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DOE OSTI2018

Wire Arc Additive Manufacturing

Project highlight. This project designs and implements a new additive manufacturing capability at Savannah River National Laboratory. Wire Arc Additive Manufacturing is an Advanced Manufacturing technology that enables materials and energy savings by producing materials that are in near net shapes to minimize material losses compared to conventional forging and machining techniques. Wire arc additive manufacturing is an evolving technology that can be used to fabricate large components with significantly less materials waste than conventional processing. This project includes an engineering model, an aspect that is largely overlooked in the Additive Manufacturing modeling work where the emphasis has been on mechanistic and microscopic modeling, to estimate the residual stresses and distortions. The Abaqus Weld Interface software coupled with user subroutines in Fortran enable the local cooling rates to be estimated to provide a coarse scale model for the secondary dendrite arm spacing, a parameter useful to estimate mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Technical Specification Surveillance Interval Extension of Digital Equipment in Nuclear Power Plants: Review and Research. Light Water Reactor Sustainability Program report

The nuclear industry has been slow to incorporate digital technology into nuclear plant designs for several reasons, including: The high cost of design change modifications to implement them, versus simply replacing them with like for like technology when the components fail; Digital technology qualification issues, particularly in safety related applications that are susceptible to software common cause failure. This is a concern both for current operating plants as well as new builds; and, General familiarity and comfort with the existing analog technology on the part of the nuclear plant engineering staff, in spite of the superior performance and reduced maintenance costs of the digital replacements. At the same time, the nuclear industry is under significant cost pressure in the electric marketplace due to the abundance of natural gas generation and renewables. The industry would benefit by investment in new technologies that could lower future operating costs while addressing obsolescence and reliability issues of the current analog technologies. However, the industry has been unable to formulate the business cases to take advantage of these labor savings and production reliability improvements. This paper discusses another potential cost savings benefit of a transition to digital technology, extending the surveillance intervals of technical specification required equipment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Can the United States Maintain Its Leadership in High-Performance Computing? - A report from the ASCAC Subcommittee on American Competitiveness and Innovation to the ASCR Office

The United States (U.S.) is no longer the unambiguous leader in the vitally important field of high performance computing (HPC). Japan, the European Union (EU), and China have fielded systems that are on par with our fastest supercomputers. The supply chain for everything from semiconductors to scientific software is globally distributed. Yet our economic future and security depend critically on our ability to innovate faster than our competitors, and the speed of innovation depends increasingly on large-scale computational science and engineering and thus HPC. How should the United States respond to this challenge? This report seeks to initiate a new and potentially transformative national discussion on this vital question. The Department of Energy’s (DOE) Advanced Scientific Computing Research (ASCR) program is well-positioned to make informed, targeted decisions about where the United States should cooperate and where it should compete in the global market for scientific exploration and discovery. By setting its sights on problems critical to our nation and the world, by establishing productive new collaborations, and by making strategic investments, ASCR can restore and maintain U.S. scientific leadership in the critical areas described in this report while strengthening our research infrastructure and training a large, diverse cohort of scientists. In doing so, ASCR and its scientists will pave the way for a secure and prosperous future for America. For more than 30 years, the ASCR program has provided the HPC and networking capabilities and expertise needed to support DOE’s mission to advance the national, economic, and energy security of the United States. The program now faces the challenge of developing and deploying the next generation of HPC systems and technologies, as well as supporting the application of HPC and artificial intelligence (AI) technologies to a wide range of scientific and engineering research problems. Through its research and development efforts, the ASCR program must also advance the state of the art in HPC and accelerate the pace of scientific discovery and technological innovation. Fulfilling this promise will require significantly increased investments, as well as innovative policies and programs. This subcommittee is aware that we are making recommendations and calls for action at a time when federal resources are limited. We understand that a wide range of competing priorities must be balanced by the nation’s leaders and that there is a need to leverage resources in new ways and seek efficiencies in facilities and operations. However, we must not let these realities limit our imagination or silence our advocacy. The ASCR program is a key part of the U.S. research infrastructure and an important component of economic growth and U.S. competitiveness. ASCR has a responsibility to pursue its mission, including advanced scientific computing, applications of AI technologies, and the required advanced research facilities, with determination and enthusiasm. To fulfill the scientific enterprise’s responsibility to the nation, the ASCR program must not only develop and publish a clear vision with an associated list of goals, priorities, and recommendations but also demonstrate scientific leadership by consistently securing long-term funding. This will allow the program to build on its achievements to date, to realize its ambitious vision, and to make lasting contributions to the field.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2012

