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All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Fast Responding Voltage Regulator and Dynamic VAR Compensator

The objectives of this project were to develop a dynamic VAR compensator (DVC) for voltage regulation through VAR support to demonstrate the ability to achieve greater levels of voltage control on electricity distribution networks, and faster response compared to existing grid technology. The goal of the project was to develop a prototype Fast Dynamic VAR Compensator (Fast DVC) hardware device, and this was achieved. In addition to developing the dynamic VAR compensator device, Varentec in partnership with researchers at North Carolina State University (NCSU) successfully met the objectives to model the potential positive impact of such DVCs on representative power networks. This modeling activity validated the ability of distributed dynamic VAR compensators to provide fast voltage regulation and reactive power control required to respond to grid disturbances under high penetration of fluctuating and intermittent distributed energy resources (DERs) through extensive simulation studies. Specifically the following tasks were set to be accomplished: 1) Development of dynamic VAR compensator to support dynamic voltage variations on the grid through VAR control 2) Extensive testing of the DVC in the lab environment 3) Present the operational DVC device to the DOE at Varentec’s lab 4) Formulation of a detailed specification sheet, unit assembly document, test setup document, unit bring-up plan, and test plan 5) Extensive simulations of the DVC in a system with high PV penetration. Understanding the operation with many DVC on a single distribution system 6) Creation and submittal of quarterly and final reports conveying the design documents, unit performance data, modeling simulation charts and diagrams, and summary explanations of the satisfaction of program goals. This report details the various efforts that led to the development of the Fast DVC as well as the modeling & simulation results. The report begins with the introduction in Section II which outlines the problems associated with increasing penetration of renewable resources on the grid and what are the challenges in solving these issues. Section III provides a brief summary of the initial concepts that were explored before the final Fast DVC prototype was developed. Section IV and V present the hardware, controls, communication, and mechanical architecture and features of the Fast DVC. Section VI presents the procedure for assembling the Fast DVC. The test plan and lab setup are expounded in Section VII and VIII. Section IX presents the results from testing the Fast DVC in the lab, several results are presented along with some pictures of the developed unit. Section X details the pilot demonstration activities. Finally, section XI showcases the efforts associated with the simulation and modeling of the Fast DVC in various scenarios with DERs and its impact in all these scenarios.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

MSU-Northern Bio-Energy Center of Excellence

The goal of this project was to establish the Bio-Energy Center (the Center) of Montana State University Northern (MSUN) as a Regional Research Center of Excellence in research, product development, and commercialization of non-food biomass for the bio-energy industry. A three-step approach, namely, (1) enhance the Center’s research and testing capabilities, (2) develop advanced biofuels from locally grown agricultural crops, and (3) educate the community through outreach programs for public understanding and acceptance of new technologies was identified to achieve this goal. The research activities aimed to address the obstacles concerning the production of biofuels and other bio-based fuel additives considering feedstock quality, conversion process, economic viability, and public awareness. First and foremost in enhancing the capabilities of the Center is the improvement of its laboratories and other physical facilities for investigating new biomass conversion technologies and the development of its manpower complement with expertise in chemistry, engineering, biology, and energy. MSUN renovated its Auto Diagnostics building and updated its mechanical and electrical systems necessary to house the state-of-the-art 525kW (704 hp) A/C Dynamometer. The newly renovated building was designated as the Advanced Fuels Building. Two laboratories, namely Biomass Conversion lab and Wet Chemistry lab were also added to the Center’s facilities. The Biomass Conversion lab was for research on the production of advanced biofuels including bio-jet fuel and bio-based fuel additives while the Wet Chemistry lab was used to conduct catalyst research. Necessary equipment and machines, such as gas chromatograph-mass spectrometry, were purchased and installed to help in research and testing. With the enhanced capabilities of the Center, research and testing activities were very much facilitated and more precise. New biofuels derived from Camelina sativa (camelina), a locally-grown oilseed crop was developed through a chemical process for converting the oil extracted into jet fuel. Promising methods of synthesizing heterogeneous metal complex catalyst that support the chemical conversion process were likewise developed. Breaking-down lignin to valuable chemicals using a metal complex catalyst was also investigated. Lignin is an organic polymer that binds around cellulose and hemicellulose fibers which strengthen cell walls in woody biomass. Test results showed promise and could lead to further exploration of using lignin for fuels and fuel additives. These findings could create another value-added product from lignin that can be sourced from beetle kill trees and product residues from cellulose ethanol plants. Coupled with these research discoveries was the provision of technical support to businesses in terms of product development and commercialization of bio-based products. This in turn opened new avenues for advancing the bio-energy industry in the region and helped support the regional agricultural-based economy through developing biofuels derived from feedstock that are grown locally. It assisted in developing biofuels that reduce exhaust emissions and improve engine performance.

