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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 OSTI2022

Physics-based modeling and information-theoretic sensor and settings selection for tool wear detection in precision machining

Precision machining of metals is an energy intensive process with applications and impacts across the manufacturing industry. The energy efficiency, product yield, and maintenance of the precision machine require a digital twin that can assist with prognostics and health management. In this report a physics-based model is developed and validated against face milling data, and then used for the timely and precise inference of machining faults that cannot be measured directly. Computer numerical control (CNC) measurements of power and force are used through this physics-based machining model to predict deviations of the outputs of power consumption and cutting forces during normal operation. A model-based fault detection and isolation methodology is applied to determine the optimal (traditional and available) sensor suite and the test settings (admissible input values) that improve the inference of tool wear in face milling. The optimal sensor suite and input test settings are obtained by solving a mixed integer non-linear program that optimizes information-theoretic metrics relevant to the detection and isolation of tool wear from steady-state or transient machining measurements. Dynamic time warping and k—NN classification are then used to validate the robustness of the optimal design for fault detection test design, including the optimal sensor suite.

42 ENGINEERING↗
DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

42 ENGINEERING↗
DOE OSTI2022

A machining digital twin for hybrid manufacturing

Hybrid manufacturing consisting of metal additively manufactured preforms and computer numerical control (CNC) machining has been established to be an effective method for high material use rates. However, hybrid manufacturing introduces unique challenges. Near-net shape designs are typically selected, which result in a smaller margin for part placement within the stock and stringent requirements for work coordinate system identification. Additionally, less stock material reduces the preform stiffness, which limits the material removal rates during machining. This paper demonstrates a digital twin for CNC machining of a wire arc additively manufactured preform that implements: 1) structured light scanning for stock model identification and tool path generation; 2) a fused filament fabrication apparatus to attach temporary fiducials and scan targets to the preform that enable coordinate system definition for both the CAM and CNC machine; 3) preform and tool tip frequency response function measurements to enable stable milling parameter selection; and 4) post-manufacturing measurements of geometry, surface finish, and structural dynamics to confirm designer intent. These efforts define key components of the machining digital twin for hybrid manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

42 ENGINEERING↗
DOE OSTI2021

NSLS-II longitudinal impedance budget

From the beginning of the NSLS-II project, the vacuum chamber of the NSLS-II storage ring has been optimized to reduce its impedance. The optimization, performed in close collaboration with the Diagnostic, Vacuum, RF, and Mechanical Engineering groups, has been achieved via calculating the impedance of the vacuum chamber components with the use of both analytical and numerical tools, with the numerical computations carried out with the GdfidL code. Fore reliable NSLS-II operation with the total beam current of 500 mA, each component of the vacuum chamber has been individually optimized to minimize the beam-induced heating and to prevent single-bunch and coupled-bunch instabilities. In this study, the impedance calculation and optimization know-how are summarized for all the chamber components, and the total longitudinal impedance budget is analyzed. As a result of this extensive research and engineering effort, the design beam current of 500 mA has been recently accumulated in NSLS-II without any major problem caused by collective effects.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Central vortex steady states and dynamics of Bose–Einstein condensates interacting with a microwave field

Here we study central vortex steady states and dynamics of a two-dimensional (2D), two-component, Gross–Pitaevskii equation (CGPE) system for two pseudo-spinor Bose Einstein condensates (BECs) interacting with an electromagnetic field (microwave) analytically and numerically. For the central vortex steady state at any given winding number S, we prove its existence in a reduced, single component detuning limit when contact-interaction strength β < β b , and nonexistence when β > β b , respectively, where β b is a threshold value, whose value is given in Theorem 3.1 in the paper. We extend the existence and nonexistence result to the general two pseudo-spinor case and prove that a central vortex steady state exists for any given S if β ≤ β b while it does not exist when β > 2β b . We then derive dynamical equations for some observables (expectations of the matter wave function) such as the center-of-mass, position of dispersion, the linear and angular momentum of the two pseudo-spinor CGPEs. Finally, numerical computations are brought in to validate and extend the existence of vortex steady state results to β b ≤ β < 2β b for the two pseudo-spinor case and to explore transient dynamics of the observables.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Exploiting ν-dependence of projected energy correlators in HICs

