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

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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Modeling plasticity-mediated void growth at the single crystal scale: A physics-informed machine learning approach

Modeling the evolution of voids during plastic flow as well as their effects on plastic dissipation is critical for both component manufacturing and lifetime estimation purposes. To this end, we propose a rate-dependent constitutive model to homogenize the effects of semi-randomly distributed voids on single crystal plasticity whilst capturing void interaction and plastic anisotropy. Here, this present work focuses on the case of face centered cubic crystals to introduce an anisotropic gauge function applicable within the crystal plasticity formalism. The approach combines analytical methods to describe the micromechanics of the system in combination with symbolic regression to capture analytically intractable mechanisms from data. The hybrid framework uses a physics-informed genetic programming-based symbolic regression algorithm to solve a multiform optimization problem simultaneously producing a new gauge function and a new strain rate equation. This is also a multi-objective optimization problem with many competing objectives. A new search and selection step is introduced to the genetic algorithm that promotes convergence toward a global solution that better satisfies all the objectives. Overall, the symbolic equations produced leverage data-driven methods to achieve greater accuracy than comparable alternatives on an analytically intractable problem while maintaining model transparency.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Scalable/Secure Cooperative Algorithms and Framework for Extremely-high Penetration Solar Integration (SolarExPert) (Final Technical Report)

This SolarExPert project has developed a Sustainable Grid Platform (SGP) with scalable architecture of distributed control and optimization. The SGP consists of the following major functions: 1) an advanced grid architecture with hierarchical and distributed communication and control, combined with the OpenFMB standard and implemented on the Multi-Agent OpenDSS (MA-OpenDSS) platform; 2) an online distributed stochastic optimal power flow; 3) an online distributed system state estimation algorithm; 4) the distributed Volt/VAR optimization and frequency control algorithms; 5) the distributed distribution system restoration strategy. The developed SGP together with advanced functions are tested in 1 million (1M)-node distribution system on the MA-OpenDSS platform. Furthermore, the models and algorithms are tested in 100,000-node system HiL simulation, and also in P-HiL implementation with 100 physical devices. The developed functions haven been validated and tested on the selected actual distribution feeder with the data collected from the field of Maui Meadows in Hawaii. The distributed PV hosting capacities with cooperative Volt/VAR and Volt/VAR/Watt control are estimated and compared to provide recommendations for customers and the utility company.

14 SOLAR ENERGY↗
DOE OSTI2020

FPGA-based tracking for the CMS Level-1 trigger using the tracklet algorithm

The high instantaneous luminosities expected following the upgrade of the Large Hadron Collider (LHC) to the High-Luminosity LHC (HL-LHC) pose major experimental challenges for the CMS experiment. A central component to allow efficient operation under these conditions is the reconstruction of charged particle trajectories and their inclusion in the hardware based trigger system. There are many challenges involved in achieving this: a large input data rate of about 20–40 Tb/s; processing a new batch of input data every 25 ns, each consisting of about 15,000 precise position measurements and rough transverse momentum measurements of particles (“stubs”); performing the pattern recognition on these stubs to find the trajectories; and producing the list of trajectory parameters within 4 µs. Here, this paper describes a proposed solution to this problem, specifically, it presents a novel approach to pattern recognition and charged particle trajectory reconstruction using an all-FPGA solution. The results of an end-to-end demonstrator system, based on Xilinx Virtex-7 FPGAs, that meets timing and performance requirements are presented along with a further improved, optimized version of the algorithm together with its corresponding expected performance.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Modeling and Optimization of Zeolites for Contaminant Removal from Coal Combustion Impoundment Leachates

Coal Combustion Residual (CCR) landfills in the U.S. can lead to elevated contaminant concentrations in groundwater and runoff, particularly of arsenic, boron, and selenium. Zeolites can be readily synthesized from materials contained within the coal combustion ash impoundments and can be cation-exchanged to enhance adsorption capacity, selectivity, and reactivity. However, the optimization of zeolites becomes a daunting task when accounting for the variety of Si:Al ratios, the species of extra-framework cations present, and the zeolite pore structure. Molecular simulations provide methods to study and guide the design of zeolites for the sorption of contaminants from aqueous solution. In this work, models that predict the sorption of arsenic, boron, and selenium from water using cation-exchanged zeolites. Because of the lack of experimental adsorption data for these species of contaminants, models were parametrized to reproduce the results of first-principles calculations and then used to predict sorption for zeolites for a dataset containing 6000 combinations of zeolites and sorption conditions. Machine learning was used to train a model to predict sorption for materials in this database based on the results of the molecular simulations. Next, a genetic algorithm was used to optimize zeolites for the removal of each contaminant from aqueous solution for individual impoundment sites based on contaminant concentrations reported by the Electric Power Research Institute.

