Results for “Accelerated Testing” — Page 74

DOE OSTI2023

Earthquake-induced impact of base-isolated buildings: theory, numerical modeling, and design solutions

Earthquake shaking more intense than that used to size the horizontal clearance between a base–isolated building and near–rigid perimeter moat wall will result in hard impact, producing high–frequency, high–amplitude acceleration response in the structure and supported equipment. Herein this paper provides a design solution for the damaging effects of hard impact by installing a compliant engineered element in the load path between the base–isolated building and the moat wall, resulting in soft impact and a much smaller acceleration response. The engineered element assumed herein is a commercial–off–the–shelf marine fender with mechanical properties determined by physical testing. The attachment of a flexible engineered element, with well–defined stiffness and damping, to a near–rigid moat wall, simplifies the numerical modeling of the building–moat wall system and eliminates the need to bound the lateral stiffness of the wall for impact calculations. The simple model of the engineered element can be implemented in commercial finite element codes. Theory is developed for two–sided impact of a single–degree–of–freedom oscillator. Analytical solutions are derived for the shifted first–mode frequency of the impacted oscillator and for its free–vibration response. The shifted first–mode frequency is a function of the composite lateral stiffness of the isolator–engineered element assembly and its earthquake–induced displacement. Local peaks in the spectral response of the impacted oscillator form at odd integer multiples of the shifted first–mode frequency. The analytical solutions can be used to verify, in part, the numerical model used for impact analysis.

42 ENGINEERING↗

DOE OSTI2022

Cell-Free Protein Synthesis for High-Throughput Biosynthetic Pathway Prototyping

Biological systems provide a sustainable and complimentary approach to synthesizing useful chemical products. Metabolic engineers seeking to establish economically viable biosynthesis platforms strive to increase product titers, rates, and yields. Despite continued advances in genetic tools and metabolic engineering techniques, cellular workflows remain limited in throughput. It may take months to test dozens of unique pathway designs even in a robust model organism, such as Escherichia coli. In contrast, cell-free protein synthesis enables the rapid generation of enzyme libraries that can be combined to reconstitute metabolic pathways in vitro for biochemical synthesis in days rather than weeks. Cell-free reactions thereby enable comparison of hundreds to thousands of unique combinations of enzyme homologs and concentrations, which can quickly identify the most productive pathway variants to test in vivo or further characterize in vitro. Furthermore, this cell-free pathway prototyping strategy provides a complementary approach to accelerate cellular metabolic engineering efforts toward highly productive strains for metabolite production.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Creep ductility limiting mechanisms in an additively manufactured Al-Ce-Ni-Mn-Zr alloy

Tensile creep response and cavitation damage evolution in an additively manufactured Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt%) alloy with peak-aging and overaging treatments were investigated in the 300–400 ºC range. Microstructural heterogeneity and its response to heat treatment and subsequent creep deformation were studied to understand the interplay between cavity formation, creep lifetime and ductility. Increasing the applied stress activated the nucleation of more cavities, an experimental observation that is well described using the vacancy accumulation model. Cavities nucleated prematurely due to localized plasticity in the denuded zones that formed at/near melt-pool or grain boundaries. Microstructure/deformation heterogeneity with consequent evolution of stress triaxiality, especially at lower stresses, causes accelerated cavitation, thus producing low creep ductility (∼ 0.2–2.4 %), compared to (∼12–21 %) ductility of the alloy measured by regular tensile tests at equivalent temperatures. A constrained diffusional cavity growth mechanism with continuous cavity nucleation during creep is established as the dominant mechanism, implying that cavitation involves vacancy diffusion, yet its growth rate is dictated by the minimum creep rate. In conclusion, the ductility-limiting creep and cavitation mechanisms discussed here provide new insight into the creep behavior of 3D-printed metallic alloys.