Hybrid Solar GHP Simulator

This project provides an easy-to-use, menu-driven, software tool for designing hybrid solar-geothermal heat pump systems (GHP) for both heating- and cooling-dominated buildings. No such design tool currently exists. In heating-dominated buildings, the design approach takes advantage of glazed solar collectors to effectively balance the annual thermal loads on the ground with renewable solar energy. In cooling-dominated climates, the design approach takes advantage of relatively low-cost, unglazed solar collectors as the heat rejecting component. The primary benefit of hybrid GHPs is the reduced initial cost of the ground heat exchanger (GHX). Furthermore, solar thermal collectors can be used to balance the ground loads over the annual cycle, thus making the GHX fully sustainable; in heating-dominated buildings, the hybrid energy source (i.e., solar) is renewable, in contrast to a typical fossil fuel boiler or electric resistance as the hybrid component; in cooling-dominated buildings, use of unglazed solar collectors as a heat rejecter allows for passive heat rejection, in contrast to a cooling tower that consumes a significant amount of energy to operate, and hybrid GHPs can expand the market by allowing reduced GHX footprint in both heating- and cooling-dominated climates. The design tool allows for the straight-forward design of innovative GHP systems that currently pose a significant design challenge. The project lays the foundations for proper and reliable design of hybrid GHP systems, overcoming a series of difficult and cumbersome steps without the use of a system simulation approach, and without an automated optimization scheme. As new technologies and design concepts emerge, sophisticated design tools and methodologies must accompany them and be made usable for practitioners. Lack of reliable design tools results in reluctance of practitioners to implement more complex systems. A menu-driven software tool for the design of hybrid solar GHP systems is provided that is based on mathematically robust, validated models. An automated optimization tool is used to balance ground loads and incorporated into the simulation engine. With knowledge of the building loads, thermal properties of the ground, the borehole heat exchanger configuration, the heat pump peak hourly and seasonal COP for heating and cooling, the critical heat pump design entering fluid temperature, and the thermal performance of a solar collector, the total GHX length can be calculated along with the area of a supplemental solar collector array and the corresponding reduced GHX length. An economic analysis module allows for the calculation of the lowest capital cost combination of solar collector area and GHX length.

Yavuzturk, Cy↗

DOE OSTI2021

FY 2021 High Performance Computing Overall Systems Availability

INL HPC capabilities were utilized by individuals at universities, industry, and government laboratories for a wide range of research and engineering activities between October 1, 2020 and September 30, 2021. The HPC systems themselves experienced minimal downtime over the course of the fiscal year. Most downtime was planned to apply critical security patches to system software. The most serious of the unplanned downtime events occurred due to maintenance on the Kohler backup generator in July. Users were kept notified of all events, both planned and unplanned, via 36 total email notifications in FY-21. The INL HPC systems continue to provide high availability for collaboration and innovation in nuclear energy systems research.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Common Cause Failure Evaluation of High Safety-significant Safety-related Digital Instrumentation and Control Systems

Digital instrumentation and control (DI&C) systems in nuclear power plants (NPPs) have many advantages over analog systems but also pose different engineering and technical challenges, such as potential threats due to common cause failures (CCFs). This paper proposes a Platform for Risk Assessment of DI&C (PRADIC) developed by Idaho National Laboratory for dealing with potential software CCFs in DI&C systems of NPPs. The methodology development of PRADIC on the quantitative evaluation of software CCFs in high safety-significant safety-related DI&C systems in NPPs is illustrated in this paper. In PRADIC, qualitative hazard analysis and quantitative reliability and consequence analysis are successively implemented to obtain quantitative risk information, compare with respective risk evaluation acceptance criteria, and provide suggestions for risk reduction and design optimization. A comprehensive case study was also performed and documented in this paper. Results show that PRADIC can effectively identify potential digital-based CCFs, estimate their failure probabilities, and evaluate their impacts to system and plant safety.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Virtual machine-based simulation platform for mobile ad-hoc network-based cyber infrastructure

