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At least 919 records · Page 51

Techno-Economic Optimization of Advanced Energy Plants with Integrated Thermal, Mechanical, and Electro-Chemical Storage (Final Report)

The increasing use of renewable energy sources is leading to increased cycling of fossil-fueled power plants (FFPP) that are designed to operate at base-loaded conditions. Integrating energy storage facilities with the FFPPs can be helpful in reducing load-following operation of FFPPs. Decentralized deployment of energy storage facilities at the FFPP level has considerable advantages due to possibilities of smaller storage capacities, immediate benefits realized by the host power plant due to the increase in the efficiency, cleaner emission and higher plant life to name a few. Most importantly, deployment at the FFPP level can exploit the existing equipment items and facilities at the host power plant, thus reducing the CAPEX and reducing the storage capacity. However, realization of these benefits will critically depend on novel configuration/integration strategies with the least impact on the power plant operation and its configuration. Furthermore, dynamics of the entire integrated system including both the FFPP and the storage technologies must be taken into account to obtain the cost-optimal solution. With these motivations, the objective of this project was to complete a focused evaluation of decentralized deployments of energy storage facilities at the FFPP level. Promising thermal, chemical, mechanical, and electro-chemical storage technologies were evaluated with due consideration of their transient response to obtain various optimal system concepts that can minimize the levelized cost of storage. For thermal storage, cryogenic energy storage along with high temperature heat storage in molten salt as well as phase change material were evaluated. For mechanical storage, cryogenic air storage and pumped hydro storages were evaluated. For chemical storage, hydrogen storage was evaluated. For electrochemical storage, the team evaluated sodium sulfur, vanadium redox flow battery as well as Li-ion batteries. Integration of these storage technologies with the natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants was considered. Six technologies, namely molten salt, cryogenics, compressed air, pumped hydro, H2 storage and Li-ion battery storage, were downselected based on their levelized cost of storage. It was observed that the ranking of the optimal storage technology can differ based on the host power plant technology even when same demand/supply/price profile for electricity are considered. It was also observed that as the variability in power demand varies, the ranking of the optimal storage technologies vary. However, for the same demand and LMP profile, top six optimal storage technologies for NGCC vs SCPC plants did not differ much even though LCOS for the same technology and optimal size of a given storage technology did differ. Detailed techno-economic assessment of these six technologies was undertaken.

01 COAL, LIGNITE, AND PEAT↗

Planning Amidst Uncertainty: Identifying Core CCS Infrastructure Robust to Storage Uncertainty

Carbon Capture and Storage (CCS) is a critical technology for reducing anthropogenic CO2 emissions, but its large-scale deployment is complicated by uncertainties in geological storage performance. These uncertainties pose significant financial and operational risks, as underperforming storage sites can lead to costly infrastructure modifications, inefficient pipeline routing, and economic shortfalls. To address this challenge, we propose a novel optimization workflow that is based on mixed-integer linear programming and explicitly integrates probabilistic modeling of storage uncertainty into CCS infrastructure design. This workflow generates multiple infrastructure scenarios by sampling storage capacity distributions, optimally solving each scenario using a mixed-integer linear programming model, and aggregating results into a heatmap to identify core infrastructure components that have a low likelihood of underperforming. A risk index parameter is introduced to balance trade-offs between cost, CO2 processing capacity, and risk of underperformance, allowing stakeholders to quantify and mitigate uncertainty in CCS planning. Applying this workflow to a CCS dataset from the US Department of Energy’s Carbon Utilization and Storage Partnership project reveals key insights into infrastructure resilience. Reducing the risk index from 15% to 0% is observed to lead to an 83.7% reduction in CO2 processing capacity and a 77.1% decrease in project profit, quantifying the trade-off between risk tolerance and project performance. Furthermore, our results highlight critical breakpoints, where small adjustments in the risk index produce disproportionate shifts in infrastructure performance, providing actionable guidance for decision-makers. Unlike prior approaches that aimed to cheaply repair underperforming infrastructure, our workflow constructs robust CCS networks from the ground up, ensuring cost-effective infrastructure under storage uncertainty. These findings demonstrate the practical relevance of incorporating uncertainty-aware optimization into CCS planning, equipping decision-makers with a tool to make informed project planning decisions.