Findley, John↗
DOE OSTI2023

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↗
DOE OSTI2023

Smarter building start – A distributed solution

A significant focus of research and new technologies for reducing energy use in buildings is on operating the systems more efficiently during the times when the systems are active. However, there is a large potential for energy savings in determining the periods when the systems should or should not be active. This scheduling aspect of operation is often overlooked even though relatively simple solutions can unlock substantial energy savings. In this paper we describe a smart building start (SBS) algorithm that considers multiple zones in a building to determine individual schedules for room controllers as well as the central systems based on solving a simple optimization problem. Application of the SBS algorithm to multiple interconnected systems enables a staggered start-up that minimizes peak loads and also ensures comfort is within a target range with minimal system run time. The SBS algorithm extends the capability of traditional optimal start and is designed to be simple to deploy and robust. Simulation results as well as results from tests in a real building with a VAV system are presented. The presented algorithm is applicable to any type of building with a zonal or multi-zone HVAC system. To function, it needs to be able to change setpoints in rooms and monitor room temperatures, as well as, if desired, turn the central system on or off.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Direct structural retrieval from gas-phase ultrafast diffraction data using a genetic algorithm

Ultrafast scattering techniques such as ultrafast electron diffraction and ultrafast x-ray diffraction have been utilized to elucidate the structural dynamics, reaction intermediates, and final products in molecular reactions following photoexcitation. The time-dependent structures are typically not directly retrieved from the experimental data, but they rely on comparison with calculations. The genetic algorithm (GA), a global optimization strategy, can be used to retrieve the molecular structures directly from diffraction patterns without any theoretical input. However, the robustness of the GA with respect to real experimental conditions such as a limited momentum transfer range, noise, and artifacts has not been studied in detail. In this work, we characterize the performance of the GA with simulated data that mimic realistic experimental conditions. We have developed and implemented a variant of the GA specific to diffraction measurements which performs better in the presence of imperfect data compared to the standard implementation of the GA. We demonstrate this method with both synthetic data and experimental ultrafast electron diffraction data on the UV-induced photodissociation of trifluoroiodomethane (C⁢F 3⁡ I) molecules.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2023

Invertible neural networks for real-time control of extrusion additive manufacturing

Material extrusion additive manufacturing (AM) has enabled an elegant fabrication pathway for a vast material library. Nonetheless, each material requires optimization of printing parameters generally determined through significant trial-and-error testing. To eliminate arduous, iteration-based optimization approaches, many researchers have used machine learning (ML) algorithms which provide opportunities for automated process optimization. Here, in this work, we demonstrate the use of an ML-driven approach for real-time material extrusion print-parameter optimization through in-situ monitoring of printed line geometry. To do this, we use deep invertible neural networks (INNs) which can solve both forward and inverse, or optimization, problems using a single network. By combining in-situ computer vision and deep INNs, the printing parameters can be autonomously optimized to print a target line width in 1.2 s. Furthermore, defects that occur during printing can be rapidly identified and corrected autonomously. The methods developed and presented in this work eliminate user-intensive, time-consuming, and iterative parameter discovery approaches that currently limit accelerated implementation of extrusion-based AM processes. Furthermore, the presented approach can be generalized to provide real-time monitoring and optimization pathways for increasingly complex AM environments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Locally adaptive activation functions with slope recovery for deep and physics-informed neural networks

Here we propose two approaches of locally adaptive activation functions namely, layer-wise and neuron-wise locally adaptive activation functions, which improve the performance of deep and physics-informed neural networks. The local adaptation of activation function is achieved by introducing a scalable parameter in each layer (layer-wise) and for every neuron (neuron-wise) separately, and then optimizing it using a variant of stochastic gradient descent algorithm. In order to further increase the training speed, an activation slope-based slope recovery term is added in the loss function, which further accelerates convergence, thereby reducing the training cost. On the theoretical side, we prove that in the proposed method, the gradient descent algorithms are not attracted to sub-optimal critical points or local minima under practical conditions on the initialization and learning rate, and that the gradient dynamics of the proposed method is not achievable by base methods with any (adaptive) learning rates. We further show that the adaptive activation methods accelerate the convergence by implicitly multiplying conditioning matrices to the gradient of the base method without any explicit computation of the conditioning matrix and the matrix–vector product. The different adaptive activation functions are shown to induce different implicit conditioning matrices. Furthermore, the proposed methods with the slope recovery are shown to accelerate the training process.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Harnessing the power of gradient-based simulations for multi-objective optimization in particle accelerators