09 BIOMASS FUELS↗
DOE OSTI2018

Low-Cost Titanium Casting Technology

This is the final report of "Low-Cost Titanium Casting Technology" project. Titanium alloys have attracted increasing attentions as structural materials for high performance and weight-sensitive applications in aerospace and biomedical fields. However, in mass-production of civil applications like automotive components, titanium alloys are scarcely used due to the unaffordable costs in manufacturing compared with other metallic materials, such as aluminum, magnesium and steel. Therefore, there is a need to reduce the manufacturing cost of titanium alloys so that titanium alloys can be more competitive in terms of property and cost considerations. In this 4-year project, we started from exploring new low-cost titanium alloy systems with the guidance of Integrated Computational Materials Engineering – Calculation of Phase Diagram (ICME-CALPHAD) framework, and determined several promising alloy systems, alloying elements including Ti-Al-Fe-Mn-B-C, that can allow further development (lab-scale and industry-scale) in the future. During the new alloy system exploration, considerable amount of scientific work was completed regarding CALPHAD modeling, microstructure morphology, mechanical properties, and processing of the new alloy systems. The relevant ternary titanium alloy systems, Ti-Al-Mn and Ti-Al-Fe, were examined and reassessed both computationally and experimentally, leading to more comprehensive understanding of these alloy systems. Based on this above study, a new low-cost casting titanium alloy was developed, Ti-6Al-5Fe-0.05B-0.05C (designated as T65-0.05BC), which has competitive as-cast strength level with current commercial titanium alloys but relatively low ductility. However, in this project, since the target application, automotive engine connecting rod, is a fatigue-limited component and does not require high ductility, this alloy shall suffice as the deliverable alloy in this project. After designing and confirming the potent of the new alloy, we designed and built a lab-scale manufacturing equipment aided by computational tools at OSU labs to conceptually prove that this alloy can be manufactured with permanent mold casting, which is low-cost and potentially a mass production process. We produced a lab-scale prototype connecting rod demonstrating the capability of permanent mold casting of this new alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

It Takes a Village: Documenting the Contributions of Non-Scientific Staff to Scientific Research [Slides]

Science, especially large-scale basic research, is a collaborative endeavor, often drawing on the skills of people from a wide variety of disciplines. These people include not just scientists, but also administrators, engineers, and many others. Fermilab, a Department of Energy National Laboratory and the United States’ premier particle physics laboratory, exemplifies this kind of research; many of its high-energy physics experiments involve hundreds of collaborators from all over the world. The Fermilab Archives seeks to document the history of the lab and the unique scientific research its staff and visitors perform. Adequately documenting the lab’s work often requires us to go far beyond things like the writings and correspondence of scientists to also capture the administrative and social histories of the experiments and the context in which they were performed. At Fermilab, we have sought to capture these elements of the lab’s activities through an oral history program that focuses on support staff as well as physicists and collection development choices that recognize the importance of records documenting the cultural life of the lab. These materials are not merely supplementary, but rather essential documentation of the many types of labor that go into the planning and execution of an experiment or the construction of an accelerator and the context in which this work is performed. Any picture of these experiments and accelerators that did not include this type of information would be incomplete. While the importance and richness of this material is especially pronounced at Fermilab due to the massive size of its experiments and accelerator facilities and its vibrant cultural life, the fruitfulness of these collecting efforts at Fermilab suggests that other archives documenting modern STEM research should also make sure the contributions of non-technical and non-scientific staff are preserved and that researchers interested in this subject should not neglect such sources.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2018

U.S. Department of Energy Fuels & Lubricants Project on Lubricant Technology - Innovation, Discovery, Design, and Engineering (Final Report)

