SEARCH · Engineering Papers

Results for “Quality control”

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.

SourceResearch connectionFrom yearThrough year

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

At least 1,261 records · Page 70

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Method to synthesize nanoparticle supercrystals

Highly ordered arrays of 3D faceted nanoparticle supercrystals are formed by self-assembly with controlled nanoparticle packing and unique facet dependent optical property by using a binary solvent diffusion method. The binary diffusion results in supercrystals whose size and quality are determined by initial nanoparticle concentration and diffusion speed. The supercrystal solids display unique facet-dependent surface plasmonic and surface-enhanced Raman characteristics. The supercrystals have potential applications in areas such as optics, electronics, and sensor platforms.

Fan, Hongyou↗

DOE OSTI2022

Systems and methods for detecting and mitigating cyber attacks on power systems comprising distributed energy resources

Extensive deployment of interoperable distributed energy resources (DER) on power systems is increasing the power system cybersecurity attack surface. National and jurisdictional interconnection standards require DER to include a range of autonomous and commanded grid-support functions which can drastically influence power quality, voltage, and the generation-load balance. Investigations of the impact to the power system in scenarios where communications and operations of DER are controlled by an adversary show that each grid-support function exposes the power system to distinct types and magnitudes of risk. The invention provides methods for minimizing the risks to distribution and transmission systems using an engineered control system which detects and mitigates unsafe control commands.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Smart sensor for online situational awareness in power grids

Waveforms in power grids typically reveal a certain pattern with specific features and peculiarities driven by the system operating conditions, internal and external uncertainties, etc. This prompts an observation of different types of waveforms at the measurement points (substations). An innovative next-generation smart sensor technology includes a measurement unit embedded with sophisticated analytics for power grid online surveillance and situational awareness. The smart sensor brings additional levels of smartness into the existing phasor measurement units (PMUs) and intelligent electronic devices (IEDs). It unlocks the full potential of advanced signal processing and machine learning for online power grid monitoring in a distributed paradigm. Within the smart sensor are several interconnected units for signal acquisition, feature extraction, machine learning-based event detection, and a suite of multiple measurement algorithms where the best-fit algorithm is selected in real-time based on the detected operating condition. Embedding such analytics within the sensors and closer to where the data is generated, the distributed intelligence mechanism mitigates the potential risks to communication failures and latencies, as well as malicious cyber threats, which would otherwise compromise the trustworthiness of the end-use applications in distant control centers. The smart sensor achieves a promising classification accuracy on multiple classes of prevailing conditions in the power grid and accordingly improves the measurement quality across the power grid.

Dehghanian, Payman↗

DOE OSTI2023

Systems and methods for detecting and mitigating cyber attacks on power systems comprising distributed energy resources

Johnson, Jay Tillay↗

DOE OSTI2022

Carrier recombination dynamics and temperature dependent optical properties of InAs–GaSb heterostructures

Heterostructures with two dissimilar materials could offer unprecedented properties if one can carefully synthesize these heterostructures with atomically smooth interfaces and reduced number of recombination centers. InAs/GaSb-based heterostructures have technological importance for long wavelength infrared photodetectors if one can synthesize these materials with high-optical quality and high-carrier lifetime. In this work, the InAs/GaSb heterostructures with a different number of heterointerfaces and growth conditions were grown by solid source molecular beam epitaxy using valved cracker sources for both arsenic and antimony. Precise control of growth parameters and shutter sequences enabled abrupt InAs/GaSb heterointerfaces, as supported by a high-resolution transmission electron microscopic study. The temperature and power-dependent optical properties by photoluminescence (PL) spectroscopic analysis of InAs/GaSb heterostructures with 4 and 28 heterointerfaces displayed donor to the acceptor and the exciton bound to complex defects (V Ga Ga Sb ) 0 . Since the optical transition in PL measurements serves to determine the quality of the material, and the observed excitonic transitions from these InAs/GaSb heterostructures is an indication of high-quality materials. The high-carrier lifetimes of 139 ns to 185 ns from InAs/GaSb heterostructures were measured using microwave photoconductivity decay (μ-PCD) technique at room temperature. The observed increase in carrier lifetime is due to the decreasing number of Ga-related carrier recombination centers or defect complexes. This is further supported by the PL spectroscopic study. In addition, the carrier lifetime with different injection levels is supported by Shockley–Read–Hall recombination. We report these InAs/GaSb heterostructures with high-optical quality and high-carrier lifetimes would offer a path for the development of high-performance infrared photodetectors.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A Case Study of Tunable White LED Lighting with Networked Lighting Controls (Emory University Cognitive Empowerment Program)

