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At least 793 records · Page 44

Development of High-Performance Ni-base Alloys for Gas Turbine Wheels Using a Coprecipitation Approach (Final Technical Report)

In this project, a synergistic approach involving experiments informed by modelling was used to develop γ'/γ'' coprecipitation-strengthened Ni-base superalloys for land-based gas turbine wheels. In thick sections of such turbine wheels, the slow cooling rate normally observed, as well as variations in cooling rate could potentially result in drastically inhomogeneous and coarsened microstructure. Thus, ten alloy compositions were selected based on coprecipitation and sluggish γ’ growth and coarsening during three iterations of alloy development, assisted by extensive CALPHAD modeling. Phase equilibrium calculations, informed by the characterization of early alloys, were successful in predicting suitable aging treatments to obtain bimodal coprecipitate distribution in several alloys. These aging treatments were applied to the subsequent round of alloys and the resulting microstructures were characterized in detail. Two different cooling rates were used during each of these heat treatments to simulate the range of cooling rates observed in a thick section forging. The microstructures were used to calibrate a multi-phase field model (MPF), which was used to study the formation mechanisms of various coprecipitate morphologies observed in the experiments. Following this, the most promising alloys in each round were selected and studied using high temperature tensile and creep tests. Considering that a slower cooling rate would lead to a strength debit, while a faster cooling rate might lead to a decline in creep rupture life of a full-scale wheel, tensile tests were carried out for slower cooled samples, while creep tests were carried out for faster cooled samples. The deformation microstructures were then characterized using advanced characterization techniques such as Diffraction Contrast-Scanning Transmission Electron Microscopy (DC-STEM) and Electron Channeling Contrast Imaging (ECCI). Further, a mean-field creep model was developed and calibrated using these experimental findings to predict long-term creep behavior of these coprecipitation-strengthened alloys.

36 MATERIALS SCIENCE↗

Energy Management Information Systems Technical Resources Report

Guide supports federal facility staff in understanding, designing, procuring, and implementing Energy Management Information Systems (EMIS) as a valuable component of their portfolio-level energy and water planning and management strategies. As a broad and rapidly evolving family of tools that monitor, analyze, and control building energy use and system performance, EMIS tools present significant opportunities for federal sector energy savings and improved operational performance. EMIS are at the forefront of transforming energy management best practices by providing building owners and operators with well-organized building performance and energy consumption data, enabling a host of analytic capabilities. These capabilities include portfolio-wide energy benchmarking, data visualization, and key performance indicator tracking; automated fault detection and diagnostics (AFDD); artificial intelligence for predictive analytics and control; automated measurement and verification of energy conservation measures; and supervisory control enabling automated system optimization and demand management.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

"Experimental Research at the Energy Frontier in High Energy Physics" (Final Technical Report)

Recent developments in particle physics and cosmology raise the exciting prospect that we are on the threshold of a major step forward in our understanding of the universe. This proposal describes a research program at the University of Illinois in experimental high-energy physics on the ATLAS experiment at CERN’s Large Hadron Collider (LHC). Our group actively collaborates with the Theory Group and other experimental efforts within the Office of Science frontiers (energy, intensity, and cosmic) to search broadly in the ATLAS data to maximize our potential for scientifc discovery. The thrust of this proposal is to search for new physics using ATLAS data. Emphasis is placed on novel use of the Higgs boson as a tool to search for new particles and interactions and development of fast particle tracking systems for use in triggering. We propose to continue our strong role in FTK commissioning and operations. To maximize the impact and vitality of the proposed physics program through the HL-LHC running, we will lead firmware efforts in the HWTT Phase-II TDAQ upgrade, leveraging our expertise acquired through development of fast tracking hardware and firmware for the FTK system.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

New Laboratory and Astrophysical Probes of Physics Beyond the Standard Model (Final Technical Report)

