SEARCH · Engineering Papers

Results for “control framework”

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 1,531 records · Page 85

All sources NASA NTRS DOE OSTI

DOE OSTI2020

Advances in Uncertainty and Sensitivity Analysis Methods and Applications in GDSA Framework.

The Spent Fuel and Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Fuel Cycle Technology (FCT) is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). Two high priorities for SFWST disposal R&D are design concept development and disposal system modeling. These priorities are directly addressed in the SFWST ''Geologic Disposal Safety Assessment'' (GDSA) control account, which is charged with developing a geologic repository system modeling and analysis capability, and the associated software, ''GDSA Framework'', for evaluating disposal system performance for nuclear waste in geologic media. ''GDSA Framework'' is supported by SFWST Campaign and its predecessor the Used Fuel Disposition (UFD) campaign. This report fulfills the GDSA Uncertainty and Sensitivity Analysis Methods work package (SF-20SN01030403) level 3 milestone — ''Advances in Uncertainty and Sensitivity Analysis Methods and Applications in GDSA Framework'' (M3SF-20SN010304032). It presents high level objectives and strategy for development of uncertainty and sensitivity analysis tools, demonstrates uncertainty quantification (UQ) and sensitivity analysis (SA) tools in GDSA Framework in FY20, and describes additional UQ/SA tools whose future implementation would enhance the UQ/SA capability of ''GDSA Framework''. This work was closely coordinated with the other Sandia National Laboratory GDSA work packages: the GDSA Framework Development work package (SF- 2051\101030404), the GDSA Repository Systems Analysis work package (SF-2051\101030405), and the GDSA PFLOTRAN Development work package (SF-20SN01030406). This report builds on developments reported in previous ''GDSA Framework'' milestones, particularly M2SF- 19SNO1030403.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Progress on Optimizing Wind Farms and Rotor Designs Using Adjoints

Modern wind plants are increasingly tasked with multiple performance objectives. In addition to designing plants that maximize power output and minimize the levelized cost of energy (LCOE), the design and operation of wind plants is increasingly influenced by challenges regarding grid integration of variable generation renewables. This places a growing emphasis on making wind plants more controllable and predictable. WindSE is a Reynolds-averaged Navier-Stokes (RANS) model designed around analytical gradient and adjoint methods, with the ability to capture terrain-induced effects, as shown in Figure 1. The recent addition of an unsteady solver with an actuator line method (ALM) and ongoing work to enable massively parallel optimizations gives it a unique niche to explore coupled plant-level controls and design problems. This code is an open source python package built on the FEniCS framework that utilizes fast, parallel PETSc solvers to model fluid flow throughout wind-farm scale domains. Two recent studies performed using WindSE demonstrate the capability to optimize under a wide variety of flow conditions and objective functions. In the first, we present an optimization focused on modifying the layout of a wind farm with a fixed number of turbines for maximum total power output [1]. This study highlights the ability to quickly perform simulations using the steady Navier-Stokes solver combined with rotors represented as actuator disks while also stressing the importance of capturing terrain-induced effects. Gradient-based optimization using the RANS equations is viable due to the inclusion of efficiently computed adjoint derivatives. We interpret the physical results of the optimal layout and also discuss the computational cost of scaling to larger problems. In the second study, we present the capabilities of the unsteady Navier-Stokes solver, where rotor-blade profiles represented by actuator lines are optimized to enhance wake steering effects and overall power production [2]. We quantify the wind plant performance gains obtained from this type of simultaneous control co-design optimization as compared to optimizing the blade design and yaw independently. Figure 2 shows the differences between a baseline two-turbine system and an optimized system where we fine-tune the blade chord profile. Results and challenges from each study are quickly summarized and used to motivate the current development efforts within WindSE. Current and future work is focused on enabling higher-resolution studies with more degrees of freedom through parallelization of both the simulation and optimization algorithms. We present benchmarking results to show that WindSE performs well in both weak- and strong-scaling tests and further demonstrate that the optimizer obtains the same convergence rates in both shared- and distributed-memory environments. Using larger wind farms, we can study deep-array effects within an optimization context, allowing the use of objective functions that have been previously unstudied. As an example, we present ongoing work on a blockage metric which characterizes the loss of available kinetic energy due to wake effects from multiple upstream turbines.

