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High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling

Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.

36 MATERIALS SCIENCE↗

A hierarchical framework for aggregating grid-interactive buildings with thermal and battery energy storage

The behind-the-meter (BTM) thermal and battery energy storage can help improve energy efficiency, reduce energy costs, and enhance energy resilience, particularly in rural areas and for disadvantaged communities. Aggregating numerous BTM energy storage systems can act as a price influencer with a significant source of load shifting and peak demand reduction. An integrated and scalable control mechanism is required to effectively utilize energy storage systems and flexible building loads to maximize the economic benefits, considering various distribution system constraints. Here, this paper presents an innovative hierarchical coordination framework for energy storage and flexible load in buildings, considering various factors such as electricity prices, thermal comfort, and distribution system modeling and constraints. At the upper level, a distribution system operator optimizes the power flow to minimize its power procurement costs from the electricity wholesale market, while at the lower level, aggregators determine the optimal dispatch of battery and thermal energy storage systems in multiple buildings on behalf of end-users to minimize operating costs according to the power prices. These problems are solved using a game-theoretic approach through negotiations between the distribution system operator and aggregators as a bi-level decision model. Simulation case studies have been performed for a test distribution network with a number of building end-users using energy storage systems to quantify the performance of aggregators. The results demonstrate that the proposed strategy can reduce peak load for a reliable electricity distribution network while saving electricity bills for customers.

25 ENERGY STORAGE↗

Optimal output feedback control of linear systems in presence of forcing and measurement noise

The problem of obtaining an optimal control law, which is constrained to be a linear feedback of the available measurements, for both continuous and discrete time linear systems subjected to additive white process noise and measurement noise was Necessary conditions are obtained for minimizing a quadratic performance function for both finite and infinite terminal time cases. The feedback gains are constrained to be time invariant for the infinite terminal time cases. For all the cases considered, algorithms are derived for generating sequences of feedback gain matrices which successively improve the performance function. A continuous time numerical example is included for the purpose of demonstration.

Joshi, S. M.↗

Sizing-stiffened composite panels loaded in the postbuckling range

Stiffened panels are widely used in aircraft structures such as wing covers, fuselages, control surfaces, spar webs, bulkheads, and floors. The detailed sizing of minimum-weight stiffened panels involves many considerations. Use of composite materials introduces additional complexities. Many potential modes of failure exist. Analyses for these modes are often not trivial, especially for those involving large out-of-plane displacements. Accurate analyses of all potential failure modes are essential. Numerous practical constraints arise from manufacturing/cost considerations and from damage tolerance, durability, and stiffness requirements. The number of design variables can be large when lamina thicknesses and stacking sequence are being optimized. A significant burden is placed on the sizing code due to the complex analyses, practical constraints, and number of design variables. On the other hand, sizing weight-efficient panels without the aid of an automated procedure is almost out of the question. The sizing code postbuckled Open-Stiffener Optimum Panels (POSTOP) has been developed to aid in the design of minimum-weight panels subject to the considerations mentioned above. Developed for postbuckled composite panels, POSTOP may be used for buckling resistant panels and metallic panels as well. The COPES/CONMIN optimizer is used in POSTOP although other options such as those in the ADS system could be substituted with relative ease. The basic elements of POSTOP are shown. Some of these elements and usage of the program are described.

Biggers, S. B.↗

Evaluation of on-line pulse control for vibration suppression in flexible spacecraft

A numerical simulation was performed, by means of a large-scale finite element code capable of handling large deformations and/or nonlinear behavior, to investigate the suitability of the nonlinear pulse-control algorithm to suppress the vibrations induced in the Spacecraft Control Laboratory Experiment (SCOLE) components under realistic maneuvers. Among the topics investigated were the effects of various control parameters on the efficiency and robustness of the vibration control algorithm. Advanced nonlinear control techniques were applied to an idealized model of some of the SCOLE components to develop an efficient algorithm to determine the optimal locations of point actuators, considering the hardware on the SCOLE project as distributed in nature. The control was obtained from a quadratic optimization criterion, given in terms of the state variables of the distributed system. An experimental investigation was performed on a model flexible structure resembling the essential features of the SCOLE components, and electrodynamic and electrohydraulic actuators were used to investigate the applicability of the control algorithm with such devices in addition to mass-ejection pulse generators using compressed air.

