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DOE OSTI2022

Optimal Portfolio Design of Distributed Energy Resources on Puerto Rico Distribution Feeders with Long Outages after Hurricane Maria

This work details a project to design reliable, resilient, and cost-effective networked microgrids considering grid constraints and resilience metrics focused on Puerto Rico distribution feeder locations with long outages after Hurricane Maria. The project consisted primarily of modeling and simulation tasks that accomplished the following objectives: 1. Selected 10 distribution feeder models in vulnerable areas. The sample feeders are geographically distributed across Puerto Rico and vary in length to capture the wide variety of feeders on the island. 2. Determined the optimal location and sizing of distributed energy resources (DERs) on the identified distribution feeders. The systems considered as part of the microgrid solutions were solar photovoltaic (PV), battery energy storage systems (BESS) and distributed fossil fuel generation (DFFG). 3. Estimated the cost-benefit of the proposed DER portfolios. 4. Provided a set of final recommendations that inform decision making on how to do targeted planning analysis for microgrids that can supply energy to critical infrastructures.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1996

Development of Multiobjective Optimization Techniques for Sonic Boom Minimization

A discrete, semi-analytical sensitivity analysis procedure has been developed for calculating aerodynamic design sensitivities. The sensitivities of the flow variables and the grid coordinates are numerically calculated using direct differentiation of the respective discretized governing equations. The sensitivity analysis techniques are adapted within a parabolized Navier Stokes equations solver. Aerodynamic design sensitivities for high speed wing-body configurations are calculated using the semi-analytical sensitivity analysis procedures. Representative results obtained compare well with those obtained using the finite difference approach and establish the computational efficiency and accuracy of the semi-analytical procedures. Multidisciplinary design optimization procedures have been developed for aerospace applications namely, gas turbine blades and high speed wing-body configurations. In complex applications, the coupled optimization problems are decomposed into sublevels using multilevel decomposition techniques. In cases with multiple objective functions, formal multiobjective formulation such as the Kreisselmeier-Steinhauser function approach and the modified global criteria approach have been used. Nonlinear programming techniques for continuous design variables and a hybrid optimization technique, based on a simulated annealing algorithm, for discrete design variables have been used for solving the optimization problems. The optimization procedure for gas turbine blades improves the aerodynamic and heat transfer characteristics of the blades. The two-dimensional, blade-to-blade aerodynamic analysis is performed using a panel code. The blade heat transfer analysis is performed using an in-house developed finite element procedure. The optimization procedure yields blade shapes with significantly improved velocity and temperature distributions. The multidisciplinary design optimization procedures for high speed wing-body configurations simultaneously improve the aerodynamic, the sonic boom and the structural characteristics of the aircraft. The flow solution is obtained using a comprehensive parabolized Navier Stokes solver. Sonic boom analysis is performed using an extrapolation procedure. The aircraft wing load carrying member is modeled as either an isotropic or a composite box beam. The isotropic box beam is analyzed using thin wall theory. The composite box beam is analyzed using a finite element procedure. The developed optimization procedures yield significant improvements in all the performance criteria and provide interesting design trade-offs. The semi-analytical sensitivity analysis techniques offer significant computational savings and allow the use of comprehensive analysis procedures within design optimization studies.

Chattopadhyay, Aditi↗

NASA NTRS2017

Reconfigurable Model Execution in the OpenMDAO Framework

NASA's OpenMDAO framework facilitates constructing complex models and computing their derivatives for multidisciplinary design optimization. Decomposing a model into components that follow a prescribed interface enables OpenMDAO to assemble multidisciplinary derivatives from the component derivatives using what amounts to the adjoint method, direct method, chain rule, global sensitivity equations, or any combination thereof, using the MAUD architecture. OpenMDAO also handles the distribution of processors among the disciplines by hierarchically grouping the components, and it automates the data transfer between components that are on different processors. These features have made OpenMDAO useful for applications in aircraft design, satellite design, wind turbine design, and aircraft engine design, among others. This paper presents new algorithms for OpenMDAO that enable reconfigurable model execution. This concept refers to dynamically changing, during execution, one or more of: the variable sizes, solution algorithm, parallel load balancing, or set of variables-i.e., adding and removing components, perhaps to switch to a higher-fidelity sub-model. Any component can reconfigure at any point, even when running in parallel with other components, and the reconfiguration algorithm presented here performs the synchronized updates to all other components that are affected. A reconfigurable software framework for multidisciplinary design optimization enables new adaptive solvers, adaptive parallelization, and new applications such as gradient-based optimization with overset flow solvers and adaptive mesh refinement. Benchmarking results demonstrate the time savings for reconfiguration compared to setting up the model again from scratch, which can be significant in large-scale problems. Additionally, the new reconfigurability feature is applied to a mission profile optimization problem for commercial aircraft where both the parametrization of the mission profile and the time discretization are adaptively refined, resulting in computational savings of roughly 10% and the elimination of oscillations in the optimized altitude profile.

