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

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A digital twin based on OpenFAST linearizations for real-time load and fatigue estimation of land-based turbines

Monitoring a wind turbine requires intensive instrumentation, which would be too cost-prohibitive to deploy to an entire wind plant. This work presents a technique that uses readily available measurements to estimate signals that would otherwise require additional instrumentation. This study presents a digital twin concept with a focus on estimating wind speed, thrust, torque, tower-top position, and loads in the tower using supervisory control and data acquisition (SCADA) measurements. The model combines a linear state-space model obtained using OpenFAST linearizations, a wind speed estimator, and a Kalman filter algorithm that integrates measurements with the state model to perform state estimations. The measurements are: top acceleration, generator torque, pitch, and rotational speed. The article extends previous work that derived the linear state-space model using a different method. The new implementation, based on OpenFAST linearization capability, allows for a systematic extension of the method to more states, inputs, outputs, and to the offshore environment. Results from the two methods are compared, and the validation is made with additional measurements using the GE 1.5-MW turbine located at the National Renewable Energy Laboratory test site. Real-time damage equivalent loads of the tower bottom moment are estimated with an average accuracy of approximately 10%. Overall, the results from this proof of concept are encouraging, and further application of the model will be considered.

17 WIND ENERGY↗
DOE OSTI2021

Creation of Laboratory-scale Testbed for Autonomous Monitoring and Control of Subsurface Systems

This report describes the results of an LDRD project aiming to develop a laboratory-scale testbed for autonomous subsurface monitoring and control systems. Modifications were made to an existing polyaxial loading frame to incorporate electrical resistivity tomography (ERT) and acoustic emission (AE) monitoring systems. This allows engineered subsurface processes to be studied under realistic temperatures and stresses in a scaled-down laboratory environment with similar monitoring systems as are deployed in field-scale systems. The paper outlines some challenges that were faced in implementing the ERT system at the laboratory scale and the solutions that were devised. Results are shown from two demonstration tests—one focusing on the ERT system, and one focusing on the AE system.

42 ENGINEERING↗
DOE OSTI2024

Modeling Approach for the Aluminum-clad Dry Storage Pilot using HFIR Fuel

To confirm that the dry storage of aluminum-clad research reactor spent nuclear fuel (ASNF) will remain within the safety envelope after applied drying schemes and that the resulting evolution of the gas space composition, temperature, and pressure conditions are understood, a dry storage pilot project is being established. The pilot will incorporate an instrumented lid for discrete interval or for on-demand gas composition and temperature monitoring of two DOE Standard Canisters (DSCs) loaded with three High Flux Isotope Reactor (HFIR) inner cores per DSC. Each DSC would be subjected to a separate alternative candidate drying scheme. Canisters will undergo 1 to 5 years of monitoring, including internal temperature and gas sampling to track pressure and composition changes. This report outlines the approach for modeling the ASNF-in-canister behavior in terms of evolving gas space conditions for the ASNF dry storage pilot using HFIR fuel. The ASNF has an adherent surface oxyhydroxide layer comprised of boehmite/bayerite that generates hydrogen when subjected to irradiation. Three-dimensional multi-physics computational fluid dynamics simulations will be executed to compute the thermal field within the DSC and provide inputs to a chemical model employed to compute pressure buildup as hydrogen is generated in the system. Implemented in Cantera, the chemical model solves gas phase and aluminum oxyhydroxide surface-mediated radiolysis reactions. Gas phase reactions are sourced from Wittman and Hanson (2015), whereas surface-mediated reactions are incorporated by fitting experimental data using an optimization algorithm (Abboud, 2023). Water radiolysis reactions from Wren and Ball (2001) are adopted with modifications as described in Abboud (2023c). Understanding the effect of the hydrogen buildup over time is important for long-term storage safety considerations. Modeling results will include the canister pressure, temperature, and composition evolution from the initial helium backfill with the addition of radiolytically-evolved chemical species (e.g., hydrogen and oxygen). The specific HFIR cores for the pilot program have not yet been selected, and the overall design is still in development. The CFD-chemical model used for this work will be based on prior models with necessary updates to allow for improved accuracy and efficiency. The experimental data obtained from the HFIR demonstration will be used to improve and validate the computational models to predict the ASNF-in-canister behavior.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Transformer power management controllers and transformer power management methods

Transformer power management controllers and transformer power management methods are described. According to one aspect, a transformer power management controller includes processing circuitry configured to monitor an electrical characteristic of electrical energy which is received from a secondary of a transformer of an electric power system, use the monitored electrical characteristic to determine transformer loading information which is indicative of an amount of power which is being supplied by the secondary of the transformer to a plurality of loads which are coupled with the secondary of the transformer, and use the transformer loading information to adjust an amount of the electrical energy which is supplied by the secondary of the transformer to at least one of the loads which is coupled with the secondary of the transformer.

