Results for “efficiency maximization” — Page 87

DOE OSTI2015

ATLAS jet trigger update for the LHC run II

The CERN Large Hadron Collider is the biggest and most powerful particle collider ever built. It produces up to 40 million proton-proton collisions per second at unprecedented energies to explore the fundamental laws and properties of Nature. The ATLAS experiment is one of the detectors that analyses and records these collisions. It generates dozens of GB/s of data that has to be reduced before it can be permanently stored, the event selection is made by the ATLAS trigger system, which reduces the data volume by a factor of 105. The trigger system has to be highly configurable in order to adapt to changing running conditions and maximize the physics output whilst keeping the output rate under control. A particularly interesting pattern generated during collisions consists of a collimated spray of particles, known as a hadronic jet. To retain the interesting jets and efficiently reject the overwhelming background, optimal jet energy resolution is needed. Therefore the Jet trigger software requires CPU-intensive reconstruction algorithms. In order to reduce the resources needed for the reconstruction step, a partial detector readout scheme was developed, which effectively suppresses the low activity regions of the calorimeter. In this paper we describe the overall ATLAS trigger software, and the jet trigger in particular, along with the improvements made on the system. We then focus on detailed studies of the algorithm timing and the performance impact of the full and partial calorimeter readout schemes. We conclude with an outlook of the jet trigger plans for the next LHC data-taking period. (authors)

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

The Cost and Benefit of Enhancing Cybersecurity for Hybrid AC/DC Grids

As critical interfaces of AC grids and DC grids inside a hybrid AC/DC grid, the voltage-sourced-converter (VSC) has been demonstrated to be vulnerable to false data injection (FDI) cyber-attacks. As a result, the cyber-attack-induced AC grid frequency deviations and DC grid voltage deviations threaten the secure operation. Here, to enhance cybersecurity in a not only feasible but also cost-effective manner, this paper proposes a cost-benefit-based cyber-defense strategy for a hybrid AC/DC grid. First, this paper establishes a spatial-temporal dual cyber-attack evaluation model, in which the cyber-attack-induced frequency and voltage deviations are modelled in both a spatially and temporally dual manner. Then, the proposed cost-benefit-based cyber-defense strategy is modelled as a VSC commitment problem to achieve the trade-off between maximizing the cyber-defense benefits and minimizing the cyber-defense costs. The VSC commitment problem is then mathematically convexified into a mixed-integer second-order cone programming (MISOCP) problem, which could be efficiently solved in an event-triggered manner against unfolding cyber-attack events. Simulation results on a test hybrid AC/DC grid verified the feasibility and the cost-effectiveness of the proposed cyber-defense strategy.

cost-benefit analysis↗

DOE OSTI2018

Tailoring Electron-Photon Interaction in Active 3D Photonic-Crystal Architectures

A photonic-crystal is an artificially engineered periodic structure. It is often referred to as an “optical semiconductor” due to its unparallel capability to mold the flow-of-light on-chip, not only in plane (the x-y plane) but also along the third direction. Examples of the unique 3D control-of-light include diffraction less light-guiding, slow light, super prism, negative refraction and high-Q cavity. A new research frontier exists in which the concept of complete control-of-light is utilized to facilitate and maximize electron-photon interaction. The close proximity and strong interaction between a photonic-crystal and an electronic medium can lead to new optoelectronic properties not easily attainable by other means. In this program, we will study this new class of active photonic-crystal and to achieve improved device performances and basic discoveries. Under this program, the PI has made significant progress in the following areas: (i) We have maximized light trapping and absorption by a 3D simple-cubic photonic-crystal; By advancing the concept of simple-cubic symmetry design, we have successfully designed a super thin-film architecture for high efficiency, crystalline silicon solar cells; Most recently, we have provided a theoretical roadmap for thin-film silicon solar cells with 30% power conversion efficiency. (ii) In the modification of thermal radiation area, we have observed quasi- optical coherence in thermal radiation from a 3D metallic photonic-crystal; Furthermore, we have made a direct confirmation of super-Planckian radiation a tungsten photonic-crystal; (iii) We have made simultaneous observation of a large light diffraction-efficiency, 82%, and efficiency enhancement by a volume hologram material (PQ-PMMA) for solar concentration application. (iv) we have also successfully fabricated a 3D metal-oxide photonic crystal. We demonstrated that this TiO 2 photonic crystal can achieve an effectively infinite optical path-length created using a simple-cubic photonic crystal for extreme light trapping.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Assessment of Potential Pennycress Availability and Suitable Sites for Sustainable Aviation Fuel Refineries in Ohio

