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At least 847 records · Page 47

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NASA NTRS2012

Process for Patterning Indium for Bump Bonding

An innovation was created for the Cosmology Large Angular Scale Surveyor for integration of low-temperature detector chips with a silicon backshort and a silicon photonic choke through flipchip bonding. Indium bumps are typically patterned using liftoff processes, which require thick resist. In some applications, it is necessary to locate the bumps close to high-aspect-ratio structures such as wafer through-holes. In those cases, liftoff processes are challenging, and require complicated and time-consuming spray coating technology if the high-aspect-ratio structures are delineated prior to the indium bump process. Alternatively, processing the indium bumps first is limited by compatibility of the indium with subsequent processing. The present invention allows for locating bumps arbitrarily close to multiple-level high-aspect-ratio structures, and for indium bumps to be formed without liftoff resist. The process uses the poor step coverage of indium deposited on a silicon wafer that has been previously etched to delineate the location of the indium bumps. The silicon pattern can be processed through standard lithography prior to adding the high-aspect-ratio structures. Typically, high-aspectratio structures require a thick resist layer so this layer can easily cover the silicon topography. For multiple levels of topography, the silicon can be easily conformally coated through standard processes. A blanket layer of indium is then deposited onto the full wafer; bump bonding only occurs at the high points of the topography.

Denis, Kevin↗

NASA NTRS2016

Composite Cure Process Modeling and Simulations using COMPRO(Registered Trademark) and Validation of Residual Strains using Fiber Optics Sensors

Composite cure process induced residual strains and warping deformations in composite components present significant challenges in the manufacturing of advanced composite structure. As a part of the Manufacturing Process and Simulation initiative of the NASA Advanced Composite Project (ACP), research is being conducted on the composite cure process by developing an understanding of the fundamental mechanisms by which the process induced factors influence the residual responses. In this regard, analytical studies have been conducted on the cure process modeling of composite structural parts with varied physical, thermal, and resin flow process characteristics. The cure process simulation results were analyzed to interpret the cure response predictions based on the underlying physics incorporated into the modeling tool. In the cure-kinetic analysis, the model predictions on the degree of cure, resin viscosity and modulus were interpreted with reference to the temperature distribution in the composite panel part and tool setup during autoclave or hot-press curing cycles. In the fiber-bed compaction simulation, the pore pressure and resin flow velocity in the porous media models, and the compaction strain responses under applied pressure were studied to interpret the fiber volume fraction distribution predictions. In the structural simulation, the effect of temperature on the resin and ply modulus, and thermal coefficient changes during curing on predicted mechanical strains and chemical cure shrinkage strains were studied to understand the residual strains and stress response predictions. In addition to computational analysis, experimental studies were conducted to measure strains during the curing of laminated panels by means of optical fiber Bragg grating sensors (FBGs) embedded in the resin impregnated panels. The residual strain measurements from laboratory tests were then compared with the analytical model predictions. The paper describes the cure process procedures and residual strain predications, and discusses pertinent experimental results from the validation studies.

Sreekantamurthy, Thammaiah↗

NASA NTRSDate not supplied

Holistic and Pragmatic Standards Processes Enable Interdisciplinary Science

Open, interdisciplinary science inevitably relies heavily on standards. Standards are those often unseen agreements that we take for granted when systems and processes are working fine. Yet standards work is perpetual, laborious, and sometimes contentious, especially for standards to work across diverse disciplines. Standards development, maintenance, and implementation is a complex, ongoing socio-technical process. NASA has developed a progressively open science policy and strategy that calls for the establishment of a data standards process reaching across the five diverse divisions of the Science Mission Directorate. This is a delicate exercise. We, therefore, seek to apply a holistic yet pragmatic approach to developing and maintaining a standards process. We adopt an ecological philosophy that focuses on the interactions within the data ecosystem and how standards facilitate those interactions. We couple high-level analysis with on the ground experimentation. We began by 1) mapping information ecosystem components (e.g. data centers, missions, services, protocols, users), 2)establishing how the components interact (e.g. sharing (meta)data, funding, personnel exchange), and 3) modelling system dynamics (e.g. creation of products from multiple data centers, redundant processes, shared services). The goal is to apply understanding of the ecosystem to real world applications (e.g. planning a new mission, implementing new policy requirements, improving process efficiency, etc.). We have also conducted studies of historical standardization efforts, documenting lessons learned and cautionary tales. We then contrast this more abstract work with real examples. We reviewed and assessed multiple existing standards development processes both within and external to NASA. We now work to implement an initial test process which can be further optimized. We seek to define a consistent approach for assigning persistent identifiers for research objects, especially for the purposes of citation. The experience from this relatively ‘simple’ test case adds a pragmatic perspective on how researchers and engineers actually work. This presentation will review the details of this methodology, our initial findings, and how they might apply to other interdisciplinary standardization efforts.