Pratt, Richard M.↗
DOE OSTI2023

Results of FY 2023 Alloy 617 and Alloy 709 High-Temperature Crack-Growth Testing

This report summarizes the work performed at Idaho National Laboratory under the “Creep, fatigue and creep-fatigue crack growth tests” task of the “Long-Term VHTR Material Qualification – INL” work package. Work was performed this year to validate the crack growth monitoring setup used with the test frames against both continuous crack length monitoring using an optical camera, as well as post-mortem analysis of marker bands on the fracture surface. Delays prevented the use of a gauge to measure load-line displacement for early tests, and so the creep-fatigue crack growth setup was evaluated using the actuator displacement for a load-line displacement setup. While not ideal, this allowed examination of the shortcomings with the current software setup that was originally designed for performing stress corrosion crack growth rate studies. The method for data collection was modified to link the crack growth monitoring software with Instron’s Wave Matrix software. Once the load-line displacement gauge arrived, the crack growth equipment was successfully modified to permit continuous monitoring of both load-line displacement and crack length. This is critical for creep-fatigue and creep crack growth rate studies for ductile material, as it permits the C* and Ct analyses. Test results are shown for Alloy 617 fatigue and creep-fatigue (without the gauge for load-line displacement measurements), as well as creep-fatigue of Alloy 709, which was performed with the completed test setup, allowing for crack length and load-line displacement monitoring.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Low-cost sensors and analytics for a digital factory

ORNL Manufacturing Demonstration Facility and Perisense worked on a low-cost solution for machining process monitoring to enable a digital factory. Enabling machine connectivity for digital factors is expensive for many small to medium manufacturers. The hypothesis for the research project is that a lowcost sensor suite, which can be retrofitted to a legacy machine tool or a new machine tool, can effectively provide real-time, in-situ sensing for manufacturing processes, which can enable improvements in process performance and efficiency. The Perisense sensor node was installed on the Haas TM1 machine with a current sensor and an accelerometer. Cutting tests were performed at different process parameters and sensor data was recorded. Results show a correlation of the current sensor to the spindle load. The accelerometer, mounted on the machine base, showed a correlation to the spindle speed as well as the spindle load. The sensor data can be used to monitor the machining process and provide insights on the machine spindle load utilization.

42 ENGINEERING↗
DOE OSTI2025

A Probabilistic Reasoner Based on Bayes Risk for Damage Detection in Structural Systems

Structural health monitoring (SHM) systems are used to inform operation of structural systems subject to loads and environments that may affect their integrity. SHM systems rely on continuous monitoring of the structure to determine its health state. These systems are often coupled with a model of the deployed structure to determine the consequences of changes in the system by forecasting the response to future states. These models, which may be thought of as digital twins, need to be updated to reflect the latest state of the structural system. This work makes use of an uncertainty-aware machine learning model that enforces distance preservation of the original input space to determine deviations from the training data input space distributions. This workflow enables domain shift detection to determine whether damage is present in the structure. The uncertainty metrics generated by this network are then used in a Bayes risk framework to design an optimal damage detector given cost and risk considerations. The approach is demonstrated on a computational example with simulated damage.

Najera-Flores, David [ATA Engineering, Inc.]↗
DOE OSTI2021

Assessing the impact of demand response on peak demand in a developing country: The case of Ghana

Peak demand on electricity grids is a growing problem that increases costs and risks to supply security. Residential sector loads often contribute significantly to seasonal and daily peak demand. Demand response refers to consumer actions that change the utility load profile in a way that reduces costs or improves grid security by applying price signals and automated load shedding technologies. The methodologies that are used to achieve demand response can hardly be applicable in developing countries. Peak pricing of electricity, for instance, can hardly be implemented in many developing countries as high prices would disproportionately affect the many low-income households who do not have the capacity to take action to avoid paying high peak prices. This study aims to develop demand response methodology that can be applied in developing countries to achieve residential peak demand reduction. We use a consumer preference survey to develop a methodology suitable for developing countries. The method of diversified demand is used with energy audit and monitored data to estimate the potential peak load reduction and its cost-effectiveness for Ghana. Results show that peak reduction of 15-210 MW is expected by 2040 with a positive return on investment of 2-22% for all designed scenarios.