Masri, Sami F.↗

[ ] or SUCCESS is Not Enough: Current Technology and Future Directions in Proof Presentation

Automated theorem provers for first order logic are now around for several decades. Over the last few years, their deductive power to solve hard problems has increased tremendously. The annual CASC system competitions [Se97] give a clear picture of this situation. However, today's automated theorem provers are restricted "more by general usability than by raw deductive power." As a result of this, there are only very few serious applications of automated theorem provers. There are numerous features which a theorem prover lacks for real-world applicability. An automated theorem prover (as it is currently seen) is nothing more than a fast and elaborate search procedure. In that sense, an ATP can compared to a formulated race car, cool and fast, but virtually unusable for shopping groceries around the corner. Many important features are missing, or are optimized for speed rather than for applicability. [Schol] identifies important features which are needed for practical usability like detection of non-theorems, handling of modal/inductive proof tasks, control of the prover, and proof output. In this paper, we will focus solely on the last point, the presentation of the ATP's result to the user. In the rest of this paper, we will first discuss the general importance of providing feedback to the user, then we will describe the system ExplainIt!, a part of the deductive synthesis system AMPHION/NAV. In the conclusions we will relate proof presentation to other ways of post-processing a proof found by an ATP and stress their role in the future of automated deduction.

Schumann, Johann↗

Constrained Aeroacoustic Shape Optimization Using the Surrogate Management Framework

Reduction of noise generated by turbulent flow past the trailing-edge of a lifting surface is a challenge in many aeronautical and naval applications. Numerical predictions of trailing-edge noise necessitate the use of advanced simulation techniques such as large-eddy simulation (LES) in order to capture a wide range of turbulence scales which are the source of broadband noise. Aeroacoustic calculations of the flow over a model airfoil trailing edge using LES and aeroacoustic theory have been presented in Wang and Moin and were shown to agree favorably with experiments. The goal of the present work is to apply shape optimization to the trailing edge flow previously studied, in order to control aerodynamic noise.

Marsden, Alison L.↗

Using SpF to Achieve Petascale for Legacy Pseudospectral Applications

Pseudospectral (PS) methods possess a number of characteristics (e.g., efficiency, accuracy, natural boundary conditions) that are extremely desirable for dynamo models. Unfortunately, dynamo models based upon PS methods face a number of daunting challenges, which include exposing additional parallelism, leveraging hardware accelerators, exploiting hybrid parallelism, and improving the scalability of global memory transposes. Although these issues are a concern for most models, solutions for PS methods tend to require far more pervasive changes to underlying data and control structures. Further, improvements in performance in one model are difficult to transfer to other models, resulting in significant duplication of effort across the research community. We have developed an extensible software framework for pseudospectral methods called SpF that is intended to enable extreme scalability and optimal performance. Highlevel abstractions provided by SpF unburden applications of the responsibility of managing domain decomposition and load balance while reducing the changes in code required to adapt to new computing architectures. The key design concept in SpF is that each phase of the numerical calculation is partitioned into disjoint numerical kernels that can be performed entirely inprocessor. The granularity of domain decomposition provided by SpF is only constrained by the datalocality requirements of these kernels. SpF builds on top of optimized vendor libraries for common numerical operations such as transforms, matrix solvers, etc., but can also be configured to use open source alternatives for portability. SpF includes several alternative schemes for global data redistribution and is expected to serve as an ideal testbed for further research into optimal approaches for different network architectures. In this presentation, we will describe our experience in porting legacy pseudospectral models, MoSST and DYNAMO, to use SpF as well as present preliminary performance results provided by the improved scalability.