adjoint optimization↗

NASA NTRSDate not supplied

Developing a Cybersecurity Architecture for Extensible Traffic Management (xTM)

This paper explores the development of a cybersecurity architecture tailored for Extensible Traffic Management (xTM) to address emerging challenges in managing diverse aerial vehicles within the National Airspace System (NAS). Driven by technological advances and the rise of uncrewed aerial systems (UAS), urban air mobility (UAM), and high-altitude traffic (ETM), the NAS is undergoing a paradigm shift. Traditional air traffic management, reliant on traditional Federal Aviation Administration (FAA) control, will give way to decentralized coordination among autonomous and semi-autonomous systems. The proposed xTM Security Architecture, designed as a high-level framework, focuses on ensuring the confidentiality, integrity, and availability of data and operations in this evolving ecosystem. Utilizing threat modeling, the research identifies potential risks across key flight phases, operations and use cases to offer security control recommendations. Key objectives include analyzing interactions between novel airspace entrants and existing NAS traffic, cataloging vulnerabilities, and developing mitigative strategies to ensure safety, operational stability, and secure data exchanges. This research lays the groundwork for regulatory and industry adaptation, providing critical insights into managing cybersecurity risks in this complex, multi-domain environment.

UAM↗

DOE OSTI2021

Uncertainty and Sensitivity Analysis Methods and Applications in the GDSA Framework (FY2021)

The Spent Fuel and Waste Science and Technology (SFWST) Campaign of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE), Office of Fuel Cycle Technology (FCT) is conducting research and development (R&D) on geologic disposal of spent nuclear fuel (SNF) and high-level nuclear waste (HLW). Two high priorities for SFWST disposal R&D are design concept development and disposal system modeling. These priorities are directly addressed in the SFWST Geologic Disposal Safety Assessment (GDSA) control account, which is charged with developing a geologic repository system modeling and analysis capability, and the associated software, GDSA Framework, for evaluating disposal system performance for nuclear waste in geologic media. GDSA Framework is supported by SFWST Campaign and its predecessor the Used Fuel Disposition (UFD) campaign. This report fulfills the GDSA Uncertainty and Sensitivity Analysis Methods work package (SF-21SN01030404) level 3 milestone, Uncertainty and Sensitivity Analysis Methods and Applications in GDSA Framework (FY2021) (M3SF-21SN010304042). It presents high level objectives and strategy for development of uncertainty and sensitivity analysis tools, demonstrates uncertainty quantification (UQ) and sensitivity analysis (SA) tools in GDSA Framework in FY21, and describes additional UQ/SA tools whose future implementation would enhance the UQ/SA capability of GDSA Framework. This work was closely coordinated with the other Sandia National Laboratory GDSA work packages: the GDSA Framework Development work package (SF-21SN01030405), the GDSA Repository Systems Analysis work package (SF-21SN01030406), and the GDSA PFLOTRAN Development work package (SF-21SN01030407). This report builds on developments reported in previous GDSA Framework milestones, particularly M3SF 20SN010304032.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Uncertainty and Sensitivity Analysis Methods and Applications in the GDSA Framework (FY2022)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1995

Advanced controls for stability assessment of solar dynamics space power generation

In support of the power requirements for the Space Station Alpha (SSA), a joint program by the U.S. and Russia for a permanently manned space station to be launched into orbit by 1998, a robust control scheme is needed to assure the stability of the rotating machines that will be integrated into the power subsystem. A framework design and systems studies for modeling and analysis is presented. It employs classical d-q axes machine model with voltage/frequency dependent loads. To guarantee that design requirements and necessary trade studies are done, a functional analysis tool CORE is used for the study. This provides us with different control options for stability assessment. Initial studies and recommendations using advanced simulation tools are also presented. The benefits of the stability/control scheme for evaluating future designs and power management are discussed.