Diawuo, FA↗
DOE OSTI2025

Estimation of cutting tool wear using an elastomeric tactile sensor

Machining performance of cutting tools and part quality are affected by the geometric condition of the cutting edge, which is influenced by thermomechanical loads experienced during the process. Tool condition monitoring (TCM) systems provide insight for timely replacement of cutting tools. However, existing TCM systems are expensive and require specialized equipment or sensors, hindering widespread adoption. A novel TCM system is developed herein using an elastomeric tactile sensor. Sensor images of the cutting edge are used to quantify wear using two distinct algorithms. In the first algorithm, the unworn and worn edges are identified based on Canny edge detect. In the second, the unworn edge is identified using edge detection while the region of wear is identified using a relative intensity method. In both cases, the maximum wear width is calculated based on an experimentally determined pixel to-physical distance scale. The TCM system is first used to estimate flank wear on a solid carbide helical end mill before evaluating its robustness by employing it to estimate insert wear of an indexable helical end mill. Measurements are also performed manually using an optical microscope and a high-resolution focus variation microscope for verification. The novel technique estimates flank wear in the solid carbide tool with a high accuracy of 98%. Larger discrepancies are observed for the inserts, however, with overlapping uncertainties. In conclusion, the technique shows promise in adaptability, automation, and closed loop control of machine tools.

Machining↗
DOE OSTI2026

Design, development and commissioning of a multi-alkali semiconductor photocathode deposition system for the IUAC Delhi light source photoinjector

A fourth-generation light source, called Delhi Light Source (DLS) based on photocathode-based RF gun has been commissioned at Inter-University Accelerator Centre, New Delhi. Presently, the electron beam is being generated from copper photocathode and the beam is being used for scheduled experiments. Soon, the semiconductor photocathode will be used to produce higher beam current. Here, to develop the semiconductor photocathode, a dedicated photocathode deposition facility was developed in collaboration with Brookhaven national Laboratory (BNL) and has been successfully commissioned and becomes operational at IUAC. This deposition facility is an integrated system with the electron gun and is a unique system as it is capable of producing, preserving (without residual gas poisoning) and in-vacuum transfer of the deposited photocathodes from the deposition chamber up to the RF electron gun. The system is designed to operate under ultra-high vacuum (UHV) and is equipped with load-lock chambers, substrate heating assembly, thickness monitoring via a quartz crystal microbalance (QCM), and an in-situ setup for quantum efficiency (QE) measurements. After testing of all the subsystems and a detailed calibration, the first deposition of a cesium telluride (Cs 2 Te) photocathode was successfully performed on a copper (Cu) substrate. This successful commissioning and initial deposition mark a significant step toward the indigenous photocathode development and lays the groundwork for further research into advanced photo emissive materials at IUAC. This paper will discuss the salient features, installation, commissioning, first semiconductor photocathode deposition and its results.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Commissioning of a replacement subatmospheric cold box for Jefferson Lab’s Central Helium Liquefier

Jefferson Lab’s Cryogenics Department has designed, fabricated, installed, and commissioned a new subatmospheric cold box to replace one of the two existing units within our Central Helium Liquefier (CHL). The replacement cold box, dubbed SC1R, pumps saturated helium vapor at 0.0385 atm from Jefferson Lab’s continuous electron beam accelerator facility (CEBAF) cryomodules to maintain an operating temperature of nominally 2.1 K. This is accomplished using a five-stage cryogenic centrifugal compressor (cold compressor) system and a brazed aluminum plate-fin heat exchanger operating between 2.1 K and 4.5 K. In this paper we will describe our experience commissioning the SC1R cold box. We will discuss pump-down of the system to 2.1 K and steady-state operation at the cold compressor design flow rates of 170, 200, and 250 g/s. Performance of the heat exchanger and cold compressors has been mapped across a range of flow rates and optimized for CEBAF operations. This commissioning data will be used to monitor future performance and adapt to changing load requirements.