Emory University and Georgia Institute of Technology (Georgia Tech) partnered to create the Charlie and Harriet Schaffer Cognitive Empowerment Program (CEP) facility in northeast Atlanta. Together with the funders they are building a program to help individuals experiencing mild cognitive impairment (MCI) to maintain their physical and cognitive health, and independence as long as possible. In addition to applying effective strategies and therapies, the two research groups are investigating the responses of the MCI members to treatments that involve acoustical conditions, exercise and movement, and lighting changes that may support retention or relearning of skills. Care partners and family members receive support and instruction to improve home and work life, promoting joy, purpose, and wellness in the family groups. The lighting system uses tunable-white LEDs, employing luminaires with both warm and cool-color emitters that can be dimmed separately to produce any white correlated color temperature (CCT) between 2700 K and 6500 K. All luminaires were dimmable to achieve subdued or lively surroundings for different treatments, time-of-day, and mood. A central networked digital control system was employed to allow tuning of multiple spaces together (for example, bright, cool morning light could be programmed for extra stimulation, or lighting in all spaces at the end of the day could be reduced in both light output and CCT to promote relaxation and not interfere with the melatonin cycle of occupants). Almost all spaces were equipped with individual room control of dimming and color temperature with touch screens to allow users to tune the lighting as desired, but each room’s controls could also be specially programmed through the server in case the research staff were investigating lighting settings on learning, for example. The server incorporates a timeclock, and it is able to send signals to switch off all lighting after occupancy hours, or enable occupancy sensors to control the lighting. The bulk of the construction work was completed in January 2020. It was clear from an initial walk-through that although the lighting system produced the expected high light level with low-glare qualities of light, that there were issues and inconsistencies to be resolved. These were noted in an initial punchlist visit and expected to be resolved when the tech representatives from the agency visited with the electrical contractor in the following few weeks. What followed was 2.5 years of identifying unexpected lighting performance in terms of light output, color, scheduling, and occupancy. This report documents the issues encountered in the effort to get the lighting and controls systems to operate as intended. It concludes with guidance for design professionals and manufacturers to help avoid problematic complexity in future projects.

42 ENGINEERING↗

DOE OSTI2021

Dynamic Building Load Control to Facilitate High Penetration of Solar Photovoltaic Generation (Final Technical Report)

Solar photovoltaic (PV) resources are the most common form of distributed generation in residential and commercial customer premises within electric distribution networks. A higher penetration of PV generation in distribution circuits will impose challenges on maintaining service voltages within the range of industry standards, power quality, and power flow. Buildings consume 74% of the electricity produced in the United States, and a significant portion of the building load is dispatchable, making them responsive to electrical grid needs. Oak Ridge National Laboratory—in collaboration with Southern Company; the University of Tennessee, Knoxville; and the Georgia Institute of Technology—is examining the PV integration issues in distribution-level electrical grids and developing integrated demand-side control and communication systems to enable responsive loads. The proposed responsive loads mechanism performs renewable generation following to increase the penetration of solar PV within each feeder. The specific objectives of this project are to (1) examine distribution-level PV integration scenarios to understand requirements, (2) undertake an end-to-end simulation-based design of a distributed control strategy of loads geographically near the PV generation asset to minimize the effect on the distribution feeder, (3) deploy and demonstrate the control technology developed in partnership with utilities, and (4) perform a scalability analysis at the utility scale. This 3-year integrated project aims to develop, demonstrate, and validate demand-side control technology to enable increased the penetration of renewables while mitigating challenges that arise due to their intermittency. Activities in Budget Period (BP) 1 focused on a literature review and the formal design of a control system for integrating local distribution with generation and loads. The team used modeling and simulation to evaluate the impact of varying buildings loads, variable PV generation, and power flow dynamics on the distribution circuit. The dynamic models developed in BP 1 were used in BP 2 to develop a model-based control design and a test bed. The test bed has enabled the simulation-based testing and comparison of different control designs and formulations applied to different configurations of the distribution grid, PVs, and building loads. The control approaches developed in BP 2 were implemented in BP 3 in the form of hardware deployed at the Central Baptist Church (CBC) in Knoxville, Tennessee, for testing and evaluation. The outcome of this project was the development and demonstration of open-source, low-cost, low-touch sensing and control retrofits to distributed PV generation and building loads that, in a coordinated fashion, provide the load-shaping response needed to integrate high levels of renewable penetration. This research addresses the target metrics by dynamically controlling a load with solar generation variability to minimize the extent of two-way power flow, enhance reliability, facilitate high PV penetration (>100% of peak load in a line segment), and generate scalable software and hardware solutions adaptable to any penetration levels. The research and development activities are focused and designed to be impactful within the relevant 2020 targets time frame.An accurate open-source integration simulation framework for end-to-end control design was developed and deployed at the CBC facility for testing and evaluation. This final report provides a detailed review of the technical results achieved during this 3-year integrated project. A novel spectral analysis of PV data is demonstrated to derive the requirements of the control design. A detailed simulation-based analysis of PV integration at increasing penetration levels is presented using 1 year of PV data to demonstrate the impact on the distribution circuits. Two different control strategies were developed and demonstrated via simulation to track variable PV generation with adaptive load dispatch. The report concludes with a summary of accomplishments and recommendations for a path forward.