Abstract Particle accelerator operation requires simultaneous optimization of multiple objectives. Multi-objective optimization (MOO) is particularly challenging due to trade-offs between the objectives. Evolutionary algorithms, such as genetic algorithms (GAs), have been leveraged for many optimization problems, however, they do not apply to complex control problems by design. This paper demonstrates the power of differentiability for solving MOO problems in particle accelerators using a deep differentiable reinforcement learning (DDRL) algorithm. We compare the DDRL algorithm with model-free reinforcement learning (MFRL), GA, and Bayesian optimization (BO) for simultaneous optimization of heat load and trip rates in the continuous electron beam accelerator facility. The underlying problem enforces strict constraints on both individual states and actions as well as cumulative (global) constraints on energy requirements of the beam. Using historical accelerator data, we develop a physics-based surrogate model which is differentiable and allows for back-propagation of gradients. The results are evaluated in the form of a Pareto-front with two objectives. We show that the DDRL outperforms MFRL, BO, and GA on high dimensional problems.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Performance Evaluation of Distributed Energy Resource Management Algorithm in Large Distribution Networks

This paper presents performance evaluation of hierarchical optimization and control for distributed energy resource management system (DERMS) in large distribution networks via an advanced hardware-in-the-loop (HIL) platform. The HIL platform provides realistic testing in a laboratory environment, including the accurate modeling of a full-scale distribution system of 11,000 nodes, the DERMS software controller, and 90 power hardware photovoltaics (PVs) and battery inverters. The applied DERMS algorithm is designed based on a realtime optimal power flow algorithm and implemented with acceleration design that performs fast dispatch of simulated PVs and real physical hardware DER devices every 4 seconds.

DERMS↗
DOE OSTI2025

Multi-Objective Optimization of Uranium Target Assembly–3: A Comparison of Genetic and Traditional Methods

Commonly produced as a byproduct of uranium fission, 99 Mo is a key medical isotope that is in high demand in the United States. An international goal is to switch from medical isotope production technologies that require highly enriched uranium to medical isotope production technologies that require only low-enriched uranium. Niowave Inc. is contributing to this goal by developing an accelerator-driven subcritical assembly called the Uranium Target Assembly (UTA). This work compares the performance of Dakota’s Multi-Objective Genetic Algorithm (MOGA) against traditional sensitivity analysis in the neutronic optimization of the UTA-3 system. The design objectives are k-eigenvalue (k eff ) and natural uranium fission power, which are directly correlated with the amount of 99 Mo produced. Dakota:MOGA did not perform as well as human engineering ingenuity in optimization studies with high numbers of input parameters, such as fuel rod type selection and fuel rod placement. However, Dakota:MOGA did outperform traditional sensitivity analysis in optimization studies with fewer than 20 parameters and revealed the degree to which each parameter influences the optimal design space for k eff and natural uranium fission power (to a lesser extent). As the design model became more complex in the final stage of design, the computational resources required to calculate the design objective values in the Monte Carlo N-Particle transport code from selected input parameter combinations limited Dakota:MOGA’s performance, and, unfortunately, human intervention was required to discern the optimal design space. In conclusion, future work will attempt to reduce computational resource constraints by incorporating areduced-order neutronics model into the optimization cycle.

Accelerator-driven systems↗
DOE OSTI2021

Advanced battery modeling for interfacial phenomena and optimal charging

Lithium ion batteries are one of the most promising energy storage systems for portable devices, transportation, and renewable grids. To meet the increasing requirements of these applications, higher energy density and areal capacity, long cycle life, fast charging rate and enhanced safety for lithium ion battery (LIBs) are urgently needed. To solve these challenges, the relevant physics at different length scale need to be understood. However, experimental study is time consuming and limited in small scale’s study. Modeling techniques provide us powerful tools to get a deep understanding of the relevant physics and find optimal solutions. This work focuses on studying the mechanism in advanced battery engineering techniques and developing a new charging algorithm by model-based optimization. The research topics are divided into six topics and each topic is reported as a form of journal publication. Paper Ⅰ provides a new aspect of how ALD coating improves the lithium ion diffusion at electrode particles. Paper Ⅱ explains the mechanisms by which 3D electrodes enhance battery performance and reveals guidelines for optimized 3D electrode designs by a 3D electrochemical-mechanical battery model. Paper Ⅲ investigates the electrolyte concentration impact on SEI layer growth and Li plating, especially under high charge rates. Paper Ⅳ proposes an optimized charging protocol for fast charging for reducing the charging time with minimal degradation. Paper Ⅴ reports a comprehensive degradation model for degradation estimation and life predication of energy storage system (ESS). Paper Ⅵ is a study of temperature-dependent state of charge (SOC) estimation for battery pack.