The first of these directions centers on new ideas in dark matter detection. As experimental scrutiny narrows the window for new physics at the weak scale, it has become apparent that the solution to the dark matter mystery may not reside there. Theoretical developments such as the hidden sector/valley paradigm have, at the same time, shown that compelling theories of dark matter reside below the weak scale. Searching for dark matter at lower mass scales requires looking beyond the current paradigm of dark matter direct detection based on nuclear recoils. It is the goal of this project to provide new ideas to guide the experimental program looking for light dark matter. I am actively proposing ideas for detecting dark matter as light as a meV, well beyond the current focus of GeV-TeV scale dark matter. Some of the ideas I have proposed, such as superconducting, superfluid, and polar material targets, are actively being developed into experiments. My group will provide the relevant calculations to determine dark matter reach, providing crucial input to experiment on which targets should be developed. We will also provide an effective field theory framework to understand which types of experiments are most sensitive to each interaction type. The second of these directions is on probes of dark matter substructure as a mean to constrain, or observe, models of dark matter. The standard ΛCDM paradigm assumes that the dark matter density perturbations are adiabatic, scale invariant, and produced during inflation. However, many standard models of dark matter will produce modifications of this prediction, such as axion models with symmetry broken below the inflationary scale. Remarkably, we have limited direct measurements of the dark matter clumpiness at mass scales below dwarf galaxies. This allows for the possibility of observing modifications from vanilla ΛCDM due to particle dynamics. In many cases, simulations of dark matter structure in the presence of non-scale invariant fluctu- ations are understudied or completely lacking. I plan to develop both theoretical predictions for small scale structure in models with additional matter power on small scales, as well as observa- tional probes of small scale halos or clumps. One idea I have been recently focused on is pulsar timing, though my group will pursue a variety of lensing and astrometric probes. Lastly, the most risky direction involves spacetime fluctuations from quantum gravity. I showed that if one assumes that metric fluctuations in the Minkowski vacuum, at a surface separating a region in and out of causal contact (which we call a “horizon”), are determined by standard thermodynamic considerations at horizon, these metric fluctuations are large enough to observe in an interferometer with similar sensitivity to LIGO. In a follow-up paper we showed that these assumption holds for the vacuum in AdS/CFT. In future work, I plan to connect this work to recent soft graviton results, to frame this work in a concrete Randall-Sundrum model, and to work out concrete phenomenological predictions from the model. This work unquestionably takes a less trodden path, and works well as part of a well-rounded portfolio of less and more risky ideas. Particle physics is currently at a juncture which requires bold exploration of qualitatively new directions. This proposal outlines some of my plans over the coming years in these directions, leaving room also for surprises.

79 ASTRONOMY AND ASTROPHYSICS↗

Advancing Solar Innovation for Low and Moderate-Income Households (Final Technical Report)

The overarching goal of this project was to deepen the understanding of the social and economic aspects of solar adoption, with a specific eye towards any pathways or barriers that could be identified that directly impact low and moderate-income households. Specific objectives included (1) identifying and assessing significant non-economic barriers that complicate the ability of LMI households to adopt and benefit from solar, even under scenarios with low economic barriers; (2) assessing the differential ability of groups to benefit from solar adoption based on their ability to invest in different solar innovations; (3) explaining why some LMI communities nonetheless experience significantly higher rates of solar adoption and benefit than others; (4) developing a methodological model for generating data addressing key issues to the project; and (5) designing and developing an interactive web portal that aggregates existing datasets, provides researchers trend analysis capabilities, standardizes project protocols for other states and communities; provides the opportunities for researchers using the same protocol in other communities to upload their results; and engages with the general public by providing them the ability to upload their own perspectives and stories of solar technology adoption. Through a common framework for conducting semi-structured field interviews. In partnership with cooperative extension services, in conjunction with survey research and the aggregation of existing solar adoption datasets, this study has identified that currently ,there is a strong values alignment and knowledge access challenge that continues to affect solar adoption. Participants in this study – many of whom are either low or moderate-income and/or live in underserved rural communities do not believe solar is an option where they live or believe solar is appropriate for their lifestyle. This perception challenge is further exacerbated by the absolute dearth of adopters in most communities and a total lack of local marketing for solar energy. What marketing that does exist is geared towards audiences other than those in the participant's community, reinforcing a perception that 22% of survey respondents (n = 1,551) have: that solar energy is not meant for them and their community. Overcoming these serious human challenges pertaining to knowledge and marketing are critical to reducing the customer acquisition costs incurred amongst LMI communities and especially those in rural America where the opportunities solar provides to increase local energy resilience, security, all while engaging in personal stewardship of the planet could align with local values. Community-Based Social Marketing, built in partnership with community leaders and geared towards meeting local visions of ideal life, is a near term opportunity to bridge the gap between local priorities and national market and policy imperatives for solar while moving towards the administration's goals for renewable energy as part of a just and equitable decarbonization program. The tools and methods developed for this study can serve as a template for identifying other specific local challenges for solar adoption in other state, and provide the opportunity for a common data framework for understanding system-wide trends and barriers to achieving uptake of residential solar in communities that may, ultimately, benefit the most from the technology.