Pennycress grain has a relatively high oil content (25–36%) and it is considered a desirable feedstock to produce sustainable aviation fuel (SAF). Pennycress crop can be integrated into the corn–soybean rotation as a winter cover crop in the midwestern U.S. to provide both ecosystem services and economic benefits for the farmers, while serving as a promising feedstock for SAF production. For pennycress-based SAF biorefineries to be established at the commercial scale, a sustainable design of the supply system is required to provide reliable information on feedstock availability and optimal facility locations. The objectives of this research were to assess the pennycress production potential in Ohio, and to identify the best locations to establish the SAF biorefineries. To estimate the pennycress production potential in Ohio, a geographic information system (GIS)-based model was developed using the spatially explicit six-year historical data on areas that were planted in the corn–soybean rotation for the period of 2013 through 2018, pennycress yield estimates from field-based experiments reported in the literature, and the soil productivity index for the region of study. Optimal SAF biorefinery locations were identified using a GIS-based location-allocation model. Annual land potentially available for pennycress production in Ohio was estimated to be ~0.6 million ha, which could produce ~1.1 million metric tons of pennycress grain as feedstock to produce ~210 million liters of SAF, depending on the pennycress yield level, oil content, and conversion efficiencies. In addition, the optimum locations for 12 biorefineries, each at an annual capacity of 18.9 million liters of SAF, were identified, and the average transportation distance was estimated to be 35 and 58 km for maximizing attendance and coverage conditions, respectively. The outcomes of this research would help minimize the risks associated with feedstock supply and cost variabilities for pennycress-based SAF production in the region.

Mousavi-Avval, Seyed Hashem↗

NASA NTRS1972

Comparison of the solar sail with electric propulsion systems

The propulsive efficiencies of the solar sail and of electric propulsion systems are compared on the basis of specific impulse. It is shown that the solar sail is more efficient at one a.u. for mission durations greater than about two months, that the advantage is increased for missions toward the inner planets, and that the same conclusions are reached when the comparison is based on maximizing the momentum transferred to the payload. Other factors that will influence the choice of a propulsion system for a specific mission are mentioned.

Macneal, R. H.↗

NASA NTRSDate not supplied

ICE-RASSOR: Intelligent Capabilities Enhanced

NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) is principally designed to mine and deliver regolith for In-Situ Resource Utilization (ISRU) processing. RAS-SOR’s design enables it to efficiently collect and deposit regolith, return collected material for processing, and myriad related ISRU activities. To reliably perform these operations on the lunar sur-face, RASSOR software and sensory systems need to be robust and maximize the information extracted from on-board sensing. Herein, we present preliminary findings from the Intelligent Capabilities Enhanced RASSOR project. We apply supervised learning using real data to estimate the soil mass collected without the need for mass flow rate monitors or other explicate sensing techniques. We also create a reduced-order simulation environment to develop autonomous trenching controllers via reinforcement learning and proto-type state estimation architectures. Our initial results suggest that excavated regolith mass can be inferred within 2.9% RMS error of full scale, and reinforcement learning for autonomous operations has learned viable trenching strategies and helped identify desirable sensing capabilities, arrangements, and considerations. Future work includes regolith mass estimation during dynamic operation, expanding our simulation to more complex environments, and transfer learning from simulation to hardware.