Momoh, James A.↗

DOE OSTI2025

A distributed voltage inference framework for cyber-physical attacks detection and localization in active distribution grids

The transition to active distribution grids with real-time monitoring and control depends on the proliferation of advanced communication networks and devices. This paradigm shift towards a cyber-physical architecture also introduces new vulnerabilities for adversaries to exploit and launch sophisticated cyber-physical attacks targeting grid observability. Current research highlights the challenges in distinguishing attacks on voltage phasor or nodal injection measurements and isolating multi-source attack locations in a multiphase distribution grid. The attack detection and localization methods in literature face accuracy issues, applications across diverse attack scenarios, or scalability limits. Here, to bridge these gaps, this paper proposes a distributed Voltage Inference framework for real-time detection and localization of cyber-physical attacks, addressing scalability, adaptability, and accuracy challenges in state-of-the-art methods. The proposed methodology leverages the distributed nature of the Voltage Inference framework through a two-step process of prediction and correction, together with a tractable graph partitioning approach, providing a reliable solution to identify compromised measurement sources and facilitate isolation. Extensive testing on IEEE 13 and 123-node distribution feeders underscores the algorithm’s efficacy, enhancing the security and resilience of active distribution grids against evolving cyber threats. Additionally, Hardware-in-the-Loop (HIL) implementation validates the proposed strategy’s practical applicability in real-world scenarios.

active distribution grids↗

NASA NTRS1998

A Human Factors Framework for Payload Display Design

During missions to space, one charge of the astronaut crew is to conduct research experiments. These experiments, referred to as payloads, typically are controlled by computers. Crewmembers interact with payload computers by using visual interfaces or displays. To enhance the safety, productivity, and efficiency of crewmember interaction with payload displays, particular attention must be paid to the usability of these displays. Enhancing display usability requires adoption of a design process that incorporates human factors engineering principles at each stage. This paper presents a proposed framework for incorporating human factors engineering principles into the payload display design process.

Dunn, Mariea C.↗

DOE OSTI2026

Multibody for Everybody (M4E) - A Linearization Approach to Enable Frequency Domain Analysis, Time Integration and Control Co-Design

1.1 Background/Objectives: Marine energy represents a promising yet underexploited source of power. To increase the harvested power, significant efforts have been made to improve wave energy converter (WEC) modeling capabilities and optimize power take-off (PTO) performance; however, these efforts have often treated WEC dynamics, PTO design, and controller development sequentially. In contrast, control co-design (CCD) is emerging as a promising strategy to address these issues directly, creating a growing need for fast analysis tools suitable for repeated simulation and parametric studies [1]. To support this need, this work presents the Multibody for Everybody (M4E) [2] linearization module, which employs a symbolic toolbox to provide deeper insight of WEC design parameters. The objective is to demonstrate that a minimal-coordinate linearization of articulated WEC dynamics can provide accurate wave response predictions and substantial computational savings relative to nonlinear time-domain simulation, while preserving compatibility with broader wave-energy analysis workflows, enabling CCD. 1.2 Approach/Activities: The proposed approach linearizes the equations of motion, generated by M4E, in minimal coordinates about a selected operating point and combines the resulting system with frequencydomain hydrodynamic terms to incorporate the reduced mass, damping, stiffness, and forcing operators. The linearized model is used for both impedance-based response amplitude operator (RAO) prediction and rapid regular-wave time integration. The methodology is demonstrated on a single-flap device and a FOSWEC configuration, with linearized M4E responses compared against the corresponding nonlinear M4E simulations and WEC-Sim results. Regular-wave time histories, RAO trends, and runtime differences are assessed. The framework is also compatible with broader wave-energy workflows, including coupling to WecOptTool, although that capability is not the focus of this work [3]. 1.3 Results/Lessons: The linearized M4E model reproduces key regularwave response characteristics such as integration and Response Amplitude over multiple frequencies. This module matches nonlinear M4E and WEC-Sim results while substantially reducing integration cost. Thus, the proposed framework can serve as a rapid analysis layer for articulated WEC design, parameter studies, and controls-oriented workflows. The analysis is most appropriate in the near-equilibrium regime, about the linearization point.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Scalable phononic metamaterials: Tunable bandgap design and multi-scale experimental validation