Mark A Parsons↗

NASA NTRSDate not supplied

Probabalistic Risk Analysis and Thermal Margin Process for an Inflatable Aeroshell

Uncertainties always exist in atmospheric entry aeroheating environments and the thermal response of thermal protection system (TPS) material. These uncertainties are mitigated in the design by ap-plying margin and factors of safety to the TPS. Entry vehicle TPS is often conservatively over-sized for the heat loads that are experienced along the entry trajectory by stacking worst-case scenarios together. Additionally, the current TPS design and margin process used by NASA offers very little insight into the risk of over-temperature during flight and the reliability of the heat shield performance [1,3]. A probabilistic margin process can be used to calculate the amount of TPS margin necessary to survive a given entry heat load at a specified level of risk [2,3,4]. The vehicle’s initial entry state (entry velocity, flight path angle, and entry mass) determines the expected atmospheric entry environmental conditions and resulting heat load that the entry vehicle will experience. If there is flexibility in the entry state, then this process can be used to select an appropriate combination of entry state parameters and TPS size to target a desired reentry reliability. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and TPS performance risk trades while preventing excessive TPS margin from being applied. The probabilistic TPS margin process has been performed to determine TPS thickness and entry heating constraints given an acceptable risk level for the Low Earth Orbit Flight Experiment of an Inflatable Decelerator (LOFTID) flight project. The process is used in a manner to size the entry heat load for a given flexible TPS (FTPS) thickness so that it meets project reliability standards while allowing the FTPS and the underlying inflatable structure (IS) to be pushed to adequately high temperatures. Since the LOFTID project is an experimental flight demonstration, it is de-sired to drive the FTPS and IS to temperatures that cover a large range of their thermal response models’ applicability. This will allow the thermal response models to be better improved and validated post-flight using LOFTID’s extensive instrumentation embedded within the aeroshell. The presentation demonstrates how uncertainty analysis is carried out using an end-to-end Monte Carlo process where three separate Monte Carlo simulations are run in sequence. The first Monte Carlo simulation operates on the entry trajectory model to generate trajectory parameter dispersions that are fed into the second Monte Carlo simulation. The second Monte Carlo simulation operates on the aerothermodynamics model to generate aeroheating parameter dispersions that are fed into the third Monte Carlo simulation. The third Monte Carlo simulation operates on the FTPS material thermal response model to generate the final FTPS/IS thermal response dispersions. The end-to-end Monte Carlo simulation propagates the uncertainties of each model into the next to quantify the resulting uncertainty of the FTPS/IS thermal response. The fractional contributions of the uncertain parameters in the trajectory, aerothermal, and thermal response models to the variance in the FTPS/IS thermal response is determined as a byproduct of the Monte Carlo analysis. The structural uncertainty of the FTPS thermal response model is evaluated by flight relevant ground testing and model error analysis using test measurements. This probabilistic TPS margin process had never been applied to an entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.

Steven A. Tobin↗

NASA NTRSDate not supplied

Design for Manufacturing of Structures with Automated Fiber Placement via Integration of Analysis and Process Planning

Under the Design for Manufacturing (DFM) task in the NASA HiCAM program, significant process has been made towards establishing a fully automated optimization process that spans the structural analysis, design, and manufacturing process planning for Automated Fiber Placement (AFP) structures. Previous efforts in this area established the data formats and mapping processes needed to exchange data between disciplines. The software tools used in the framework are HyperX (structural optimization), CAPP (process planning), and VCP (AFP path generation). The work has culminated with automation of data exchanges and an optimization process that drives the three software toward convergence. Within this framework, HyperX is used to generate mass-optimum composite designs which are iterated with VCP and CAPP to improve manufacturability of the designs. As the ply manufacturing process is adjusted by CAPP and VCP, HyperX continually re-assesses the structural integrity of the part and makes adjustments to the laminate as needed. For example, the position of fiber steering and tow overlaps/gaps can necessitate changes to the laminate design. Once the design converges, the end result is a stack of plies that meets both structural and manufacturing requirements. This paper presents the details of the framework and demonstrations the automated process on several parts with significant double-curvature.