In 2016, the Vehicle Technologies Office (VTO) of the Department of Energy (DOE) issued a solicitation for the AOP Lab Call research in FY2017 on a number of topics related to vehicles. Topic 6A of the Lab Call focused on research related to advanced lubricants: '...(in) support of the lubricants program goal to, by 2020, demonstrate novel formulations for powertrain and driveline lubricants, compatible with new and legacy vehicles, to achieve at least a 4 percent real-world fuel economy improvement.' Argonne National Laboratory (ANL) in collaboration with Oak Ridge National Laboratory (ORNL) and Pacific Northwest National Laboratory (PNNL) was awarded a 3-year multilab project on 'Lubricant Technology - Innovation, Discovery, Design, and Engineering.' Research on the project began in FY2017 at the three laboratories with industry participation; however, in FY2018, the project was terminated due to budgetary constraints. The following is the final report for the project and highlights progress made during the first year of research. The report is divided into sections that highlight the following: goals, objectives, milestones and deliverables; project highlights; outreach - publications, conferences, and reports; milestones accomplished; research progress.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

A Proposed Path Forward for Transportation of High-Assay Low-Enriched Uranium

Many of the advanced reactors that are being designed will use high-assay low-enriched uranium (HALEU) as the reactor fuel. HALEU is fuel that is enriched between 5% – 20% uranium-235. With the change to higher enriched material, the industry will have new challenges with the development and regulatory approval of enrichment and fuel fabrication facilities and suitable transportation packages to support the economic use of HALEU materials. One area of concern relates to ensure sub-criticality of the material during transportation as identified by the Nuclear Energy Institute (NEI). To evaluate the relevant work, experts, and industry perspectives on HALEU, a workshop was organized to share relevant experience and insights into HALEU transportation, handling, and management. At the August 30 and 31, 2018 workshop, NEI and industry provided the following recommendations to DOE and the national lab complex. 1. DOE and the lab complex should communicate and educate the Nuclear Regulatory Commission (NRC) on criticality issues related to HALEU. 2. Idaho National Laboratory (INL) should support work needed to certify package design for the transportation of HALEU. a. Suggest amending the Certificate of Compliance of an existing package used for the shipment of commercial quantities. b. Suggest DOE provide funding to package designer(s) for analysis and engineering work for a package to be submitted to NRC for approval. 3. INL should provide specific, or a range, of the expected impurities that will be present in recycled naval fuel. 4. In the longer term, DOE and the lab complex should increase the availability of criticality benchmark data to further reduce conservatism in package design. In addition, a couple key takeaways were identified, including: 1. Although the labs can provide additional criticality experiments, industry has enough data to license facilities, overpacks, and cylinders. Validation from additional critical experiments to establish less uncertainty in the benchmarks will be helpful. 2. A collective effort from industry is needed to express consistency on how much information exists or is needed related to criticality. Based on interactions with industry, DOE, and national laboratories, it appears that large-volume transportation of fresh HALEU appears feasible from a criticality perspective. Specifically, an initial review of applicable criticality benchmark experiments identified numerous applicable experiments. However, a more thorough review of a realistic transportation package design is suggested. Therefore, the following next steps are proposed: 1. Evaluate a large volume package with uranium dioxide enriched to 20%. Specifically, the GNF-A NPC package was proposed as a potentially viable option. 2. Based on the results of (1), determine if additional package designs and fuel material should be evaluated. 3. Based on the results of (1), determine if additional criticality experiments would be beneficial to improve the margins for criticality due to uncertainties. 4. Determine DOE transportation needs (packages sizes, shielding requirements, handling/operational requirements, and timing of availability) related to HALEU. 5. Continue to interface with NEI and interested industry companies to determine the appropriate time to engage the NRC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

FRMAC Laboratory Analysis Rad Responder Enhancements Requirements

This document will describe the requirements for improvements to the Rad Responder platform to meet the needs of FRMAC Lab Analysis and other users of the sample control and lab analysis modules. The report is broken down into specific sections and organized by the specific deliverables under the FY19 FEMA-NIRT project. This report describes requirements that go beyond what was originally funded under the FY19 FEMA-NIRT project since auxiliary funding is being used on top of FEMA-NIRT funding through the DOE eFRMAC working group. This document describes all the lab analysis requirements for FRMAC Lab Analysis operations. Under each section the reader will find specific user "stories" or use-cases along with specific and technical requirements for each feature. Mock ups and data models will be provided as needed.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Improvements to the New CTH Code Verification & Validation Test Suite (FY2020)