DYNAMO↗

Closed Loop Control Compact Exercise Device for Use on MPCV

Long duration space travel to Mars or to an asteroid will expose astronauts to extended periods of reduced gravity. To combat spaceflight physiological deconditioning, astronauts will use resistive and aerobic exercise regimens for the duration of the space flight to minimize the loss of bone density, muscle mass and aerobic capacity that occurs during exposure to a reduced gravity environment. Unlike the International Space Station (ISS), the mass and volume available for an exercise device in the next generation of spacecraft is limited. Therefore, compact exercise device prototypes are being developed for human in the loop evaluations. The NASA Human Research Program (HRP) is managing Advanced Exercise Concepts (AEC) requirements development and candidate technology maturation for all exploration mission profiles from Multi-Purpose Crew Vehicle (MPCV) exploration missions (e.g., EM-2, up to 21 day) to Mars Transit (up to 1000 day) missions. Numerous technologies have been considered and evaluated against HRP-approved functional requirements and include flywheel, pneumatic and closed-loop microprocessor-controlled motor driven power plants. Motor driven technologies offer excellent torque density and load accuracy characteristics as well as the ability to create custom mechanical impedance (the dynamic relationship between force and velocity) and custom load versus position exercise algorithms. Further, closed-loop motor-driven technologies offer the ability to monitor exercise dose parameters and adapt to the needs of the crewmember for real time optimization of exercise prescriptions. A simple proportional-integral-derivative (PID) controller is demonstrated in a prototype motor driven exercise device with comparison to resistive static and dynamic load set points and aerobic work rate targets. The resistive load term in the algorithm includes a constant force component (Fcmg) as well as inertial component (Fima) and a discussion of system tuning is presented in terms of addressing key functional requirements and human interfaces. The device aerobic modality is modelled as a rowing exercise using ground data sets obtained from Concept 2 rowers as well as competitive rowing1. A discussion of software and electronic implementations are presented which demonstrate unique approaches to meeting the constrained mass, volume and power requirements of the MPCV. . In addition to utilizing traditional PID control, controllers utilizing state feedback with gains solved using a Linear Quadratic Regulator will be developed. Controllability and observability will be utilized to investigate the need for state measurement in the design. As the control system directly interacts with human test subjects, robust methods such as H-infinity are also being investigated.1. Kleshnev V. Biomechanics. In: Rowing, Handbook of Sports Medicine and Science. ed. by Secher N., Voliantis S. IOC Medical Commission, Blackwell Pub. pp. 22-34, 2007

microgravity↗

A Fast Dynamic Internal Predictive Power Scheduling Approach for Power Management in Microgrids: Preprint

This paper presents a Dynamic Internal Predictive Power Scheduling (DIPPS) approach for optimizing power management in microgrids, particularly focusing on external power exchanges among diverse prosumers. DIPPS utilizes a dynamic objective function with a time-varying binary parameter to control the timing of power transfers to the external grid, facilitated by efficient usage of energy storage for surplus renewable power. The microgrid power scheduling problem is modeled as a mixed-integer nonlinear programming (MINLP-PS) and subsequently transformed into a mixed-integer linear programming (MILPPS) optimization through McCormick's relaxation to reduce computational complexity. A predictive window window with 6 data points is solved at an average of 0.92s, a 97.6% improvement over the 38.27s required for the MINLP-PS formulation, implying the numerical feasibility of the DIPPS approach for real-time implementation. Finally, the approach is validated against a static objective using real-world load data across three case studies with different time-varying parameters, demonstrating the ability of DIPPS to optimize power exchanges and efficiently utilize distributed resources while shifting the external power transfers to specified time durations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Rapid Airplane Parametric Input Design (RAPID)

RAPID is a methodology and software system to define a class of airplane configurations and directly evaluate surface grids, volume grids, and grid sensitivity on and about the configurations. A distinguishing characteristic which separates RAPID from other airplane surface modellers is that the output grids and grid sensitivity are directly applicable in CFD analysis. A small set of design parameters and grid control parameters govern the process which is incorporated into interactive software for 'real time' visual analysis and into batch software for the application of optimization technology. The computed surface grids and volume grids are suitable for a wide range of Computational Fluid Dynamics (CFD) simulation. The general airplane configuration has wing, fuselage, horizontal tail, and vertical tail components. The double-delta wing and tail components are manifested by solving a fourth order partial differential equation (PDE) subject to Dirichlet and Neumann boundary conditions. The design parameters are incorporated into the boundary conditions and therefore govern the shapes of the surfaces. The PDE solution yields a smooth transition between boundaries. Surface grids suitable for CFD calculation are created by establishing an H-type topology about the configuration and incorporating grid spacing functions in the PDE equation for the lifting components and the fuselage definition equations. User specified grid parameters govern the location and degree of grid concentration. A two-block volume grid about a configuration is calculated using the Control Point Form (CPF) technique. The interactive software, which runs on Silicon Graphics IRIS workstations, allows design parameters to be continuously varied and the resulting surface grid to be observed in real time. The batch software computes both the surface and volume grids and also computes the sensitivity of the output grid with respect to the input design parameters by applying the precompiler tool ADIFOR to the grid generation program. The output of ADIFOR is a new source code containing the old code plus expressions for derivatives of specified dependent variables (grid coordinates) with respect to specified independent variables (design parameters). The RAPID methodology and software provide a means of rapidly defining numerical prototypes, grids, and grid sensitivity of a class of airplane configurations. This technology and software is highly useful for CFD research for preliminary design and optimization processes.

