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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Evaluating Indicators and Life Cycle Inventories for Processes in Early Stages of Technical Readiness

This presentation examines different methods for analyzing manufacturing processes in the early stages of technical readiness. Before developers know much detail about their processes, it is valuable to apply various assessments to evaluate their performance. One type of assessment evaluates performance indicators to describe how closely processes approach desirable objectives. Another type of assessment determines the life cycle inventories (LCI) of inputs and outputs for processes, where for a functional unit of product, the user evaluates the resources used and the releases to the environment. These results can be compared to similar processes or combined with the LCI of other processes to examine up-and down-stream chemicals. The inventory also provides a listing of the up-stream chemicals, which permits study of the whole life cycle. Performance indicators are evaluated in this presentation with the U.S. Environmental Protection Agency's GREENSCOPE (Gauging Reaction Effectiveness for ENvironmental Sustainability with a multi-Objective Process Evaluator) methodology, which evaluates processes in four areas: Environment, Energy, Economics, and Efficiency. The method develops relative scores for indicators that allow comparisons across various technologies. In this contribution, two conversion pathways for producing cellulosic ethanol from biomass, via thermochemical and biochemical routes, are studied. The information developed from the indicators and LCI can be used to inform the process design and the potential life cycle effects of up- and down-stream chemicals.

09 BIOMASS FUELS↗
DOE OSTI2020

Process Development of the Vaporizing Foil Actuator Welding Technique

The industrial focus on continuous improvement for products is leading design engineers to consider multi-material design concepts more frequently. The design concepts use the advantages of each material while simultaneously minimizing the drawbacks. It also allows for the overall weight of the products to be reduced. Some traditional joining methods, though, struggle to join dissimilar material combinations. A technique known as vaporizing foil actuator welding, which was developed around ten years ago, is a solid-state joining method that has the potential to overcome the barriers to dissimilar material joining. The biggest drawbacks of vaporizing foil actuator welding are that it is still exclusively used in laboratory settings and early in the technology development process. As such, there is not enough confidence in the process for it to be transitioned to manufacturing environments yet. This work begins by analyzing the current state of the technology and identifying a roadmap to achieve a transition to manufacturing. The analysis found that increased confidence in the technology requires sample to sample repeatability to be improved. Beyond that, the process also needs to be fully automated before it can be considered as a viable technique for mass production. In order to further develop the technique, a fully automated work cell was constructed. By removing the human element from the process, this cell helped identify iii the aspects which contribute to process variability. The positioning of the vaporizing foil actuator was identified as the most important factor in process stability. A small set of samples were made in the automated cell with the addition of one component epoxy adhesive around the perimeter of the weld. These samples showed improved process repeatability compared with the samples made without adhesive. This indicates that small amounts of adhesive may be critical in using the process in industrial settings. Additionally, work was performed with manual positioning and adhesive dispensing. This work found that a hybrid joint behaves like traditional weld bonding, where the addition of adhesive makes the joint stronger than if either of the two joining methods were used on their own. To realize this performance with vaporizing foil actuator welding, though, the adhesive needs to be protected from burning during the rapid compression of air during the impact process.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Radioactive Spent Ion-Exchange Resins Conditioning by the Hot Supercompaction Process at Tihange NPP - Early Experience - 12200

