Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “casting”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,099 records · Page 61

Investigation of Ring-heterogeneous Geometry Approximation for Efficient and Practical SFR Analysis

A novel geometry approximation scheme named ring-heterogeneous approximation for intermediate resolution multiphysics analysis of SFRs is presented. This approach particularly targets neutronics coupled with thermo-mechanics feedback, which dominate the passive safety of SFR designs. The ring-heterogeneous approximation casts an array of pins into volume-preserving bands of materials that constitute the pins. It allows to efficiently simulate SFRs with an unstructured mesh and also to explicitly consider the deformation of each material by retaining their heterogeneity. Verification results with single assembly and core problems of the ABTR benchmark demonstrated that the ring-heterogeneous approximation is a reasonable approximation for SFRs. For a 2D full core problem, the ring-heterogeneous approximation significantly reduced the number of elements by at least a factor of 70 from a fully-heterogeneous mesh while almost exactly preserving the reference fully-heterogeneous solutions with the RMS error of only 0.02% in the ring-wise fission reaction rate.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Characterization of compositional variation and solidification condition on rapid solidification behavior of beta stabilized titanium

Rapid solidification (RS) is a field of study that has increased in importance due to the rise of additive manufacturing (AM) techniques. The breakdown of equilibrium at the solid-liquid interface results in an inability to use traditional solidification models that have been applied to great success in casting. As such, there is a current need for a high-throughput testing method to screen alloys at rapid solidification conditions without the significant cost for powder atomization. In this work, twin hammer splat quenching (SQ) is utilized and theoretically developed as a technique uniquely placed to test alloy systems for AM applications. Using analytical thermal spray models and numerical heat transfer simulations, the cooling rate and solidification conditions of splat quenching are compared across several parameters to evaluate the key parameters for generating cooling rates relevant to AM process. Once a framework for the cooling rates and relevancy of SQ are developed, SQ was used to process alloy compositions in the Ti5553 alloy space (AMS 7026) to study the formation of detrimental secondary phases occurring upon rapid quenching from the melt. A martensitic phase is found to occur at the lower end of the standard, but the composition listed in the standard were found to be safe. Finally, the rapid solidification behavior of Ti-5553 is evaluated by comparing splat quenching, laser welding, and plasma atomization that offer a wide window of solidification conditions. The segregation and solidification structure are analyzed and compared to models to provide a deeper understanding of the solidification behavior of beta stabilized titanium alloys.

Williamson, Christopher J.↗

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Neural Lyapunov Approach to Transient Stability Assessment in Interconnected Microgrids

We propose a neural Lyapunov approach to assessing transient stability in power electronic-interfaced microgrid interconnections. The problem of transient stability assessment is cast as one of learning a neural network-structured Lyapunov function in the state space. Based on the function learned, a security region is estimated for monitoring the security of interconnected microgrids in real-time operation. The efficacy of the approach is tested and validated in a grid-connected microgrid and a three-microgrid interconnection. A comparison study suggests that the proposed method can achieve a less conservative characterization of the security region, as compared with a conventional approach.

Huang, Tong↗

Development of a Performance Portable Non-Equilibrium Plasma Fluid Solver on Adaptive Grids

This presentation will describe the numerical techniques, programming paradigms, verification, and performance of a non-equilibrium plasma fluid solver that can effectively utilize current and upcoming central processing and graphics processing unit (CPU+GPU) architectures. Our plasma fluid model solves the conservation equations for self-consistent electrostatic Poisson, electron and heavy species transport, and electron temperature on adaptive Cartesian grids. Our solver is written using performance portable adaptive mesh management library, AMReX (Zhang et al., JOSS, 4 (37) 1370, 2019), and can be built and run on widely available vendor specific GPU architectures (NVIDIA/AMD/Intel). We utilize a non-subcycled second order semi-implicit time-stepping method where all adaptive mesh refinement (AMR) levels are advanced with the same time step. The composite multi-level multigrid solver from within AMReX is used for each of the governing equations that are cast into a Helmholtz equation form. We have also developed a python based chemical mechanism parser framework that uses a similar format as CANTERA (Goodwin et al., Zenodo, 2018) yaml files as input. Our custom parser reads the yaml file and provides C++ files with transport and production rate functions that can be executed on both host (CPU) and device (GPU). We present verification of our solver using method of manufactured solutions that indicate formal second order accuracy with central diffusion and fifth order weighted-essentially-non-oscillatory (WENO) advection scheme. We also verify our solver with published literature on low-pressure capacitive and high-pressure streamer discharges. Our initial performance studies indicate 10X speed-up using 20 NVIDIA GPUs versus 200 CPUs for an atmospheric streamer discharge problem solved on a 512 x 1024 x 512 grid.