machine learning↗

DOE OSTI2020

Investigation of Off-Stoichiometry in Ternary Nitrides by EDS and HRTEM

We demonstrate an inverted metamorphic multijunction (IMM) photovoltaic cell comprising lattice-mismatched 1.2 eV AlGaInAs and 1.0 eV GaInAs junctions optimized for high-temperature thermophotovoltaic (TPV) applications. This device differs from traditional IMM solar cells because the mismatched junctions are grown at a single lattice constant. This architecture enables removal of the compositionally graded buffer which otherwise filters light from the junctions below and absorbs sub-bandgap light via free-carrier absorption. Sub-bandgap absorption dramatically reduces the efficiency of TPV systems using high reflectivity cells to enable bandedge spectrum filtering. Three components required development to enable this device: 1) a lattice-mismatched 1.2 eV AlGaInAs junction, 2) a metamorphic contact layer grown after the graded buffer, and 3) a transparent tunnel junction that sits in front of the 1.0 eV GaInAs junction. Growth conditions that minimize oxygen defect incorporation maximize AlGaInAs cell quality, enabling a 0.41 V bandgap open circuit voltage offset at 22 mA/cm2 under AM1.5D. A mismatched GaInAs:Se layer is developed as a low resistance contact. Lastly we develop a GaAsSb:C/GaInP:Se tunnel junction suitable for high-power densities with more transparency than the GaAsSb:C/GaInP:Se structure used in past IMM cells. We characterize the tandem device under a high-intensity spectrum that approximates the emission from a 2150 °C blackbody radiator and deduce a projected ideal TPV efficiency of 39.9% at ~30% of the blackbody irradiance, and 36% ideal TPV efficiency under the full 118 W/cm2 irradiance. Improvements to the back-surface reflectivity and series resistance are expected to increase the ideal TPV efficiency well above 40%.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2014

TH-E-BRE-11: Adaptive-Beamlet Based Finite Size Pencil Beam (AB-FSPB) Dose Calculation Algorithm for Independent Verification of IMRT and VMAT

Purpose: In current IMRT and VMAT settings, the use of sophisticated dose calculation procedure is inevitable in order to account complex treatment field created by MLCs. As a consequence, independent volumetric dose verification procedure is time consuming which affect the efficiency of clinical workflow. In this study, the authors present an efficient Pencil Beam based dose calculation algorithm that minimizes the computational procedure while preserving the accuracy. Methods: The computational time of Finite Size Pencil Beam (FSPB) algorithm is proportional to the number of infinitesimal identical beamlets that constitute the arbitrary field shape. In AB-FSPB, the dose distribution from each beamlet is mathematically modelled such that the sizes of beamlets to represent arbitrary field shape are no longer needed to be infinitesimal nor identical. In consequence, it is possible to represent arbitrary field shape with combinations of different sized and minimal number of beamlets. Results: On comparing FSPB with AB-FSPB, the complexity of the algorithm has been reduced significantly. For 25 by 25 cm2 squared shaped field, 1 beamlet of 25 by 25 cm2 was sufficient to calculate dose in AB-FSPB, whereas in conventional FSPB, minimum 2500 beamlets of 0.5 by 0.5 cm2 size were needed to calculate dose that was comparable to the Result computed from Treatment Planning System (TPS). The algorithm was also found to be GPU compatible to maximize its computational speed. On calculating 3D dose of IMRT (∼30 control points) and VMAT plan (∼90 control points) with grid size 2.0 mm (200 by 200 by 200), the dose could be computed within 3∼5 and 10∼15 seconds. Conclusion: Authors have developed an efficient Pencil Beam type dose calculation algorithm called AB-FSPB. The fast computation nature along with GPU compatibility has shown performance better than conventional FSPB. This completely enables the implantation of AB-FSPB in the clinical environment for independent volumetric dose verification.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2019

Absorption of pulsed laser radiation by composites based on hexogen and aluminium nanoparticles

Absorption of the second-harmonic radiation from a pulsed YAG : Nd {sup 3+} laser by composites based on hexogen and aluminium nanoparticles (of a diameter 100 nm) is theoretically and experimentally investigated. The absorption efficiency factor (the ratio of the light absorption cross section to the geometrical cross section) is calculated by using the Mie theory for Al inclusions in a hexogen medium for various particle diameters and wavelengths corresponding to laser fundamental and second-harmonic radiation. Dependences of the absorption coefficient and amplitude of an acoustic signal on the concentration of inclusions under laser irradiation of composite samples are measured by using a piezo-acoustic transducer. It is shown that the radiation is directly absorbed by nanoparticles. The optimal concentration is found, which provides the maximal signal of the piezo-acoustic transducer. (paper)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Inverted Metamorphic AlGaInAs/GaInAs Tandem Thermophotovoltaic Cell Designed for Thermal Energy Grid Storage Application

