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Developing a predictive model for the chemical composition of soot nanoparticles

In order to provide the scientific foundation to enable technology breakthroughs in transportation fuel, it is important to develop a combustion modeling capability to optimize the operation and design of evolving fuels in advanced engines for transportation applications. The goal of this proposal is to develop a validated predictive model to describe the chemical composition of soot nanoparticles in premixed and diffusion flames. Atomistic studies in conjunction with state-of-the-art experiments are the distinguishing characteristics of this unique interdisciplinary effort. The modeling effort has been conducted at the University of Michigan by Prof. A. Violi. The experimental work has entailed a series of studies using different techniques to analyze gas-phase soot precursor chemistry and soot particle production in premixed and diffusion flames. Measurements have provided spatial distributions of polycyclic aromatic hydrocarbons and other gas-phase species and size and composition of incipient soot nanoparticles for comparison with model results. The experimental team includes Dr. N. Hansen and H. Michelsen at Sandia National Labs' Combustion Research Facility, and Dr. K. Wilson as collaborator at Lawrence Berkeley National Lab's Advanced Light Source. Our results show that the chemical and physical properties of nanoparticles affect the coagulation behavior in soot formation, and our results on an experimentally validated, predictive model for the chemical composition of soot nanoparticles will not only enhance our understanding of soot formation since but will also allow the prediction of particle size distributions under combustion conditions. These results provide a novel description of soot formation based on physical and chemical properties of the particles for use in the next generation of soot models and an enhanced capability for facilitating the design of alternative fuels and the engines they will power.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Combustion energy frontier research center (CEFRC) final report (August 1, 2009 – July 31, 2016)

The Combustion Energy Frontier Research Center (CEFRC) was established to tackle the single overarching grand challenge of energy sustainability, energy security and global warming: to develop a “validated, predictive, multi-scale, combustion modeling capability to optimize the design and operation of evolving fuels in advanced engines for transportation applications,” as identified in the DOE report on “Basic Energy Needs for Clean and Efficient Combustion of 21st Century Transportation Fuels”. The challenge is particularly daunting since energy conversion efficiencies and exhaust emissions are governed by coupled chemical and transport processes at multiple length scales ranging from electron excitation to molecular rearrangements to nanoscale particulate formation to turbulent fuel/air mixing. To tackle this challenge, the CEFRC assembled a world-class team of 15 principal investigators, with the objectives to: 1) develop and test theoretical models to predict elementary reaction rates, molecule thermalization rates, chemical bond dissociation energies, and nonequilibrium transport properties using quantum chemistry calculations that account for strong electron correlation and multiple electronic potential energy surfaces; 2) develop automated kinetic mechanism generation, reduction, and error control methods for predicting alternative fuel including biofuel oxidation, fuel droplet decomposition, and NOx and particulate formation; 3) validate and improve the predictions of these models by measuring ignition delay times, species profiles, flame structures, burning limits, turbulence-kinetic coupling, and NOx and soot emissions at high-pressures and near-limit conditions, by using advanced experimental diagnostic techniques including multiple laser techniques, molecular beam sampling and synchrotron photoionization, and by conducting the measurements in high-pressure shock tubes, jet-stirred and flow reactors, flame bombs, counterflow flames, and advanced-design rapid compression ignition instruments; and 4) develop a suite of validated petascale high-fidelity simulation and modeling capabilities to understand and predict chemistry-turbulence-radiation coupling for new fuels in new regimes, including the high pressure, low-temperature combustion in advanced engine and turbine designs, and 5) establish a knowledge highway between researchers and engineers in academia, national laboratories, and industry to facilitate the dissemination and exchange of knowledge on national and international levels, and enrich the talent pool and capabilities of the next generation of combustion scientists and engineers. The technical activities of the CEFRC were conducted through three Disciplinary Working Groups – Chemistry Theory, Experiment and Mechanism, and Reacting Flows, which coordinated the Center’s research on the development of combustion chemistry of Foundation Fuels (C0–C4 hydrocarbons), Alcohols, and Biodiesel through three corresponding Mechanism Thrust Groups. Such a two-dimensional coordinated and tightly interwoven research structure has been proven to be highly effective in assuring the interplay between the developments of the fundamentals of combustion science and the utilization of the various categories of fuels. The Center has accomplished the above goals over the five year period (August 1, 2009 – July 31, 2014) with appropriated funding, followed by two additional no-cost-extension (NCE) years. The research results are documented in 230 journal publications, with six legacy review papers on the study of combustion chemistry using shock tubes, flow reactors, rapid compression machines, and flames, on uncertainty quantification, and on theoretical reaction dynamics and chemical modeling of combustion. A robust outreach program complemented these PI-led research activities, consisting of: 1) a roving post-doc program comprised of a corps of Center-appointed, co- or multi-sponsored post-doctoral fellows with rotating assignments to conduct seed projects initiated by at least two PIs, in residence with these sponsoring PIs, to rapidly pursue new and high-risk, high-payoff interdisciplinary ideas; 2) an annual summer school on combustion heavily attended (~200) by senior graduate students and practicing researchers covering advanced topics on chemical kinetics, fluid mechanics, turbulent combustion, engine combustion, new technologies, etc.; 3) a robust open web-site providing Center and community information as well as the lecture videos and notes of the summer school; and 4) widely distributed biannual newsletters.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Advanced Fluid Reduced Order Models for Compressible Flow.