The CTH multiphysics hydrocode, which is used for a wide range of important calculations, has undertaken in recent years to overhaul its software quality and testing processes. A key part of this effort entailed building a new, robust V&V test suite made up of traditional hydrocode verification problems, such as those listed in the ASC Tri-Lab Test Suite and the Enhanced Tri-Lab Test Suite, as well as validation problems for some of CTHs most frequently used equations of state, materials models, and other key capabilities. Substantial progress towards this goal was made in FY19. In FY20, this test suite has been expanded to include verification and validation tests of the Sesame and JWL equation of state models as well as the Mader verification problem from the Tri-Lab Test Suite and the Blake verification problem - a linear elastic analog to the Hunter problem from the Enhanced Tri-Lab Test Suite. This report documents CTH performance on the new test suite problems. Verification test results are compared to analytic solutions and, for most tests, convergence results are presented. Validation test results are compared to experimental data and mesh refinement studies are included. CTH performs well overall on the new test problems. Convergence rates for the Blake and Mader problems are comparable to those for similar ASC codes. The JWL and Sesame verification tests show good agreement with analytic solutions. Likewise, CTH simulation results show good agreement with experimental validation data for the Sesame and JWL equations of state for the materials tested. Future V&V work will focus on adding tests for other key capabilities like fracture and high explosive models.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

DOE National Laboratories: Vital to U.S. science and technology [Slides]

DOE has extremely challenging and diverse missions, each born out of national need. The national labs serve as the science and technology engine for DOE missions. Each Lab stewards distinctive capabilities which DOE leverages through networks of labs address core missions, dynamic programs and rapid response needs. National lab networks have transformative impact.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Radiation Hardened Foam Cold Test Plan – Phase-I: Foam Adhesion, Contamination Fixation, Moisture Stresses, Pipe Cutting, and Thermal Profile Testing

This document outlines the Phase-I test objectives and implementation plan for a down-selective foam fixative technology intended to facilitate activities in support of the Savannah River Site (SRS) F/H labs deactivation and decommissioning (D&D) efforts. It is a collaborative effort between Savannah River National Laboratory (SRNL), Florida International University (FIU), and the SRS F/H labs team intended to test and evaluate the potential of an intumescent, fire-retardant foam in mitigating the release of contamination during dismantling operations on radioactively contaminated piping in legacy facilities. The cold test plan addresses specific requirements highlighted by site and safety personnel and will be executed in FIU’s Outdoor Test and Evaluation Facility using a mock-up that replicates the operational conditions at the proposed hot test location at F/H labs. Results from the cold test plan will inform the hot test at F/H labs, which will use the foam fixative to confine and/or isolate residual contamination within a 3-dimensional void space of Hastelloy C-22 piping designated for removal from the site and transported to a proper disposal facility. Phase-I testing will address eight test objectives: (1) evaluation of the adhesion and bonding properties of foam fixative in piping, (2) evaluation of the adhesion of the foam fixative in piping under varying moisture conditions, (3) determination of the heat profile of the foam fixative during curing, (4) determination of the relationship between pipe diameter and foam fixative quantity, (5) determination of the internal pipe pressure after foam deployment and curing, (6) development of a leak test standard operating procedure to test for the effectiveness of the foam plug, (7) initiation of a literature review to determine if using a hot tap is a viable method to deliver foam into piping, and (8) initiation of a 10-foot mock up test that will be used in Phase-II cold testing. The cold test will be conducted at FIU and all testing activities will comply with SRNL Conduct of R&D Protocols (SRNL-IM-2020-00019).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Are You Philanthropy-Ready? How to Work with Foundations on Mission-Aligned Community Solar