Spent ion-exchange resins are considered to be problematic waste that, in many cases, requires special approaches and precautions during their conditioning to meet the acceptance criteria for disposal. In Belgium, for economical reasons, the Volume Reduction Factor is a key criterion. After Tractebel Engineering performed a technical and economical comparison of the industrially available systems, Tihange NPP decided to install a spent ion-exchange resins hot supercompaction unit with Tractebel Engineering in the role of architect-engineer. The treatment and conditioning unit processes the spent ion-exchange resins through the following steps: dewatering of the resins, drying the resins under deep vacuum, discharging the dried resins into compactable drums, super-compacting the drums to generate pellets, grouting the pellets into standard 400 litres waste drums (overpacks) licensed for final disposal in the near-surface repository in Belgium. Several developments were required to adapt the reference process and equipment to PWR spent ion-exchange bead resins and Belgian radioactive waste acceptance criteria. In order to avoid cracks on the compacted drum, and external surface contamination from resin leaks, some improvements were achieved to minimize spring-back as well as the risk of cracking the drum wall. Placing the compactable drum inside a second, slightly larger drum, guarantees clean and reproducible pellets. Currently the commissioning phase is on-going. Numerous process validation tests have been completed. An acceptance file was transmitted to the Belgian Waste Management Authority recently. This will be followed by demonstration tests necessary to obtain their final acceptance of the installation. More than 3 800 drums of mixed powdered and bead resins have been processed by the reference Hot Compaction process, achieving a Volume Reduction Factor (VRF) of 2.5. The equipment has been proven to be a reliable technology with low operation and maintenance costs. Tractebel Engineering has managed the construction of a new application of this process in Belgium at Tihange NPP. Several developments were required to adapt the reference process and equipment to PWR spent ion-exchange bead resins and Belgian radioactive waste acceptance criteria. The chosen method of conditioning (draining, drying and compaction of the spent resins followed by grouting of the pellets in a 400 litres drum) immobilizes the spent resins under the form of a solid, compact, stable, and non dispersible block free of interstitial water. The various series of inactive tests which were conducted at Tihange NPP, helped among others to determine the best design of the compactable drum and lid and to set the value of critical parameters such as vapour temperature at the end of drying, speed, force and duration of compaction. In an environment of very limited space for interim storage and in the absence of an operational final repository site, or in the case of high final disposal costs, the process exhibits the following key advantages: - Achieving a Volume Reduction Factor (VRF) close to 1 (overpack included) for the interim storage instead of increased volumes observed with other currently available processes; - Achieving a water free end product; - Creating a flexible waste product for interim storage (pellet), which can be retrieved and routed into alternative types of package later, if not initially grouted; - Using well proven standard technologies like drying and compaction; - Flexible use of the system components for the supercompaction of other operational solid waste streams when not conducting resins conditioning campaigns. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

The DOE Unreviewed Safety Question Process, Addressing New Information For Credible Nuclear Accidents

The Department of Energy (DOE) Unreviewed Safety Question (USQ) process is in use for hazardous nuclear facilities operated within the DOE nuclear complex. DOE, which is the federal nuclear safety regulator for its nuclear facilities, requires that each nuclear facility have a Documented Safety Analysis that defines the controls for each credible accident based on a detailed accident analysis. The DOE USQ process provides key mechanisms for formally identifying to the regulator potential accident analysis issues at operating nuclear facilities including those that stem from emergent or new information on hazards. The DOE USQ process provides for formal evaluation of those emergent issues and for determining the need for formal regulator (DOE) review and approval of any resulting immediate or long-term actions. Regarding the March 2011 accident at the Fukushima Daiichi Nuclear Power Station, lessons learned on the evaluation and disposition of new information have been noted by the Institute of Nuclear Power Operations (INPO) and the National Research Council. These organizations noted that: - when new information indicates the potential for conditions that could significantly reduce safety margins or exceed current design assumptions, a timely, formal, and comprehensive assessment of the potential for substantial consequences should be conducted, and - if the new information analysis results in substantial changes to the risk profile or could impact the function of important safety systems, then compensatory actions or countermeasures need to be established without delay. The objective of this paper is to raise awareness regarding the salient requirements and guidance of the DOE USQ process used at DOE's operating nuclear facilities that bear on handling of emergent or new information on hazards and that address the lessons learned noted above by INPO and the National Research Council. There is no analysis or intent to make any implications regarding how use of the DOE USQ process might have affected events at Fukushima. The DOE USQ process, when applied as intended at DOE nuclear facilities, addresses lessons learned identified by INPO and the National Research Council regarding use of emergent or new information on hazards. The DOE USQ process ensures a timely, formal, and comprehensive assessment of the potential for substantial consequences resulting from new information on hazards. When the new information analysis results in substantial changes to the risk profile or shows an impact to the function of important safety systems, the DOE USQ process calls for compensatory actions or countermeasures to be established in a timely manner. The DOE USQ process ensures a formal evaluation by the regulator and approval of the planned actions addressing the vulnerabilities made know by new information on hazards. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