Olson, Daniel↗

A Two-Step Control Approach for Torque Ripple and Vibration Reduction in Switched Reluctance Motor Drives

The objective of this work is to reduce the torque ripple and vibration in Switched Reluctance Motor (SRM) drives. To achieve such a goal, a two-step approach is proposed. In the first step, the reference current is profiled using an optimization method, aimed to reduce the torque pulsation. In the second, the optimum current profile is applied to the SRM through an adaptive hysteresis band controller to actively cancel the radial vibration. The proposed technique uses an optimization procedure based on the Field Reconstruction Method (FRM) and Non-Derivative Optimization Method to find the optimal current profile that mitigates the torque pulsation, however, the investigation has shown that the proposed excitation leads to a higher radial vibration, which has been mitigated by using an adaptive hysteresis band controller. The theoretical basis for the proposed approach is initially presented, followed by system modeling and simulation. In addition, experimental verification has been conducted using an 8/6 SRM to show the feasibility of the proposed approach. The proposed method alleviates the acoustic noise and torque pulsation in SRM and offers an effective step towards the prevalent use of SRM in a wide range of applications.

42 ENGINEERING↗

ISS-Crystal Growth of Photorefractive Materials (BSO): Critical Design Issues for Optimized Data Extraction from Space Experiments

Realization of the full potential of photorefractive materials in device technology is seriously impeded by our inability to achieve controlled formation of critical defects during single crystal growth and by difficulties in meeting the required degree of compositional uniformity on a micro-scale over macroscopic dimensions. The exact nature and origin of the critical defects which control photorefractivity could not as yet be identified because of gravitational interference. There exists, however, strong evidence that the density of defect formation and their spatial distribution are adversely affected by gravitational interference which precludes the establishment of quantifiable and controllable heat and mass transfer conditions during crystal growth. The current, NASA sponsored research at MIT is directed at establishing a basis for the development of a comprehensive approach to the optimization of property control during melt growth of photorefractive materials, making use of the m-g environment, provided in the International Space Station. The objectives to be pursued in m-g research on photorefractive BSO (Bi12SiO20) are: (a) identification of the x-level(s) responsible for photorefractivity in undoped BSO; (b) development of approaches leading to the control of x-level formation at uniform spatial distribution; (c) development of doping and processing procedures for optimization of the critical, application specific parameters, spectral response, sensitivity, response time and matrix stability. The presentation will focus on: the rationale for the justification of the space experiment, ground-based development efforts, design considerations for the space experiments, strategic plan of the space experiments, and approaches to the quantitative analysis of the space experiments.

Hyers, Robert W.↗

Optimization of Graphite–SiO blend electrodes for lithium-ion batteries: Stable cycling enabled by single-walled carbon nanotube conductive additive

Lithium-alloying materials are of great interest to improve the gravimetric and volumetric energy density of lithium-ion batteries, though their associated volume fluctuation with cycling often leads to poor cycling performance. Active-inactive alloys and blending alloys with carbon materials are common strategies to accommodate volume fluctuation. Herein we set out to optimize graphite-SiO blend electrode formulations to eliminate rapid capacity fade. Electrodes with highly stable cycling were prepared by simple planetary mixing procedures, enabled by the use of just a fraction of a weight percent of commercial SWCNTs as the only conductive additive, and by the appropriate choice of binder/stabilizing agent. In fact, the use of SWCNTs allowed for graphite-free SiO electrodes with approximately 74% higher volumetric energy density relative to traditional graphite electrodes, and superior capacity retention in coin-type full-cell testing versus NMC532 cathodes.