25 ENERGY STORAGE↗
DOE OSTI2020

An experimental investigation of the effectiveness of Ar-CO 2 shielding gas mixture for the wire arc additive process

Wire arc additive manufacturing (AM) is the process by which a large, metallic structure is built layer-by-layer using a welding arc to melt a wire feedstock. A novel opportunity exists to alter the shielding gas composition to fabricate distinct geometrical features without altering the other AM parameters. In this paper, shielding gases with varied concentrations of Argon (Ar) and CO 2 was used to deposit three distinct geometric shapes (walls, infill, and overhang) using a wire-based additive manufacturing system utilizing the gas metal arc welding (GMAW) surface tension transfer (STT) process. Computer-aided design (CAD) models were sliced with a custom-built slicer, and the sliced algorithm was converted into optimal robotic toolpaths. A custom virtual instrument (VI) was built in LabVIEW to compare the temperature profiles on the surface during each deposition process. After each deposition, the geometric features were scanned, and the surface waviness value was evaluated. Tensile and Charpy impact coupons were extracted from the wall geometries in the longitudinal and transverse directions and tested. The results indicated that a higher CO 2 content produced higher melt pool temperatures to an extent, while lower contents of CO 2 resulted in a dimensionally accurate geometry. The data also indicated that the 2%/98% CO 2 /Ar blend produced scatter in tensile strength and the analysis of variance (ANOVA) shows significant difference. However, the intermediate range of CO 2 (5–10%) resulted in uniform tensile properties. Altogether, these results indicate that a 5%/95% CO 2 /Ar blend is the ideal shielding gas for lowering process temperatures and improving mechanical properties in wire arc additive manufacturing using the gas metal arc welding surface tension transfer process. Additionally, varying concentrations of Ar/CO 2 can be used within the same part in order to modify the local properties or process parameters such as strength, toughness, temperature, or dimensional features. This may improve overall manufacturing quality without sacrificing specific properties.

42 ENGINEERING↗
DOE OSTI2024

A conservative discontinuous-Galerkin-in-time (DGiT) multirate time integration framework for interface-coupled problems with applications to solid–solid interaction and air–sea models

In this paper we extend the DGiT multirate framework, developed in Connors and Sockwell (2022) for scalar transmission problems, to a solid–solid interaction (SSI) problem involving two coupled elastic solids and a coupled air–sea model with the rotating, thermal shallow water equations. In so doing we aim to demonstrate the broad applicability of the mathematical theory and governing principles established in Connors and Sockwell (2022) to coupled problems characterized by subproblems evolving at different temporal scales. Further, multirate time integration algorithms employing different time steps, optimized for the dynamics of each subproblem, can significantly improve simulation efficiency for such coupled problems. However, development of multirate algorithms is a highly non-trivial task due to the coupling, which can impact accuracy, stability or other desired properties such as preservation of system invariants. DGiT provides a general template for multirate time integration that can achieve these properties. To elucidate the manner in which DGiT accomplishes this task, we fully detail each step in the application of the framework to the SSI and air–sea coupled problems. Numerical examples illustrate key properties of the resulting multirate schemes for both problems.

42 ENGINEERING↗
DOE OSTI2025

A scalable multidimensional fully implicit solver for Hall magnetohydrodynamics

We propose an optimally performant fully implicit algorithm for the Hall magnetohydrodynamics (HMHD) equations based on multigrid-preconditioned Jacobian-free Newton-Krylov methods. HMHD is a challenging system to solve numerically because it supports stiff fast dispersive waves. The preconditioner is formulated using an operator-split approximate block factorization (Schur complement), informed by physics insight. We use a vector-potential formulation (instead of a magnetic field one) to allow a clean segregation of the problematic $\nabla$ x $\nabla$ x operator in the electron Ohm's law subsystem. This segregation allows the formulation of an effective damped block-Jacobi smoother for multigrid. We demonstrate by analysis that our proposed block-Jacobi iteration is convergent and has the smoothing property. The resulting HMHD solver is verified linearly with wave propagation examples, and nonlinearly with the GEM challenge reconnection problem by comparison against another HMHD code. We demonstrate the excellent algorithmic and parallel performance of the algorithm up to 16384 MPI tasks in two dimensions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