14 SOLAR ENERGY↗

DOE OSTI2021

Upgrading of C1 Building Blocks

This project is developing the centerpiece technology for a market-responsive, integrated biorefinery concept based on the conversion of renewable C1 intermediates (e.g., syngas, CO2, methanol) to a suite of fuels and co-products with improved carbon efficiency, reduced capital expense, and control of the product distribution to meet market demand. Advanced upgrading technologies of syngas are critically needed for the successful commercialization of fuel production at a scale relevant for biomass gasification. Research tasks within this project leverage complementary catalyst and process design for the conversion of CO2-rich syngas (15-20% CO2 in syngas) to achieve high carbon yields of gasoline and jet fuels as the major products. The conversion pathways generate high quality fuels (e.g., high octane gasoline with low aromatics, desirable jet-range hydrocarbons), and potential to achieve favorable cost targets by 2022. Research progress is compared against the Mobil Olefin to Gasoline and Distillate (MOGD) process, which also offers control over the gasoline and distillate products, as an industrial benchmark. The pathway for direct conversion of CO2-rich syngas to hydrocarbon fuels seeks to exceed the carbon efficiency of biomass-sourced MOGD (31.8%). Recent catalyst and process development achievements are highlighted by improvements in carbon-selectivity to fuels and carbon yields, along with evidence of incorporation of carbon from CO2 into the hydrocarbon products.

bioenergy↗

DOE OSTI2021

Object-space optimization of tomographic reconstructions for additive manufacturing

Volumetric 3D printing motivated by computed axial lithography enables rapid printing of homogeneous parts but requires a high dimensionality gradient-descent optimization to calculate image sets. Here we introduce a new, simpler approach to image-computation that algebraically optimizes a model of the printed object, significantly improving print accuracy of complex parts under imperfect material and optical precision by improving optical dose contrast between the target and surrounding regions. Quality metrics for volumetric printing are defined and shown to be significantly improved by the new algorithm. The approach is extended beyond binary printing to grayscale control of conversion to enable functionally graded materials. The flexibility of the technique is digitally demonstrated with realistic projector point spread functions, printing around occluding structures, printing with restricted angular range, and incorporation of materials chemistry such as inhibition. Finally, simulations show that the method facilitates new printing modalities such as printing into flat, rather than cylindrical packages to extend the applications of volumetric printing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Cast Film Production with Polyethylene Recycled from a Post-Industrial Printed Multilayer Film by Solvent-Targeted Recovery and Precipitation