25 ENERGY STORAGE↗

Leveraging Stereochemistry to Optimize the Properties of Polyhydroxyalkanoates

The recycling of low-density polyethylene (LDPE) is challenging due to difficulties with sorting and contamination, leading to environmental harm. Polyhydroxyalkanoates (PHAs) are at the forefront of high-performance biodegradable alternatives to olefinic plastics, but few offer LDPE-like properties such as low strength and crystallinity while maintaining high ductility and thermal stability. Herein, we report a series of isoenriched transpoly( 3-hydroxy-2-methylbutyrates) (trans-PHMBs) with tunable mechanical and thermal properties. These polymers were synthesized through ring-opening polymerization of racemic trans-3,4-dimethylpropiolactone (rac-trans-DMPL), sourced from C1 and C4 feedstocks, using a new class of “sandwich” C 2 symmetric rac-( Ar BDI*)ZnO i Pr catalysts (where BDI = β-diketiminate). Variation of aromatic groups (Ar) and polymerization temperature yielded mm%s between 45−79% and melting temperatures (T m ) between 141−174 °C. trans-PHMB with intermediate isotacticities of 73 and 75 mm% exhibit similar stress−strain profiles to LDPE, indicating that these polymers have the potential to serve as higher melting, degradable substitutes for LDPE.

Biopolymers↗

A machine learning framework for accurate and robust analysis of radiation detector pulses

The microscopic properties of atomic nuclei are used to study various scientific questions. They are essential for understanding the fundamental forces of nature and the chemical evolution of the universe. Detecting decay radiation from radioactive nuclei makes it possible to probe these fundamental nuclear properties. Detector waveform traces may contain additional information about the radiation. Generally, advanced signal processing techniques are needed to extract this additional information, often involving fitting the waveform with model response functions using non-linear least-squares optimization with second-order gradient methods. While this is a powerful technique, it is also computationally expensive, leading to slow processing time, which scales with the volume of data. To address this problem, we have developed a machine learning (ML) approach that infers the characteristics of traces from a model detector response function. In particular, we are interested in classifying whether a single recorded trace consists of one or two pulse constituents and estimating the pulse parameters. Furthermore, our proposed ML method can precisely extract the pulses’ parameters, such as energy and timing information, and accurately classify the pulse multiplicity of a trace. Unlike non-learning-based approaches, our ML approach uses neural networks that are significantly faster at inference, as they do not require any optimization during this stage.

Curve fitting↗

Optimization of the N ∥ Upshift in the DIII-D high field side lower hybrid current drive experiment

High field side lower hybrid current drive (LHCD) is one potential candidate for efficient non-inductive current drive in tokamak power plants, and the first test of this technology will occur on the DIII-D tokamak during the 2024 campaign. Previous LFS launch experiments operated in the multi-pass regime and relied on scrape-off layer interactions to close the spectral gap. In the DIII-D experiment, single-pass damping is achievable via an upshift in the parallel refractive index N ∥ caused by mode converting twice (slow → fast → slow). This mode conversion affects the ray trajectories and can lead to enhanced N ∥ upshift depending on where mode conversion occurs. Compared to multi-pass absorption experiments, the optimization of launched N ∥ and plasma parameters can be counter-intuitive: increased density may increase efficiency and smaller N ∥,launch tend to damp closer to the separatrix. A hard x-ray camera installed to measure the bremsstrahlung (50–250 keV) radiation from LHCD-generated fast electrons is capable of verifying the trends reporting in this paper through comparison to the ray-tracing/Fokker–Planck codes GENRAY/CQL3D.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Monitoring Airspace Complexity and Determining Contributing Factors