graphics processing units↗

Resilient Observer Design for Cyber-Physical Systems with Data-Driven Measurement Pruning

Resilient observer design for Cyber-Physical Systems (CPS) in the presence of adversarial false data injection attacks (FDIA) is an active area of research. The existing state-of-the-art algorithms tend to break down as more and more knowledge of the system is built into the attack model; also as the percentage of attacked nodes increases. From the view of optimization theory, the problem is often cast as a classical error correction problem for which a theoretical limit of has been established as the maximum percentage attacked nodes for which state recovery is guaranteed. Beyond this limit, the performance of -minimization based schemes, for instance, deteriorates rapidly. Similar performance degradation occurs for other types of resilient observers beyond certain percentages of attacked nodes. In order to increase the corresponding percentage of attacked nodes for which state recoveries can be guaranteed, researchers have begun to incorporate prior information into the underlying resilient observer design framework. For the most pragmatic cases, this prior information is often obtained through a data-driven machine learning process. Existing results have shown a strong positive correlation between the maximum attacked percentages that can be tolerated and the accuracy of the data-driven model. Motivated by these results, this chapter examines the case for pruning algorithms designed to improve the Positive Prediction Value (PPV) of the resulting prior information, given stochastic uncertainty characteristics of the underlying machine learning model. Theoretical quantification of the achievable improvement is given. Simulation results show that the pruning algorithm significantly increases the maximum correctable percentage of attacked nodes, even for machine learning model whose prediction power is comparable to the random flip of a coin.

Resilient Observer, Cyber-physical Systems, Data-D↗

PBI films formed without use of organic solvents

A novel process for making PBI films starting from gel PBI membranes polymerized and casted in the PPA process wherein acid-imbibed gel PBIs are neutralized in a series of water baths and undergo controlled drying in association with a substrate material, yielding a PBI film without the use of organic solvents.

Murdock, Laura A.↗

Methods of sheet metal production and sheet metal products produced thereby

Processes for producing sheet metal products by machining a solid metal body with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid metal body, and without performing a hot rolling operation thereon, cold rolling the continuous bulk form to produce a sheet metal product. The machining step is a large-strain machining process capable of being directly performed on an as-cast ingot or other solid body to produce a continuous intermediate product that can be directly cold rolled without any intervening hot rolling operation, and optionally without homogenization or annealing.

Trumble, Kevin Paul↗

Scintillator array for radiation detection

A radiation detector includes a photodetector and a scintillator coupled thereto. The scintillator is formed of a scintillator material comprising an organic glass scintillator (OGS) material and at least one of a polymer additive or a plasticizer additive. The scintillator emits light when radiation is received at the scintillator, and the light is received by the photodetector. The radiation detector can further include a frame that has an interior cavity that holds the scintillator in position with respect to the photodetector, such that the light emitted by the scintillator is transmitted to the photodetector. The scintillator can be formed by casting amorphous scintillator material in the interior cavity of the frame. The frame can then be coupled to the photodetector to form the radiation detector.

Carlson, Joseph↗

Fabrication and Scale-Up of Porous Polybenzimidazole (PBI) Supports for Gas Separation Composite Membranes

Industrial gas separation often uses thin film composite (TFC) membranes comprising a porous support overlaid with a single-/multi-layer gas-selective thin film. An optimal porous support should possess high surface porosity to minimize gas transport resistance and nano-sized pores to ease pore penetration occurring during the thin film coating process. Good chemical and thermal stabilities are essential to withstand the aggressive solvents and heat required for the thin film coating and curing. However, few porous membranes satisfy all these requirements. This study presents a scalable membrane formation method of making highly porous polybenzimidazole (PBI) supports via non-solvent induced phase separation. This presentation also details the scale-up fabrication of PBI supports using a custom roll-to-roll membrane casting machine.

gas separation↗

Impact of Synthesis and Aging on Titanium Carbide MXenes for Printed Microsystems

This work investigates the long-term electrical stability of Ti3C2Tx MXene Inks under accelerated aging conditions. Inks were synthesized from commercial MAX-Phase precursors, drop-cast onto custom PCB’s and monitored automated in-situ measurements. Samples aged at 85°C/85% RH, 85°C/0% RH and ambient conditions revealed distinct degradation trends. Wet aged inks showed rapid resistance increased while etched formulations exhibited long term stability. These findings highlight the influence of synthesis stage and environmental exposure on MXene Inks reliability, offering critical insights for printed MEMS and sensor applications. Ongoing measurements extend the aging timeline beyond prior studies, marking the longest evaluation under accelerated aging conditions to date.