The solvent-targeted recovery and precipitation (STRAP) process separates and recovers the constituent resins in multilayer plastic packaging films by selective polymer dissolution. In this work, three different experimental methods were considered to recover a polyethylene (PE) resin from a printed multilayer film by STRAP. The methods consisted of (1) a filter bag system, (2) a Soxhlet extraction, and (3) a jacketed dissolution vessel. Cast films were produced with the PE recovered from each method and were analyzed for color, mechanical properties, and number of impurities. High-quality recycled PE cast films can be produced by increasing the solvent to plastic ratio, including a filter pore size of 100 μm, and optimizing temperature control in STRAP. Furthermore, this study demonstrates that STRAP polymers can be recycled back into plastic films, enabling the potential circularity of these packaging materials.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Automated tabletop exfoliation and identification of monolayer graphene flakes

Over the past two decades, graphene has been intensively studied because of its remarkable mechanical, optical, and electronic properties. Initial studies were enabled by manual “Scotch Tape” exfoliation; nearly two decades later, this method is still widely used to obtain chemically pristine flakes of graphene and other 2D van der Waals materials. Unfortunately, the yield of large, pristine flakes with uniform thickness is inconsistent. Thus, significant time and effort are required to exfoliate and locate flakes suitable for fabricating multilayer van der Waals heterostructures. Here, we describe a relatively affordable tabletop device (the “eXfoliator”) that can reproducibly control key parameters and largely automate the exfoliation process. In a typical exfoliation run, the eXfoliator produces 3 or more large (≥ 400 μm 2 ) high-quality graphene monolayer flakes, allowing new users to produce such flakes at a rate comparable to manual exfoliation by an experienced user. Furthermore, we use an automated mapping system and a computer vision algorithm to locate candidate flakes. Our results provide a starting point for future research efforts to identify more precisely which parameters matter for the success of exfoliation and to optimize them.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

A Semi-Analytical Solution Approach for Solving Constant-Coefficient First-Order Partial Differential Equations

Simulation and control of many dynamic systems involve solving partial differential equations (PDE). This letter proposes a semi-analytical solution (SAS) approach for fast and high-quality solution of first-order PDEs. The region of interest of the studied PDE is divided into a grid, and an SAS is derived for each grid cell in the form of the multivariate polynomials, of which the coefficients are identified using initial value and boundary value conditions. The solutions are solved in a “time-stepping” manner, i.e. within one time step, the coefficients of the SAS are identified and the initial value of the next time step is evaluated. This approach achieves a significantly larger grid cell than the widely used finite difference method, and thus enhances the computational efficiency significantly. Furthermore, the simulation result on the natural gas pipeline model demonstrates the advantages of SAS in accuracy and computational efficiency.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Avoiding excess computation in asynchronous evolutionary algorithms

Abstract Asynchronous evolutionary algorithms are becoming increasingly popular as a means of making full use of many processors while solving computationally expensive search and optimization problems. These algorithms excel at keeping large clusters fully utilized, but may sometimes inefficiently sample an excess of fast‐evaluating solutions at the expense of higher‐quality, slow‐evaluating ones. We have previously introduced a steady‐state parent selection strategy, SWEET (“Selection whilE EvaluaTing”), that sometimes selects individuals that are still being evaluated and allows them to reproduce early. We perform a takeover‐time analysis that confirms that this strategy gives slow‐evaluating individuals that have higher fitnesses an increased ability to multiply in the population. We also find that SWEET appears effective at improving optimization performance on problems in which solution quality is positively correlated with evaluation time. We evaluate our approach on six simulated real‐valued optimization problems and three real‐world applications: an autonomous vehicle controller problem that involves tuning a spiking neural network and two adversarial EA problems. We further evaluate SWEET versus a basic asynchronous process in a simulated setting. We present evidence that SWEET outperforms basic asynchronous processes in a use‐case in which performance is positively correlated with evaluation time, and performs comparably (and often better) than basic asynchronous processes in several use‐cases where performance is negatively correlated with evaluation time. That said, in the cases where performance and evaluation time are negatively correlated the variance of outcomes for SWEET is notably high.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Improve Learning from Crowds via Generative Augmentation

Crowdsourcing provides an efficient label collection schema for supervised machine learning. However, to control annotation cost, each instance in the crowdsourced data is typically annotated by a small number of annotators. This creates a sparsity issue and limits the quality of machine learning models trained on such data. In this paper, we study how to handle sparsity in crowdsourced data using data augmentation. Specifically, we propose to directly learn a classifier by augmenting the raw sparse annotations. We implement two principles of high-quality augmentation using Generative Adversarial Networks: 1) the generated annotations should follow the distribution of authentic ones, which is measured by a discriminator; 2) the generated annotations should have high mutual information with the ground-truth labels, which is measured by an auxiliary network. Extensive experiments and comparisons against an array of state-of-the-art learning from crowds methods on three real-world datasets proved the effectiveness of our data augmentation framework. It shows the potential of our algorithm for low-budget crowdsourcing in general.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2023