The national airspace has evolved over many years to accommodate increased traffic demand [1] while simultaneously maintaining one of the safest forms of transportation [2], [3]. One of the reasons for this success is the ability of the system and the operators to adapt and accommodate to situations that routinely disrupt optimal operations. These situations may include: adverse weather, delays, early arrivals, equipment outages, and other factors that are outside the operators ability to control. These factors can lead to states where automation is unable to properly handle these issues and therefore air traffic controllers and pilots have to intervene, ultimately increasing communication between operators resulting in higher workload. As controller workload increases to handle sub-optimal operating conditions this can be viewed as an increase in complexity. The reasoning for this is because humans are now required to make tactical decisions in response to external factors, resulting in a departure from the strategic plan where operations would be more efficiently managed. Human operators control airspace complexity under rigid regulations that are constantly changing. The airspace is divided into sectors and the number of aircraft assigned to each controller is limited for safe handling. There has been past work that devised airspace complexity metrics in commercial aviation and related these metrics to controller workload (e.g., [4],[5]). The upper bounds on the system load are pre-determined. Such bounds on complexity make for a safe system, but the system cannot scale and adapt to autonomous, dense, and heterogeneous traffic, including the many types of Unmanned Aerial Vehicles (UAVs) envisioned to be added to the operations. We hypothesize that, as traffic density and heterogeneity grow, and other key metrics change, there will be phase transitions at which the way traffic should be managed changes significantly [6]. We offer a method for in-time detection of contributing factors that lead to phase transitions, characterized by increased complexity. To the best of our knowledge, there is no tool similar to our proposed effort that identifies such contributing factors or precursor patterns. To define the scope we are proposing to measure complexity from the viewpoint of the Terminal Radar Approach Control Facilities (TRACON) controller’s perspective. In particular we are analyzing arrivals into KSFO. With safety as the top concern for airspace operators, it is important to recognize that as density and heterogeneity grow, the focus of the system will change. Times of the day when the airspace has low density and heterogeneity, the flights will follow more efficient paths where the aircraft move on established routes that are more or less directly to the destination. However, when density and heterogeneity increases, the system will begin changing focus to avoiding conflicts and collisions and route the flights in a more flexible way. Higher flexibility requires more communication and coordination between controllers and pilots which the current automation is unable to handle. This paper proposes a novel approach that monitors airspace complexity at multiple scales, uses a Machine Learning-based tool that predicts when operations will transition to a regime of greater complexity, and identifies actions that can reduce the complexity while still maintaining efficient and safe operations. We demonstrate our proposed approach using data from multiple complementary sources. This includes, but is not limited to: historical aircraft surveillance data from NASA’s Sherlock Data Warehouse [7], METAR weather data, and airport configuration data from Aviation System Performance Metrics (ASPM). The surveillance data flight paths are sampled at a variable sample rate — increasing as the aircraft approaches the airport. This is due to how Sherlock manages flight track stitching between different radar facilities which have different sampling rates. The weather and performance data are logged at defined intervals throughout the day at a courser refresh rate. In addition to the logged data and metrics, we leverage pre-defined Standard Terminal Arrival Routes (STARs) procedures to characterize the path of each flight. Each flight files for one of these routes in the flight plan well before entering the terminal airspace, and approximately follows the route until it leaves the STAR, typically on the final fix of a runway transition. However, most flights do not always fly the full STAR procedure to completion [8], but the majority do adhere to the fixes within the common route of the procedure. Our approach leverages fixes in the common route of each of the STARs to build a reference path to the airport. This allows us to characterize the flight paths in what we are defining as the “maneuvering area” (the airspace between the STAR and before the flight is lined up on the runway’s final approach) to determine how off nominal the flights are to calculate its complexity score. Determining airspace complexity is a concept that does not have a concrete answer. In designing this metric, we consider what increases the