A Sensitivity-informed, Process Model Abstraction Implementation in GoldSim - 19276

System-level Performance Assessment (PA) models rely on specific process-level models for some inputs, such as infiltration. For probabilistic PA, the value of the process model output depends on the values of input parameters that also vary in the PA model. The simplest conceptual solution is to draw values of the input parameters from their distributions, run the process level model at these values, and then use the output where it is needed in the PA model. However, this solution is unsatisfactory for multiple reasons: (1) the PA Model should be set up such that new runs can be made and distributions can change without having to go back and run the process-level model; (2) calling the process model from the system model is possible, but technical difficulties remain in coupling the two; and (3) there is no uncertainty in the process-level model results incorporated into the PA model. Therefore, it is desirable to develop a method that maps the values of PA Model inputs to process level model outputs, in real time within the PA Model set up and using as simple of a map as possible without losing key features of the relationship. This has been termed 'model abstraction' because information about process model runs is 'abstracted' to be used with the PA model. A simple 'nearest neighbor' abstraction approach is presented to overcome these problems, in which a sensitivity-informed distance metric is used to map a system-level model realization to the most appropriate process-level model realization. (authors)

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Comparison of Silicon Decarbonization Methods to Reduce Process Emissions and Energy Consumption

The demand for silicon is rising due to its use in solar cells, electronics, and alloying as part of the green transition. However, these products require silicon metal (metallurgical grade silicon, >98% Si) as their main raw material before undergoing further chemical refining, usually via gas phase in methods such as the Siemens process. Silicon metal is currently produced in a submerged arc furnace via carbothermic reduction of quartz, which results in 10-12 tCO2/tSi. More than 40% of these emissions are process emissions, meaning they do not include contributions from electricity generation or transport. This talk will discuss promising methods to reduce or eliminate these process emissions. These include the use of biocarbon and carbon capture, aluminothermic reduction, electrochemical reduction with molten salts, and use of hydrogen in a modified Siemens process. Biocarbon and carbon capture is a straightforward method to reduce the net carbon emissions of the process, but long-term sustainable production of high-quality charcoal is a challenge. Aluminothermic reduction makes good use of aluminum byproducts such as dross but is perhaps limited in its applications to aluminum-silicon alloy products. Electrochemical reduction is promising as a method of producing high purity Si from quartz, without further need for the Siemens process, but is still in early stages of research and slow processing times are a concern. Finally, the use of hydrogen in a modified Siemens process would also result in a high purity Si product from quartz, however the process has considerable logistical challenges with corrosive and unstable gases at high temperatures. This talk will further expand on the potential merits and challenges of each method, while comparing their potential to reduce emissions and/or energy consumption while meeting global demand.

decarbonization↗
DOE OSTI2025

A fast computational framework for the design of solvent-based plastic recycling processes

Multicomponent plastics cannot be processed using mechanical recycling technologies, hindering efforts to deal with plastic waste. Multicomponent plastics include multilayer plastic films, which are widely used for food and healthcare packaging. Multilayer films combine several layers (potentially dozens) of different polymers to protect products from external factors (e.g., oxygen, water, temperature, shock, and light). Solvent-based separation processes have emerged as a promising alternative to recycle these complex materials. For instance, the Solvent-Targeted Recovery and Precipitation (STRAP TM ) process uses sequential solvent washes to selectively dissolve and separate constituent polymers from multicomponent plastic waste, including films. STRAP TM process design (separation sequence, type of solvents, and operating conditions) changes significantly depending on the design of the multilayer plastic film (e.g., number, types, and proportions of polymers). The ability to quickly quantify the economic and environmental benefits of diverse STRAP TM process designs is essential to accelerate the development of sustainable recycling processes and more recyclable multilayer film products. In this work, we present a fast computational framework that integrates molecular-scale models, process modeling, and techno-economic and life cycle analysis to quickly evaluate STRAP TM designs. The computational framework is general and can be used to study the processing of complex multilayer plastic waste streams that contain many layers. Furthermore, we highlight the different uses of the framework via targeted case studies.