In modeling and simulating complex systems such as mobile ad-hoc networks (MANETs) in de-fense communications, it is a major challenge to reconcile multiple important considerations: the rapidity of unavoidable changes to the software (network layers and applications), the difficulty of modeling the critical, implementation-dependent behavioral effects, the need to sustain larger scale scenarios, and the desire for faster simulations. Here we present our approach in success-fully reconciling them using a virtual time-synchronized virtual machine(VM)-based parallel ex-ecution framework that accurately lifts both the devices as well as the network communications to a virtual time plane while retaining full fidelity. At the core of our framework is a scheduling engine that operates at the level of a hypervisor scheduler, offering a unique ability to execute multi-core guest nodes over multi-core host nodes in an accurate, virtual time-synchronized manner. In contrast to other related approaches that suffer from either speed or accuracy issues, our framework provides MANET node-wise scalability, high fidelity of software behaviors, and time-ordering accuracy. The design and development of this framework is presented, and an ac-tual implementation based on the widely used Xen hypervisor system is described. Benchmarks with synthetic and actual applications are used to identify the benefits of our approach. The time inaccuracy of traditional emulation methods is demonstrated, in comparison with the accurate execution of our framework verified by theoretically correct results expected from analytical models of the same scenarios. In the largest high fidelity tests, we are able to perform virtual time-synchronized simulation of 64-node VM-based full-stack, actual software behaviors of MANETs containing a mix of static and mobile (unmanned airborne vehicle) nodes, hosted on a 32-core host, with full fidelity of unmodified ad-hoc routing protocols, unmodified application executables, and user-controllable physical layer effects including inter-device wireless signal strength, reachability, and connectivity.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Modeling of interdendritic porosity defects in an integrated computational materials engineering approach for metal casting

Modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components in order to accelerate the introduction of new cast alloys. The data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. Here in this paper, the required models for the prediction of interdendritic casting defects, such as microporosity and hot tears, are reviewed. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Numerical simulation results for microporosity are presented for A356, 356 and 319 aluminum alloys using ProCAST TM software. The calculated pressure drop of the interdendritic liquid was observed to be quite significant and the regions of high-pressure drop can be used as an indicator of the severity of interdendritic microporosity defects.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Assessment and Usage of In-Situ Monitoring Data for American Society of Mechanical Engineers Part Qualification

In-situ monitoring and anomaly detection are important components for qualification of directed energy deposition (DED) additive manufacturing (AM) processes and components. The use of in-situ monitoring requires an understanding of anomalies that can be identified during the process and how those anomalies correlate to mechanical properties of the component post-production. There is also a need to qualify the algorithms and software used to interpret the process signals for DED AM. There is no single process signal that can be used with a single algorithm that will identify all anomalies that will translate to a defect in a process. The process signals are affected by changes in material, location, resolution, acquisition rate, component geometry, and the machine itself. It is observed that multiple process signals are required to identify relevant features that can be correlated to mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Spatio-temporal Estimates of Disease Transmission Parameters for COVID-19 with a Fully-Coupled, County-Level Model of the United States

Sandia National Laboratories has developed a capability to estimate parameters of epidemiological models from case reporting data to support responses to the COVID-19 pandemic. A differentiating feature of this work is the ability to simultaneously estimate county-specific disease transmission parameters in a nation-wide model that considers mobility between counties. The approach is focused on estimating parameters in a stochastic SEIR model that considers mobility between model patches (i.e., counties) as well as additional infectious compartments. The inference engine developed by Sandia includes (1) reconstruction and (2) transmission parameter inference. Reconstruction involves estimating current population counts within each of the compartments in a modified SEIR model from reported case data. Reconstruction produces input for the inference formulations, and it provides initial conditions that can be used in other modeling and planning efforts. Inference involves the solution of a large-scale optimization problem to estimate the time profiles for the transmission parameters in each county. These provide quantification of changes in the transmission parameter over time (e.g., due to impact of intervention strategies). This capability has been implemented in a Python-based software package, epi_inference, that makes extensive use of Pyomo [5] and IPOPT [10] to formulate and solve the inference formulations.