14 SOLAR ENERGY↗

Interagency Agreement No. DE-SC0006988 (Final Technical Report)

The overarching goal of this project was to advance understanding of deep convection updraft microphysics—the source of long-lived stratiform ice—by combining detailed mining of in situ and remote sensing data from the MC3E field campaign with detailed 3D simulations. The project began with parallel work, first strictly on the remote-sensing observation side via dedicated analysis of polarimetric radar signatures, which is a relatively new area, on the one hand. On the other hand, a more traditional but well-formulated preparation and comparison of detailed aerosol-aware simulations with in situ measurements was prepared. In the final phase of this work, these parallel elements were brought together into an integrated analysis of in situ and remote-sensing observations with model results. The project also supported team member involvement in collaborative activities.

54 ENVIRONMENTAL SCIENCES↗

Energy Management Information Systems Technical Resources Report

This report illustrates how energy management information systems (EMIS) can enable federal agencies to improve energy performance, reduce costs, and meet energy goals. The guide discusses how to identify and implement needed EMIS functions and capabilities, covering the entire EMIS life cycle including system design, procurement, implementation, and ongoing maintenance.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Land-Based Wind Energy Siting: A Foundational and Technical Resource

This land-based wind energy siting resource was created by the U.S. Department of Energy Wind Energy Technologies Office’s WINDExchange initiative and presents foundational information about land-based utility-scale wind energy that local decision makers can use when making community decisions about wind energy development. Consolidated, accessible, and easy to understand, this information resource focuses on land-based wind energy from the community perspective and examines siting-related impacts and mitigation strategies. Other impacts and strategies exist, such as those related to economics, climate, health, water, emissions, and waste; however, they are not covered in this resource. For more information on economic considerations, see the “Land-Based Wind: Economic Development Guide” and “Advancing the Growth of the U.S. Wind Industry: Federal Incentives, Funding, and Partnership Opportunities.” The intended audience for this guide is county-level decision officials, as they are often responsible for approving both wind energy ordinances and applicable permits needed for wind energy development. This guide may also provide relevant information to decision makers from other government jurisdictions and interested community members.

17 WIND ENERGY↗

Stabilizing the Power System in 2035 and Beyond: Evolving from Grid-Following to Grid-Forming Distributed Inverter Controllers (Final Technical Report)

Under existing grid operations, large synchronous generators provide sufficient rotational inertia to form a rigid backbone for the bulk power system. With photovoltaics (PV) forecasted to provide more than 600 GW of generation by 2050 under the U.S. Department of Energy’s SunShot Initiative objectives, however, it is clear that power electronic inverters will play a dominant role in future systems, and low-inertia stability must be ensured to maintain system reliability. Today, the risks to system stability can be observed on geographically small islands, such as Hawaii, which contain a relatively large amount of installed PV. These risks stem from a fundamental shortcoming of contemporary control strategies—existing inverter controllers cannot guarantee grid stability. Given that future power systems driven by sustainable resources will be characterized by low inertia, locations such as Hawaii provide a glimpse into the obstacles facing future power systems. Considering these challenges, the aim of this project was to develop and demonstrate distributed inverter controllers that enable the reliable control of low-inertia power systems with hundreds of gigawatts of integrated PV.

14 SOLAR ENERGY↗

Phasor-Based Control for Scalable Solar PV Integration (Final Technical Report)

This project demonstrated that solar PV can be recruited to stabilize the grid, smooth out disturbances, manage power flows, and assist circuit switching operations. It developed a radically new, layered control framework for Distributed Energy Resources (DER) to act in response to real-time, measured conditions on their local distribution circuit, rather than waiting for a price signal to indicate preferred behavior. By enabling resources to act as good citizens on the electric grid, Phasor-Based Control (PBC) facilitates arbitrarily high solar penetration levels.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Simplified Performance Rating Method - Review of Existing Tools, Rulesets, and Programs. Literature and technical review