Computational framework↗
DOE OSTI2019

Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects

Additive manufacturing provides an appealing means to process titanium alloy parts with new levels of conformability, complexity, and weight reduction. However, due to the heating/cooling rates and heat transfer associated with directed energy source material processing, the as-built AM parts contain unique material and microstructural features. In order to confidently manufacture fatigue critical additive manufactured (AM) Ti-6Al-4V parts, a better understanding of the interrelationships between powder feedstock, AM processes, structure of the processed parts, their resulting mechanical properties, and their performance under realistic loadings is necessary. Part I of this two-part collection focuses on the powder-process-structure relationships and how powder feedstock, manufacturing, and post-processing conditions can affect the microstructure and defect features that ultimately contribute to the fatigue performance of Ti-6Al-4V parts. The material and physical phenomena inherent to the AM process of Ti-6Al-4V are discussed in detail and related to the phase composition/structure, grain morphology, surface characteristics, defect size/distribution, and post-process treatments available for AM parts. This investigation is the foundation for the structure-performance relationships that will be covered in detail in Part II.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A high-throughput approach for statistical process optimization in Laser Powder Bed Fusion

Process variability is inherent in metal additive manufacturing (AM). However, it is often overlooked in process optimization frameworks, constraining the understanding of process uncertainties and their influence on parameter selection. To address this, we present an integrated framework that combines high-throughput single-track experiments, GAN-based melt pool geometry extraction, robust statistical and machine learning modeling, and uncertainty-quantified process mapping. Process variability is characterized through single-track melt pool behaviors, and its influence on defect formation is systematically quantified to enable statistically guided process parameter optimization. This approach is demonstrated on Laser Powder Bed Fusion (L-PBF) of stainless steel 316L, effectively capturing the interplay between process parameters, melt pool variability, and defect probability. By integrating uncertainty quantification into process optimization, this study provides a structured methodology for addressing variability challenges in AM quality control, ultimately contributing to enhanced manufacturing reliability.

Laser Powder Bed Fusion↗
DOE OSTI2012

THE s-PROCESS IN ASYMPTOTIC GIANT BRANCH STARS OF LOW METALLICITY AND THE COMPOSITION OF CARBON-ENHANCED METAL-POOR STARS

We present models for the slow neutron-capture process (s-process) in asymptotic giant branch stars of metallicity [Fe/H] = -2.3 and masses 0.9-6 M{sub Sun }. We encountered different regimes of neutron-capture nucleosynthesis listed here increasing in importance as the stellar mass decreases: the {sup 22}Ne({alpha}, n){sup 25}Mg reaction activated during the thermal pulses (TPs), the {sup 13}C({alpha}, n){sup 16}O reaction activated in radiative conditions during the interpulse periods, and the {sup 13}C({alpha}, n){sup 16}O reaction activated during the TPs, also as a result of mild proton-ingestion episodes. The models where the {sup 13}C burns radiatively (masses {approx_equal}2 M{sub Sun }) produce an overall good match to carbon-enhanced metal-poor (CEMP) stars showing s-process enhancements (CEMP-s), except they produce too much Na and F. On the other hand, none of our models can provide a match to the composition of CEMP stars also showing rapid-process enhancements (CEMP-s/r). The models fail to reproduce the observed Eu abundances, and they also fail to reproduce the correlation between the Eu and Ba abundances. They also cannot match the ratio of heavy-to-light s-process elements observed in many CEMP-s/r stars, which can be more than 10 times higher than in the solar system. To explain the composition of CEMP-s/r stars we need to invoke the existence of a different 's/r' neutron-capture process either with features in between the s- and the r-processes, or generated by superpositions of different neutron-capture processes in the same astrophysical site or in sites linked to each other-for example, in multiple stellar systems.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2011

