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An adjustable reamer permitting scratch-free extraction from the machined hole is described. Formulas for the geometric parameters of reamers with diameters in the range 32–140 mm are presented. The results required for the development of design documentation are derived.
Predictive Design Technologies, LLC (PDT) proposed to employ Integrated Computational Materials Engineering (ICME) tools to help the manufacturing industry in the United States regain the competitive advantage in the global economy. ICME uses computational materials science tools within a holistic system in order to accelerate materials development, improve design optimization, and unify design and manufacturing. With the advent of accurate modeling and simulation along with significant increases in high performance computing (HPC) power, virtual design and manufacturing using ICME tools provide the means to reduce product development time and cost by alleviating costly trial-and-error physical design iterations while improving overall quality and manufacturing efficiency. To reduce the computational cost necessary for the large-scale HPC simulations and to make the methodology accessible for small and medium-sized manufacturers (SMMs), metamodels are employed. Metamodels are approximate models (functional relationships between input and output variables) that can reduce the simulation times by one to two orders of magnitude. In Phase I, PDT, partnered with Mississippi State University (MSU), demonstrated the feasibility of the proposed methodology by employing MSU?s internal state variable (ISV) plasticity-damage model with the help of metamodels to optimize the microstructure-process-property-cost for tube manufacturing processes used by Plymouth Tube Company (PTC), which involves complicated temperature and mechanical loading histories. PDT quantified the microstructure-property relationships for PTC?s SAE J525 electric resistance-welded cold drawn low carbon hydraulic 1010 steel tube manufacturing processes at seven different material states and calibrated the ISV plasticity material parameters to fit experimental tensile stress-strain curves. PDT successfully performed large scale finite element (FE) simulations in an HPC environment using the ISV plasticity model in Abaqus FE analyses of the tube forming, sizing, drawing, welding, and normalizing processes. The simulation results coupled with the manufacturing cost data were used to develop prototype metamodeling (quick response) codes which could be used to predict and optimize the microstructure-process-property-cost relationships. The developed ICME metamodeling toolkits are flexible enough to be applied to other manufacturing processes (e.g. forging, forming, casting, extrusion, rolling, stamping, and welding/joining) and metamodeling codes can run on laptop computers. Based on the work completed in Phase I, in Phase II, PDT proposes to continue to refine the ISV model by correlating and incorporating the uncertainties in the microstructure, mechanical testing, and modeling. Following the model refinement, FE analyses will be simulated and will provide even more realistic predictions as they include an appropriate window of uncertainty. Using the HPC output (FE analyses) as input, the quick-response metamodel codes will more accurately predict and optimize the microstructure-process-property-cost relationships. Furthermore, PDT propose to employ the ICME metamodeling toolkits to help develop a new tube product using entirely new high strength steel. The modeling of the high strength steel manufacturing process will replace the costly and time consuming trial-and-error methods that were used in the tubing industry previously. This simulation-based process prototyping will greatly benefit our industrial partners by opening up new market spaces due to new products with greater capabilities.
This presentation for the Fourth Wind Energy Systems Engineering Workshop explains the NREL wind energy systems engineering initiative-developed analysis platform and research capability to capture important system interactions to achieve a better understanding of how to improve system-level performance and achieve system-level cost reductions. Topics include Wind-Plant Integrated System Design and Engineering Model (WISDEM) and multidisciplinary design analysis and optimization.
ITER diagnostic first walls (DFWs) and diagnostic shield modules (DSMs) inside the port plugs (PPs) are designed to protect diagnostic instrument and components from a harsh plasma environment and provide structural support while allowing for diagnostic access to the plasma. The design of DFWs and DSMs are driven by 1) plasma radiation and nuclear heating during normal operation 2) electromagnetic loads during plasma events and associate component structural responses. A multi-physics engineering analysis protocol for the design has been established at Princeton Plasma Physics Laboratory and it was used for the design of ITER DFWs and DSMs. The analyses were performed to address challenging design issues based on resultant stresses and deflections of the DFW-DSM-PP assembly for the main load cases. ITER Structural Design Criteria for In-Vessel Components (SDC-IC) required for design by analysis and three major issues driving the mechanical design of ITER DFWs are discussed. The general guidelines for the DSM design have been established as a result of design parametric studies.