Phononic metamaterials offer unprecedented control over wave propagation, making them essential for applications such as vibration isolation, waveguiding, and acoustic filtering. However, achieving scalable and precisely tunable bandgap properties across different length scales remains challenging. This study presents a user-friendly design framework for phononic metamaterials, enabling ultra-wide bandgap tunability (B/ω c ratios up to 172 %) across multiple frequency ranges and scales. Using finite element simulations of a Yablonovite-inspired unit cell, we establish a comprehensive parametric design space that illustrates how geometric parameters, such as sphere size and beam diameter, controls bandgap width and frequency. The scalability and robustness of the framework are validated through experimental testing on additively manufactured structures at both macro (10 mm) and micro (80 µm) scales, fabricated using Stereolithography and Two-Photon Polymerization. Transmission loss measurements, conducted with piezoelectric transducers and laser vibrometry, closely match simulations in the kHz and MHz frequency ranges, confirming the reliability and consistency of the bandgap behavior across scales. This work bridges theory and experiments at multiple scales, offering a practical methodology for the rapid design of phononic metamaterials and expanding their potential for diverse applications across a broad range of frequencies.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Facets of hydro power and future trends in a Nordic Context

Hydropower technologies bolster high penetration of variable renewable energies (VREs) in the net zero emissions scenarios. Nevertheless, there are various challenges to meeting the ambitious goal, such as stability, reliability, resiliency, security, lack of reactive power, voltage support and inertia, large-scale storage deployment and coordination, interconnectedness, demand-side response, higher thermal cycles with increased start/stops, and inadequate Levelized Cost of Energy (LCOE) for system-wise VRE integration and profitability. This survey conducts a bottom-up analysis to unveil the opportunities to utilize hydropower facilities and disentangle the nested problem for intertwining design features, control algorithms, operation, optimization approaches, incentives, services, and market mechanisms using a three-pillar framework perspective: grid owners, power producers, and machine designers. The survey identified emerging trends in real-time and capacity markets, flexible power systems, and enhanced grid capabilities, including advanced voltage support and updated grid codes. These developments present significant opportunities for hydropower, such as achieving super-flexibility through hybridization, expanded reactive power capabilities, and advanced operational modes like a synchronous condenser and power adequator functionalities. These opportunities require novel design philosophies — including new winding, stator, and rotor configurations, optimized ventilation, and active cooling systems — to enhance performance under stressed grid and climate conditions. Finally, integrating climate and energy models for multi-basin optimization with finer spatial and temporal granularity enhances the planning accuracy for water management of hydropower while addressing environmental challenges. The review delivers helpful prospective suggestions and tools that would serve researchers, power engineers, and stakeholders in making decisions about hydropower technologies and services in 2050 and beyond.

13 HYDRO ENERGY↗

DOE OSTI2022

Energy and mobility impacts of connected autonomous vehicles with co-optimization of speed and powertrain on mixed vehicle platoons

Intersections are known to be traffic bottlenecks where a significant amount of energy consumption could be caused due to deceleration/acceleration in the presence of red signals. With an increased level of connectivity and automation of intelligent transportation systems, connected autonomous vehicles (CAVs) are expected to be able to proactively adjust their driving strategies subject to constraints imposed by the predicted future traffic. As a result, many potential benefits can be achieved, such as improved energy efficiency, enhanced traffic safety, among many others. Notably, the way CAVs are controlled affects the following legacy vehicles (LVs) due to complex traffic dynamics. Here, we are particularly interested in studying the energy and mobility impact of CAVs with an improved traffic prediction method on mixed vehicle platoons at various market penetration rates. Leveraging traffic prediction, CAVs are controlled with co-optimization of their speed and gear position. Specifically, a traffic prediction framework in a rolling horizon fashion is employed based upon a modified Payne–Whitham (PW) model capable of handling mixed traffic consisting of CAVs and LVs. The prediction error of the modified PW model is reduced by 53.62% compared to that of the standard PW model under test scenarios. According to the predicted traffic conditions, speed and gear position of CAVs are co-optimized with the primary goal of minimizing energy consumption when driving on a signalized arterial. The energy benefits achieved by CAVs and the impact of CAVs on LVs behind are studied comprehensively for mixed vehicle platoons. The lead LV follows a real-world speed profile collected on TH-55 in Minnesota. Numerical results show that energy benefits achieved by the vehicle platoon range from 2% to 16%, and a 1% to 5% reduction in travel time for LVs behind CAVs is also observed, at different penetration rates of CAVs in various traffic scenarios. Furthermore, it is observed that CAVs using the proposed eco-driving approach appear to have a positive impact on the LVs behind in terms of energy consumption, regardless of the driving styles of the LVs ahead.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Microphase Separation in Polyelectrolyte Blends: Weak Segregation Theory and Relation to Nuclear "Pasta".