We demonstrate an inverted metamorphic multijunction (IMM) photovoltaic cell comprising lattice-mismatched 1.2 eV AlGaInAs and 1.0 eV GaInAs junctions optimized for high-temperature thermophotovoltaic (TPV) applications. This device differs from traditional IMM solar cells because the mismatched junctions are grown at a single lattice constant. This architecture enables removal of the compositionally graded buffer that otherwise filters light from the junctions below and absorbs sub-bandgap light via free-carrier absorption. Sub-bandgap absorption dramatically reduces the efficiency of TPV systems using high reflectivity cells to enable band edge spectrum filtering. Three components required development to enable this device: (1) a lattice-mismatched 1.2 eV AlGaInAs junction, (2) a metamorphic contact layer grown after the graded buffer, and (3) a transparent tunnel junction that sits in front of the 1.0 eV GaInAs junction. Growth conditions that minimize oxygen defect incorporation maximize AlGaInAs cell quality, enabling a 0.41 V bandgap open circuit voltage offset at 22 mA/cm2 under AM1.5D. A mismatched GaInAs:Se layer is developed as a low resistance contact. Lastly, we develop a GaAsSb:C/GaInP:Se tunnel junction suitable for high-power densities with more transparency than the GaAsSb:C/GaInAs:Se structure used in past IMM cells. We characterize the tandem device under a high-intensity spectrum that approximates the emission from a 2150°C blackbody radiator and deduce a projected ideal TPV efficiency of 39.9% at ~30% of the blackbody irradiance and 36% ideal TPV efficiency under the full 118 W/cm2 irradiance. Improvements to the back-surface reflectivity and series resistance are expected to increase the ideal TPV efficiency well above 40%.

25 ENERGY STORAGE↗

DOE OSTI2023

UPC++ v1.0 Programmer’s Guide (Rev. 2023.9.0)

UPC++ is a C++ library that supports Partitioned Global Address Space (PGAS) programming. It is designed for writing efficient, scalable parallel programs on distributed-memory parallel computers. The key communication facilities in UPC++ are one-sided Remote Memory Access (RMA) and Remote Procedure Call (RPC). The UPC++ control model is single program, multiple-data (SPMD), with each separate constituent process having access to local memory as it would in C++. The PGAS memory model additionally provides one-sided RMA communication to a global address space, which is allocated in shared segments that are distributed over the processes. UPC++ also features Remote Procedure Call (RPC) communication, making it easy to move computation to operate on data that resides on remote processes. UPC++ was designed to support exascale high-performance computing, and the library interfaces and implementation are focused on maximizing scalability. In UPC++, all communication operations are syntactically explicit, which encourages programmers to consider the costs associated with communication and data movement. Moreover, all communication operations are asynchronous by default, encouraging programmers to seek opportunities for overlapping communication latencies with other useful work. UPC++ provides expressive and composable abstractions designed for efficiently managing aggressive use of asynchrony in programs. Together, these design principles are intended to enable programmers to write applications using UPC++ that perform well even on hundreds of thousands of cores.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

UPC++ v1.0 Programmer’s Guide (Revision 2022.3.0)

UPC++ is a C++ library that supports Partitioned Global Address Space (PGAS) programming. It is designed for writing efficient, scalable parallel programs on distributed-memory parallel computers. The key communication facilities in UPC++ are one-sided Remote Memory Access (RMA) and Remote Procedure Call (RPC). The UPC++ control model is single program, multiple-data (SPMD), with each separate constituent process having access to local memory as it would in C++. The PGAS memory model additionally provides one-sided RMA communication to a global address space, which is allocated in shared segments that are distributed over the processes. UPC++ also features Remote Procedure Call (RPC) communication, making it easy to move computation to operate on data that resides on remote processes. UPC++ was designed to support exascale high-performance computing, and the library interfaces and implementation are focused on maximizing scalability. In UPC++, all communication operations are syntactically explicit, which encourages programmers to consider the costs associated with communication and data movement. Moreover, all communication operations are asynchronous by default, encouraging programmers to seek opportunities for overlapping communication latencies with other useful work. UPC++ provides expressive and composable abstractions designed for efficiently managing aggressive use of asynchrony in programs. Together, these design principles are intended to enable programmers to write applications using UPC++ that perform well even on hundreds of thousands of cores.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

