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Techno-Economic Wind Blade Manufacturing Model to Identify Opportunities for Cost Improvements Phase II IACMI Project 4.6/4.8

In IACMI Project 4.6 and IACMI Project 4.8, an Excel-based Techno-Economic Model (TEM) of the manufacturing process for composite wind turbine blades and a DELMIA Factory Flow Simulation of a generic wind blade manufacturing facility was developed. Together, these two tools provide a combined economic modeling capability that accounts for the material, labor, overhead and full-lifecycle operating costs associated with wind blade manufacturing as well as the impact of process flow and factory layout on overall manufacturing efficiency. The tools provide a novel means of detailed comparative analysis of the economic feasibility of proposed technologies and process changes for blade manufacturing. The modeling tools were developed with close support from members of industry and visits to multiple blade manufacturing facilities. With industry oversight, a detailed generalized manufacturing process plan and facility layout were developed with manufacturing parameters, material costs and economic factors based on historical data. Dassault Systèmes and the University of Texas at Dallas (UTD) contributed to the development of the Techno-Economic Model by providing macros to enable the generation of Bill of Material (BOM) data from a 3D blade design in either CATIA or NuMAD format, respectively. The TEM was built with the capability to directly import a Bill of Materials for economic analysis, and with the addition of the macros provided by Dassault and UTD, the TEM can directly import blade designs from both CATIA and NuMAD file formats. The modeling tools developed in Project 4.6 were used to investigate four wind blade manufacturing concepts in detail and select one to explore with laboratory-scale experimentation in Project 4.8. The four manufacturing concepts that were investigated were down-selected by the full project team from a larger list of concepts. The selections were made based on a number of criteria ranking viability and level of interest for each concept. The ‘One-Step Close’ manufacturing concept was ultimately selected for investigation in Project 4.8 and the demonstration was performed at the NREL CoMET facility. The TPI advanced manufacturing facility in Warren, RI contributed the production of several prototype components, the designs for which were developed by Janicki Industries. The demonstration project provided clear indication of the viability of the One-Step Close manufacturing concept for blade manufacturing and good validation of the Techno-Economic Model’s prediction of its economic impact.

17 WIND ENERGY↗

What causes the spread of model projections of ocean dynamic sea-level change in response to greenhouse gas forcing?

Abstract Sea levels of different atmosphere–ocean general circulation models (AOGCMs) respond to climate change forcing in different ways, representing a crucial uncertainty in climate change research. We isolate the role of the ocean dynamics in setting the spatial pattern of dynamic sea-level ( ζ ) change by forcing several AOGCMs with prescribed identical heat, momentum (wind) and freshwater flux perturbations. This method produces a ζ projection spread comparable in magnitude to the spread that results from greenhouse gas forcing, indicating that the differences in ocean model formulation are the cause, rather than diversity in surface flux change. The heat flux change drives most of the global pattern of ζ change, while the momentum and water flux changes cause locally confined features. North Atlantic heat uptake causes large temperature and salinity driven density changes, altering local ocean transport and ζ . The spread between AOGCMs here is caused largely by differences in their regional transport adjustment, which redistributes heat that was already in the ocean prior to perturbation. The geographic details of the ζ change in the North Atlantic are diverse across models, but the underlying dynamic change is similar. In contrast, the heat absorbed by the Southern Ocean does not strongly alter the vertically coherent circulation. The Arctic ζ change is dissimilar across models, owing to differences in passive heat uptake and circulation change. Only the Arctic is strongly affected by nonlinear interactions between the three air-sea flux changes, and these are model specific.

54 ENVIRONMENTAL SCIENCES↗

Assessing Metal Ion Assignment Accuracy in Protein Data Bank Models via Elemental Spectroscopy

Accurate representation of metal ions in macromolecular structures is critical for chemical interpretation, computational modeling, and machine-learning methods that rely on Protein Data Bank (PDB) entries. However, the elemental identity of metals modeled in crystallographic structures is often inferred indirectly and rarely validated experimentally. Here, we combine Particle Induced X-ray Emission (PIXE) and X-ray Fluorescence Spectroscopy (XRFS) to determine the elemental composition of protein samples used to generate 70 deposited metalloprotein crystal structures. By analyzing the original protein material employed for crystallization, but before the addition of crystallization buffer solutions, we assess whether the modeled metal ions in deposited structures are consistent with experimentally detectable elemental content. We find that in a majority of cases, the metals modeled in the corresponding PDB entries are inconsistent with the metals present in the protein samples before crystallization, or that additional metals are present but not represented in the structural models. Spectroscopic results were integrated with automated crystallographic validation metrics, including real-space Z-difference (RSZD) analysis and systematic rerefinement, to evaluate atomic-number mismatch at metal sites. PIXE and XRFS show strong agreement for dominant elemental signals and provide complementary, scalable approaches for identifying suspect metal assignments. This work does not address physiological or functional metalation but instead highlights a widespread data integrity issue in deposited macromolecular structures, PDB-wide. These results establish an experimentally corroborated link between elemental identity and crystallographic validation metrics, enabling the large-scale detection of chemically inconsistent annotations in structural databases used for computational modeling and machine learning.

Crystallization↗

IPPOG: a global network for particle physics outreach and education

We present the International Particle Physics Outreach Group (IPPOG), a global network dedicated to connecting students, educators, and the general public with the world of particle physics. In this paper, we outline the need to bridge the existing gap between the particle physics community and the wider audience, and we present the solutions that IPPOG has implemented to overcome it through three pillar Activities: the International Masterclasses and the Global Cosmics hands-on activities network, which have engaged together over 200,000 high-school students to date, and the curation of an Outreach Resource Database and web portal.

Abreu, Pedro [University of Lisboa (Portugal); IPP↗

Selected advances in the accelerator design of the Future Circular Electron-Positron Collider (FCC-ee)

In autumn 2023, the FCC Feasibility Study underwent a crucial “mid-term review”. We describe some accelerator performance risks for the proposed future circular electron-positron collider, FCC-ee, identified for, and during, the mid-term review. For the collider rings, these are the collective effects when running on the Z resonance – especially resistive wall, beam-beam, and electron cloud –, the beam lifetime, dynamic aperture, alignment tolerances, and beam-based alignment. For the booster, the primary concern is the vacuum system, with regard to impedance and effects of the residual gas. For the injector, the layout and the linac repetition rate are primary considerations. We discuss the various issues and report the planned mitigations.

43 PARTICLE ACCELERATORS↗