Mastracci, B.↗
DOE OSTI2020

A robust dynamic state estimation approach against model errors caused by load changes

Dynamic state estimation (DSE) plays an important role in power system security monitoring and online control. In practice, there are two approaches to implementing DSE. The first approach is distributed DSE, which is based on the assumption that the terminal bus of each generator can be measured by PMUs (phasor measurement units). The assumption cannot be satisfied currently, however, because PMUs usually are installed at important high-voltage buses such as 500-kV buses installed in portions of the grid overseen by the Western Electricity Coordinating Council. Another issue of this approach is that performance of DSE is vulnerable to bad measurement data. The reason for this vulnerability is that DSE is performed separately through measurements at each terminal bus, and measurements at terminal buses are the only measurement upon which DSE can rely. Therefore, important redundant measurements are not included in this approach. The second approach is centralized DSE. This approach does not have the requirement for PMU location, and redundant measurements can be considered fully. However, load changes and grid topology changes impact centralized DSE. In this paper, we propose a new approach for handling the impact of load changes on DSE. We have developed a new algorithm that includes two sequential steps. In the first step, errors caused by load changes are detected by analyzing the difference between prediction results and measured results. In the second step, once model error is detected, a model optimization procedure is run to correct the error so the state estimation error can be mitigated. Simulation results from the IEEE 68 bus system show that the proposed approach can effectively handle model errors caused by load changes.

robust dynamic state estimation, load change, powe↗
DOE OSTI2023

Structuring Nutrient Yields throughout Mississippi/Atchafalaya River Basin Using Machine Learning Approaches

To minimize the eutrophication pressure along the Gulf of Mexico or reduce the size of the hypoxic zone in the Gulf of Mexico, it is important to understand the underlying temporal and spatial variations and correlations in excess nutrient loads, which are strongly associated with the formation of hypoxia. This study’s objective was to reveal and visualize structures in high-dimensional datasets of nutrient yield distributions throughout the Mississippi/Atchafalaya River Basin (MARB). For this purpose, the annual mean nutrient concentrations were collected from thirty-three US Geological Survey (USGS) water stations scattered in the upper and lower MARB from 1996 to 2020. Eight surface water quality indicators were selected to make comparisons among water stations along the MARB over the past two decades. Principal component analysis (PCA) was used to comprehensively evaluate the nutrient yields across thirty-three USGS monitoring stations and identify the major contributing nutrient loads. The results showed that all samples could be analyzed using two main components, which accounted for 81.6% of the total variance. The PCA results showed that yields of orthophosphate (OP), silica (SI), nitrate–nitrites (NO 3 -NO 2 ), and total suspended sediment (TSS) are major contributors to nutrient yields. It also showed that land-planted crops, density of population, domestic and industrial discharges, and precipitation are fundamental causes of excess nutrient loads in MARB. These factors are of great significance for the excess nutrient load management and pollution control of the Mississippi River. It was found that the average nutrient yields were stable within the sub-MARB area, but the large nitrogen yields in the upper MARB and the large phosphorus yields in the lower MARB were of great concern. t-distributed stochastic neighbor embedding (t-SNE) revealed interesting nonlinear and local structures in nutrient yield distributions. Clustering analysis (CA) showed the detailed development of similarities in the nutrient yield distribution. Moreover, PCA, t-SNE, and CA showed consistent clustering results. This study demonstrated that the integration of dimension reduction techniques, PCA, and t-SNE with CA techniques in machine learning are effective tools for the visualization of the structures of the correlations in high-dimensional datasets of nutrient yields and provide a comprehensive understanding of the correlations in the distributions of nutrient loads across the MARB.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Catalyst Layer Design, Manufacturing and In-line Quality Control

In this project we successfully demonstrated the capabilities of the Reactive Spray Deposition Technology (RSDT) to fabricate large-scale CCMs for advanced PEMWEs that have one-order of magnitude lower PGM loading in their catalyst layers, and performance comparable with the commercial state-of-the-art CCMs. The RSDT is a unique methodology that combines the catalyst synthesis and CCM fabrication in one step and reduces dramatically the time for CCM manufacturing. As fabricated large-scale CCMs with geometric area of 680 cm2 demonstrated excellent activity and durability performance, and the novel duo-recombination layer design paves the way for solving the safety concerns related to PEMWEs. In addition, excellent activity and durability performance has been demonstrated with RSDT fabricated CCMs with thinner membranes and duo RL design. This is a novel approach for further performance improvement of the MEAs for PEMWEs that has been successfully demonstrated for the first time in this project. The integration of the in-situ laser diagnostics system along with the in-line optical quality control system within the RSDT that has been achieved and demonstrated in this project, is an example for possibility of designing and building advanced manufacturing technologies that can meet the requirements of the future manufacturing. Therefore, the RSDT offers a precise real-time monitoring and control of the particles size, composition, loading, porosity, thickness, and defects in the catalysts’ layers, which render this technology as the best candidate for manufacturing of cost effective CCMs for PEMWEs. By using RSDT we successfully met all project’s milestones, Go/No-Go decision, objectives, goals, and deliverables.