workload for the air traffic controllers. Consequently more specialized vectoring maneuvers results in higher workload. Accordingly, we start with a theory: each flight has a direct path it takes from the STAR’s common route to the final approach’s outer marker fix for the flight’s landing runway. It is important to note that the direct path is only used as a reference. If the majority of the flights have a large consistent offset as compared to other routes it does not necessarily mean that those flights have higher complexity. We are merely building a distribution based on this direct path for that particular STAR and runway pair to determine the normal mode of operations for that route. Flights that are in the upper tail of these distributions will result in higher complexity scores and flights that fly in the median will represent the normal mode of operations and therefore will have lower complexity scores. Since flights following each STAR route take different paths to the airport, we have a different distribution for each STAR route and therefore can model these distributions to compute a complexity score from their respective normalized distributions. To evaluate the effectiveness of our proposed airspace complexity metric we will compare against an established approach based on trajectory clustering [9]. This unsupervised learning technique consists of the following steps: (1) identify the general maneuvering areas (waypoints) by performing $\kappa$-means or DBSCAN clustering on locations where aircraft frequently turn based on the surveillance radar track data, (2) map flight trajectories onto sequences of waypoints, and (3) cluster the sequences based on their common subsequences. From a high-level perspective, this baseline model learns nominal operations in the airspace through the sequence of waypoints that are representative of where aircraft change direction and defines deviations from the nominal operations as “complex.” Therefore, more deviations from the nominal operations correspond to higher complexity values. For our validation, we re-implemented this technique and tune model hyper-parameters to correctly detect waypoints for the arrival traffic into the San Francisco bay area. We will compute the complexity measure over a one-year period using our proposed technique as well as the baseline. Our validation will be based on each technique’s ability to detect a set of undesirable outcomes (e.g., go-arounds, holding patterns, average time in the airspace, etc.). Since our current complexity metric is derived from the offset from the direct reference path, it’s important to understand what causes these offsets. In many of the flights with high offset distance, flights performing holding patterns and S turns can be observed. These maneuvering tactics are utilized to add distance between the aircraft and the destination runway to prevent multiple flights from having conflicting arrival times. In order to predict a rise in complexity (or the precursor to complexity), it’s necessary to be able to identify these potential conflicts (which in turn, result in higher offsets). To do this, we define a “representative flight” for each STAR route and runway pair. This flight is approximately the path the flight would take if there was a clear path with no other flights in the airspace — including the time remaining to the airport. We first identify the flights for a given STAR runway pair using the offset to the reference path distributions that fall between the 44-55 percentiles. This yields the flights that conform to the most normal mode of operation. Each of these flights is partitioned based on the percent complete from the entry point into the maneuvering areas from 0\% – 100\% complete. Then for each percent “bin”, we take the median value of the flight’s latitude/longitude coordinates, airspeed, and (non causal) time remaining to the airport to construct a lookup table for each percent complete bin on a given route. As a flight enters the maneuvering area, we can find the estimated arrival time of a flight to the airport by finding the closest point to the representative path’s percent complete bin (relative to the flight’s current position at any snapshot in the airspace) and therefore retrieve the corresponding remaining time left on the “representative path”. We assume that the flight will follow the representative path to completion when deriving these estimates. We can then compare these estimated arrival times against other flights for the same snapshot in time to identify potential conflicts. If more flights are estimated to arrive within a tolerance window than there are runways available, then we have a potential conflict. We can use this derived measure along with other factors expected to add disruption to the operation such as weather and runway configuration changes as an input to machine learning tools to detect precursors that increases in our complexity measure. This novel method will assist in uncovering insights into the contributing factors that lead to increased complexity that may allow for in-time responses to avoid reaching a high complexity state in the airspace.