Additive manufacturing↗

DOE OSTI2020

Density Functionals for Hydrogen Storage: Defining the H2Bind275 Test Set with Ab Initio Benchmarks and Assessment of 55 Functionals

Efficient and high-capacity storage materials are indispensable for a hydrogen-based economy. In silico tools can accelerate the process of discovery of new adsorbent materials with optimal hydrogen adsorption enthalpies. Density functional theory is well-poised to become a very useful tool for enabling high-throughput screening of potential materials. In this work, we have identified density functional approximations that provide good performance for hydrogen binding applications following a two-pronged approach. First, we have compiled a data set (H2Bind275) that comprehensively represents the hydrogen binding problem capturing the chemical and mechanistic diversity in the binding sites encountered in hydrogen storage materials. We have also computed reference interaction energies for this data set using coupled-cluster theory. Second, we have assessed the performance of 55 density functional approximations for predicting H 2 interaction energies and have identified two hybrid density functionals (ωB97X-V and ωB97M-V), two double hybrid density functionals (DSD-PBEPBE-D3(BJ) and PBE0-DH), and one semilocal density functional (B97M-V) as the best performing ones. We have recommended the addition of empirical dispersion corrections to systematically underbinding density functionals such as revPBE, BLYP, and B3LYP for improvements in performance at negligible additional cost. We have also recommended the usage of the def2-TZVPP basis set as it represents a good compromise between accuracy and cost, limiting the finite basis set errors to less than 1 kJ/mol.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Suppression of pair beam instabilities in a laboratory analogue of blazar pair cascades

The generation of dense electron–positron pair beams in the laboratory can enable direct tests of theoretical models of γ-ray bursts and active galactic nuclei. We have successfully achieved this using ultrarelativistic protons accelerated by the Super Proton Synchrotron at (CERN). In the first application of this experimental platform, the stability of the pair beam is studied as it propagates through a meter-length plasma, analogous to TeV γ-ray-induced pair cascades in the intergalactic medium. It has been argued that pair beam instabilities disrupt the cascade, thus accounting for the observed lack of reprocessed GeV emission from TeV blazars. If true, this would remove the need for a moderate strength intergalactic magnetic field to explain the observations. We find that the pair beam instability is suppressed if the beam is not perfectly collimated or monochromatic, hence the lower limit to the intergalactic magnetic field inferred from γ-ray observations of blazars is robust.

blazar jets↗

DOE OSTI2020

The dynamic synthesis time-lag control for the 1.3 GHz LCLS-II Cryomodule test at Fermilab

The 1.3GHz LCLS-II Cryomodule (CM) has 8 cavities and each cavity has 9 RF cells and 80W heater. The 1.3GHz LCLS-II CM is 12.2-meter-long and contains a total 241.3 liters (equivalent liquid) of liquid helium, which is filling up by the 4KW@2.0K cryogenic plant at the Fermilab Cryomodule Test Facility (CMTF). The dynamic synthesis 2K cryogenic control system is built to control the long time-lag, unstable CM cryogenic system, under different modes operations. A report on the results obtained from the dynamic synthesis long time-lag control in the CMTF 1.3GHz CM test will be presented.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Modular cell-free expression plasmids to accelerate biological design in cells

Industrial biotechnology aims to produce high-value products from renewable resources. This can be challenging because model microorganisms—organisms that are easy to use like Escherichia coli—often lack the machinery required to utilize desired feedstocks like lignocellulosic biomass or syngas. Non-model organisms, such as Clostridium, are industrially proven and have desirable metabolic features but have several hurdles to mainstream use. Namely, these species grow more slowly than conventional laboratory microbes, and genetic tools for engineering them are far less prevalent. To address these hurdles for accelerating cellular design, cell-free synthetic biology has matured as an approach for characterizing non-model organisms and rapidly testing metabolic pathways in vitro. Unfortunately, cell-free systems can require specialized DNA architectures with minimal regulation that are not compatible with cellular expression. In this work, we develop a modular vector system that allows for T7 expression of desired enzymes for cell-free expression and direct Golden Gate assembly into Clostridium expression vectors. Utilizing the Joint Genome Institute’s DNA Synthesis Community Science Program, we designed and synthesized these plasmids and genes required for our projects allowing us to shuttle DNA easily between our in vitro and in vivo experiments. We next validated that these vectors were sufficient for cell-free expression of functional enzymes, performing on par with the previous state-of-the-art. Lastly, we demonstrated automated six-part DNA assemblies for Clostridium autoethanogenum expression with efficiencies ranging from 68% to 90%. We anticipate this system of plasmids will enable a framework for facile testing of biosynthetic pathways in vitro and in vivo by shortening development cycles.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