42 ENGINEERING↗

DOE OSTI2022

Resilient, Rural, and Revolutionary: Salisbury Square's Direct-Current Affordable Microgrid Community: Preprint

The technology to interconnect buildings with a dedicated direct-current (DC) power distribution network is in place today; what is missing is a turnkey approach to designing a DC microgrid - and the business models allowing such systems to be deployed, owned, and operated at scale. To close this gap, the Salisbury Square Development Team, comprising clean-energy experts, has engineered a resilient community DC microgrid for an affordable housing community in Randolph, Vermont. Ten single-family, occupant-owned residences and 12 multifamily rental units will share locally generated and stored solar energy via a DC power distribution bus capable of operating during extended grid outages. With a DC power distribution network in place, each home will be equipped with high-efficiency DC lighting and appliances, operating alongside alternating current (AC) appliances, even during an islanded mode of operation. To obtain a comprehensive understanding of what is possible and achievable, the Team collaborated with the local utility, regulatory agencies, a national laboratory, energy-as-service providers, and vendors. The collaborators evaluated microgrid typologies, business models, and energy modeling, and analyzed electrification and resilience. Further, the Team applied the URBANoptTM (Urban Renewable Building and Neighborhood optimization, NREL 2022) software development kit (SDK) to Salisbury Square's single-family and multifamily buildings to validate workflows and identify needs for advanced capability. This paper addresses the barriers to entry, scalability, and impact on residents and system ownership. It also examines the analysis that informed the design and engineering of the DC microgrid and the opportunities to streamline the process.

DER↗

DOE OSTI2021

A software environment for effective reliability management for pulsed power design

The reliable design of magnetically insulated transmission lines (MITLs) for very high current pulsed power machines must be accomplished in the future by utilizing a variety of sophisticated modeling tools. The complexity of the models required is high and the number of sub-models and approximations large. The potential for significant analyst error using a single tool is large, with possible reliability issues associated with the plasma modeling tools themselves or the chosen approach by the analyst to solve a given problem. Here, we report on a software infrastructure design that provides a workable framework for building self-consistent models and constraining feedback to limit analyst error. The framework and associated tools aid the development of physical intuition, the development of increasingly sophisticated models, and the comparison of performance results. The work lays the computational foundation for designing state-of-the-art pulsed-power experiments. The design and useful features of this environment are described. We discuss the utility of the Git source code management system and a GitLab interface for use in project management that extends beyond software development tasks.

42 ENGINEERING↗

DOE OSTI2023

Comparing Top-Down Proteoform Identification: Deconvolution, PrSM Overlap, and PTM Detection

Generating top-down tandem mass spectra (MS/MS) for complex mixtures of proteoforms has become possible through improvements in fractionation, on-line separation, dissociation, and mass analysis. The algorithms to match tandem mass spectra to sequences have undergone a parallel evolution, with both spectral alignment and peak matching being paired with diverse methods for scoring proteoform-spectral matches (PrSMs). This study assesses state-of-the-art algorithms for top-down identification through three distinct challenges. The first is identifying a large yield of PrSMs while controlling false discovery rate (FDR) in identifying thousands of proteoforms from complex cell lysates via four software workflows: ProSight Proteome Discoverer, TopPIC, Informed Proteomics, and pTop. The second is the deconvolution of data from both Thermo Orbitrap-class and Bruker maXis Q-TOF instruments to produce consistent precursor charge and mass determinations while generating fragment mass lists to optimize identification. The third attempts to detect diverse post-translational modifications (PTMs) in proteoforms from cow milk and human ovarian tissue. The data demonstrate that existing software suites produce admirable sensitivity, in some cases identifying a third of collected tandem mass spectra with FDR controlled below 2%; the overlap in these PrSMs, however, illustrates real value in searching data with multiple search engines. Differences among identification workflows seem to result from each search algorithm incorporating its own deconvolution algorithm. By transmitting deconvolution data from multiple deconvolution routes (Thermo Xtract, Bruker Auto MSn, Mascot Distiller, TopFD, and FLASHDeconv) to the downstream TopPIC search algorithm, we were able to detect common causes of deconvolution disagreement. The detection of PTMs was very inconsistent among search algorithms, with some workflows suggesting as little as 1% of PrSMs from cow’s milk were singly-phosphorylated while other workflows found that 18% of PrSMs were singly-phosphorylated. Taken together, these results make a strong argument for top-down researchers to adopt a standard practice of analyzing each MS/MS experiment with at least two different search engines.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2013