We extend the recently derived factorization formula for energy-energy correlators to study the analytic structure of general ν-point projected energy correlators in heavy ion collisions. The ν-point projected energy correlators (or, ν-correlators) are an analytically continued family of the integer N-point projected energy correlators, which probe correlations between N final-state particles. By tracking the largest separation (χ) between the N particles, in vacuum, their structure is closely related to the DGLAP splitting functions and exhibits a classical scaling behavior ∼ 1/χ which is modified by resummation through the anomalous dimensions. We show that, in a thermal medium, the ν-correlators display non-trivial angular scaling already at the leading order in perturbation theory. We find that for non-integer values, particularly ν < 1, medium-induced jet function is enhanced compared to ν > 1. This is particularly manifested in the ratios of ν-correlators with respect to the two-point energy correlator, which encodes intrinsic angular information for ν < 1 when compared to large ν values. Moreover, for small-ν values, the ν-correlators appear to saturate at ν = 0.01 . We further confirm our leading-order numerical computations against simulated events from JEWEL for the parton-level production cross-section. Finally, we qualitatively discuss the effect of BFKL resummation for various values of ν.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Particle removal from a flat surface using a translating bounded vortex flow

A bounded vortex flow is a hydrodynamic approach for removal of particles from a surface without scattering the particles onto nearby surfaces. The bounded vortex flow field is generated by a nozzle that combines azimuthally tilted jets arranged in a circular pattern and a central suction port. When the nozzle face is directed toward an ‘impingement surface’, the flow develops a wall-normal intake vortex below the suction outlet, which causes high shear stress on the impingement surface. When particles are present on the impingement surface, the high shear stress causes particles to roll along the surface and to be lifted off the surface and transported up the core of the wall-normal vortex into the suction outlet. In typical applications, the nozzle would be translated along the impingement surface to clean particles from the surface. The current paper reports on an experimental study of the effect of nozzle translation on the effectiveness of the bounded vortex flow field for particle mitigation. The effectiveness of particle mitigation was examined as a function of flow rate through the nozzle, particle size, and nozzle translation velocity relative to the impingement surface. As a result, numerical computations are used to relate the flow rate to the maximum shear stress on the impingement surface, which is then used to theoretically predict onset of particle motion.

42 ENGINEERING↗
DOE OSTI2022

Autonomous aerial flight path inspection using advanced manufacturing techniques

Robotic systems have shown capabilities to perform inspection tasks in dangerous and difficult-to-access environments, such as those found in different components of power plants. However, most of the current robotic inspection technology is designed for specific components. Aerial robots, commonly termed as Drones, have raised an option to inspect a wider range of structural components. Nevertheless, current aerial inspecting technology still relies on a human pilot with limited line of sight, field of view and a reduced perception as the drone flies away, which prevents performing close-quarter inspection in intricate, structurally complex and GPS-denied environments. This work introduces offline inspection path generation methods based on robotics-integrated to manufacturing techniques. One method uses computer-aided manufacturing (CAM) techniques and the other an additive manufacturing (AM) approach to generate the flight path. That is to say, the drone would fly along the path described by a 3D (Three Dimensional) printer’s extruder or a CNC (Computer Numerical Control) machining tool, enabling to fly very close the structure even in physical structures with a complex geometry. Once the trajectories are generated, they are introduced for its validation in the Gazebo robotics simulator. Simulation results demonstrate the proper performance of the method and confirm that this approach can be used for close inspection of structural components.

42 ENGINEERING↗
DOE OSTI2026

Ab Initio Modeling of Aqueous Methanol Mixtures at DFT-SCAN Level Using Machine Learning Interatomic Potentials

Abstract Methanol–water mixtures find use in many applications, particularly catalytic energy conversion processes. Their importance has motivated numerous computational studies, most of which employed molecular dynamics based on classical force fields. These enable simulations of large systems on long time scales but do not reliably describe reactive dynamics involving bond breaking and bond formation. In contrast, ab initio molecular dynamics (AIMD) based on density functional theory (DFT) is generally more reliable for such applications but has a high computational cost, which discourages systematic studies of alcohol-water mixtures. To remedy this, we trained a machine learning interatomic potential capable of probing the properties of aqueous methanol mixtures at the DFT level using the SCAN functional. Our results show that SCAN qualitatively reproduces multiple key experimental features arising from the amphiphilic nature of methanol, including density, diffusion coefficients, X-ray structure factors, and Kirkwood–Buff integrals. We also find that structural correlations between water molecules are somewhat overestimated, leading to a stronger preferential association than that predicted by experiments. However, increasing the temperature by 30 K mitigates this effect and also recovers the correct mobilities of both methanol and water. These results indicate that SCAN provides an accurate description of methanol–water mixtures, making it a reliable choice for investigating the reactive dynamics in such systems.