We develop the weak segregation theory of micro phase separation in stoichiometric blends of oppositely and weakly charged polyelectrolytes, which would be immiscible in the absence of charged units. Short-range repulsions between polycation and polyanion monomers induce the formation of oppositely charged domains, the size of which is controlled by their excess Coulomb energy. The diagram of blend morphologies is constructed in the framework of Leibler's mean-field approach and to account for fluctuations within the Brazovskii-Fredrickson-Helfand approximation. Phase behavior of the polyelectrolyte blends is fully analogous to that of neutral diblock copolymers. The mean-field analysis predicts that the order-disorder transition (ODT) is second order for the symmetric blend. In asymmetric mixtures, an increasing incompatibility between polyelectrolytes triggers the usual cascade of first-order phase transitions, dis -> bcc -> hex -> lam. Fluctuations alter the phase diagram topology and allow the direct transitions from the disordered state (dis) to hex and lam microphases; for the symmetric blend, ODT becomes weakly first order. We also discuss that both microphase separation in polyelectrolyte blends and the formation of nuclear "pasta" phases within neutron stars are governed by similar physical principles, despite the 6 orders of magnitude difference in the periods of these structures.

Rumyantsev, Artem M.↗

DOE OSTI2026

Ultrafast Reactive Laser Sintering of Highly Conductive Garnet-Type LLZTO Solid Electrolytes

Rapid and scalable fabrication of garnet-type solid electrolytes remains a major challenge for the practical deployment of lithium metal batteries. Here, we report reactive laser sintering (RLS) as an ultrafast and potentially scalable strategy for fabricating garnet-type Li 6.4 La 3 Zr 1.4 Ta 0.6 O 12 (LLZTO) solid electrolytes. RLS of LLZTO enables simultaneous reaction and densification, achieving ∼95% relative density while minimizing lithium loss and suppressing secondary phase formation. Compared to conventional furnace sintering, RLS promotes enhanced grain growth and improved densification, leading to improved ionic conductivity (0.36 ± 0.08 mS cm −1 ) while maintaining comparable activation energies for Li + transport. Structural characterization by X-ray diffraction (XRD), Raman spectroscopy, and solid-state 6 Li/ 7 Li NMR confirms the formation of cubic garnet LLZTO with homogeneous microscale elemental distribution. In addition, nanoindentation measurements demonstrate that RLS preserves the mechanical properties of the garnet framework despite ultrafast localized thermal processing. By integrating simultaneous reaction and densification with tunable microstructural control, reactive laser sintering provides a promising manufacturing pathway for high-performance garnet solid electrolytes toward next-generation solid-state batteries.

CO2 laser↗

DOE OSTI2020

Improving Energy Transfer within Metal–Organic Frameworks by Aligning Linker Transition Dipoles along the Framework Axis

Crystalline metal-organic frameworks (MOFs) can assemble chromophoric molecules into a wide range of spatial arrangements, which are controlled by the MOF topology. Like natural light-harvesting complexes (LHCs), the precise arrangement modulates interchromophoric interactions, in turn determining excitonic behavior and migration dynamics. To unveil the key factors that control efficient exciton displacements within MOFs, we first developed linkers with low electronic symmetry (as defined by large transition dipoles) and then assembled them into MOFs. These linkers possess extended conjugation along one molecular axis, engendering low optical bandgaps and improved oscillator strength for their lowest-energy transition (S 0 → S 1 ). This enhances absorption-emission spectral overlap and boosts the efficiency of Forster resonance energy transfer, which was observed experimentally by a sizable decrease in emission quantum yield (QY), accompanied by a faster population decay profile. We find that MOFs that orient these elongated linkers along their asymmetric pore channel, e.g., the hexagonal pores in an xly network, manifested >50% decrease in their emission QY with faster decay profiles relative to their corresponding solution dissolved linkers. This is due to an efficient migration of photogenerated excitons at the crystallite peripheral sites to internal sites, which was facilitated by polarized absorption-emission overlap among the parallelly aligned linkers. In contrast, symmetric MOFs, such as those with sqc-a topological net, orient elongated linkers along two perpendicular crystal axes, which hinders efficient exciton migration. This study underscores that MOFs are promising to develop artificial LHCs, but that to achieve an efficient exciton displacement, appropriate topology-guided assembly is required to fully realize the true potential of linkers with low electronic symmetry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Equilibrium-gated pattern formation: How molecular dissociation thermodynamics drive emergent behavior in dissipative polymeric systems