THE INTEGRATION OF PROCESS HEAT APPLICATIONS TO HIGH TEMPERATURE GAS REACTORS

A high temperature gas reactor, HTGR, can produce industrial process steam, high-temperature heat-transfer gases, and/or electricity. In conventional industrial processes, these products are generated by the combustion of fossil fuels such as coal and natural gas, resulting in significant emissions of greenhouse gases such as carbon dioxide. Heat or electricity produced in an HTGR could be used to supply process heat or electricity to conventional processes without generating any greenhouse gases. Process heat from a reactor needs to be transported by a gas to the industrial process. Two such gases were considered in this study: helium and steam. For this analysis, it was assumed that steam was delivered at 17 MPa and 540 C and helium was delivered at 7 MPa and at a variety of temperatures. The temperature of the gas returning from the industrial process and going to the HTGR must be within certain temperature ranges to maintain the correct reactor inlet temperature for a particular reactor outlet temperature. The returning gas may be below the reactor inlet temperature, ROT, but not above. The optimal return temperature produces the maximum process heat gas flow rate. For steam, the delivered pressure sets an optimal reactor outlet temperature based on the condensation temperature of the steam. ROTs greater than 769.7 C produce no additional advantage for the production of steam.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

EGS Collab Experiment 1: Circulation Testing Processed data

This submission includes processed and reduced data for circulation testing that was conducted at the 164' fracture on the 4850 ft level of the Sanford Underground Research Facility. The circulation tests were done to test the flow through the 164' fracture in the EGS Collab Experiment 1 testbed on the 4850 ft level of the Sanford Underground Research Facility in order to validate computer models concerned with flow processes and heat exchange processes in EGS. This data was processed from raw data that is available in the GDR submission linked below: "EGS Collab Circulation Testing Raw Data and Documentation." Python scripts used to process and reduce the data are included. The scripts also serve as "documentation" as well as examples for data processing. More information about the test itself as well as the rationale and process of data processing is available at wiki page linked below.

15 GEOTHERMAL ENERGY↗
DOE OSTI2011

ISOLOK VALVE ACCEPTANCE TESTING FOR DWPF SME SAMPLING PROCESS

Evaluation of the Defense Waste Processing Facility (DWPF) Chemical Process Cell (CPC) cycle time identified several opportunities to improve the CPC processing time. Of the opportunities, a focus area related to optimizing the equipment and efficiency of the sample turnaround time for DWPF Analytical Laboratory was identified. The Mechanical Systems & Custom Equipment Development (MS&CED) Section of the Savannah River National Laboratory (SRNL) evaluated the possibility of using an Isolok{reg_sign} sampling valve as an alternative to the Hydragard{reg_sign} valve for taking process samples. Previous viability testing was conducted with favorable results using the Isolok sampler and reported in SRNL-STI-2010-00749 (1). This task has the potential to improve operability, reduce maintenance time and decrease CPC cycle time. This report summarizes the results from acceptance testing which was requested in Task Technical Request (TTR) HLW-DWPF-TTR-2010-0036 (2) and which was conducted as outlined in Task Technical and Quality Assurance Plan (TTQAP) SRNL-RP-2011-00145 (3). The Isolok to be tested is the same model which was tested, qualified, and installed in the Sludge Receipt Adjustment Tank (SRAT) sample system. RW-0333P QA requirements apply to this task. This task was to qualify the Isolok sampler for use in the DWPF Slurry Mix Evaporator (SME) sampling process. The Hydragard, which is the current baseline sampling method, was used for comparison to the Isolok sampling data. The Isolok sampler is an air powered grab sampler used to 'pull' a sample volume from a process line. The operation of the sampler is shown in Figure 1. The image on the left shows the Isolok's spool extended into the process line and the image on the right shows the sampler retracted and then dispensing the liquid into the sampling container. To determine tank homogeneity, a Coliwasa sampler was used to grab samples at a high and low location within the mixing tank. Data from the two locations were compared to determine if the contents of the tank were well mixed. The Coliwasa sampler is a tube with a stopper at the bottom and is designed to obtain grab samples from specific locations within the drum contents. A position paper (4) was issued to address the prototypic flow loop issues and simulant selections. A statistically designed plan (5) was issued to address the total number of samples each sampler needed to pull, to provide the random order in which samples were pulled and to group samples for elemental analysis. The TTR required that the Isolok sampler perform as well as the Hydragard sampler during these tests to ensure the acceptability of the Isolok sampler for use in the DWPF sampling cells. Procedure No.L9.4-5015 was used to document the sample parameters and process steps. Completed procedures are located in R&D Engineering job folder 23269.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗
DOE OSTI2023