STEPS: A Portable Numerical Simulation Toolkit for Electrical Power System Dynamic Studies

Numerical simulation is the key technique for large scale power system analysis. Redistribution of global renewable power via international interconnections requires new simulation tools to study the interconnected systems with different nominal frequencies as a whole. In this paper we introduce an open source simulation toolkit for electrical power systems (STEPS) which is hosted at Github. Its kernel is coded in C++ with major functions of power flow and electro-mechanical dynamic simulation. Flexible options are provided and configurable to improve power flow solution and dynamic simulation. Common devices and models are supported in STEPS for AC/DC hybrid system studies. Studies of interconnected systems with different nominal frequencies is supported in STEPS for research of international interconnection. Application program interfaces are provided and wrapped with Python to enable high-level interfaces for general applications. STEPS is thread safe and parallel computation is supported in both kernel and script levels to accelerate simulation. It is portable and works on Windows and GNU/Linux platforms. Cases from small to large scale systems are thoroughly tested to validate the toolkit with commercial packages as benchmarks.

42 ENGINEERING↗

DOE OSTI2026

From the Great Wave of Translation to the Force between Quarks

Here, the chance observation of a novel traveling wave in a canal led over time to the formulation of a nonlinear wave equation—the Korteweg–de Vries equation—that describes strikingly robust disturbances now called solitons. The figure of an isolated soliton corresponds to a reflectionless potential that supports a single bound state in the one-dimensional Schrödinger equation. An appropriate combination of individual solitons yields a symmetric reflectionless potential that supports multiple bound states. Thus, the KdV equation opens the path to solving the inverse scattering problem for a collection of bound states. Applied to the quarkonium spectra, this formalism allows the construction of reflectionless approximations to the confining potentials that account for the force between quarks, and to tests of the flavor-independence of the interquark interaction.

Inverse Scattering↗

DOE OSTI2024

USPAS Digital Low-Level RF firmware and software suite (uspas_llrf) v1.0

The USPAS Digital Low-Level RF firmware and software suite was originally developed for the USPAS 2023 LLRF course, for demonstrating the close loop RF control on the BerkeleyLab Marble FPGA carrier and Zest digitizer platform in controlling the RF field for various accelerators. The suite features Register-transfer level (RTL) designs for the board-support layer, digital signal processing and verification test benches, system-on-chip architecture, and Experimental Physics and Industrial Control System (EPICS) support, utilizing a open-source tool chain.

Du, Qiang↗

DOE OSTI2021

Density of Next-Generation Caustic-Side Solvent Extraction Solvent

This report recommends the appropriate modifier concentration to employ in the Next Generation Solvent (NGS) to be used in the Salt Waste Processing Facility (SWPF) at the Savannah River Site for removal of cesium from legacy tank waste. The Next Generation Caustic-Side Solvent Extraction (NG-CSSX) process employing the NGS is a marked improvement over the original Caustic-Side Solvent Extraction (CSSX) process, as it provides more effective removal of cesium from highly alkaline radioactive wastes and concentrates this removed cesium into an aqueous solution that is easy to vitrify for final disposal. Considerable effort has been devoted to optimizing the chemistry and process conditions of both systems, and their effectiveness has been demonstrated at the pilot scale at the Modular CSSX Unit (MCU). Due to the success of the demonstration and pilot-scale tests, the Salt Waste Processing Facility (SWPF) has been built to process larger volumes of waste with the CSSX process. To accelerate the waste-processing rate of the SWPF beyond its design throughput, plans call for the replacement of the CSSX process by the NG-CSSX process. To implement the NG-CSSX process in equipment optimized for CSSX, adjusting the density of the NGS to match the CSSX solvent density of 0.851 ± 0.0008 g/mL is considered advisable to obtain comparable hydraulic performance. Toward this objective, the density of the NGS has been measured at different temperatures and modifier concentrations to determine that a concentration of 0.650 M Cs-7SB modifier provides the best match for the desired density.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