Hwang, John T.↗

DOE OSTI2026

An information-matching approach to optimal experimental design and active learning

The efficacy of mathematical models heavily depends on the quality of the training data, yet collecting sufficient data is often expensive and challenging. Many modeling applications require inferring parameters only as a means to predict other quantities of interest (QoI). Because models often contain many unidentifiable (sloppy) parameters, QoIs often depend on a relatively small number of parameter combinations. Therefore, we introduce an information-matching criterion based on the Fisher information matrix to select the most informative training data from a candidate pool. This method ensures that the selected data contain sufficient information to learn only those parameters that are needed to constrain downstream QoIs. It is formulated as a convex optimization problem, making it scalable to large models and datasets. Here, we demonstrate the effectiveness of this approach across various modeling problems in diverse scientific fields, including power systems and underwater acoustics. Finally, we use information-matching as a query function within an active learning (AL) loop for materials science applications. In all these applications, we find that a relatively small set of optimal training data can provide the necessary information for achieving precise predictions. These results are encouraging for diverse future applications, particularly AL in large machine-learning models.

Materials science↗

DOE OSTI2023

DESIGN AND OPTIMIZATION OF AN ERL FOR COOLING EIC HADRON BEAMS

The baseline scheme for hadron beam cooling in the Electron Ion Collider (EIC) calls for Coherent electron Cooling (CeC) of the hadrons with non-magnetized electrons at high energy (150 MeV electrons) and additional cooling via conventional bunched beam cooling using a precooler system. The electron beam parameters for these concepts are at or beyond the current state of the art, with electron bunch charges on the order of 1 nC and average currents on the order of 100 mA and requiring an Energy Recovery Linac (ERL) to produce such beams. Using specifications provided by BNL and JLab, physicists and engineers at Xelera Research are working on a complete design of an ERL system capable of cooling EIC hadrons.

Gulliford, C.↗

NASA NTRS1991

Thermal design of a Mars oxygen production plant

The optimal design of the thermal components of a system that uses carbon dioxide from the Martian atmosphere to produce oxygen for spacecraft propulsion and/or life support is discussed. The gases are pressurized, heated and passed through an electrochemical cell. Carbon dioxide is reduced to carbon monoxide and oxygen due to thermal dissociation and electrocatalysis. The oxygen thus formed is separated from the gas mixture by the electrochemical cell. The objective of the design is to optimize both the overall mass and the power consumption of the system. The analysis shows that at electrochemical cell efficiencies of about 50 percent and lower, the optimal system would require unspent carbon dioxide in the exhaust gases to be separated and recycled. Various methods of efficiently compressing the intake gases to system pressures of 0.1 MPa are investigated. The total power requirement for oxygen production rates of 1, 5, and 10 kg/day at various cell efficiencies are presented.

Sridhar, K. R.↗

DOE OSTI2017

Moderator Demonstration Facility Design and Optimization

The Spallation Neutron Source (SNS) facility at Oak Ridge National Laboratory (ORNL) is implementing a Moderator Demonstration Facility (MDF) to demonstrate the performance characteristics of advanced moderators central to the Second Target Station (STS) for SNS. The MDF will use the "spare" front-end installation within the SNS accelerator support complex – an ion source, radio-frequency quadrupole (RFQ) accelerator, and medium-energy beam transport (MEBT) chopper - to provide a 2.5 MeV proton beam of peak current 50 mA and maximum pulse length of less than 10 s at a repetition rate of no more than 60 Hz to a suitable neutron-producing target to demonstrate those aspects of moderator performance necessary to meet the goals of the STS design e ort. The accelerator beam parameters are not open to variation beyond that described above - they are fixed by the nature of the spare front-end installation (the Integrated Test Stand Facility; ITSF). Accordingly, there are some neutronic challenges in developing prototypic moderator illumination from a very non-prototypic primary neutron source; the spallation source we are attempting to mimic has an extended neutron source volume approximately 40 cm long (in the direction of the proton beam), approximately 10 cm wide (horizontally transverse to the proton beam) and approximately 5 cm high (vertically transverse to the proton beam), and an isotropic evaporation energy spectrum with mean energy above 1 MeV. In contrast, the primary neutron source available from the 7Li(p,n) reaction (the most prolific at 2.5 MeV proton energy by more than an order of magnitude) is strongly anisotropic, with an energy spectrum that is both strongly dependent on emission angle and kinematically limited to less than 700 keV, and the interaction zone between the incident protons and any target material (neutron-producing or not) is intrinsically limited to a few tens of microns. The MDF will be unique and innovative amongst the world’s moderator test facilities in that it will be intended to be very prototypic in terms of "moderator illumination" - the spatial variation of the neutron flux entering the moderator itself - as well as capable of testing so-called high-brightness moderators in a wing configuration.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Recent progress in the design of the K-DEMO divertor