This report summarizes fiscal year (FY) 2017 progress towards developing and implementing within the SPARC in-house finite volume flow solver advanced fluid reduced order models (ROMs) for compressible captive-carriage flow problems of interest to Sandia National Laboratories for the design and qualification of nuclear weapons components. The proposed projection-based model order reduction (MOR) approach, known as the Proper Orthogonal Decomposition (POD)/Least- Squares Petrov-Galerkin (LSPG) method, can substantially reduce the CPU-time requirement for these simulations, thereby enabling advanced analyses such as uncertainty quantification and de- sign optimization. Following a description of the project objectives and FY17 targets, we overview briefly the POD/LSPG approach to model reduction implemented within SPARC . We then study the viability of these ROMs for long-time predictive simulations in the context of a two-dimensional viscous laminar cavity problem, and describe some FY17 enhancements to the proposed model reduction methodology that led to ROMs with improved predictive capabilities. Also described in this report are some FY17 efforts pursued in parallel to the primary objective of determining whether the ROMs in SPARC are viable for the targeted application. These include the implemen- tation and verification of some higher-order finite volume discretization methods within SPARC (towards using the code to study the viability of ROMs on three-dimensional cavity problems) and a novel structure-preserving constrained POD/LSPG formulation that can improve the accuracy of projection-based reduced order models. We conclude the report by summarizing the key takeaways from our FY17 findings, and providing some perspectives for future work.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

ADMS State of the Industry and Gap Analysis

An Advanced distribution management system (ADMS) is a platform for optimized distribution system operational management. This platform comprises of distribution management system (DMS) applications, supervisory control and data acquisition (SCADA), outage management system (OMS), and distributed energy resource management system (DERMS). One of the primary objectives of this work is to study and analyze several ADMS component and auxiliary systems. All the important component and auxiliary systems, SCADA, GISs, DMSs, AMRs/AMIs, OMSs, and DERMS, are discussed in this report. Their current generation technologies are analyzed, and their integration (or evolution) with an ADMS technology is discussed. An ADMS technology state of the art and gap analysis is also presented. There are two technical gaps observed. The integration challenge between the component operational systems is the single largest challenge for ADMS design and deployment. Another significant challenge noted is concerning essential ADMS applications, for instance, fault location, isolation, and service restoration (FLISR), volt-var optimization (VVO), etc. There are a relatively small number of ADMS application developers as ADMS software platform is not open source. There is another critical gap and while not being technical in nature (when compared the two above) is still important to consider. The data models currently residing in utility GIS systems are either incomplete or inaccurate or both. This data is essential for planning and operations because it is typically one of the primary sources from which power system model are created. To achieve the full potential of ADMS, the ability to execute acute Power Flow solution is an important pre-requisite. These critical gaps are hindering wider Utility adoption of an ADMS technology. The development of an open architecture platform can eliminate many of these barriers and also aid seamless integration of distribution Utility legacy systems with an ADMS.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Crossroads Workflows

The Department of Energy (DOE) compute facilities operate as resources for the National Nuclear Security Administration (NNSA) and Office of Science. In this document we describe a subset of scientific work flows which are run on current platforms. There is significant commonality to how Los Alamos National Laboratory (LANL), Sandia National Laboratory (SNL), Lawrence Liver- more National Laboratory (LLNL) and the National Energy Research Scientific Computing Center (NERSC) operate and conduct scienti c inquiry with supercomputers. In addition to presenting the commonality between the sites, we believe that opportunities exist to significantly optimize the operation of our facilities and more rapidly advance our scientific goals. In describing how our scientific work flows move from inception to realization we believe that we can enable significant improvements in how computer architectures support real scientific work flows. Briefly, in order for a team of scientists to access the large supercomputers at these facilities, the team must be granted an allocation. Allocations last for a fixed amount of time (usually 6 or 12 months), and a large number of teams will have overlapping allocations ensuring that a large amount of work is available in the scheduling queue. During the allocation, the scientists will construct work flows as described in this document. Many simultaneous allocations may use identical work flows with different data and scientific goals.