Development of High Performance Medium Velocity Superconducting Elliptical Cavities for Hadron Linacs

There is a solid scientific need for continuous wave (CW) proton or heavy ion linear accelerators (linacs) in the energy range up to about 1 GeV per nucleon (GeV/u). Only superconducting (SC) cavities can provide cost-efficient acceleration in CW mode. While low velocity, bc < 0.5 (b is the relative velocity of a charged particle and c is the speed of light), and high velocity, bc > 0.9, SC accelerating structures are established, there is a need in high-performance medium velocity SC accelerating structures. Currently, no superconducting (SC) CW proton or ion accelerators operate in the medium velocity range. We have developed a robust technology for producing high-performance medium-velocity elliptical cavities operating in the frequency range between 600 and 700 MHz. The project was performed in collaboration with Fermi and Argonne National Laboratories. The 5-cell, βopt = 0.65, 644 MHz elliptical cavities built at MSU have been used for this research. An advanced surface treatment method based on nitrogen doping to achieve a high-quality factor and a high accelerating gradient has been demonstrated. The surface treatment has been performed at ANL, and nitrogen doping at FNAL. A stable resonance control with the slow and fast tuner system has also been verified. FNAL developed a dedicated resonance control system for the stable operation of the combined tuner.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

A Vector Sensor-Based Acoustic Characterization System for Marine Renewable Energy

NoiseSpotter is a passive acoustic monitoring system that characterizes, classifies, and geo-locates anthropogenic and natural sounds in near real time. It was developed with the primary goal of supporting the evaluation of potential acoustic effects of offshore renewable energy projects. The system consists of a compact array of three acoustic vector sensors, which measures acoustic pressure and the three-dimensional particle velocity vector associated with the propagation of an acoustic wave, thereby inherently providing bearing information to an underwater source of sound. By utilizing an array of three vector sensors, the application of beamforming techniques can provide sound source localization, allowing for characterization of the acoustic signature of specific underwater acoustic sources. Here, performance characteristics of the system are presented, using data from controlled acoustic transmissions in a quiet environment and ambient noise measurements in an energetic tidal channel in the presence of non-acoustic flow noise. Data quality is demonstrated by the ability to reduce non-acoustic flow noise contamination, while system utility is shown by the ability to characterize and localize sources of sound in the underwater environment.

16 TIDAL AND WAVE POWER↗

DOE OSTI2020

Towards controlled synthesis of 2D crystals by chemical vapor deposition (CVD)

We report the emergence of two-dimensional (2D) materials has captured the imagination of researchers since graphene was first exfoliated from graphite in 2004. Their exotic properties give rise to many exciting potential applications in advanced electronic, optoelectronic, energy and biomedical technologies. Scalable growth of high quality 2D materials is crucial for their adoption in technological applications the same way the arrival of high quality silicon single crystals was to the semiconductor industry. A huge amount of effort has been devoted to grow large-area, highly crystalline 2D crystals such as graphene and transition metal dichalcogenides (TMDs) through various methods. While CVD growth of wafer-scale monolayer graphene and TMDs has been demonstrated, considerable challenges still remain. In this perspective, we advocate for the focus on the crystal growth morphology as an underpinning for understanding, diagnosing and controlling the CVD process and environment for 2D material growth. Like snowflakes in nature, 2D crystals exhibit a rich variety of morphologies under different growth conditions. The mapping of crystal shapes in the growth parameter space “encodes” a wealth of information, the deciphering of which will lead to better understanding of the fundamental growth mechanism and materials properties. To this end, we envision a collective effort by the 2D materials community to establish the correlation between crystal shapes and the intrinsic thermodynamic and kinetic parameters for CVD reactions through integrated crystal growth experiment, database development and machine learning assisted predictive modeling, which will pave a robust path towards controlled synthesis of 2D materials and heterostructures.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