Emergent patterns in biological systems arise through dissipative processes that balance reaction and transport phenomena, producing highly functional properties from self-regulating mechanisms. Synthetic fabrication, by contrast, often relies on user-controlled, multistep methods that lack the self-organizing capabilities of natural systems. Inspired by nature, we sought chemical systems that integrate strongly coupled reaction and transport phenomena, identifying frontal ring-opening metathesis polymerization (FROMP) as a method capable of creating diverse forms and functions through reactive processing. By employing discrete molecular initiators, FROMP allows precise control of key reaction steps—inhibition, initiation, and propagation. Using an integrated computational and experimental framework, we uncover how near-equilibrium inhibition dynamics, coupled with far-from-equilibrium reaction kinetics, drive pattern formation in frontally polymerized synthetic materials. We propose the concept of equilibrium-gated pattern formation, demonstrating how initiator chemistry can be tuned to achieve programmable macroscale properties. Our study reveals a surprising insight: Emergent behavior in FROMP systems arises from the inhibition-dominated regime of resin composition, expanding prior observations that such behavior is confined to a narrow compositional space near the boundary between front quenching and uniform front propagation. We identify a broader compositional window, far from the quenching regime, where emergent behavior reliably manifests. This expanded design space significantly enhances the operational flexibility of reactive systems and their capacity for self-organization. Furthermore, these insights provide a roadmap for designing bioinspired materials with self-organizing capabilities, unlocking possibilities in synthetic manufacturing.

Architected Polymers↗

DOE OSTI2026

IPC-Fusion (Infrastructure Perception and Control (IPC): Multisensor Data Fusion Software) [SWR-25-153]

As part of the National Laboratory of the Rockies' (NLR’s) Infrastructure Perception and Control Laboratory, the IPC-Fusion toolkit provides a probabilistic, scalable, multi-sensor fusion framework that integrates (late-stage fusion) heterogeneous object detection data from traffic sensors to enable robust, real-time tracking of roadway occupants. The algorithmic design of the toolkit is motivated by the need for creating a digital twin of traffic at the edge in a scalable and affordable manner. The software operates by combining object-level measurements (such as position and velocity) from a suite of sensors (such as radar, lidar, camera) using Kalman filtering and probabilistic data association techniques to overcome individual sensor limitations and achieve superior tracking performance in complex traffic zones. The framework addresses key challenges including heterogeneous measurement uncertainties, asynchronous data streams, varying spatiotemporal data resolutions, robust data association, and adaptive object lifecycle management. Validated on real-world traffic intersection data including vehicles and pedestrians, IPC-Fusion demonstrates enhanced tracking reliability across scenarios involving occlusions, sensor failures, and varying traffic densities, supporting the broader IPC initiative's goal of transforming transportation infrastructure through advanced perception capabilities for intelligent transportation systems, traffic safety applications, and autonomous vehicle support.

Sandhu, Rimple [National Laboratory of the Rockies↗

DOE OSTI2021

Computational Tools for Additive Manufacture of Tailored Microstructure and Properties

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Currently most additive builds use a single set of process parameters (e.g. laser power and scan speed) which results in a part with a homogenous microstructure that provides a singular performance level. To move beyond this state, Raytheon Technologies Research Center worked to create a set of computational tools to track material evolution through each step of the additive process. Computational fluid dynamics and phase field models for microstructure evolution as a function of processing parameters, and crystal plasticity models fully coupling microstructure and mechanical properties for performance predictions were leveraged to establish a connection between additive parameters and the final microstructure. This framework was utilized to tailor spatially-varying mechanical properties in a part by appropriately controlling the microstructure evolution during the additive process. Specifically, a turbine blade was 3D printed from nickel superalloy IN718 using laser powder bed fusion with coarse grains in the airfoil section which experiences the highest temperatures and is creep limited while finer grains were printed in the root of the blade which experience higher stresses but at lower temperatures and is therefore fatigue limited. The benefit of being able to intentionally insert coarse grains in the high temperature region of the blade was showcased with a microstructure sensitive creep model that indicates longer creep life for coarser grains.

20 FOSSIL-FUELED POWER PLANTS↗