Model-independent particle accelerator tuning

We present a new model-independent dynamic feedback technique, rotation rate tuning, for automatically and simultaneously tuning coupled components of uncertain, complex systems. The main advantages of the method are: 1) It has the ability to handle unknown, time-varying systems, 2) It gives known bounds on parameter update rates, 3) We give an analytic proof of its convergence and its stability, and 4) It has a simple digital implementation through a control system such as the Experimental Physics and Industrial Control System (EPICS). Because this technique is model independent it may be useful as a real-time, in-hardware, feedback-based optimization scheme for uncertain and time-varying systems. In particular, it is robust enough to handle uncertainty due to coupling, thermal cycling, misalignments, and manufacturing imperfections. As a result, it may be used as a fine-tuning supplement for existing accelerator tuning/control schemes. We present multi-particle simulation results demonstrating the scheme’s ability to simultaneously adaptively adjust the set points of twenty two quadrupole magnets and two RF buncher cavities in the Los Alamos Neutron Science Center Linear Accelerator’s transport region, while the beam properties and RF phase shift are continuously varying. The tuning is based only on beam current readings, without knowledge of particle dynamics. We also present an outline of how to implement this general scheme in software for optimization, and in hardware for feedback-based control/tuning, for a wide range of systems.

42 ENGINEERING↗

DOE OSTI2024

Inverter Model Validation and Calibration Using Phasor Measurement Unit Data

As the penetration of inverter-based renewable energy resources increases in the power grid, especially at the distribution and microgrid levels, the need to accurately represent them in planning studies increases as well. However, due to the lack of well-established standard procedures, and vendor reluctance towards the detailed sharing of proprietary models, automated dynamic model validation and parameter calibration tools for inverter based resources (IBRs) remain scarce. This work presents a model validation and parameter calibration platform for representing IBRs with generic phasor-domain models. Phasor measurements of power system events are used for continuous validation using the data playback method, and model parameters are re-calibrated if a significant mismatch between measurements and model response is observed. Unique features of the proposed platform include- (a) an iterative Bayesian optimization approach towards parameter calibration to address a possible mismatch between the structures of generic models implemented in simulation softwares and actual commercial inverters, (b) error metrics designed to account for a possible mismatch between the time resolution of simulation and measurements, and (c) analysis of the measurement-simulation mismatch to provide guidance to engineering personnel regarding model shortcomings. The performance of the platform has been illustrated using both simulated data and field measurements to validate/calibrate inverter models in GridLAB-D.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗

DOE OSTI2019

hfem3d_parfrac

A toolkit of FORTRAN90 and PYTHON routines to automate calculation of electrostatic response of fracture networks in geomaterials, specifically designed for distributed memory compute clusters. Software integrates pre-processing of Cubit-generated meshes with calculations from HFEM3D and post-processing for aggregate data analysis.SAND2019-11083 M 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.

Beskardes, Gungor↗

DOE OSTI2019

XPCA - R Implementation

Principal component analysis (PCA) is arguably the most popular tool in multivariate exploratory data analysis. We consider the question of how to handle heterogeneous variables that include continuous, binary, and ordinal. In the probabilistic interpretation of low-rank PCA, the data has a normal multivariate distribution and, therefore, normal marginal distributions for each column. If some marginals are continuous but not normal, the semiparametric copula-based principal component analysis (COCA) method is an alternative to PCA that combines a Gaussian copula with nonparametric marginals. If some marginals are discrete or semi-continuous, we present a new extended PCA (XPCA) method that also uses a Gaussian copula and nonparametric marginals and accounts for discrete variables in the likelihood calculation by integrating over appropriate intervals. Like PCA, the factors produced by XPCA can be used to find latent structure in data, build predictive models, and perform dimensionality reduction. We implement the new model, XPCA, and its ancestors PCA and COCA in both R and Python. This software provides implementations of XPCA, COCA, and probabilistic PCA in both R and Python. XPCA is written in arXiv report https://arxiv.org/abs/1808.07510. 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. SAND2019-10591 M

Kincher-Winoto, Kina↗