complexity↗

Diagnosing Barren Plateaus with Tools from Quantum Optimal Control

Variational Quantum Algorithms (VQAs) have received considerable attention due to their potential for achieving near-term quantum advantage. However, more work is needed to understand their scalability. One known scaling result for VQAs is barren plateaus, where certain circumstances lead to exponentially vanishing gradients. It is common folklore that problem-inspired ansatzes avoid barren plateaus, but in fact, very little is known about their gradient scaling. In this work we employ tools from quantum optimal control to develop a framework that can diagnose the presence or absence of barren plateaus for problem-inspired ansatzes. Such ansatzes include the Quantum Alternating Operator Ansatz (QAOA), the Hamiltonian Variational Ansatz (HVA), and others. With our framework, we prove that avoiding barren plateaus for these ansatzes is not always guaranteed. Specifically, we show that the gradient scaling of the VQA depends on the degree of controllability of the system, and hence can be diagnosed through the dynamical Lie algebra $\mathfrak{g}$ obtained from the generators of the ansatz. We analyze the existence of barren plateaus in QAOA and HVA ansatzes, and we highlight the role of the input state, as different initial states can lead to the presence or absence of barren plateaus. Taken together, our results provide a framework for trainability-aware ansatz design strategies that do not come at the cost of extra quantum resources. Moreover, we prove no-go results for obtaining ground states with variational ansatzes for controllable system such as spin glasses. Our work establishes a link between the existence of barren plateaus and the scaling of the dimension of $\mathfrak{g}$.

97 MATHEMATICS AND COMPUTING↗

Optimization of lamp spectrum for vegetable growth

An increase in the demand for and production of vegetables in the winter, mainly in northern and Siberian regions, inevitably leads to mass building of structures for growing plants under completely artificial conditions. An industrial lighting technology is required whose main parameters (spectrum, irradiance, photoperiod) should be assigned carefully and should uniquely determine, along with other important characteristics of the artificial climate, the productivity of the plant-production facility. The most widespread crops grown in our country under indoor conditions are cucumber and tomato plants, which account for more than 98% of the area in greenhouses. These plants are good prospects for growing completely under intense artificial lighting conditions (photocultures). Optimization of the main parameters of optical radiation when growing these plants is the most important task of achieving their profitable production. At present, considerable experience has been gained in studying the dependence of productivity of cucumber and tomato communities on irradiation conditions. Fundamental studies of the Agrophysical Research Institute of the Russian Academy of Sciences, Timiryazev Institute of Plant Physiology of the Russian Academy of Sciences, Timiryazev Agricultural Academy, and other institutes create a good basis for a detailed study of the given problem. Commercial sources of radiation substantially differing in spectral characteristics in the region of photosynthetically active radiation (PAR) were used in the studies.

Prikupets, L. B.↗

Peak-Seeking Optimization of Trim for Reduced Fuel Consumption: Architecture and Performance Predictions

A peak-seeking control approach for real-time trim configuration optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control approach is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an FA-18 airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois) are controlled for optimization of fuel flow. This presentation presents the design and integration of this peak-seeking controller on a modified NASA FA-18 airplane with research flight control computers. A research flight was performed to collect data to build a realistic model of the performance function and characterize measurement noise. This model was then implemented into a nonlinear six-degree-of-freedom FA-18 simulation along with the peak-seeking control algorithm. With the goal of eventual flight tests, the algorithm was first evaluated in the improved simulation environment. Results from the simulation predict good convergence on minimum fuel flow with a 2.5-percent reduction in fuel flow relative to the baseline trim of the aircraft.

peak-seeking↗

Development and Optimization of Additively Manufactured NASA HR-1 for Space Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This presentation will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

Additive Manufacturing↗

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗

Liquid-Cooled Heat Sink Optimization for Thermal Imbalance Mitigation in Wide-Bandgap Power Modules

Power semiconductor die layout in substrates used in power modules is generally optimized for minimum electrical parasitics (e.g., stray inductance) by considering the minimum spacing between dies for thermal decoupling. The layout assumes sufficient heat spreading and transfer from dies to the cooling structure. For module designs using a direct substrate cooling method, the base plate is removed, leading to a steady-state thermal asymmetry in the power module due to insufficient heat spreading/transfer. This causes significant temperature differences among the devices. Such unintentional thermal asymmetries can lead to undesirable asymmetries in power conversion among semiconductor devices, which impact reliability. This article proposes a thermal imbalance mitigation method that uses evolutionary optimized liquid-cooled heat sinks to improve the thermal loading among devices.