Engineering feedstock supply systems that deliver affordable, high-quality biomass remains a challenge for the emerging bioenergy industry. Cellulosic biomass is geographically distributed and has diverse physical and chemical properties. Because of this feedstock supply systems that deliver cellulosic biomass resources to biorefineries require integration of a broad set of engineered unit operations. These unit operations include harvest and collection, storage, preprocessing, and transportation processes. Design decisions for each feedstock supply system unit operation impact the engineering design and performance of the other system elements. These interdependencies are further complicated by spatial and temporal variances such as climate conditions and biomass characteristics. This paper develops an integrated model that couples a SQL-based data management engine and systems dynamics models to design and evaluate biomass feedstock supply systems. The integrated model, called the Biomass Logistics Model (BLM), includes a suite of databases that provide 1) engineering performance data for hundreds of equipment systems, 2) spatially explicit labor cost datasets, and 3) local tax and regulation data. The BLM analytic engine is built in the systems dynamics software package PowersimTM. The BLM is designed to work with thermochemical and biochemical based biofuel conversion platforms and accommodates a range of cellulosic biomass types (i.e., herbaceous residues, short- rotation woody and herbaceous energy crops, woody residues, algae, etc.). The BLM simulates the flow of biomass through the entire supply chain, tracking changes in feedstock characteristics (i.e., moisture content, dry matter, ash content, and dry bulk density) as influenced by the various operations in the supply chain. By accounting for all of the equipment that comes into contact with biomass from the point of harvest to the throat of the conversion facility and the change in characteristics, the BLM evaluates economic performance of the engineered system, as well as determining energy consumption and green house gas performance of the design. This paper presents a BLM case study delivering corn stover to produce cellulosic ethanol. The case study utilizes the BLM to model the performance of several feedstock supply system designs. The case study also explores the impact of temporal variations in climate conditions to test the sensitivity of the engineering designs. Results from the case study show that under certain conditions corn stover can be delivered to the cellulosic ethanol biorefinery for $35/dry ton.
The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.
The use of glovebox confinement at US Department of Energy (DOE) tritium facilities has been discussed in numerous publications. Glovebox confinement protects the workers from radioactive material (especially tritium oxide), provides an inert atmosphere for prevention of flammable gas mixtures and deflagrations, and allows recovery of tritium released from the process into the glovebox when a glovebox stripper system (GBSS) is part of the design. Tritium recovery from the glovebox atmosphere reduces emissions from the facility and the radiological dose to the public. Location of US DOE defense programs facilities away from public boundaries also aids in reducing radiological doses to the public. This is a study based upon design concepts to identify issues and considerations for design of a Seismic GBSS. Safety requirements and analysis should be considered preliminary. Safety requirements for design of GBSS should be developed and finalized as a part of the final design process.
A threaded joint for pipelines and high-pressure hoses is described. The benefits of the new design are outlined. A test prototype is presented.
This technical report describes a detailed blade cost model for wind turbine blades in the range of 30 to 100 meters in length. The model estimates the bill of materials, the number of labor hours and the cycle time, and the costs related to direct labor, overhead, buildings, tooling, equipment, maintenance, and capital. The model applies to multimegawatt wind turbine blades manufactured via vacuum-assisted resin transfer molding, which is the most commonly adopted manufacturing method for modern wind turbine blades. The model is implemented both in a large Excel file and in Python. The latter is freely available in the repository of the Wind-Plant Integrated System Design and Engineering Model (WISDEM[R]) github.com/WISDEM. WISDEM is a multidisciplinary analysis and optimization design framework developed at the National Renewable Energy Laboratory. This blade cost model represents a valuable tool to run design optimization studies for wind turbines. In this report, the model is first presented with its approach and assumptions and then computes the costs of three blades, namely the 33-meter-long Wind Partnership for Advanced Component Technologies (WindPACT) study blade, the 63-meter-long International Energy Agency (IEA) Wind Task 37 land-based reference wind turbine blade, and the 100-meter-long SNL-100-03 blade developed at Sandia National Laboratories.
We present a thorough analysis of active learning strategies for polymer sequence engineering and design.
The National Renewable Energy Laboratory (NREL), together with the Colorado School of Mines (CSM) and Colorado State University (CSU), has developed a machine learning-enhanced approach to the design of new battery materials. Currently, such materials are designed in part via numerous expensive high-fidelity computational simulations that predict the performance of a given composition. Even with computational screening tools, the vast landscape of possible molecular or crystal structures exceeds current and future computational capacity. Improving the efficiency by which new materials can be optimized will therefore disrupt the cost, risk, and time required to bring new energy solutions to the marketplace. Predicting the properties of an organic molecule or periodic crystalline material given its structure has grown increasingly common. These approaches leverage large-scale computational and experimental databases and ML approaches such as graph neural networks. The inverse design problem of finding a material that possesses desired properties is substantially more challenging, since enumerating all valid material structures is not feasible. In this project, we leveraged recent success in reinforcement learning to efficiently navigate this high-dimensional search space. Just as algorithms can find the optimal chess moves from nearly limitless options, we train an approach to evolve a simple starting structure into a complex structure that possess the desired properties. Our solution has been demonstrated by applying it to two related design application tasks for short- and long-term energy storage, respectively: (1) the design of solid-state ion conductors and (2) the design of organic redox-active materials. The project has resulted an open-source software library for material design, documented examples of applying the library to both organic and inorganic material optimization, and peer-reviewed publications detailing the data, computational models, and resulting candidate materials.