Park, Sanghyun J. [Princeton University , , , ,]↗
DOE OSTI2021

Quantifying and modeling of stress-driven short-circuits in lithium-ion batteries in electrified vehicles

Despite the huge expansion of electric vehicle sales in the market, customers are discouraged by the possible catastrophic consequences brought by the safety issues of lithium-ion batteries, such as internal short circuits, especially in crash scenarios. Herein, we reveal the quantitative relationship between the deformations of the battery and the internal short circuit. By in situ and ex situ observations and post mortem characterization of the component materials, we quantify the stress-driven internal short circuit and failure behavior of the component material. With the aid of a validated numerical computational model as well as the in situ characterization of the global-field temperature, we successfully identify the minor and major short circuits of the cells upon various mechanical abusive loadings. Finally, we establish the internal short circuit criteria for typical formats of batteries. Furthermore, this discovery also provides a fundamental understanding of both internal and external stress-driven short circuits in a much broader context.

25 ENERGY STORAGE↗
DOE OSTI2021

Boundary layer description of directional polymer crystallisation

Nearly fifty years ago Lovinger and Gryte suggested that the directional crystallization of a polymer was analogous to the quiescent isothermal crystallization experiment but at a supercooling where the crystal growth velocity was equal to the velocity of the moving front. Our experiments showed that this equivalence holds in a detailed manner at low directional velocities. To understand the underlying physics of these situations, we modeled the motion of a crystallization front in a liquid where the left side boundary is suddenly lowered below the melting point (Stefan's problem) but with the modification that the crystallization kinetics follow a version of the Avrami model. Our numerical results surprisingly showed that the results of the polymer analog track with the Stefan results which were derived for a simple liquid that crystallizes completely at its melting point; in particular, the position of the crystal growth-front evolved with time exactly as in the Stefan problem. The numerical solution also showed that the temperature in the immediate vicinity of the growth-front decreased with increasing front velocity, which is in line with Lovinger and Gryte's ansatz. To provide a clear theoretical understanding of these numerical results we derive a boundary layer solution to the governing coupled differential equations of the polymer problem. The analytical results are in agreement with our observations from experiments and numerical computations but show that this equivalence between the small molecule and polymer analog only holds in the limit where the crystallization enthalpy is much larger than the rate at which heat is conducted away in the polymer. In particular, in the context of the temperature profile, the enthalpy generated by the crystallisation process which is spread out over a narrow spatial region can be approximated as a point source whose location and temperature correspond to the Lovinger–Gryte ansatz.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Diffusioosmotic flow reversals due to ion–ion electrostatic correlations

Existing theories of diffusioosmosis have neglected ion–ion electrostatic correlations, which are important in concentrated electrolytes. Here, we develop a mathematical model to numerically compute the diffusioosmotic mobilities of binary symmetric electrolytes across low to high concentrations in a charged parallel-plate channel. We use the modified Poisson equation to model the ion–ion electrostatic correlations and the Bikerman model to account for the finite size of ions. We report two key findings. First, ion–ion electrostatic correlations can cause a unique reversal in the direction of diffusioosmosis. Such a reversal is not captured by existing theories, occurs at ≈ 0.4 M for a monovalent electrolyte, and at a much lower concentration of ≈ 0.003 M for a divalent electrolyte in a channel with the same surface charge. This highlights that diffusioosmosis of a concentrated electrolyte can be qualitatively different from that of a dilute electrolyte, not just in its magnitude but also its direction. Second, we predict a separate diffusioosmotic flow reversal, which is not due to electrostatic correlations but the competition between the underlying chemiosmosis and electroosmosis. This reversal can be achieved by varying the magnitude of the channel surface charge without changing its sign. However, electrostatic correlations can radically change how this flow reversal depends on the channel surface charge and ion diffusivity between a concentrated and a dilute electrolyte. Furthermore, the mathematical model developed here can be used to design diffusioosmosis of dilute and concentrated electrolytes, which is central to applications such as species mixing and separation, enhanced oil recovery, and reverse electrodialysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Autonomous elemental characterization enabled by a low cost robotic platform built upon a generalized software architecture

