacles are often encountered during the workflow lifecycle that trace directly to shortcomings in the implementation of the FAIR principles. Here, we detail some cases, without naming names, in which data and workflows were Findable but otherwise lacking in areas commonly needed and expected by modern FAIR methods, tools, and users. We describe how some of these problems, all of which were overcome successfully, have motivated us to push on systems and approaches for fully FAIR workflows.

Wilkinson, Sean↗
DOE OSTI2022

Instrumentation for Assessing DC Electrical Distribution Systems in Buildings

Direct current (DC) distribution systems is emerging as a favorable option over alternating current in buildings due to its energy and non-energy benefits (e.g., efficiency, resilience, safety). However, limited guidelines exist to evaluate the DC electrical distribution infrastructure. This paper aims to fill that gap by detailing our experience with metering a building-level electrical DC distribution system. Our case study is a DC microgrid at the Direct Energy Partners Research & Development facility located in Charlotte, North Carolina. This paper presents our approach, technical challenges, and lessons learned with DC metering and instrumentation.

buildings↗
DOE OSTI2022

An Experiment-based Distribution Level Performance Comparison among PMUs

This paper presents a experiment-based distribution level performance comparison among three Phasor Measurement Units (PMUs). Several evaluation criteria, including the total vector error, the phase angle error, the frequency error, the rate of change of frequency, the response time, the settling time, the overshoot, and the algorithm window size, are selected to compare the static and dynamic performances of the PMUs under steady state and step response test conditions. In order to have a more realistic test environment, a test is setup in which PMUs under evaluation have exactly the same input signals. The quantitative experiment result analysis gives an end-user guideline to the PMU selection regarding distribution level applications.

Yin, He↗
DOE OSTI2020

A Flexible and Secure Evaluation Platform for Overvoltage Protection in Power Electronics Systems

This paper summarizes the fault mechanisms specifically for the overvoltage protection schemes in power electronic converters and the resulted power electronics enabled systems. A flexible and secure evaluation platform for overvoltage protection, has also been presented based on this conceptual mechanism. The proposed platform aims at testing the protection performance of distinctive overvoltage protection schemes. It would be applied to verify the effectiveness, identify potential strengths and weaknesses, and obtain the most critical protection response time to provide sufficient engineering insights for the designer. The operation principle and detailed design guideline have been presented first. The comprehensive component stress has been analyzed. An intensive set of LTSpice simulations have been conducted to show the validity of the proposed assessment approach.

Zheng, Sheng↗