Community solar is emerging as a popular way to deliver a range of economic and social benefits that go beyond clean energy. The US Department of Energy (DOE) has set a goal for America to deploy enough community solar projects to power the equivalent of five million households by 2025 and create $1 billion in energy bill savings. To reach the goal, DOE has created the Community Power Accelerator, as part of the National Community Solar Partnership (NCSP). The Accelerator is an online ecosystem bringing together developers, lenders, foundations, community organizations, and other stakeholders to support the deployment of mission-aligned community solar. The Accelerator is especially focused on projects that deliver "meaningful benefits" to customers and communities, including: access by low- to moderate-income households; greater bill savings; resilience and grid benefits; community ownership; and local workforce development. Many philanthropic organizations are looking at community solar as a way to capture these benefits in their grant-making and investment programs, while also reducing pollution and promoting environmental justice. To help community-based organizations (CBOs), non-profit organizations, and mission-aligned developers seeking philanthropic support, Berkeley Lab and the National Renewable Energy Lab prepared Are You Philanthropy-Ready? How to Work with Foundations on Mission-Aligned Community Solar. The guide provides an overview of how foundations work, gives tips on what they seek in a fundable project, and provides guidance on crafting effective proposals. In short, this guide aims to help the fund-seeker become philanthropy-ready.

14 SOLAR ENERGY↗
DOE OSTI2023

Radiation Hardened Foam Cold Test Plan - Phase II: Foam Characterization Testing and Environmental Chamber Testing of FoamBag Fixative Foam

This document outlines the Phase II test objectives and implementation plan for a down-select foam fixative technology intended to facilitate activities in support of the Savannah River Site (SRS) F/H labs deactivation and decommissioning (D&D) efforts. It is a collaborative effort between Savannah River National Laboratory (SRNL), Florida International University (FIU), and the SRS F/H labs team intended to test and evaluate the potential of a polyurethane resin foam in mitigating the release of contamination during dismantling operations on radioactively contaminated piping in legacy facilities. The cold test plan addresses specific requirements highlighted by site and safety personnel and will be executed at FIU and SRNL test and lab facilities. Results from the cold tests will inform the hot test at F/H labs, which will use the foam fixative to confine and/or isolate residual contamination within a 3-dimensional void space of Hastelloy C-22 piping designated for removal from the area and transported to a designated disposal facility. Phase I testing was previously conducted using Hilti CP620 fixative foam. Results from Phase I testing indicate Hilti CP-620 fixative foam is incompatible with SRS site hot taps as an effective foam delivery method into Hastelloy C-22 piping. Phase II testing will be conducted using FoamBag TM fixative foam as an alternative fixative foam option. Phase II testing will address eight test objectives: (1) evaluation of the adhesion and bonding properties of FoamBag TM in Hastelloy C-22 piping, (2) evaluation of the adhesion of FoamBag TM in piping under various moisture conditions, (3) determination of the heat profile of FoamBag TM during curing, (4) determination of the internal pipe pressure after FoamBag TM deployment and curing, (5) conduct a leak test to determine if FoamBag TM is effective at creating a full seal within piping, (6) headspace testing of FoamBag TM to determine if there are any associated off-gas hazards during FoamBag TM curing, (7) conduct environmental chamber testing of FoamBag TM to understand how environmental parameters impacts FoamBag TM curing, and (8) conduct fire testing to evaluate FoamBag TM fire retardant characteristics.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

35 years of CEBAF - Historic Review

Jefferson Lab, the youngest of the DOE Science laboratories, is now more than thirty years old, time to look back and understand how the lab has become a pillar of nuclear physics research in the world. Initially, a 2GeV conventional linac and stretcher ring was foreseen, but as soon as Hermann Grunder was nominated as Lab Director, he changed the design to a superconducting, recirculating linac. It is this accelerator, CEBAF, which has become the workhorse at Jefferson Lab, first at 4 GeV, then 6 GeV, and then an upgrade to 12GeV. The talk will follow this evolution of the accelerator complex.