08 HYDROGEN↗
DOE OSTI2021

Measuring Saturn's Electron Beam Energy Spectrum using Webb's Wedges

It is very difficult to measure the voltage of the load on the Saturn accelerator. Time-resolved measurements such as vacuum voltmeters and V-dot monitors are impractical at best and completely change the pulsed power behavior at the load at worst. We would like to know the load voltage of the machine so that we could correctly model the radiation transport and tune our x-ray unfold methodology and circuit simulations of the accelerator. Step wedges have been used for decades as a tool to measure the end - point energies of high energy particle beams. Typically, the technique is used for multi-megavolt accelerators, but we have adapted it to Saturn's modest <2 MV end-point energy and modified the standard bremsstrahlung x-ray source to extract the electron beam without changing the physics of the load region. We found clear evidence of high energy electrons >2 MV. We also attempted to unfold an electron energy spectrum using a machine learning algorithm and while these results come with large uncertainties, they qualitatively agree with PIC simulation results.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Time and Frequency Analysis of Load Profile Data

Technology advancements and integration of modern advanced metering systems can monitor, forecast, inform, control, and operate the building's mechanical, electrical, and plumbing (MEP) systems. They offer a higher level of information, which can contribute to making smart buildings more energy efficient and to making them closer to becoming grid-interactive energy efficient buildings (GEB). This paper builds on the ongoing research on variability analysis of a case study building with a 1-minute load profile and examines the Discrete Wavelet Transform (DWT) process in the frequency domain to quantify the signal's energy in each bandwidth, with respect to each end-use category. Moreover, the amount of variability in the total variability is not similar among the end-use categories. This information is needed to understand the behavior of the variability in the frequency domain for future applications, such as generating synthetic load profiles with a similar frequency spectrum as the measured signal.

decomposition↗
DOE OSTI2020

A method for characterization of multiple dynamic constitutive parameters of FRCs

We propose a method to measure multiple dynamic material constitutive parameters of unidirectional fiber reinforced composites (FRCs) in a single experiment. Dynamic short-beam shear (DSBS) experiments were performed on a modified Kolsky compression bar, with integration of high-speed imaging and digital image correlation (DIC). The unidirectional FRCs investigated were S-2 glass fiber reinforced matrix of TGDDM-Jeffamine® D230 with monoamine functionalized partially reacted substructures (mPRS) and commercially available SC-15. Analytical solutions of normal and shear strains of a composite beam were derived based on Timoshenko beam theory, assuming material to be transversely isotropic and have different moduli in tension and compression in each principle material orientation. Tensile and compressive moduli were inversely computed through monitoring normal strain slope when specimen was constantly loaded at a speed of ~7.3 m/s within a small deflection. Non-linear shear stress-strain behavior of the composite was described via Ramberg–Osgood equation. Finite element (FE) analysis was conducted in ABAQUS, simultaneously defining via user subroutine UMAT the transverse isotropy of material, bi-modulus constitutive model, and non-linear shear stress-strain relation. The method proposed in this work was validated by comparing strain distributions computed by FE model and DIC measurements. Comparing with traditional dynamic tensile, compressive, and shear experiments on FRCs, this method significantly simplifies the specimen preparation and design of complicated gripping fixtures for multiple experiments. Here, systematic errors resulting from variations of specimen geometry and dimension, loading direction, and instrumentation are reduced, thereby providing compatible data for numerical studies on impact behavior of composites.

36 MATERIALS SCIENCE↗
DOE OSTI2025

OpenSAMPL

OpenSAMPL (Open Synchronization Analytics and Monitoring PLatform) is a Python framework for processing, loading, and managing clock probe time series data and metadata from different vendors.

Grant, Josh [Oak Ridge National Laboratory (ORNL),↗