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At least 1,063 records · Page 59

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DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗

DOE OSTI2021

Prediction of Thermal Conditions of DED With FEA Metal Additive Simulation

This paper presents the integration of wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. This results in the need to allow the part to cool between consecutive layers, which is the most time-consuming part of the additive process. Finite element analysis (FEA) was used in conjunction with monitored build plate surface temperatures during deposition samples to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. The GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. A FEA model was designed and verified using the monitored samples. The model will be used to determine improved depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure. It was determined the FEA software can be used to accurately model and predict the thermal response of WAAM AM components.

Heinrich, Lauren↗

DOE OSTI2023

In-Situ Detection and Prediction of WAAM Cross Feature Geometry

Abstract Wire arc additive manufacturing (WAAM) is increasingly used by manufacturers due to its relatively low cost and high deposition rate compared to other metal AM methods, but the parts produced by WAAM can be subject to localized variations in part quality. One such variation is the cross-feature defect, whereby a localized part height increase occurs due to the crossing of deposition toolpaths. Mitigation of this defect is typically achieved using manual path planning strategies, but closed-loop control is underutilized. Since the nature of this defect and of the WAAM process is such that the previous layer’s geometry influences that of the subsequent layer’s, the cross-feature defect geometry changes throughout the deposition. Therefore, any closed-loop control strategy will need to incorporate the dynamic trait of this defect. The present work seeks to implement an in-situ process modeling approach where a regression model can be continuously updated to predict the defect geometry of the subsequent deposition layer based on the historical process data. Several multi-layer cross-feature geometries are deposited and current, voltage, and optical camera data is taken for each layer. The resulting cross-feature geometries are characterized using 3D scanning and the performance and accuracy of the in-situ modeling approach is evaluated.

Thien, Austen↗

DOE OSTI2024

Impact of Heat Input and Step Over Distance on Part Geometry for Multi-Bead WAAM Components

Abstract This study investigates the impact of heat input and overlap ratio or stepover distance on part geometry in wire arc additive manufacturing (WAAM). In this work, an experimental approach was taken to quantify the variation in height and aspect ratio of walls at different combinations of overlap and heat input. Multi-bead walls were deposited with the overlap ratio varying from ½, ⅔, and 1 at a low, medium, and high-power set point on the welding power supply. A relationship between heat input, overlap ratio, and the resultant part geometry is established. Trials with an overlap ratio of one and low to medium heat input exhibited greater lack of fusion defects than the high heat input trials. At higher heat input levels, the as-deposited geometry was found to have less variation in height and an increase in aspect ratio compared to lower heat input trials. The aspect ratio of deposited walls ranged from approximately 1, for the low-power trial with an overlap ratio of ½, to approximately 7, for the high-power trial with an overlap ratio of 1. Additionally, the low and medium power trials with an overlap ratio of ⅔ exhibited the least height variation in the top surface for those heat input levels with an average range of 2.9 mm and 1.8 mm respectively. For the high heat input trials, an overlap ratio of 1 was observed to have the least variation in height with a standard deviation of 0.42 mm and an average range of 1.7 mm; however, lack of fusion defects were present in the top surface and the part cross section.

Hussein, Zaky↗

DOE OSTI2022

Performance and characterization of the SPT-3G digital frequency-domain multiplexed readout system using an improved noise and crosstalk model

The third-generation South Pole Telescope camera (SPT-3G) improves upon its predecessor (SPTpol) by an order of magnitude increase in detectors on the focal plane. The technology used to read out and control these detectors, digital frequency-domain multiplexing (DfMUX), is conceptually the same as used for SPTpol, but extended to accommodate more detectors. A nearly 5× expansion in the readout operating bandwidth has enabled the use of this large focal plane, and SPT-3G performance meets the forecasting targets relevant to its science objectives. However, the electrical dynamics of the higher-bandwidth readout differ from predictions based on models of the SPTpol system due to the higher frequencies used and parasitic impedances associated with new cryogenic electronic architecture. To address this, we present an updated derivation for electrical crosstalk in higher-bandwidth DfMUX systems and identify two previously uncharacterized contributions to readout noise, which become dominant at high bias frequency. The updated crosstalk and noise models successfully describe the measured crosstalk and readout noise performance of SPT-3G. These results also suggest specific changes to warm electronics component values, wire-harness properties, and SQUID parameters, to improve the readout system for future experiments using DfMUX, such as the LiteBIRD space telescope.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Laser and optical transport line for laser-based ion beam diagnostics and control in the SNS linear accelerator

We report our recent upgrade of the laser and optical transport line for the laser-based ion beam diagnostics (laser wire) system at the linear accelerator (linac) of the Spallation Neutron Source (SNS). A new light source based on diodepumped solid-state laser amplifiers has been developed to provide near diffraction-limited laser beam with a variety of pulse structures. The free-space optical transport line has been modified to include image relay optics with remote control, which greatly improved the laser beam quality and position stability at individual measurement stations. The upgraded system enables novel beam diagnostics/control capabilities including longitudinal profile measurement and high-energy proton beam extraction from the SNS linac.