HiCAM↗

DOE OSTI2018

Cooling process and system for dry cooling power plants

A seasonal process that captures stores and uses water in an ambient temperature-dependent manner to improve the efficiency of a natural gas power plant, comprising: (a) providing a natural gas power plant, the natural gas power plant having a flue gas stream, a cooling tower, and a gas turbine; (b) providing a water collection system; (c) providing a water storage facility; wherein the flue gas stream comprises uncondensed water vapor; wherein the water collection system is operably connected to the flue gas stream and the flue gas stream is directed to flow, at least in part, into the water collection system; wherein the water collection system is operably connected to the water storage facility; wherein the water storage facility is operably connected to the cooling tower and the water storage facility is operably connected to the gas turbine; wherein the process comprises the following steps of condensing flue gas water or using water that has been condensed from the flue gas stream based on outdoor ambient dry bulb temperature: (I) Only condensing water from the flue gas stream to produce a condensed water stream if outdoor ambient dry bulb temperature is less than 85° F.; (II) Only using condensed water to spray cool the cooling tower if outdoor ambient dry bulb temperature is at least 85° F.; (III) Only using condensed water to fog cool the gas turbine if outdoor ambient dry bulb temperature is at least 55° F.; wherein condensed water that is not immediately used to cool the cooling tower or to fog cool the gas turbine is stored in the water storage facility; and wherein the process uses a total amount of water on an annual basis to cool the cooling tower and to fog cool the gas turbine that does not exceed the annual amount of water condensed from the flue gas stream. Optionally, the process has a cooling tower that is a dry cooling tower and condensed water is used to spray cool the dry cooling tower, or the cooling tower is a wet cooling tower, or the cooling tower is a hybrid wet-dry cooling tower. The process may further comprise a water collection system having a three stage desiccant cycle and a calcium chloride desiccant that recovers at least about 60 wt % of the water from the flue gas, operates at or above ambient pressure or comprises plastic piping or plastic vessels. Or the process may further comprise using a water collection system having at least one direct contact condensing column that recovers at least about 60 wt % of the water from the flue gas, operates at or above ambient pressure or comprises plastic piping or plastic vessels. Or the process may further comprise using a water collection system having at least one direct contact condenser and a rotating wheel heat exchanger that recovers at least about 60 wt % of the water from the flue gas, operates at or above ambient pressure, or further comprises plastic piping or plastic vessels. The coefficient of performance for the cooling process is optionally at least 2.0.

Srinivas, Girish↗

DOE OSTI2020

Process Heating Assessments Using DOE’s Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite

Process heating is the most energy-intensive manufacturing process for most sectors of industry. To quantify energy savings from various energy conservation measures, the Department of Energy (DOE) sponsored the development of the Process Heating Assessment and Survey Tool (PHAST) and similar tools for other industrial systems in the early 2000s. It has been used extensively in the Save Energy Now Program’s Energy Savings Assessments and the Better Plants Program’s In-Plant Trainings. Since the initial development of the legacy tools, both computer operating systems and software development have evolved significantly. Thus, DOE has invested in the modernization of PHAST and other legacy software tools to create the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool suite. MEASUR offers a collection of software tools that can aid manufacturing facilities in improving the efficiency of energy systems and equipment (specifically pumps, fans, steam, and process heating) and in conducting “Energy Treasure Hunts”. Eventually, the tool will also add compressed air and process cooling systems. The Process Heating Assessment (PHA) module of MEASUR is an upgrade of the PHAST tool. PHA provides the means to model fuel-fired, steam-based, and electric process heating systems, covering process heating for most industrial plants in manufacturing sector. It also includes several key upgrades, including the ability to consider multi-component charge loads and account for several different areas of energy losses. The new tool includes a comprehensive flue gas calculator to quantify available heat and heat loss for various gaseous, liquid, and solid fuels and new heat loss calculators. It generates a report and a dynamic Sankey diagram to show the energy consumption in various areas of energy use. MEASUR has significantly improved the user experience by adopting a modern software design. This paper details the structure and workflow of PHA and presents a real-world case study to demonstrate energy savings quantification and MEASUR’s outstanding reporting capabilities.