Sahu, Raj↗

Advances in laser-based bremsstrahlung x-ray sources. I. Optimizing laser-accelerated electrons

In this work, we have performed a suite of kinetic simulations of relativistic laser–plasma interaction under settings relevant to recent and planned experiments on a variety of laser systems. The goal of the study is to illuminate the physics of laser–target coupling and to provide guidance for how to optimize these sources for applications. It is shown that the production of relativistic electrons is maximized when conditions of relativistic induced transparency (RIT) in dense plasmas can be achieved over a large interaction volume at the time of arrival of most intense part of the laser pulse. RIT is shown to enhance both the numbers of relativistic electrons and the energies of the electrons, leading to an increased x-ray dose. A variety of approaches to enhancing laser–target coupling are considered. These include optimizing the effects of low-density pre-plasma (arising either from finite laser pedestal or from the use of foam coatings) and of modifying the laser focusing geometry to reduce effects of filamentation and self-focusing. Evidence of a novel approach to achieving stable laser propagation over distances of tens of micrometers in a plasma gradient is also presented. These conditions coincide with plasma and laser conditions explored in recent experiments on the Omega EP laser system and compare favorably with an analytic criterion for stable laser propagation in relativistically underdense plasma obtained from a nonlinear Wentzel–Kramers–Brillouin analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Optimal Distribution System Voltage Regulation using State Estimation and DER Grid-Support Functions

Increasing solar energy penetrations may create challenges for distribution system operations because production variability can lead to large voltage deviations or protection system miscoordination. Instituting advanced management systems on distribution systems is one promising method for combating these challenges by intelligently controlling distribution assets to regulate voltage and ensure protection safety margins. While it is generally not the case today, greater deployment of power system sensors and interoperable distributed energy resources (DER)e.g., photovoltaic (PV) inverters, energy storage systems (ESS), electric vehicles (EVs)will enable situational awareness, control, and optimization of distribution systems. In this work, a control system was created which measures power system parameters to estimate the status of a feeder, forecasts the distribution state over a short-term horizon, and issues optimal set point commands to distribution-connected equipment to regulate voltage and protect the system. This two-year project integrated multiple research innovations into a management system designed to safely allow PV penetrations of 50% or greater. The integrated software was demonstrated through extensive real-time (RT) and power hardware-in-the-loop studies and a field demonstration on a live power system with a 684 kVA PV system.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Fault Tree Based Diagnosis with Optimal Test Sequencing for Field Service Engineers

When field service engineers go to customer sites to service equipment, they want to diagnose and repair failures quickly and cost effectively. Symptoms exhibited by failed equipment frequently suggest several possible causes which require different approaches to diagnosis. This can lead the engineer to follow several fruitless paths in the diagnostic process before they find the actual failure. To assist in this situation, we have developed the Fault Tree Diagnosis and Optimal Test Sequence (FTDOTS) software system that performs automated diagnosis and ranks diagnostic hypotheses based on failure probability and the time or cost required to isolate and repair each failure. FTDOTS first finds a set of possible failures that explain exhibited symptoms by using a fault tree reliability model as a diagnostic knowledge to rank the hypothesized failures based on how likely they are and how long it would take or how much it would cost to isolate and repair them. This ordering suggests an optimal sequence for the field service engineer to investigate the hypothesized failures in order to minimize the time or cost required to accomplish the repair task. Previously, field service personnel would arrive at the customer site and choose which components to investigate based on past experience and service manuals. Using FTDOTS running on a portable computer, they can now enter a set of symptoms and get a list of possible failures ordered in an optimal test sequence to help them in their decisions. If facilities are available, the field engineer can connect the portable computer to the malfunctioning device for automated data gathering. FTDOTS is currently being applied to field service of medical test equipment. The techniques are flexible enough to use for many different types of devices. If a fault tree model of the equipment and information about component failure probabilities and isolation times or costs are available, a diagnostic knowledge base for that device can be developed easily.

Iverson, David L.↗