Liu, Yun↗

DOE OSTI2025

Surface conduction and reduced electrical resistivity in ultrathin noncrystalline NbP semimetal

The electrical resistivity of conventional metals such as copper is known to increase in thin films as a result of electron-surface scattering, thus limiting the performance of metals in nanoscale electronics. Here, in this study, we find an unusual reduction of resistivity with decreasing film thickness in niobium phosphide (NbP) semimetal deposited at relatively low temperatures of 400°C. In films thinner than 5 nanometers, the room temperature resistivity (~34 microhm centimeters for 1.5-nanometer-thick NbP) is up to six times lower than the resistivity of our bulk NbP films, and lower than conventional metals at similar thickness (typically about 100 microhm centimeters). The NbP films are not crystalline but display local nanocrystalline, short-range order within an amorphous matrix. Our analysis suggests that the lower effective resistivity is caused by conduction through surface channels, together with high surface carrier density and sufficiently good mobility as the film thickness is reduced. These results and the fundamental insights obtained here could enable ultrathin, low-resistivity wires for nanoelectronics beyond the limitations of conventional metals.

42 ENGINEERING↗

DOE OSTI2020

mSphere of Influence: Comprehensive Genetic Analysis

Jason M. Peters works in the fields of antibiotic resistance and biofuel production. In this mSphere of Influence article, he reflects on how the paper “A global genetic interaction network maps a wiring diagram of cellular function” by Costanzo et al. (Science 353:aaf1420, 2016, https://doi.org/10.1126/science.aaf1420 ) has impacted his work by highlighting the power of gene networks to uncover new biology.

Peters, Jason M.↗

DOE OSTI2024

Scintillation light in SBND: simulation, reconstruction, and expected performance of the photon detection system

SBND is the near detector of the Short-Baseline Neutrino program at Fermilab. Its location near to the Booster Neutrino Beam source and relatively large mass will allow the study of neutrino interactions on argon with unprecedented statistics. This paper describes the expected performance of the SBND photon detection system, using a simulated sample of beam neutrinos and cosmogenic particles. Its design is a dual readout concept combining a system of 120 photomultiplier tubes, used for triggering, with a system of 192 X-ARAPUCA devices, located behind the anode wire planes. Furthermore, covering the cathode plane with highly-reflective panels coated with a wavelength-shifting compound recovers part of the light emitted towards the cathode, where no optical detectors exist. We show how this new design provides a high light yield and a more uniform detection efficiency, an excellent timing resolution and an independent 3D-position reconstruction using only the scintillation light. Finally, the whole reconstruction chain is applied to recover the temporal structure of the beam spill, which is resolved with a resolution on the order of nanoseconds.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Production, quality assurance and quality control of the SiPM Tiles for the DarkSide-20k Time Projection Chamber

The DarkSide-20k dark matter direct detection experiment will employ a 21 m 2 silicon photomultiplier (SiPM) array, instrumenting a dual-phase 50 tonnes liquid argon Time Projection Chamber (TPC). SiPMs are arranged into modular photosensors called Tiles, each integrating 24 SiPMs onto a printed circuit board (PCB) that provides signal amplification, power distribution, and a single-ended output for simplified readout. Tiles are further grouped into Photo-Detector Units (PDUs). This paper details the production of the Tiles and the Quality Assurance and Quality Control (QA-QC) protocol established to ensure their performance and uniformity. The production and QA-QC of the Tiles are carried out at Nuova Officina Assergi (NOA), an ISO-6 clean room facility at LNGS. This process includes wafer-level cryogenic characterisation, precision die attaching, wire bonding, and extensive electrical and optical validation of each Tile. The overall production yield exceeds 83.5%, matching the requirements of the DarkSide-20k production plan. These results validate the robustness of the Tile design and its suitability for operation in a cryogenic environment.