97 MATHEMATICS AND COMPUTING↗

Research and Development for HI Intensity Mapping

Development of the hardware, data analysis, and simulation techniques for large compact radio arrays dedicated to mapping the 21 cm line of neutral hydrogen gas has proven to be more difficult than imagined twenty years ago when such telescopes were first proposed. Despite tremendous technical and methodological advances, there are several outstanding questions on how to optimally calibrate and analyze such data. On the positive side, it has become clear that the outstanding issues are purely technical in nature and can be solved with sufficient development activity. Such activity will enable science across redshifts, from early galaxy evolution in the pre-reionization era to dark energy evolution at low redshift.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Cooperative Research and Development Agreement between National Energy Technology Laboratory and The Pennsylvania State University (Final Report)

This project will use bipolar membranes to produce efficient vapor-phase electrolysis cells for splitting CO 2 to CO and oxygen. CO is a valuable chemical feedstock that can be combined catalytically with hydrogen in the Fischer-Tropsch process to make liquid fuels. CO is arguably the best target for CO 2 reduction since, as a gaseous product, it is easily collected and is relatively immune to membrane crossover losses. The keys to success in this project are to design and synthesize hydrophilic, low resistance bipolar membranes and to create optimized electrode/catalyst/electrolyte architectures based on these new membranes and advanced catalysts in order to achieve high current density at low overpotentials for CO 2 conversion. High current density is key to achieving industrially relevant throughput for the process and low overpotentials maintain high overall efficiency for the process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Advanced Data Preparation Module for Metals Additive Manufacturing

The Mission: Provide the LLNL metals additive manufacturing (AM) team with an advanced AM data preparation module that will analyze and optimize build parameters for metal AM parts fabricated in a laser powder bed fusion (LPBF) system in order increase the first pass success ratio.

42 ENGINEERING↗

Biopolymer Concrete

Cement production for concrete has been responsible for ~7–8% of global greenhouse gas (GHG) emissions, and nearly equally contribution for steel production processes (EPA, 2020). In order to achieve carbon neutrality by 2050, a novel solution has to be investigated. This project aims to develop fundamental mechanistic understanding and experimental characterization to create a 3D printable biopolymer concrete using plant-based polyurethane as an innovative and sustainable alternative for Portland cement concrete, with significantly low carbon footprint. Future construction will utilize the advances in digital additive manufacturing (3D printing) to produce optimal geometries with a minimum waste of materials. Understanding the polymerization process, factors impacting the composite rheology, and the structural behavior of this biopolymer concrete will enable us to engineer the next generation of concrete structures with low carbon footprint. This project aims to improve the nation’s ability to control Greenhouse Gas emission neutrality for the set goal of 2050 via introducing a structurally viable bio-based polymer concrete.

42 ENGINEERING↗

Model Predictive Control of the Exit Part Temperature for an Austenitization Furnace

Quench hardening is the process of strengthening and hardening ferrous metals and alloys by heating the material to a specific temperature to form austenite (austenitization), followed by rapid cooling (quenching) in water, brine or oil to introduce a hardened phase called martensite. The material is then often tempered to increase toughness, as it may decrease from the quench hardening process. The austenitization process is highly energy-intensive and many of the industrial austenitization furnaces were built and equipped prior to the advent of advanced control strategies and thus use large, sub-optimal amounts of energy. The model computes the energy usage of the furnace and the part temperature profile as a function of time and position within the furnace under temperature feedback control. In this paper, the aforementioned model is used to simulate the furnace for a batch of forty parts under heuristic temperature set points suggested by the operators of the plant. A model predictive control (MPC) system is then developed and deployed to control the the part temperature at the furnace exit thereby preventing the parts from overheating. An energy efficiency gain of 5.3% was obtained under model predictive control compared to operation under heuristic temperature set points tracked by a regulatory control layer.

36 MATERIALS SCIENCE↗

Digital Twin Applications in the Water Sector: A Review

As cities develop and resource demands rise, the water sector faces crucial challenges to deliver reliable, sustainable, and efficient services. Digital Twins (DTs), virtual replicas of physical systems, offer a promising tool to transform how we manage water infrastructure. Originally developed in the aerospace industry, DTs are now gaining traction in the water sector, enabling real-time monitoring, simulation, and predictive control of water and wastewater treatment, collection and distribution networks, and water reclamation and reuse systems. While still emerging in the water sector, DTs have shown potential to enhance operational efficiency, reduce environmental impacts, and support smarter, more resilient water management. This review study provides a comprehensive overview of current DT applications in the water sector, highlighting successful case studies, technical challenges, and knowledge gaps. It also explores how DTs can help bridge the water–energy nexus by optimizing resources utilized across interconnected systems. By synthesizing recent advances and identifying future research directions, this paper illustrates how DTs can play a central role in building sustainable, adaptive, and digitally-enabled water infrastructure.