Nimbalkar, Sachin U.↗

DOE OSTI2021

Nuclear Materials Process Modeling at the Y-12 National Security Complex

The Y-12 National Security Complex (Y-12) has implemented process modeling for various accountable nuclear materials operations that are performed throughout the plant. Using a discrete, event-based dynamic simulation program, key nuclear material streams are modeled, allowing Y-12 to effectively manage numerous points of interest within the plant’s production operations. Integration of the various material processes into a single, interdependent supply and demand model is one of the ongoing focuses within Y-12’s process modeling effort. The primary purpose of using dynamic simulation modeling is to allow for analysis of the nuclear materials inventories and forecasted supplies based on future demands. Analysis of these inventories includes capacity evaluation, bottleneck mitigation, and assessments of individual pieces of equipment to inform future facility investment decisions and associated project schedules. Modeling of the nuclear materials processes throughout the complex also allows for incorporation of changes relevant to production capabilities such as the upcoming transition of specific operations to the new Uranium Processing Facility. Prior to implementation of process modeling, Y-12 forecasted supply and demand of accountable nuclear materials streams using Microsoft Excel. With deterministic models such as Microsoft Excel, the annual forecasts, generated within data input condition parameters, can only provide a fixed point of data. Fixed data cannot simulate integrated material streams and account for the possibility of occurrences and other changes that dynamic simulations take into consideration. Y-12’s dynamic process modeling allows integrated simulations of multiple accountable nuclear materials processes, including supply and demand forecasting and analysis, and is a coordinated effort involving many steps of verification and validation (V&V), site briefings, testing, reporting, data mining, planning, and documentation that spans various programs throughout the Y-12 complex.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Innovative Approaches to the Decommissioning of a Redundant Plutonium Processing Facility - 20147

At Sellafield, in the North West of the United Kingdom (UK), there are a number of redundant plutonium processing facilities. Over the past three decades several decommissioning strategies have been deployed to clean up these redundant facilities. Whilst there have been many successes previously reported, there remain many challenges. As previously presented at WM2017 (Paper Ref 17081) some of these challenges have recently been addressed through a new approach which introduced a number of innovations. The purpose of these innovations is to seek ways to significantly reduce risks to both decommissioning personnel and the environment by minimising the extent of physical 'hands on' decommissioning activities and by simplifying the waste production process. This paper provides an update on the progress of these innovations since 2017. Additionally, the paper also provides details of the new decommissioning technologies which have been introduced over the past 2 years to enable the most challenging aspects of the redundant plutonium processing facility to be decommissioned. These new decommissioning technologies address challenges associated with the preparation of process vessels and pipework to enable their safe in-situ size reduction by remote means: - New decommissioning techniques have been introduced to allow penetrations to be remotely cut into process vessels and pipework to provide a means of accessing and controlling the venting of any potential hydrogen gas present. - Additionally, a new large scale bespoke remote diamond wire cutting machine has been designed and manufactured to enable the process vessels to be size reduced in situ. Both of these new cutting technologies have involved collaborative working with specialist equipment suppliers including extensive development, trialling demonstration and commissioning prior to bringing the equipment into operational service. Several years of work have now culminated in reaching the final stages of decommissioning of the redundant plutonium processing facility with decommissioning of the final process vessels now underway and completion expected by the end of 2019. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

A Novel Flash Ironmaking Process

The project goal is to develop an entirely new transformational process for alternate ironmaking based on the direct gaseous reduction of iron oxide concentrates in a flash reduction process, with the ultimate objective of significantly increasing energy productivity (by reducing energy consumption by up to 57 %) and reducing environmental emissions, especially CO 2 emissions, versus the conventional blast furnace ironmaking route.The Novel Flash Ironmaking Process uses gaseous reducing agents, such as natural gas, hydrogen, other syngas, or a combination thereof. The proposed technology is to be applied to the production of iron as a feed to the steelmaking process, eventually replacing the blast furnace and other alternate ironmaking processes. The process can also be a part of a continuous direct steelmaking process.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A comparative analysis of residual stresses from friction stir processing of aluminum cast 380 and wrought 7075 alloy sheets: experimental characterization and modeling