Acerbi, F. [Fondazione Bruno Kessler]↗

DOE OSTI2025

Cryogenic thermal modeling of microwave high density signaling

Superconducting quantum computers require microwave control lines running from room temperature to the mixing chamber of a dilution refrigerator. Adding more lines without preliminary thermal modeling to make predictions risks overwhelming the cooling power at each thermal stage. In this paper, we investigate the thermal load of SC-086/50-SCN-CN semi-rigid coaxial cable, which is commonly used for the control and readout lines of a superconducting quantum computer, as we increase the number of lines to a quantum processor. We investigate the makeup of the coaxial cables, verify the materials and dimensions, and experimentally measure the total thermal conductivity of a single cable as a function of the temperature from cryogenic to room temperature values. We also measure the cryogenic DC electrical resistance of the inner conductor as a function of temperature, allowing for the calculation of active thermal loads due to Ohmic heating. Fitting this data produces a numerical thermal conductivity function used to calculate the static heat loads due to thermal transfer within the wires resulting from a temperature gradient. The resistivity data is used to calculate active heat loads, and we use these fits in a cryogenic model of a superconducting quantum processor in a typical Bluefors XLD1000-SL dilution refrigerator, investigating how the thermal load increases with processor sizes ranging from 100 to 225 qubits. We conclude that the theoretical upper limit of the described architecture is approximately 200 qubits. However, including an engineering margin in the cooling power and the available space for microwave readout circuitry at the mixing chamber, the practical limit is approximately 140 qubits.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Application of the Solute-Solvent EMF Cell to Measure Activity of NiF 2 in Molten FLiNaK

Electromotive force (emf) measurements made using a combination of solute- and solvent-based electrodes were used to determine the activity of NiF 2 in molten FLiNaK eutectic at 823 K across a concentration range of x NiF2 = 5.2 × 10 –4 –1.0 × 10 –2 . The solute emf values were measured using electrodes consisting of Ni wires immersed in FLiNaK with dissolved NiF 2 contained in graphite crucibles. The measured emf values were then converted to the FLiNaK Eutectic Potassium Electrode (FEKE) potential and used to quantify the activity of dissolved NiF 2 . This quantification was based upon comparative measurements of a reference solvent electrode consisting of a K-Bi alloy immersed in pure FLiNaK contained in a boron nitride crucible and a solute electrode. Short cell lives were characteristic of the measurements due to the corrosive nature of the fluoride salts. Quantifying the activity of NiF 2 will improve the utility of Ni 2+ /Ni reference electrodes in molten fluoride salts, which are notoriously difficult electrolytes to work with because of their reactivity. In conclusion, this work demonstrates the general nature of the solute-solvent approach as a repeatable, easily employed method for measuring the activity values of electroactive species in a variety of molten salts to improve understanding of the electroactive species behavior in these systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Mitigating Electrochemical Impedance Spectroscopy Artifacts in PEMWE Reference Electrode Measurements

This study investigates strategies to improve the quality of electrochemical impedance spectroscopy (EIS) measurements using reference electrodes (RE) in proton exchange membrane water electrolyzers (PEMWE). We demonstrate that adding a low impedance wire in parallel to the RE significantly enhances signal accuracy, especially at high frequencies. Additionally, we identify electrical pad heaters as a source of measurement noise. EIS measurements fulfilling Kramers–Kronig validity criteria were only achieved in their absence. These insights advance the diagnostic capabilities of REs in water electrolyzers and support more reliable, spatially resolved analysis of electrochemical losses within the cell.

08 HYDROGEN↗

DOE OSTI2021

ModuleOT

ModuleOT is an open hardware security platform which provides all features necessary for securing remote energy resources. The platform consists of a physical bump in-the wire device which runs a custom-built application built with Go and Python and leverages AES-NI Instruction set available on modern hardware for cryptographic acceleration. By combining these features, ModuleOT acts as an all-in-one low-cost solution to enable cryptographically secured communications to any critical remote servers or devices. Because the software application has been built using Golang, this source can be easily compiled for different hardware platforms. The module is designed to provide the following core features: (1) encrypted communications across an untrusted network, (2) certificate-based authentication with secure storage, (3) hardware cryptographic acceleration, (4) IP-based whitelisting, (5) local firewall management, and (6) legacy (RS485) device support.