UPC++ v1.0 Programmer’s Guide, Revision 2023.3.0

UPC++ is a C++ library that supports Partitioned Global Address Space (PGAS) programming. It is designed for writing efficient, scalable parallel programs on distributed-memory parallel computers. The key communication facilities in UPC++ are one-sided Remote Memory Access (RMA) and Remote Procedure Call (RPC). The UPC++ control model is single program, multiple-data (SPMD), with each separate constituent process having access to local memory as it would in C++. The PGAS memory model additionally provides one-sided RMA communication to a global address space, which is allocated in shared segments that are distributed over the processes. UPC++ also features Remote Procedure Call (RPC) communication, making it easy to move computation to operate on data that resides on remote processes. UPC++ was designed to support exascale high-performance computing, and the library interfaces and implementation are focused on maximizing scalability. In UPC++, all communication operations are syntactically explicit, which encourages programmers to consider the costs associated with communication and data movement. Moreover, all communication operations are asynchronous by default, encouraging programmers to seek opportunities for overlapping communication latencies with other useful work. UPC++ provides expressive and composable abstractions designed for efficiently managing aggressive use of asynchrony in programs. Together, these design principles are intended to enable programmers to write applications using UPC++ that perform well even on hundreds of thousands of cores.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

UPC++ v1.0 Programmer’s Guide, Revision 2022.9.0

UPC++ is a C++ library that supports Partitioned Global Address Space (PGAS) programming. It is designed for writing efficient, scalable parallel programs on distributed-memory parallel computers. The key communication facilities in UPC++ are one-sided Remote Memory Access (RMA) and Remote Procedure Call (RPC). The UPC++ control model is single program, multiple-data (SPMD), with each separate constituent process having access to local memory as it would in C++. The PGAS memory model additionally provides one-sided RMA communication to a global address space, which is allocated in shared segments that are distributed over the processes. UPC++ also features Remote Procedure Call (RPC) communication, making it easy to move computation to operate on data that resides on remote processes. UPC++ was designed to support exascale high-performance computing, and the library interfaces and implementation are focused on maximizing scalability. In UPC++, all communication operations are syntactically explicit, which encourages programmers to consider the costs associated with communication and data movement. Moreover, all communication operations are asynchronous by default, encouraging programmers to seek opportunities for overlapping communication latencies with other useful work. UPC++ provides expressive and composable abstractions designed for efficiently managing aggressive use of asynchrony in programs. Together, these design principles are intended to enable programmers to write applications using UPC++ that perform well even on hundreds of thousands of cores.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Multiobjective Optimal Controlled Variable Selection for a Gas Turbine–Solid Oxide Fuel Cell System Using a Multiagent Optimization Platform

Hybrid gas turbine–fuel cell systems have immense potential for high efficiency in electrical power generation with cleaner emissions compared with fossil-fueled power generation. We report a systematic controlled variable (CV) selection method is deployed for a hybrid gas turbine–fuel cell system in the HyPer (hybrid performance) facility at the U.S. Department of Energy’s National Energy Technology Laboratory (NETL) for maximizing its economic and control performance. A three-stage approach is used for the CV selection comprising a priori analysis, multiobjective optimization, and a posteriori analysis. The a priori analysis helps to screen off several candidate CVs, thus reducing the size of the combinatorial optimization problem for multiobjective CV selection. For optimal CV selection, a transfer function model of the HyPer facility is identified. By considering several candidate models, the final transfer function model is selected using Akaike’s Final Prediction Error criterion. Experimental data from the HyPer facility are used to estimate the noise in the measurement data. For solving the combinatorial multiobjective optimization problem for CV selection, a multiagent optimization platform comprising simulated annealing, genetic algorithm, and efficient ant colony optimization algorithms is used. Pareto-optimal CV sets exhibit a high trade-off between the economic and control objective. The a posteriori analysis is undertaken for several top Pareto-optimal CV sets. An optimal CV set is selected that shows the best compromise between process economics and controllability under both nominal and off-design conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Building simulation: Ten challenges