Residual stresses are often overlooked in friction stir processing (FSP), but their significant impact on fatigue performance necessitates their consideration in optimizing processing parameters. The first step in this effort is understanding how process conditions influence residual stress distributions, especially across different alloys. This study focuses on determining and explaining the through-thickness residual stress variations and the effect of process temperature on the residual stress magnitude in wrought AA7075 and cast AA380.0 alloys. Additionally, for AA380.0, the impact of a second FSP pass was investigated. To achieve this, hole-drilling electronic speckle pattern interferometry (ESPI) and the thermal pseudo-mechanical (TPM) model within finite element analysis were employed to study the 3D distributions of in-plane residual stresses in processed samples under various conditions. A key finding was the varying impact of process temperatures on residual stress magnitudes. Higher process temperatures reduced stresses in AA380.0 but increased them in AA7075. Additionally, the through-thickness stress distributions differed between the two alloys. Further analysis revealed that yield stresses are crucial in explaining these phenomena and the effects of additional FSP passes. Further, this fundamental understanding will be vital in guiding the efforts to mitigate residual stresses and assess their impact on the performance of FSP aluminum alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Systematic Method and Tool for Sustainable Process Synthesis, Designanalysis and Innovation

Computer-aided tools have been successfully developed and used in different segments of the entire process development cycle. For example, there are established tools for chemical process design, simulation, heat exchanger network synthesis and many more. However, one needs an integrated platform to perform process synthesis, design and analysis of chemical processes in a systematic manner. Also, in order to obtain a truly innovative and sustainable solution, it is necessary to search the entire feasible search space of alternatives and select the best process alternative, which is not very easy and will be time consuming. Therefore, it is beneficial to utilize computer-aided methods and tools to enumerate, analyze and determine within the design space, the more sustainable processes. This work highlights the development of a computer aided methodology and corresponding integrated platform for fast, reliable and consistent generation of process flowsheets. As a result, this paper gives an overview of the key concepts and the method is presented along with details of the developed computer-aided tool.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Phenomena-based graph representations and applications to chemical process simulation

Rapid and robust simulation of chemical processes is critical to conduct process design, optimization, techno-economic analysis, and sustainability analysis. Yet, efficiently solving simulation models remains a challenge due to the highly coupled and nonlinear nature of the underlying algebraic equations that capture the physical phenomena taking place in the process (e.g., material and energy conservation, phase equilibrium, reactions). In this work, we show that graph-theoretic representations of the physical phenomena within unit operations can help navigate and decompose equations to systematically identify alternative approaches for fast and robust numerical solutions. Specifically, we present a graph-theoretic abstraction that captures the connectivity between the model variables/equations and use this abstraction to group variables/equations into fundamental phenomena. We show that phenomena-based decomposition of the underlying equations can help decouple nonlinearities and enforce material/energy conservation at the process level to accelerate convergence. The proposed decomposition approach differs from the more traditional sequential modular simulation approach, in which equations are grouped and decomposed by unit operations. We implemented the phenomena-based decomposition in BioSTEAM—an open-source process simulation platform in Python—and demonstrated that this approach can converge a variety of separation process models. Compared to sequential modular simulation, the phenomena-based approach can converge idealized systems faster, but it can be slower for (or even fail to converge) highly coupled and nonideal process systems.

Convergence↗

DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer: Radio frequency (RF) assisted drying of paper and board

Conventional multi-cylinder drying of paper and board typically relies on both conductive drying from steam-heated cylinders and convective drying, where heated air flows over the paper web surface. Conduction primarily contributes to heat transfer, while convection is the main driver of mass transfer. However, conventional drying systems are heavily dependent on steam, usually powered by fossil fuels, and are often energy-inefficient with high levels of waste. Additionally, these surface-driven processes result in a lower percentage of energy absorption compared to the energy supplied, leading to significant energy losses. To improve this long-standing process, an experimental system was developed to investigate a process intensification approach involving the integration of Radio Frequency (RF) heating, a volumetric electromagnetic technology, alongside traditional conduction and convection drying methods. This study also emphasizes the use of sensors to continuously monitor key parameters such as moisture content, supply system temperatures, sample temperatures, air flows, and drying rates in real-time. The effect of RF as an auxiliary energy source in localized environments at varying moisture levels was explored to optimize industrial drying systems, quantify potential improvements, and provide insights for future studies. Experimental results from trials combining RF with convection and with the base case alternating conduction-convection drying processes are presented. It is shown that RF is a viable process intensification approach for paper drying improving the drying rate and energy intensity at higher moisture contents. These findings offer valuable insights for process intensification and contribute to the process development, modeling, and simulation of advanced paper drying techniques.