Hutton, Andrew↗
DOE OSTI2023

Poster commemorates the Laboratory’s 80th anniversary

To celebrate the 80th anniversary of the Laboratory, award-winning artist and graphic designer Paul Ziomek (CEA-MP) created an original commemorative poster for Lab staff. The two-sided poster includes a montage of iconic images from the Lab’s collections in the National Security Research Center. The front showcases historic photographs of the secret laboratory and personnel from 1943 and then today’s National Security Sciences Building headquarters building. The back side includes explanations of the Lab’s earliest scientific achievements and Manhattan Project leader General Leslie Groves and Lab Director J. Robert Oppenheimer.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

Ice Dusty Plasma (Final Report)

The NSF/DOE funding described in this final report was for constructing a substantial upgrade that would enable operation at variable and much lower cryogenic temperatures than was available in a previous experiment that operated from 2013 to 2019. Components for the upgraded experiment were designed and ordered from August to December 2019 and assembly began in early 2020. However, COVID-19 halted all lab work for much of 2020 and then when lab work resumed, numerous restrictions on lab access and in-lab time further impeded progress. Because of these delays, first plasma was obtained in late 2021 and a normal work pace resumed only in mid-2022. A no-cost extension was requested because the COVID-19 delays prevented work from being done at the anticipated rate. Constructing a water-ice experiment was a significant gamble because the parameter regime differs substantially from conventional laboratory plasmas and injecting water vapor into a plasma goes very much against convention as one normally goes to great lengths to avoid water vapor. This experiment opens a new frontier, namely the study of how charged ice grains form, grow, and interact with a plasma environment. The just-completed upgrade was a further gamble because it combines technology never previously used together (cryocoolers, plasma, and ice).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Managing changes in peak demand from building and transportation electrification with energy efficiency [Slides]

The Department of Energy funded Berkeley Lab to provide technical assistance to two municipal utilities on how energy efficiency and demand flexibility can mitigate the peak demand impacts of building and transportation electrification. Berkeley Lab worked with these utilities, Sacramento Municipal Utility District (SMUD) and Fort Collins Utilities, to identify research questions that supported their planning needs. For both utilities, Berkeley Lab developed scenario-based load forecasts that considered baseline and high-efficiency building electrification. For SMUD, the forecast also explored the sensitivity of peak demand to extreme weather (a winter cold snap) at the system-level. For Fort Collins Utilities, the forecast addressed the impacts of low, medium, and high levels of building and transportation technology adoption on select distribution feeders. Berkeley Lab is also developing a guidance document for utilities that will draw on lessons learned from the technical assistance and provide a framework for conducting similar analyses.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Organisation of Diverse Mechanisms of Secondary Ice Production among Basic Convective and Stratiform Cloud-types

This 3-year DoE-funded joint project had the over-arching aim of understanding how ice is initiated in clouds of various types. Focus was given to processes of fragmentation of pre-existing ice, which can occur in positive feedback loops (‘ice multiplication’). A basic question to address was which fragmentation processes prevail in which basic cloud-types. The approach was to use cloud models and field observations, while pioneering our own lab observations of ice initiation to break the deadlock from the past lack of lab observations. Historically, the tendency of the cloud physics community to avoid doing lab observations has allowed a vast gap in knowledge about ice initiation to persist for decades. During the first part of the project, new formulations were created to treat two overlooked types of fragmentation of ice. First, sublimational breakup of ice was treated based on a theoretical formula that we fitted to a pooled dataset of lab observations published previously in the literature. Second, a new mode of fragmentation of freezing raindrops was treated, which involves a supercooled drop being hit by a more massive ice particle. Some of the secondary droplets from the impact freeze. This work was done at Manchester University by Co-I Connolly. Then during the second part, both formulations were implemented in our ‘aerosol-cloud model’ (AC). AC has a hybrid bin/bulk microphysics scheme, and now represents four processes of SIP. The accuracy of AC was evaluated for four cases typifying four basic cloud-types: slightly cold-based stratiform cloud and cold-, warm- and very warm-based convective clouds. We discovered that the warmth of cloud-base, especially in the tropics, promotes SIP processes of raindrop-freezing fragmentation and rime-splintering, and surprisingly, sublimational breakup too. It was found that breakup in ice-ice collisions is ubiquitous. Finally, a portable laboratory chamber was constructed at Lund and deployed in northern Sweden to observe breakup in graupel-snow collisions outdoors. This was seen to be even more prolific than treated in our 2018 formulation. Papers describing results are either published or soon to be published.

54 ENVIRONMENTAL SCIENCES↗