digital twin↗

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗

Analysis of potential helicopter vibration reduction concepts

Several recent helicopter vibration reduction research programs are described. Results of studies of blade design parameters in rotor vibratory response and of an advanced blade design for reduced vibration are examined. An optimization approach to develop a general automated procedure for rotor blade design is described, and analytical results for an articulated rotor operating at a steady 160 kt flight condition are reported. The use of a self-adaptive controller to implement higher harmonic control in closed-loop fashion is addressed, and a computer simulation used to evaluate and compare the performance of alternative algorithms included in the generic active controller is discussed. Results are presented for steady level flight conditions, short-duration maneuvers, blade stresses and rotor performance, blade-appended aeroelastic devices, vibratory airloads, wake-induced blade airloads, and airloads from blade motions, the interaction of rotor and fuselage, and the interaction of rotor and empennage.

Landgrebe, A. J.↗

Improving turbine blade fatigue life

Turbine airfoil design, materials, and cooling system management are variables which, when optimized, can contribute to longer turbine component lives. These advancements have been identified as redesign techniques to improve the turbine fatigue life of the SSME High Pressure Fuel Turbopump. This paper discusses the general program approach toward improving turbine fatigue life.

Buddenbohm, H. W.↗

Supercomputer optimizations for stochastic optimal control applications

Supercomputer optimizations for a computational method of solving stochastic, multibody, dynamic programming problems are presented. The computational method is valid for a general class of optimal control problems that are nonlinear, multibody dynamical systems, perturbed by general Markov noise in continuous time, i.e., nonsmooth Gaussian as well as jump Poisson random white noise. Optimization techniques for vector multiprocessors or vectorizing supercomputers include advanced data structures, loop restructuring, loop collapsing, blocking, and compiler directives. These advanced computing techniques and superconducting hardware help alleviate Bellman's curse of dimensionality in dynamic programming computations, by permitting the solution of large multibody problems. Possible applications include lumped flight dynamics models for uncertain environments, such as large scale and background random aerospace fluctuations.

Chung, Siu-Leung↗

S3D: An interactive surface grid generation tool

S3D, an interactive software tool for surface grid generation, is described. S3D provides the means with which a geometry definition based either on a discretized curve set or a rectangular set can be quickly processed towards the generation of a surface grid for computational fluid dynamics (CFD) applications. This is made possible as a result of implementing commonly encountered surface gridding tasks in an environment with a highly efficient and user friendly graphical interface. Some of the more advanced features of S3D include surface-surface intersections, optimized surface domain decomposition and recomposition, and automated propagation of edge distributions to surrounding grids.

Luh, Raymond Ching-Chung↗

Nondestructive evaluation of ceramic and metal matrix composites for NASA's HITEMP and enabling propulsion materials programs

In a preliminary study, ultrasonic, x-ray opaque, and fluorescent dye penetrants techniques were used to evaluate and characterize ceramic and metal matrix composites. Techniques are highlighted for identifying porosity, fiber alignment, fiber uniformity, matrix cracks, fiber fractures, unbonds or disbonds between laminae, and fiber-to-matrix bond variations. The nondestructive evaluations (NDE) were performed during processing and after thermomechanical testing. Specific examples are given for Si3N4/SiC (SCS-6 fiber), FeCrAlY/Al2O3 fibers, Ti-15-3/SiC (SCS-6 fiber) materials, and Si3N4/SiC (SCS-6 fiber) actively cooled panel components. Results of this study indicate that the choice of the NDE tools to be used can be optimized to yield a faithful and accurate evaluation of advanced composites.

Generazio, Edward R.↗

Overview of Current Turbine Aerodynamic Analysis and Testing at MSFC

An overview of the current turbine aerodynamic analysis and testing activities at NASA/Marshall Space Flight Center (MSFC) is presented. The presentation is divided into three areas. The first area is the three-dimensional (3D), unsteady Computational Fluid Dynamics (CFD) analysis of the Fastrac turbine. Results from a coupled nozzle, blade, and exit guide vane analysis and from an uncoupled nozzle and coupled blade and exit guide vane will be presented. Unsteady pressure distributions, frequencies, and exit profiles from each analysis will be compared and contrasted. The second area is the testing and analysis of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine with instrumented first stage blades. The SSME HPFTP turbine was tested in air at the MSFC Turbine Test Equipment (TTE). Pressure transducers were mounted on the first stage blades. Unsteady, 3D CFD analysis was performed for this geometry and flow conditions. A sampling of the results will be shown. The third area is a status of the Turbine Performance Optimization task. The objective of this task is to improve the efficiency of a turbine for potential use on a next generation launch vehicle. This task includes global optimization for the preliminary design, detailed optimization for blade shapes and spacing, and application of advanced CFD analysis. The final design will be tested in the MSFC TTE.

Griffin, Lisa W.↗