The University of North Dakota (UND), in collaboration with a comprehensive team of technical, business and host-site partners, built on prior technology development to complete a front-end engineering and design (FEED) and business planning study to recover and refine rare earth elements (REE) and critical minerals (CM) from North Dakota (ND) lignite mine wastes. The end of project goal was to have an investment quality project and a committed team ready to commercialize the proposed technologies in a future construction and operations phase.
The Boston Architectural College's Urban Sustainability initiative is a demonstration project as defined by the National Energy Technology Laboratory. BAC's proposed project with the U.S. Department of Energy - NETL, is a large part of that overall initiative. The BAC's Urban Sustainability Initiative is a multi-part project with several important goals and objectives that will have a significant impact on the surrounding neighborhood including: energy conservation, reduction of storm water runoff, generation of power through alternative energy sources, elimination/reduction of BAC carbon footprint, and to create a vehicle for ongoing public outreach and education. Education and outreach opportunities will serve to add to the already comprehensive Sustainability Design courses offered at BAC relative to energy savings, performance and conservation in building design. At the finish of these essential capital projects there will be technical materials created for the education of the design, sustainability, engineering, community development and historic preservation communities, to inform a new generation of environmentally-minded designers and practitioners, the city of Boston and the general public. The purpose of the initiative, through our green renovations program, is to develop our green alley projects and energy saving renovations to the BAC physical plant, to serve as a working model for energy efficient design in enclosed 19th century and 20th century urban sites and as an educational laboratory for teaching ecological and sustainable technologies to students and the public while creating jobs. The scope of our project as it relates to the BAC and the U.S. Department of Energy- NETL combined efforts includes: Task I of the project is Phase II (Green Alley). Task I encompasses various renovation activities that will demonstrate the effectiveness of permeable paving and ground water recharge systems. It will aid in the reduction of storm water runoff into the Charles River Basin in one of its most significantly polluted sections and, will provide a green renovation mechanism for the redirected storm water of a public alley way. This activity is designed to improve the quality of water recharging the ground water and protecting the vulnerable wood pilings under many of the historic masonry buildings in Boston's Back Bay. Sustainable design research and system monitoring opportunities will also be incorporated, providing ongoing tools for public outreach and education through innovative signage and "virtual tour" technology. The monitoring will include a "building performance dash board" that reflects real time operating conditions and improvements in environmental and economic performance to be prominently displayed on the face of our 320 Newbury Street building (approximately 1.5 million people walk by annually). The project site and demonstration area is located at the rear of 951 Boylston Street, Boston, MA 02115 and the parking area adjacent to Public Alley #444 in Boston's historic Back Bay. Task II of the project is Geothermal Solution. This task involves the installation of approximately seven Geothermal wells which will tap into the earth's constant underground temperatures to provide air-conditioning and heating for BAC facilities. The environmentally friendly geothermal system uses no fossil fuel, produces no emissions and runs silently, providing a sustainable model for commercial and residential buildings throughout Boston. Ultimately the combination of this project and other projects will assist in making the BAC "carbon-neutral", and could generate enough additional energy to provide free power to the Engine 33 and Ladder 15 Firehouse located at 941 Boylston Street. The project is located at the rear of 951 Boylston Street, Boston, MA 02115 and the parking area adjacent to Public Alley #444 in Boston's historic Back Bay. Task III of the project is the Sustainability Design Curriculum at the BAC. The BAC is the nation’s largest independent, multi-disciplinary college of spatial design, and a leader in sustainable design education. The Sustainabiltiy Design program, in particular, focuses on energy efficiency,energy performance, energy modeling, energy and air quality principles, green building, renewable energy alternatives and much more. Additionally, the Urban Sustainability Initiative has an objective of providing courses relative to the BAC's demonstration project with DOE, the project’s period of performance activities, subsequent performance data and anticipated sustainability teaching tools. In keeping with BAC's practice based curriculum, students have been involved in the discussion and planning of this project since its inception and sustainability issues have become a part of other programs throughout the college as well. Students will continue to benefit from this hands-on learning opportunity. The project is located at 320 Newbury Street Boston, MA 02115. Task IV of the project is Program Management and Reporting. This task will involve BAC's oversight and general management of the entire project including subcontract administration, contracts administration, technical and financial reporting, design and renovation assistance, other deliverables in accordance with the Federal Assistance reporting Checklist and other contractual obligations and provisions.