The Optics of Deterrence: How Science Assures the Nuclear Stockpile's Reliability In Lieu of Testing

When designing a product intended to perform a certain function and satisfy some set of criteria, the standard engineering method to assess its ability to perform is to test it. This nearly universal concept works consistently, assuring proper function and generally avoiding or mitigating the consequence of failure to within acceptable limits. What would happen if the product developers were told that they must continue to certify and validate the performance without testing it, that the landscape in which the product must serve its purpose is constantly evolving, and that the product in question is the United States’ nuclear weapons stockpile? This is the position the National Nuclear Security Administration (NNSA) finds itself in; the reliability of the stockpile must be verified without actually testing it to see if it works as intended.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Development and Performance of RFD Crab Cavity Prototypes for HL-LHC AUP

The US will be contributing to the HL-LHC upgrade at CERN with the fabrication and qualification of RFD crabbing cavities in the framework of the HL-LHC Accelerator Upgrade Project (AUP) managed by Fermilab. AUP received Critical Decision 3 (CD-3) approval by DOE in December 2020 launching the project into the production phase. The electro-magnetic design of the cavity was inherited from the LHC Accelerator Research Program (LARP) but needed to be revised to meet new project requirements and to prevent issues encountered during beam tests performed at CERN in the R&D phase. Two prototype cavities were manufactured in industry and cold tested. Challenges specific to the RFD cavity were the stringent interface tolerances, the pole symmetry, and the higher-order-mode impedance spectrum. Chemical pro-cessing and heat treatments were performed initially at FNAL/ANL and are now being transferred to industry for the production phase. HOM dampers are manufactured and validated by JLAB. A summary of cold test results with and without HOM dampers is presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Exploitation of Defects in High Entropy Ceramic Barrier Materials

A critical mission need exists to develop new materials that can withstand extreme environments and multiple sequential threats. High entropy materials, those containing 5 or more metals, exhibit many exciting properties which would potentially be useful in such situations. However, a particularly hard challenge in developing new high entropy materials is determining a priori which compositions will form the desired single phase material. The project outlined here combined several modeling and experimental techniques to explore several structure-property-relationships of high entropy ceramics in an effort to better understand the connection between their compositional components, their observed properties, and stability. We have developed novel machine learning algorithms which rapidly predict stable high entropy ceramic compositions, identified the stability interplay between configurational entropy and cation defects, and tested the mechanical stability of high entropy oxides using the unique capabilities at the Dynamic Compression Sector facility and the Saturn accelerator.

36 MATERIALS SCIENCE↗

DOE OSTI2023

ACT W-DED Mid-year report

Thus far in FY 23 the Sandia team has made accomplishments on several fronts. A major focus has been completing testing to compare small scale tensile properties found through high throughput tensile (HTT) tests to bulk tensile properties found through standard ASTM E8 test methods. These comparisons have been completed in previously manufactured wire arc additively manufactured (WAAM) Ti-6Al-4V material and electron beam additively manufactured (EBAM) Ti-6Al-4V material in the as built and heat-treated conditions. Figure 1 shows the distribution of both HTT and E8 test results indicating the distributions are not significantly different. This result gives confidence that HTT coupon geometries can be utilized for accelerated process development and optimization moving forward

36 MATERIALS SCIENCE↗

DOE OSTI2022

Performance Testing of a Moving Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Gasification of Mixed Blends of Coal, Biomass, and Plastic Waste

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