The preliminary conceptual design of the Korean fusion demonstration reactor (K-DEMO) with a major radius of 6.8 m and the fusion power of 2200 MW has been studied since 2012. The overall configuration of the K-DEMO divetor system based on the ITER-like water-cooled tungsten technology is a double-null type symmetric divertor subdivided into 32 toroidal modules for the vertical maintenance. A detached divertor scenario with impurity seeding was considered as the primary approach for the power exhaust to reduce the peak heat flux lower than the engineering limit of 10 MW/m 2 . The power exhaust performance at the scrap off layer was estimated by using UEDGE-2D code, a two-dimensional fluid transport code for collisional edge plasma and neutral species like N, Ne, and Ar. Particle and heat flux on inboard and outboard divertor targets were calculated for the detached cased depending on parameters such as the impurity seeding rate, pumping rate, and the pedestal density. On the other hand, a magnetic solution like X-divertor, snowflake divertor, and super X-divertor to expand the plasma wet area was considered for K-DEMO since the detached divertor increasing a radiation fraction by impurity seeding might be able to be unstable. However, the extremely high current of poloidal coils was required more than the engineering limit, 20 MA, to form magnetic field lines for the alternative divertors. Based on the physical calculation of the edge plasma, engineering analyses were carried out to find out the thermal and structural reliability. The thermo-hydraulic analysis confirmed thermal stability, whether all comprising materials are operating within their allowable temperature windows when the case of the peak heat flux is set to 10 MW/m 2 on the outboard divertor target. The response surface optimization method derived two optimal design candidates employing two kinds of heat sink materials, respectively: the reduced activation ferritic martensitic (RAFM) steel and CuCrZr alloy. Additionally, the drawbacks and merits of the two materials were definite. The optimal design with applying RAFM steel was vulnerable to withstand thermal and mechanical loads since low thermal conductivity caused too thin thickness of the heat sink. On the other hand, the CuCrZr alloy has critical drawbacks in terms of activation and radioactive waste despite its high thermal conductivity. Meanwhile, preliminary electromagnetic (EM) analysis was carried out to estimate the EM loads caused by the abnormal behaviors of plasma since EM loads are one of the most critical external loads for designing a DEMO divertor.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2005

Towards Rocket Engine Components with Increased Strength and Robust Operating Characteristics

High-energy rotating machines, powering liquid propellant rocket engines, are subject to various sources of high and low cycle fatigue generated by unsteady flow phenomena. Given the tremendous need for reliability in a sustainable space exploration program, a fundamental change in the design methodology for engine components is required for both launch and space based systems. A design optimization system based on neural-networks has been applied and demonstrated in the redesign of the Space Shuttle Main Engine (SSME) Low Pressure Oxidizer Turbo Pump (LPOTP) turbine nozzle. One objective of the redesign effort was to increase airfoil thickness and thus increase its strength while at the same time detuning the vane natural frequency modes from the vortex shedding frequency. The second objective was to reduce the vortex shedding amplitude. The third objective was to maintain this low shedding amplitude even in the presence of large manufacturing tolerances. All of these objectives were achieved without generating any detrimental effects on the downstream flow through the turbine, and without introducing any penalty in performance. The airfoil redesign and preliminary assessment was performed in the Exploration Technology Directorate at NASA ARC. Boeing/Rocketdyne and NASA MSFC independently performed final CFD assessments of the design. Four different CFD codes were used in this process. They include WIL DCA T/CORSAIR (NASA), FLUENT (commercial), TIDAL (Boeing Rocketdyne) and, a new family (AardvarWPhantom) of CFD analysis codes developed at NASA MSFC employing LOX fluid properties and a Generalized Equation Set formulation. Extensive aerodynamic performance analysis and stress analysis carried out at Boeing Rocketdyne and NASA MSFC indicate that the redesign objectives have been fully met. The paper presents the results of the assessment analysis and discusses the future potential of robust optimal design for rocket engine components.