Buildings consume more than one-third of the world’s primary energy. Reducing energy use and greenhouse-gas emissions in the buildings sector through energy conservation and efficiency improvements constitutes a key strategy for achieving global energy and environmental goals. Building performance simulation has been increasingly used as a tool for designing, operating and retrofitting buildings to save energy and utility costs. However, opportunities remain for researchers, software developers, practitioners and policymakers to maximize the value of building performance simulation in the design and operation of low energy buildings and communities that leverage interdisciplinary approaches to integrate humans, buildings, and the power grid at a large scale. This paper presents ten challenges that highlight some of the most important issues in building performance simulation, covering the full building life cycle and a wide range of modeling scales. In conclusion, the formulation and discussion of each challenge aims to provide insights into the state-of-the-art and future research opportunities for each topic, and to inspire new questions from young researchers in this field.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2001

Three-Dimensional Stereoscopic Tracking Velocimetry and Experimental/Numerical Comparison of Directional Solidification

Measurement of three-dimensional (3-D) three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. The experiments in these fields most likely inhibit the application of conventional planar probes for observing 3-D phenomena. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields, which include diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. STV is advantageous in system simplicity for building compact hardware and in software efficiency for continual near-real-time monitoring. It has great freedom in illuminating and observing volumetric fields from arbitrary directions. STV is based on stereoscopic observation of particles-Seeded in a flow by CCD sensors. In the approach, part of the individual particle images that provide data points is likely to be lost or cause errors when their images overlap and crisscross each other especially under a high particle density. In order to maximize the valid recovery of data points, neural networks are implemented for these two important processes. For the step of particle overlap decomposition, the back propagation neural network is utilized because of its ability in pattern recognition with pertinent particle image feature parameters. For the step of particle tracking, the Hopfield neural network is employed to find appropriate particle tracks based on global optimization. Our investigation indicates that the neural networks are very efficient and useful for stereoscopically tracking particles. As an initial assessment of the diagnostic technology performance, laminar water jets with and without pulsation are measured. The jet tip velocity profiles are in good agreement with analytical predictions. Finally, for testing in material processing applications, a simple directional solidification apparatus is built for experimenting with a metal analog of succinonitrile. Its 3-D velocity field at the liquid phase is then measured to be compared with those from numerical computation. Our theoretical, numerical, and experimental investigations have proven STV to be a viable candidate for reliably measuring 3-D flow velocities. With current activities are focused on further improving the processing efficiency, overall accuracy, and automation, the eventual efforts of broad experimental applications and concurrent numerical modeling validation will be vital to many areas in fluid flow and materials processing.

Lee, David↗

DOE OSTI2014

Replication of engine block cylinder bridge microstructure and mechanical properties with lab scale 319 Al alloy billet castings

In recent years, aluminum alloy gasoline engine blocks have in large part successfully replaced nodular cast iron engine blocks, resulting in improved vehicle fuel efficiency. However, because of the inadequate wear resistance properties of hypoeutectic Al–Si alloys, gray iron cylinder liners are required. These liners cause the development of large tensile residual stress along the cylinder bores and necessitate the maximization of mechanical properties in this region to prevent premature engine failure. The aim of this study was to replicate the engine cylinder bridge microstructure and mechanical properties following TSR treatment (which removes the sand binder to enable easy casting retrieval) using lab scale billet castings of the same alloy composition with varying cooling rates. Comparisons in microstructure between the engine block and the billet castings were carried out using optical and scanning electron microscopy, while mechanical properties were assessed using tensile testing. The results suggest that the microstructure at the top and middle of the engine block cylinder bridge was successfully replicated by the billet castings. However, the microstructure at the bottom of the cylinder was not completely replicated due to variations in secondary phase morphology and distribution. The successful replication of engine block microstructure will enable the future optimization of heat treatment parameters. - Highlights: • A method to replicate engine block microstructure was developed. • Billet castings will allow cost effective optimization of heat treatment process. • The replication of microstructure in the cylinder region was mostly successful. • Porosity was more clustered in the billet castings compared to the engine block. • Mechanical properties were lower in billet castings due to porosity and inclusions.

36 MATERIALS SCIENCE↗