Smith, Robert E.↗

Numerical analysis of air dehumidification through electrospray-enhanced vortical flow cyclone separator

The dehumidification of air is a highly energy-intensive process, typically requiring vapor compression systems to cool the air significantly below its dew point temperature. Here, this study numerically investigates air dehumidification achieved by electrostatic and dielectrophoresis forces in a converging duct and centrifugal principles in cyclone separators. An electrospray was employed to energize water droplets, which then captured water vapor via dielectrophoresis. A novelty of the present study is the inclusion of a cyclone separator positioned downstream of the electrospray. This combination increased the dehumidification efficiency and controlled the flow of the condensate. By integrating electrospray technology and applying an electric field, this study examines the impact of particle separation efficiency, pressure drops, and cyclone performance on air dehumidification. The control parameters for air dehumidification were investigated. Three cyclones were modelled for airflow rates of 5 cubic feet per minute [cfm] (0.0024 m 3 /s), 38 cfm (0.0179 m 3 /s), and 200 cfm (0.094 m 3 /s). The results indicated air dehumidification was up to 5.7 % under environmental conditions, similar to those used to validate the CFD model. The degree of air dehumidification was primarily influenced by the electric charge acquired by the water droplets, their flight trajectory, and the vorticity intensity within the cyclone. Air dehumidification could increase by up to 13 % by increasing the number of droplets injected into the air stream, the flight time, and the electrical charge. The breakdown electric field strength threshold near the electrospray was a limiting factor for further enhancing dehumidification performance. This study examines the optimization of an electro-assisted dehumidification system that includes cyclone-based droplet separation through numerical analysis. The results provide insights into the design of energy-efficient air treatment technologies.

42 ENGINEERING↗

ONIX: An open-source depletion code

Open Source software enables innovative, community-based software development. ONIX brings this concept to the field of depletion calculations. It is an open-source depletion software to be used for nuclear reactor simulations, for fissile material production analysis as well as for nuclear arms control applications. ONIX provides a module to solve the depletion equation using a Chebyshev Rational Approximation Method. For the generation of one-group cross sections, it includes a coupling interface for the open-source neutron transport code, OpenMC, as well as a module to read pre-computed values in a stand-alone mode. ONIX has special features to optimize nuclear data libraries, to update isomeric branching ratio during burnup, and to support automation of simulations for nuclear archaeology. In conclusion, ONIX has been validated against results from numerical and experimental benchmarks, and its results agree with other methods within expected error ranges.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Distributed Data-Driven Optimization for Voltage Regulation in Distribution Systems

Here, this paper proposes a distributed data-driven optimization framework for voltage regulation in distribution systems. The recursive kernel regression and alternating direction method of multipliers (ADMM) are selected to cover the system learning and distributed optimization tasks. The proposed distributed data-driven framework is capable of having a rapid response to system or load changes while considering the operation optimality. Besides, the distributed algorithm parallels the computation tasks and reduces the computational expense of a single agent. To validate the performance of the proposed method, a hypothetical 7-Bus system and the IEEE 123-Bus system are selected to show the effectiveness of the proposed data-driven framework. According to the numerical study results, the proposed method offers great flexibility for selecting customized kernel models for different regions and can effectively improve the system voltage profile in a distributed manner.

24 POWER TRANSMISSION AND DISTRIBUTION↗

An algorithm for the weighting matrices in the sampled-data optimal linear regulator problem

The sampled-data optimal linear regulator problem provides a means whereby a control designer can use an understanding of continuous optimal regulator design to produce a digital state variable feedback control law which satisfies continuous system performance specifications. A basic difficulty in applying the sampled-data regulator theory is the requirement that certain digital performance index weighting matrices, expressed as complicated functions of system matrices, be computed. Infinite series representations are presented for the weighting matrices of the time-invariant version of the optimal linear sampled-data regulator problem. Error bounds are given for estimating the effect of truncating the series expressions after a finite number of terms, and a method is described for their computer implementation. A numerical example is given to illustrate the results.