Marcu, Bogdan↗

DOE OSTI2016

Structural design and optimization of near-ultraviolet light-emitting diodes with wide wells

The characteristics of the near-ultraviolet (NUV) light-emitting diodes (LEDs) with wide (14-nm-thick) and narrow (2-nm-thick) wells under the situations of different numbers of wells and degree of polarization are systematically investigated. The simulation results show that the Auger recombination can be efficiently suppressed with the increase of number of wells in NUV LEDs. For the LEDs with wide wells, the quantum-confined Stark effect and Shockley–Read–Hall recombination play an important role when the number of wells increases, especially when the LED is under low current injection or high degree of polarization. In order to take the advantage of using wide wells, it is proposed that the quaternary Al{sub 0.1}In{sub 0.05}Ga{sub 0.85}N barriers be used in wide-well NUV LEDs along with the use of Al{sub 0.3}Ga{sub 0.7}N/Al{sub 0.1}Ga{sub 0.9}N superlattice electron-blocking layer to mitigate the polarization effect and electron overflow. With this band-engineering structural design, the optical performance of the wide-well NUV LEDs is much better than its thin-well counterpart even under the situation of high degree of polarization.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

ASCR Workshop on In Situ Data Management: Enabling Scientific Discovery from Diverse Data Sources

In January 2019, the U.S. Department of Energy, Office of Science program in Advanced Scientific Computing Research, convened a workshop to identify priority research directions for in situ data management (ISDM). The workshop defined ISDM as the practices, capabilities, and procedures to control the organization of data and enable the coordination and communication among heterogeneous tasks, executing simultaneously in a high-performance computing system, cooperating toward a common objective. The workshop revealed two primary, interdependent motivations for processing and managing data in situ. The first motivation is that the in situ methodology enables scientific discovery from a broad range of data sources over a wide scale of computing platforms: leadership-class systems, clusters, clouds, workstations, and embedded devices at the edge. The successful development of ISDM capabilities will benefit real-time decision-making, design optimization, and data-driven scientific discovery. The second motivation is the need to decrease data volumes. ISDM can make critical contributions to managing large data volumes from computations and experiments to minimize data movement, save storage space, and boost resource efficiency, often while simultaneously increasing scientific precision. A fundamental finding of this workshop is that the methodologies used to manage data among a variety of tasks in situ can be used to facilitate scientific discovery from many different data sources—simulation, experiment, and sensors, for example—and that being able to do so at numerous computing scales will benefit real-time decision-making, design optimization, and data-driven scientific discovery across the Office of Science mission space. Applications wanting to use the in situ capabilities include those where data analysis feeds back to the simulation, decisions are made autonomously, big data or machine learning is among the tasks to be coordinated, and computations need to be completed in real time. The workshop identified six priority research directions that highlight the components and capabilities needed for ISDM to be successful for the wide variety of applications discussed: making ISDM capabilities more pervasive, controllable, composable, and transparent, with a focus on greater coordination with the software stack and a diversity of fundamentally new data algorithms.

97 MATHEMATICS AND COMPUTING↗

NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive Manufacturing↗

DOE OSTI2024

Comparative study of machine learning techniques for post-combustion carbon capture systems

Computational analysis of countercurrent flows in packed absorption columns, often used in solvent-based post-combustion carbon capture systems (CCSs), is challenging. Typically, computational fluid dynamics (CFD) approaches are used to simulate the interactions between a solvent, gas, and column's packing geometry while accounting for the thermodynamics, kinetics, heat, and mass transfer effects of the absorption process. These simulations can then be used explain a column's hydrodynamic characteristics and evaluate its CO 2 -capture efficiency. However, these approaches are computationally expensive, making it difficult to evaluate numerous designs and operating conditions to improve efficiency at industrial scales. In this work, we comprehensively explore the application of statistical ML methods, convolutional neural networks (CNNs), and graph neural networks (GNNs) to aid and accelerate the scale-up and design optimization of solvent-based post-combustion CCSs. We apply these methods to CFD datasets of countercurrent flows in absorption columns with structured packings characterized by several geometric parameters. We train models to use these parameters, inlet velocity conditions, and other model-specific representations of the column to estimate key determinants of CO 2 -capture efficiency without having to simulate additional CFD datasets. We also evaluate the impact of different input types on the accuracy and generalizability of each model. We discuss the strengths and limitations of each approach to further elucidate the role of CNNs, GNNs, and other machine learning approaches for CO 2 -capture property prediction and design optimization.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1987