Despite the rapidly growing applications of robots in industry, the use of robots to automate tasks in scientific laboratories is less prolific due to the lack of generalized methodologies and the high cost of hardware. This paper focuses on the automation of characterization tasks necessary for reducing cost while maintaining generalization and proposes a software architecture for building robotic systems in scientific laboratory environments. A dual-layer (Socket.IO and ROS) action server design is the basic building block, which facilitates the implementation of a web-based front end for user-friendly operation and the use of ROS Behavior Trees for convenient task planning and execution. A robotic platform for automating mineral and material sample characterization is built upon the architecture, with an open-source, low-cost three-axis computer numerical control gantry system serving as the main robot. A handheld laser induced breakdown spectroscopy (LIBS) analyzer is integrated with a 3D printed adapter, enabling (1) automated 2D chemical mapping and (2) autonomous sample measurement (with the support of an RGB-Depth camera). We demonstrate the utility of automated chemical mapping by scanning the surface of a spodumene-bearing pegmatite core sample with a 1071-point dense hyperspectral map acquired at a rate of 1520 bits per second. Furthermore, we showcase the autonomy of the platform in terms of perception, dynamic decision-making, and execution, through a case study of LIBS measurement of multiple mineral samples. The platform enables controlled and autonomous chemical quantification in the laboratory that complements field-based measurements acquired with the same handheld device, linking resource exploration and processing steps in the supply chain for lithium-based battery materials.

Cao, Xuan [Lawrence Berkeley National Laboratory (↗
DOE OSTI2023

Twisted bilayer graphene as topological heavy fermion: II. Analytical approximations of the model parameters

The recently-introduced topological heavy fermion (THF) model [1] of twisted bilayer graphene (TBG) aims to reconcile the quantum-dot-like electronic structure of the latter observed by scanning tunneling microscopy, with its electron delocalization seen in transport measurements. The THF model achieves this by coupling localized (heavy) fermions with anomalous conduction electrons. Originally, the parameters of the THF model were obtained numerically from the Bistritzer–Macdonald (BM) model of TBG [1]. In this work, we derive analytical expressions for the THF model parameters as a function of the twist angle, the ratio between the tunneling amplitudes at the AA and AB regions (w 0 /w 1 ), and the screening length of the interaction potential. By numerically computing the THF model parameters across an extensive experimentally-relevant parameter space, we show that the resulting approximations are remarkably good, i.e., within the 30% relative error for almost the entire parameter space. At the single-particle level, the THF model accurately captures the energy spectrum of the BM model over a large phase space of angles and tunneling amplitude ratios. When interactions are included, we also show that the THF description of TBG is good around the magic angle for realistic values of the tunneling amplitude ratios (0.6 ≤ w 0 /w 1 ≤ 1.0), for which the hybridization between the localized and conduction fermions γ is smaller than the onsite repulsion of the heavy fermions U 1 (i.e., |γ| < U 1 ).

Approximation methods↗
DOE OSTI2021

Asymmetry between deuterium and tritium turbulent particle flows

The asymmetry between deuterium (D) and tritium (T) turbulent particle fluxes in mixed D–T plasmas is studied with numerical simulations of nonlinear gyrokinetic turbulence in ion temperature gradient-dominated and trapped electron mode-dominated regimes. At 50–50 D–T concentration, the asymmetry, or flow separation, between D and T fluxes is such that the tritium is better confined than the deuterium in both regimes. To supplement the nonlinear simulations, an analytic quasilinear theory of the particle flux symmetry breaking is developed and is valid for general electron dynamics. Furthermore, this theory correctly predicts the numerically computed deviation in the ion density fraction (from 50–50), or ion density gradient (from the electron gradient), required to restore equal deuterium and tritium fluxes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Pressure drop in a prototypical 3D magnetohydrodynamic flow across contraction of a fusion blanket manifold

Predicting 3D magnetohydrodynamic (MHD) pressure losses associated with liquid metal flows in complex geometry ducts is required to design breeding blankets for fusion reactors. Of such components, manifolds exhibit major pressure losses. Recent correlations [T. Rhodeset al. Magnetohydrodynamic pressure drop and flow balancing of liquid metal flow in a prototypic fusion blanket manifold. Phys. Fluids. 2018; 30: 057101.] demonstrate promise for predicting pressure drops in electrically insulated inlet manifolds. In the present work, the extend to which these correlations can be applied to outlet manifolds, which feature sudden contractions, is investigated in both viscous-electromagnetic (VE) and inertial-electromagnetic (IE) regimes for Reynolds numbers 50 < Re < 1500, Hartmann numbers 2500 < Ha < 5475, and expansion/contraction ratio 10. Numerical computations have shown that the MHD pressure drops in the eutectic lead-lithium (PbLi) flows in contractions are almost identical to those in the flows featuring expansion with slightly higher magnitudes in the contraction cases. The small discripancy in the MHD pressure drop between contractions and expansions (<8%) suggests that the earlier obtained correlations for the 3D MHD pressure drop in a duct flow with a sudden expansion can also be applied to flows with a sudden contraction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