Reinforcement learning for real-time process control in high-temperature superconductor manufacturing

With high efficiency and low energy loss, high-temperature superconductors (HTS) have demonstrated their profound applications in various fields, such as medical imaging, transportation, accelerators, microwave devices, and power systems. The high-field applications of HTS tapes have raised the demand for producing cost-effective tapes with long lengths in superconductor manufacturing. However, achieving the uniform and enhanced performance of a long HTS tape is challenging due to the unstable growth conditions in the manufacturing process. Although it is confirmed that the process parameters during the advanced metal organic chemical vapor deposition (A-MOCVD) process influence the uniformity of the produced HTS tapes, the high-dimensional process parameter signals and their complicated interactions make it difficult to develop an effective control policy. In this paper, we propose a local measure for the uniformity of HTS tapes to provide instant feedback for our control policy. Then, we model the manufacturing of HTS tapes as a Markov decision process (MDP) with continuous state and action spaces to assess the instant reward in real time in our feedback control model. As our MDP involves continuous and high-dimensional state and action spaces, a neural fitted Q-iteration (NFQ) algorithm is adopted to solve the MDP with artificial neural network (ANN) function approximation. The collinearity of process parameters can restrict our capability of adjusting the process parameters, which is addressed by the principal component analysis (PCA) in our method. The control policy adjusts the PCA of process parameters using the NFQ algorithm. In conclusion, based on our case studies on real A-MOCVD dataset, the obtained control policy increases the average uniformity of tapes by 5.6% and performs especially well on sample HTS tapes with a low uniformity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. Here, the predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A manufacturing process design for producing a membrane-based energy recovery ventilator with high aspect ratio support ribs

Heating, ventilation, and air conditioning systems represent nearly half of building energy usage in the United States. Recent building regulations requiring increased air turnover within buildings will result in even greater air conditioning usage. To alleviate these concerns, membrane-based heat-and-moisture exchangers known as energy recovery ventilators have been developed to reduce the energy expenditure of air conditioning systems by pre-conditioning incoming air through sensible and latent heat transfer with building air exhaust. Here in this work, we propose and validate a manufacturing process design for channel lamination based on surface mount adhesives capable of meeting the process requirements of a membrane-based ventilator. In particular, the device requires rib supports with height-to-width aspect ratios greater than one. The proposed manufacturing process design is capable of meeting this process requirement by stretching the adhesive after initial adhesive tacking. A manufacturing process flow diagram, a machine tool specification and a cost model are proposed for meeting process requirements. A set of design constraints are developed detailing the adhesive requirements necessary for meeting requirements. The cost model is validated by building a sub-scale mesochannel array demonstrating the ability to meet process requirements. Results show that additional work is needed to validate the curing step but that the process is capable of producing a mesochannel array with an acceptable level of variation.

42 ENGINEERING↗
DOE OSTI2020

Database development and exploration of process–microstructure relationships using variational autoencoders

The paper demonstrates graphical representation of a large database containing process–microstructure relationships using an unsupervised machine learning algorithm. Correlating microstructural features to processing is an essential first step to answer the difficult problem of process sequence design. Here, a large database of 346,200 orientation distribution functions resulting from a variety of process sequences is constructed, where each sequence comprises up to four stages of tension, compression and rolling along different directions in various permutations. This open-source database is constructed for collaborative development of process design algorithms. The paper demonstrates a novel application of the large database: graphical representation of texture–process relationships. A variational autoencoder is used to reduce the entire database to a two dimensional latent space where variations in processes and properties can be visualized. Using proximity analysis in this latent space, we can quickly unearth multiple process solutions to the problem of texture or property design.

36 MATERIALS SCIENCE↗