Hasandka, Adarsh↗

DOE OSTI2020

BEEAM (Building Electrical Efficiency Analysis Model) [SWR-20-107]

Modern high-performance buildings exhibit an increasing number of building loads that use direct current (DC) electricity internally, rather than alternating current (AC), due to the advent of low-cost computing and advanced power electronics. Powering DC devices from the AC grid requires AC/DC power conversion, which introduces energy losses and reduces efficiency. As DC loads proliferate, the cumulative wasted energy associated with hundreds of millions of AC/DC converters has become one of the broadest energy savings opportunities in buildings. DC power distribution systems have been proposed as an elegant and transformative solution to the problem of DC devices. In a DC distribution system, the building's wires carry DC electricity, rather than AC; and a few centralized, highly efficient AC/DC converters replace the many smaller, less efficient converters that serve individual DC loads. Unfortunately, the trade-offs associated with DC distribution systems are not well understood. Reported energy savings associated with DC power distribution differ widely and have not been well validated. The Building Electrical Efficiency Analysis Model (BEEAM) is a Modelica library that simulates the efficiency of building electrical distribution systems using harmonic power flow. BEEAM can model a wide variety of building distribution topologies, including three-phase AC, single-phase AC, unipolar DC, bipolar DC, and hybrid networks under both balanced and unbalanced load conditions. BEEAM accurately models power electronic converter losses, provides granular estimates of losses throughout the distribution system, and properly models efficiency at part load conditions. Users can package BEEAM within a functional mockup unit (FMU), enabling co-simulation with other modeling platform, such as EnergyPlus. In summary, BEEAM provides a tool suite for fair and accurate comparison of the efficiency of building electrical distribution systems, including AC, DC, and hybrid systems.

Frank, Stephen↗

DOE OSTI2020

Heat Equation Neural Simulation

This code solves a steady state heat equation problem on a wire with random walks implemented using a spiking neural algorithm. SAND2020-12194 M

Reeder, Leah↗

DOE OSTI2022

DER Cybersecurity Detection and Response Suite

SAND2024-08475O The Distributed Energy Resource (DER) Cybersecurity Detection and Response Suite is a solution for distributed energy resource (DER) systems. The DER Security Orchestration, Automation, and Response (SOAR) solution that uses alerts from signature- and behavior-based Intrusion Detection Systems are intended to be deployed as bump-in-the-wire (BITW) devices in front of DER equipment. The fielded application would use multiple intrusion detection systems that report data to SOAR to respond to cyberattacks. The suite consists of two software components: • The proactive intrusion detection and mitigation system (PIDMS) secures grid-edge photovoltaic smart inverters and other equipment in distributed energy resource systems. It is a distributed BITW solution; cyber and physical data are automatically processed using network inspection tools and custom machine learning algorithms to detect abnormal events and correlate cyber-physical events. • The Security Orchestration, Automation, and Response for Distributed Energy Resources (SOAR4DER) application ingests data from several intrusion detection systems to quickly block attacks and revert DER systems to good states. Using a collection of intrusion detection system technologies on a BITW device, it incorporates physical and cyber data to detect abnormal and potential malicious behaviors. Multiple SOAR playbooks then use the intrusion detection system data streams to automatically defend the system. SOAR4DER system testing showed detection and response times under 30 seconds for all adversary reconnaissance, denial-of-service attacks, malicious Modbus commands, brute-force logins, and machine-in-the-middle attacks. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Johnson, Jay↗

DOE OSTI2025

OPET Hardware (Open PV Electrical Tool Hardware) [SWR-25-42]

OPET (Open-source Photovoltaic Electrical Tool) is used for performance measurements of solar photovoltaic (PV) devices in the field under natural sunlight or in the lab under artificial light. Its primary use is in research and development of solar cells and modules, specifically in reliability and durability research of PV devices. Some features and functions include: -IV curve measurements with linear or cosine distributed measurement points -PV device active loading at open circuit voltage (Voc), short circuit current (Isc) and maximum power point (Pmp) -Bias power supply to overcome series resistance in contact wires for Isc measurements and loading -PV voltage input in five ranges from 1V to 100V -PV current input ranges -Low current version, six current ranges from 1.1mA to 340mA -High current version, six current ranges from 50mA to 15A -IO ports for I2C and SPI temperature sensor Arduino extension boards -Integrated fan control This repository contains everything relating to the hardware of the OPET device. If you are looking for the firmware or software repositories, links are below: https://github.com/NREL/opet-firmware https://github.com/NREL/opet-control

McDanold, Byron [National Renewable Energy Laborat↗