Aging↗

Design and Development of Novel Equiatomic Refractory Multi Principal elemental Alloys Based on MoNbTi System for Use in Irradiation Environments

Multi Principal Elemental Alloys (MPEA) have emerged as promising materials for next-generation nuclear reactors due to their exceptional irradiation resistance. Eight equiatomic MPEA based on the MoNbTi system, comprising of elements with low thermal neutron absorption cross-sections were explored using a combined approach employing empirical parameter estimations, and CALPHAD simulations by which the phases and elemental segregation observed in all the alloys in the as-cast state were predicted. Solution heat treatment at 1500°C transformed five alloys into single-phase matrix materials, enhancing homogeneity and reducing hardness. The densities of the alloys ranged between 6.47 to 7.68 g/cm3, hardness between 472 and 656 VHN, Young’s modulus between 142 GPa to 169 GPa, shear modulus between 54 GPa and 62 GPa, bulk modulus between 117 GPa to 194 GPa and Poisson’s ratio between 0.3 to 0.35. The in-situ high temperature Xray diffraction results, differential scanning calorimetry and dilatometry results up to 1000°C suggested the high temperature phase stability of the MPEA. Subsequent ageing heat treatment at 800 and 1000 oC for 96 hours revealed significant secondary phase precipitation in MoNbTiZr, MoNbTiZrV, and MoNbTiCrA. Oxidation studies at 800 oC for 24 hours in air revealed superior oxidation resistance and cubic rate law dependence in Cr containing MPEA especially in MoNbTiCrAl, while severe mass gain resulting in total disintegration and exfoliation in MoNbTiZr and MoNbTiZrV. This comprehensive study underscores the potential of novel MPEA as promising materials for advanced nuclear reactor applications, shedding light on their microstructural control, mechanical properties, thermal stability, and oxidation resistance.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Modeling the Effect of the Heliospheric Magnetic Field on Cosmic Ray Muon Shadows

Shadows cast in the cosmic ray (CR) muon sky by the Sun were located using muon data from the MINOS far detector in Northern Minnesota. The shadows were observed independently across three time periods; near solar minimum, near solar maximum, and over the entire 13 year span of the data. A distribution of muon positions for each shadow was then sampled to simulate CR motions near the Sun using the Parker spiral model of the Heliospheric Magnetic Field (HMF) and a dipole model of the Geomagnetic Field (GMF). The resulting particle distributions were then compared to their position with respect to the Sun. Results show that the Parker spiral model is most consistent with the solar minimum shadow and least consistent with the solar maximum shadow, as expected. The simple Parker spiral is more consistent with the data for a harder CR spectrum than is actually present, indicating the need for a more detailed HMF model. Plausible modifications to the Parker spiral model which would affect the overall shift of the Sun's CR shadow are discussed.

Adamson, P. [Fermilab]↗

Combined-Accelerated Stress Testing of Photovoltaic Materials

By applying multiple environmental stresses in fieldrepresentative combinations and sequences, combined-accelerated stress testing (CAST) identifies degradation modes and failure mechanisms of photovoltaic (PV) modules and components that are missed by single stress factor accelerated testing.

14 SOLAR ENERGY↗

Learning to Trigger: Reinforcement Learning at the Large Hadron Collider

High-throughput scientific facilities such as the Large Hadron Collider depend on real-time event filtering (\textit{triggering}) under tight constraints on bandwidth, latency, and storage. In practice, trigger menus are largely static and hand-tuned and can become suboptimal as detector conditions, pileup, and background composition drift over time. We cast online threshold tuning as a sequential decision-making problem: a reinforcement learning agent ingests streaming summaries of recent rates and signal-sensitive features and updates trigger thresholds to maximize signal efficiency while tracking a target background rate within a tolerance band. We adapt Group-Filtered Policy Optimization (GFPO) to streaming control and introduce two variants (GFPO-F, GFPO-FR) that enforce background rate feasibility during training. On a benchmark that emulates realistic collider operation, we study two representative triggers: a total transverse energy ($H_{T}$) trigger sensitive to pileup variation, and an anomaly-detection (AD) trigger based on reconstruction loss for rare or non-standard signatures. On Monte Carlo streams, our agent increases the fraction of in-tolerance time intervals by 48% ($H_T$) and 28% (AD), with a cumulative gain of up to 2% in signal efficiency on those in-tolerance intervals. Transferring from simulation to \emph{real} collision data (CMS Run 283408), the same agent, without fine-tuning, achieves a 56% ($H_T$) and 28% (AD) in-tolerance improvement over baselines, with further signal-efficiency gain on both triggers. To our knowledge, this is the \emph{first} demonstration of RL-based trigger control on real Large Hadron Collider collision data. Code is available at https://github.com/Zixind/GFPO_LHC (see repo for details).