Armstrong, E. S.↗

Development of a distributed-parameter mathematical model for simulation of cryogenic wind tunnels

A one-dimensional distributed-parameter dynamic model of a cryogenic wind tunnel was developed which accounts for internal and external heat transfer, viscous momentum losses, and slotted-test-section dynamics. Boundary conditions imposed by liquid-nitrogen injection, gas venting, and the tunnel fan were included. A time-dependent numerical solution to the resultant set of partial differential equations was obtained on a CDC CYBER 203 vector-processing digital computer at a usable computational rate. Preliminary computational studies were performed by using parameters of the Langley 0.3-Meter Transonic Cryogenic Tunnel. Studies were performed by using parameters from the National Transonic Facility (NTF). The NTF wind-tunnel model was used in the design of control loops for Mach number, total temperature, and total pressure and for determining interactions between the control loops. It was employed in the application of optimal linear-regulator theory and eigenvalue-placement techniques to develop Mach number control laws.

Tripp, J. S.↗

SpF: Enabling Petascale Performance for Pseudospectral Dynamo Models

Pseudospectral (PS) methods possess a number of characteristics (e.g., efficiency, accuracy, natural boundary conditions) that are extremely desirable for dynamo models. Unfortunately, dynamo models based upon PS methods face a number of daunting challenges, which include exposing additional parallelism, leveraging hardware accelerators, exploiting hybrid parallelism, and improving the scalability of global memory transposes. Although these issues are a concern for most models, solutions for PS methods tend to require far more pervasive changes to underlying data and control structures. Further, improvements in performance in one model are difficult to transfer to other models, resulting in significant duplication of effort across the research community.We have developed an extensible software framework for pseudospectral methods called SpF that is intended to enable extreme scalability and optimal performance. High-level abstractions provided by SpF unburden applications of the responsibility of managing domain decomposition and load balance while reducing the changes in code required to adapt to new computing architectures. The key design concept in SpF is that each phase of the numerical calculation is partitioned into disjoint numerical kernels that can be performed entirely in-processor. The granularity of domain-decomposition provided by SpF is only constrained by the data-locality requirements of these kernels. SpF builds on top of optimized vendor libraries for common numerical operations such as transforms, matrix solvers, etc., but can also be configured to use open source alternatives for portability. SpF includes several alternative schemes for global data redistribution and is expected to serve as an ideal testbed for further research into optimal approaches for different network architectures.In this presentation, we will describe the basic architecture of SpF as well as preliminary performance data and experience with adapting legacy dynamo codes. We will conclude with a discussion of planned extensions to SpF that will provide pseudospectral applications with additional flexibility with regard to time integration, linear solvers, and discretization in the radial direction.

Pseudospectral (PS)↗

Design of a supervisory control system for autonomous operation of advanced reactors

Advanced reactors to be deployed in the coming decades will face deregulated energy markets, and may adopt flexible operation to boost profitability. To aid in the transition from baseload to flexible operation paradigm, autonomous operation is sought. This work focuses on the control aspect of autonomous operation. Specifically, a hierarchical control system is designed to support constraint enforcement during routine operational transients. Within the system, data-driven modeling, physics-based state observation, and classical control algorithms are integrated to provide an adaptable and robust solution. A 320 MW Fluoride-cooled High-temperature Pebble-bed Reactor is the design basis for demonstrating the proposed control system. The hierarchical control system consists of a supervisory layer and low-level layer. The supervisory layer receives requests to change the system's operating conditions (e.g., the current reactor power to meet a load -follow), and accepts or rejects them based on constraints that have been assigned. Constraints are issued to keep the plant within an optimal operating region. The low-level layer interfaces with the actuators of the system to fulfill requested changes, while maintaining tracking and regulation duties. Further, to accept requests at the supervisory layer, the Reference Governor algorithm was adopted. To model the dynamics of the reactor, a system identification algorithm, Dynamic Mode Decomposition, was utilized. To estimate the evolution of process variables that cannot be directly measured (e.g., the propagation of delayed neutron precursors), the Unscented Kalman Filter, incorporating a nonlinear model of nuclear dynamics, was adopted. The composition of these algorithms led to a numerical demonstration of constraint enforcement during a 40% power drop transient (at a rate of 5 %/min). Uncontrolled secondary-side temperatures were successfully constrained. Adaptability of the proposed system was demonstrated by modifying the constraint values, and enforcing them during the transient. Robustness was also demonstrated by enforcing constraints under noisy environments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