The Performance Rating Method (PRM) in ASHRAE Standard 90.1 (ASHRAE 2016) is a simulation ruleset for establishing minimum code compliance and for rating a building’s beyond-code applications. Building energy modeling (BEM) to comply with the PRM is often expensive and time consuming due to the complexity of code requirements. The goal of this project is to develop and codify a simplified PRM (S-PRM) approach for commercial buildings that will expand the use of BEM for small or simple buildings by defining a low-cost, simplified approach for creating robust and detailed models. This report summarizes a review of (i) the more commonly used existing codes, (ii) incentive programs, and (iii) the existing simplified energy modeling tools to identify which requirements are good candidates for simplification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Scalable/Secure Cooperative Algorithms and Framework for Extremely-high Penetration Solar Integration (SolarExPert) (Final Technical Report)

This SolarExPert project has developed a Sustainable Grid Platform (SGP) with scalable architecture of distributed control and optimization. The SGP consists of the following major functions: 1) an advanced grid architecture with hierarchical and distributed communication and control, combined with the OpenFMB standard and implemented on the Multi-Agent OpenDSS (MA-OpenDSS) platform; 2) an online distributed stochastic optimal power flow; 3) an online distributed system state estimation algorithm; 4) the distributed Volt/VAR optimization and frequency control algorithms; 5) the distributed distribution system restoration strategy. The developed SGP together with advanced functions are tested in 1 million (1M)-node distribution system on the MA-OpenDSS platform. Furthermore, the models and algorithms are tested in 100,000-node system HiL simulation, and also in P-HiL implementation with 100 physical devices. The developed functions haven been validated and tested on the selected actual distribution feeder with the data collected from the field of Maui Meadows in Hawaii. The distributed PV hosting capacities with cooperative Volt/VAR and Volt/VAR/Watt control are estimated and compared to provide recommendations for customers and the utility company.

14 SOLAR ENERGY↗

CIS Project 22359, Final Technical Report. Discretized Posterior Approximation in High Dimensions

Our primary aim in this work is to understand how to efficiently obtain reliable uncertainty quantification in automatic learning algorithms with limited training datasets. Standard approaches rely on cross-validation to tune hyper parameters. Unfortunately, when our datasets are too small, holdout datasets become unreliable—albeit unbiased—measures of prediction quality due to the lack of adequate sample size. We should not place confidence in holdout estimators under conditions wherein the sample variance is both large and unknown. More poigniantly, our training experiments on limited data (Duersch and Catanach, 2021) show that even if we could improve estimator quality under these conditions, the typical training trajectory may never even encounter generalizable models.

97 MATHEMATICS AND COMPUTING↗

Assess and Benchmark Magneto-Inertial Fusion (MIF) Scaling. Final Technical Report for the SNL/Rochester ALPHA Follow-on Project

This project was a follow-on to the Sandia National Laboratories (SNL) and the Laboratory for Laser Energetics (LLE) ARPA-E ALPHA project entitled “Demonstrating Fuel Magnetization and Laser Heating Tools for Low-Cost Fusion Energy”. The primary purpose of this follow-on project was to obtain additional data at the OMEGA facility to help better understand how MagLIF, a platform that has already demonstrated the scientific viability of magneto-inertial fusion, scales across a factor of 1000 in driver energy. A secondary aspect of this project was to extend simulations and analysis at SNL to cover a wider magneto-inertial fusion (MIF) parameter space and test scaling of those models across this wide range of input energies and conditions of the target. This work was successful in improving understanding of how key physics elements of MIF scales and improves confidence in setting requirements for fusion gain with larger drivers. The OMEGA experiments at the smaller scale verified the hypothesis that preheating the fuel plays a significant role in introducing wall contaminants that mix into the fuel and significantly degrade fusion performance. This contamination not only impacts target performance but the optimal input conditions for the target. However, analysis at the Z-scale showed that target performance at high preheat levels is limited by the Nernst effect, which advects magnetic flux from the hot spot, reducing magnetic insulation and consequently reduces the temperature of the fuel. The combination of MagLIF experiments at the disparate scales of OMEGA and Z along with a multiscale 3D simulation analysis has led to new insight into the physical mechanisms responsible for limiting target performance and provides important benchmarks to assess target scaling more generally for MIF schemes. Finally, in addition to the MagLIF related work, a semi-analytic model of liner driven Field Reversed Configuration (FRC) was developed that predicts the fusion gain for such systems. This model was also validated with 2D radiation magneto-hydrodynamic simulations and predicts that fusion gains of near unity could be driven by the Z machine.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