Ding, Zixin [Chicago U.]↗

ELASTOMERIC MICROVASCULAR SELF-HEALING MATERIALS

Damaged elastomeric diaphragms within pneumatic controllers used in the oil and gas industry lead to an unintended release of methane. Self-healing microvascular materials capable of healing various types of damage have been fabricated. These microvascular materials are designed to replace currently available commercial diaphragms found in pneumatic controllers and provide a solution to reduce unintended methane leaks. Poly(dimethylsiloxane) (PDMS) was used as the main matrix material, with additional testing conducted on polyurethane and flexibilised epoxy materials. Microvascular networks were implemented into the elastomeric membranes to act as ves- sels to deliver healing agents to the damaged areas. The complex, interdigitated channel networks were created using a 3D printed custom compounded filament composed of polylactic acid (PLA) and tin(II) oxalate. Two-part liquid casting polymers were poured around the channels into a mould to create samples with the scaffolding of the microvascular channels intact. Hollow microvascular networks were created by placing the samples within a vacuum oven at 250◦C which causes the thermal depolymerisation of PLA into its gaseous monomers. The manufactured materials were placed in test stands and pressurized using nitrogen gas to determine their healing and mechanical behaviour. Self-healing behaviour was demonstrated using PDMS matrix materials and healing chemistries within a pressure test cell. This test cell was designed to detect any damage to a sample by record- ing an outlet pressure. Damages including puncture holes, diagonal cuts and star-shaped central iv cuts were applied to the samples and a reduction in the outlet pressure was recorded for all sam- ples. A variation in channel spacing and diameter was studied to determine the optimal design of the microvascular network for self-healing performance. The mechanical performance of elastomeric membrane materials within a diaphragmatic pressurised stand was observed. Deformations and strains around the channels and channel inter- sections at the midplane of the materials were recorded using digital image correlation. Normal stresses were calculated using Hooke’s law and the material properties of the PDMS matrix. A reduction in leak rate, implying the success of self-healing, was recorded within manu- factured diaphragm samples tested within a commercial valve. PDMS is the favourable material when compared to polyurethane and flexibilised epoxy for creating

03 NATURAL GAS↗

CTRL-STEER: Closed-Loop Neuron Activation Control in Vision-Language-Action Models

Vision-Language-Action (VLA) models enable test-time behavioral steering via neuron-level interventions, but existing methods use fixed strengths and operate in open loop. This static modulation fails under evolving task dynamics, leading to overcorrection, oscillations, and reduced task success—especially for temporal attributes like speed. We propose CTRL-STEER, a control-theoretic framework that casts activation steering as closed-loop feedback with adaptive, time-varying interventions. Instead of assuming neurons encode temporal concepts, we steer along motion-aligned residual directions and regulate intervention magnitude via feedback. We instantiate this with both PID and reinforcement learning controllers that jointly optimize concept adherence and task success. Experiments on fine-tuned OpenVLA policies across four LIBERO suites show improved stability and a better steering–success trade-off over fixed-coefficient baselines, without retraining the base model.

Babu, Abhijith [Florida International University, ↗

Selective Heating Through Y-Junction Waveguide Designed by Acoustic Shape Optimization

Unlike phononic crystals or systems designed by topology optimization, waveguides designed by shape optimization do not have voids or internal defects, making the fabrication process more suitable for additive manufacturing. By designing a Y-junction waveguide through shape optimization, an ultrasonic wave can be controlled so that it propagates to a predetermined location just by adjusting its frequency. These demultiplexed ultrasonic waves can be used to transport signals or stimulate nearby materials. As an example, the ultrasonic wave is converted to heat at different locations, which can be applied to mechanisms that can take advantage of heating. First, shape optimization is performed on a cylindrical structure to selectively propagate ultrasonic waves of a particular frequency while attenuating others, which is analyzed through a finite element model. The numerical study results are compared with experimental measurements from samples fabricated through additive manufacturing methods. After verifying the concept, the Y-junction waveguide is fabricated to demultiplex the wave and selectively heat different locations. Here the results show that the method of combining shape optimization with additive manufacturing is exceptionally simple and capable of demultiplexing ultrasonic waves, which can replace complex electrical components with single-material waveguides.

36 MATERIALS SCIENCE↗