42 ENGINEERING↗

DOE OSTI2018

Toward supplying food, energy, and water demand: Integrated solar desalination process synthesis with power and hydrogen coproduction

The increase in population coupled with rising per capita income and associated change in consumption habits will put unprecedented stress on food, energy and water (FEW) resources. Sustainable and reliable fresh water supply is central for life and also for all sectors that support our existence. Uncertainty on water security prompted interest in investigation of renewable energy driven desalination processes. One particularly promising option is to produce fresh water from the two most abundant resources on earth: solar energy and seawater. In this study, using Solar Electricity, Water, Food and Chemical (SEWFAC) process synthesis concept, we explore and identify synergistic integration alternatives of multi stage flash desalination, solar thermal power, and hydrogen production processes. The promising options have been analyzed by detailed process simulation and optimization using an integrated Aspen Plus and MATLAB modeling environment. The proposed process designs can meet the water and electricity demand with rather high conversion efficiencies. Furthermore, integration of solar hydrogen production and hydrogen-fired power plant can enable continuous production of fresh water and electricity in solar-rich water-poor regions. In addition to other metrics, we have evaluated the performance of the desalination process from power point of view with a new metric, Electricity Equivalent Water (EEW) to demonstrate the marginal energy penalty of desalination. Integration of thermal desalination processes with electricity and hydrogen production is a synergistic alliance and can play a pivotal role in approaching FEW nexus.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Water Processing for Isotope Recovery Using Porous Zero Valent Iron

Reduction-oxidation cycles of metals can be harnessed to create a reusable tritiated water processing system. The concept is straightforward; a tritium-contaminated steam passes over a hot metal bed converting the metal to a metal oxide and liberating hydrogen isotopes for further processing and isotope separation. The bed is regenerated by converting the metal oxide back to a bare metal using protium gas, creating a clean water stream. Free oxygen is not produced during the cyclical process, making it safe for use in a hydrogen processing facility, and the only by-product is detritiated water. Porous zero valent iron (p-ZVI) has been identified as an ideal candidate material for this process due to its low cost, unique morphology, and favorable thermodynamics. Therefore, investigations of p-ZVI were conducted to better understand how a bed composed of such material would behave in a tritium processing facility. The thermal and physical properties were assessed, along with cycling and isotope effects. The results indicate that p-ZVI beds could serve as a low-cost, reusable system for the treatment of water in tritium processing facilities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Recursive Use of the Short-Time Fast Fourier Transform for Signature Analysis in Continuous Processes

Although a nuclear reactor is a hostile environment for sensing and electrical communications, the reactor core is amenable to acoustic communication. An acoustic measurement infrastructure (AMI) has been installed in the Advanced Test Reactor (ATR) to record acoustic signals that can capture its different operating regimes. AMI uses coolant pumps as continuous signal sources, coolant and structural components as transmission lines, and accelerometers to capture system motion. A recursive signal processing technique based on the short-time fast Fourier transform (STFFT) for continuous processes provides unique signatures for diagnostic and prognostic analyses from the system motion data. Here this article presents a recursive STFFT methodology that processes acoustic signals from continuous industrial processes. The article first discusses the initial STFFT use with simulated data to elucidate the basic principles necessary to understand and interpret the STFFT results from actual pump vibration data. Each repetitive use of the STFFT on pump vibration data using the results from the prior STFFT processing will generate additional complimentary time-frequency-based signatures. These signatures are generated by the coolant pumps operating under different process conditions. After each use of the STFFT, the resulting signatures provide exemplary examples of the diversity and intuitive nature of recursively using the STFFT. This article focuses on recursively using the STFFT to provide numerous complimentary and diverse signatures that will ultimately be inputs for machine learning algorithms that provide predictive data analytics. The intuitive nature of the information and signatures from recursive STFFT processing will also bring intuitive interpretation capabilities to machine learning and predictive data analytic techniques.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

In-Situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, we report an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.

42 ENGINEERING↗