This project was inspired by two needs. The first is a need for tools to help scientists and engineers to design effective data visualizations for communicating information, whether to the user of a system, an analyst who must make decisions based on complex data, or in the context of a technical report or publication. Most scientists and engineers are not trained in visualization design, and they could benefit from simple metrics to assess how well their visualization's design conveys the intended message. In other words, will the most important information draw the viewer's attention? The second is the need for cognition-based metrics for evaluating new types of visualizations created by researchers in the information visualization and visual analytics communities. Evaluating visualizations is difficult even for experts. However, all visualization methods and techniques are intended to exploit the properties of the human visual system to convey information efficiently to a viewer. Thus, developing evaluation methods that are rooted in the scientific knowledge of the human visual system could be a useful approach. In this project, we conducted fundamental research on how humans make sense of abstract data visualizations, and how this process is influenced by their goals and prior experience. We then used that research to develop a new model, the Data Visualization Saliency Model, that can make accurate predictions about which features in an abstract visualization will draw a viewer's attention. The model is an evaluation tool that can address both of the needs described above, supporting both visualization research and Sandia mission needs.
Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.
In the last ~20 years, a multitude of natural enzymes have been discovered that can catalyze the breakdown of the common plastic poly(ethylene terephthalate) (PET). While enzymatic PET recycling is an attractive alternative end-of-life route for this waste plastic, the enzymes are not yet optimized for efficient and economical industrial use. Here, we discuss recent advances in engineering these PET-degrading enzymes, which include PET, bis(2-hydroxyethyl) terephthalate (BHET), and 2-hydroxyethyl terephthalic acid (MHET) hydrolases, toward industrially-relevant engineering goals. We place emphasis on trends from past efforts in rational and semi-rational design and emerging areas in directed evolution/high throughput screening and computational design for engineering these enzymes.
As wind turbines continue to grow ever larger to reduce the cost of energy, their blades follow suit, with the largest commercial offshore blades extending past 100 m. Massive blades such as these raise key transportation and manufacturing challenges, especially for land-based turbines. Segmented blades are one solution and are garnering increased industry and research interest. In this work, a detailed mechanical joint model is integrated into the Wind-Plant Integrated System Design and Engineering Model (WISDEM ® ), which will facilitate future segmented blade research and optimization. WISDEM is used to design a wind turbine with 100-m segmented blades. This wind turbine design is compared to other machines with 100-m monolithic blades designed for rail-transportability. The designs are compared in terms of blade mass and cost, turbine capital cost, annual energy production, and levelized cost of energy, with monolithic designs being the lightest and most economical. However, this result may vary by wind plant location. A variety of segmentation joint types exist, and they will inevitably vary in parameters such as cost, spanwise location, and physical characteristics. This work examines the sensitivity of wind turbine design drivers and annual energy production to a variety of the aforementioned parameters, using the open-source wind turbine design codes OpenFAST and WISDEM, finding that joint mass, stiffness, and location can have significant effects on design drivers.
This report documents conceptual design development for the Deep Borehole Field Test (DBFT), mainly the test packages (not containing waste) and the system for demonstrating emplacement and retrieval of those packages in the Field Test Borehole (FTB). For the DBFT to have demonstration value, it must be based on conceptualization of a deep borehole disposal (DBD) system for specific waste forms. This document therefore describes a current reference DBD concept, and analyzes key design options for disposal, to guide selection of options for the DBFT. The most important of these options is the emplacement mode, i.e. whether packages are emplaced using a wireline or a string of drill pipe (with a drill rig). This choice is analyzed using cost and risk models, in Sections 5 and 6. Other emplacement mode options are also identified and discussed. The reference DBD concept and the analysis of waste packaging and emplacement options, are used to develop requirements and assumptions for the DBFT and to recommend DBFT specifications. Design issues are identified, and priorities are developed for further conceptual design development and additional engineering analysis, anticipating future design activities. Conceptual design development is part of a process that proceeds in three stages: 1) conceptual design including feasibility studies; 2) preliminary design that includes technical and cost information necessary for final design; and 3) final design sufficient for fabrication or construction. The DBFT engineering demonstration will follow such an evolution. Whereas design evolution typically begins with bench-scale and pilot-scale investigations proceeding to conceptual, preliminary, and final designs, the DBFT can proceed directly to design because of extensive previous work and published literature on scientific drilling, characterization methods, waste packaging and handling, industrial deep-hole drilling and construction, and downhole operations. Hence it is anticipated that this report will lead to completion of conceptual design, then preliminary and final design, fabrication and testing, and demonstration of waste emplacement in a deep borehole.