Integrated analysis and applications

A select overview is provided of ongoing research focusing on the development and verification of integrated structural analysis and optimal design capabilities for advanced aerospace propulsion and power systems. Subjects discussed include the following: (1) Composites - analytical models (composite mechanics), integrated computational methods, and characterization of composite structural response and durability for resin-, metal-, and ceramic-matrix systems; (2) Advanced inelastic analysis - algorithm/numerical methods for more accurate and efficient analysis; (3) Constitutive modeling - theoretical formulation and characterization of thermoviscoplastic material behavior; (4) Computational simulation - engine structures from components to assembly, and up to an entire engine system subjected to simulated test-stand and mission load histories; (5) Probabilistic structural analysis - quantification of the effects of uncertainty in geometry, material, loads, and boundary conditions on structural response for true reliability assessment; and (6) Interdisciplinary optimization - incorporation of mathematical optimization and multidisciplinary analyses to provide streamlined, autonomous optimal design systems.

Hopkins, Dale A.↗

DOE OSTI2013

Device Architecture Simplification of Laser Pattering in High-Volume Crystalline Silicon Solar Cell Fabrication using Intensive Computation for Design and Optimization

Prices of Si based solar modules have been continuously declining in recent years. Goodrich is pointing out that a significant portion of these cost reductions have come about due to ‘economies of scale’ benefits, but there is a point of diminishing returns when trying to lower cost by simply expanding production capacity. Developing innovative high volume production technologies resulting in an increase of conversion efficiency without adding significant production cost will be necessary to continue the projected cost reductions. The Foundational Program to Advance Cell Efficiency (FPACE) is seeking to achieve this by closing the PV efficiency gap between theoretical achievable maximum conversion efficiency - 29% for c-Si - and the current typical production - 18.5% for a typical full area back contact c-Si Solar cell – while targeting a module cost of $0.50/Watt . The research conducted by SolarWorldUSA and it’s partners within the FPACE framework focused on the development of a Hybrid metal-wrap-through (MWT) and laser-ablated PERC solar cell design employing a extrusion metallization scheme to achieve >20% efficient devices. The project team was able to simulate, develop and demonstrate the technologies necessary to build p-type MWT PERC cells with extruded front contacts. Conversion efficiencies approaching 20% were demonstrated and a path for further efficiency improvements identified. A detailed cost of ownership calculation for such a device was based on a NREL cost model and is predicting a $/Watt cost below 85 cents on a 180 micron substrate.

14 SOLAR ENERGY↗

DOE OSTI2012

Neutronic optimization in high conversion Th-{sup 233}U fuel assembly with simulated annealing

This paper reports on fuel design optimization of a PWR operating in a self sustainable Th-{sup 233}U fuel cycle. Monte Carlo simulated annealing method was used in order to identify the fuel assembly configuration with the most attractive breeding performance. In previous studies, it was shown that breeding may be achieved by employing heterogeneous Seed-Blanket fuel geometry. The arrangement of seed and blanket pins within the assemblies may be determined by varying the designed parameters based on basic reactor physics phenomena which affect breeding. However, the amount of free parameters may still prove to be prohibitively large in order to systematically explore the design space for optimal solution. Therefore, the Monte Carlo annealing algorithm for neutronic optimization is applied in order to identify the most favorable design. The objective of simulated annealing optimization is to find a set of design parameters, which maximizes some given performance function (such as relative period of net breeding) under specified constraints (such as fuel cycle length). The first objective of the study was to demonstrate that the simulated annealing optimization algorithm will lead to the same fuel pins arrangement as was obtained in the previous studies which used only basic physics phenomena as guidance for optimization. In the second part of this work, the simulated annealing method was used to optimize fuel pins arrangement in much larger fuel assembly, where the basic physics intuition does not yield clearly optimal configuration. The simulated annealing method was found to be very efficient in selecting the optimal design in both cases. In the future, this method will be used for optimization of fuel assembly design with larger number of free parameters in order to determine the most favorable trade-off between the breeding performance and core average power density. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1982

The use of optimization techniques to design controlled diffusion compressor blading

A method for automating compressor blade design using numerical optimization, and applied to the design of a controlled diffusion stator blade row is presented. A general purpose optimization procedure is employed, based on conjugate directions for locally unconstrained problems and on feasible directions for locally constrained problems. Coupled to the optimizer is an analysis package consisting of three analysis programs which calculate blade geometry, inviscid flow, and blade surface boundary layers. The optimizing concepts and selection of design objective and constraints are described. The procedure for automating the design of a two dimensional blade section is discussed, and design results are presented.

Sanger, N. L.↗