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At least 19 records

Ultrasonic Testing (UT) Reference Standard for Additive Manufacturing Quality Control

Many additive manufacturing (AM) reference standards for build quality verification concentrate primarily on external features. In contrast, EPRI proposes a pair of AM reference blocks that feature only internal and embedded forms. This report presents, collates, and discusses quantitative nondestructive evaluation (NDE) results from various techniques, including visual testing (VT), radiographic testing (RT), conventional ultrasonic testing (UT), and full matrix capture/total focusing method (FMC/TFM) scanning. The blocks are intended, as part of a larger series of blocks, to evaluate build quality and the relative performance of different NDE techniques in detecting various features. The limits of detectability and the closeness of the as-built shape to the intended form for certain features are quantified, facilitating direct comparison. Upon analysis of the results of this testing, it was found that FMC/TFM was consistently superior in detection, followed by conventional UT, then VT, and lastly RT.

36 MATERIALS SCIENCE↗

Ultrasonic Testing (UT) and Computed Tomography (CT) Comparative Scanning of Proposed Additive Manufacturing Reference Standard

This report presents qualitative results of ultrasonic full matrix capture/total focusing method (FMC/TFM) scanning of two series of blocks, additively manufactured by powder bed fusion, containing a variety of internal features and structures that would not be achievable by conventional manufacturing techniques. The purpose of the first series of additively manufactured (AM) blocks was to explore the possibility of building calibration blocks for FMC/TFM ultrasonic testing (UT). It was confirmed that AM is a suitable candidate for generation of unusual and novel reflector forms, such as rotating slots, purposely embedded voids, and tapering holes, and that FMC/TFM was very capable of characterizing them. The intended use of the second series of AM blocks was as UT reference blocks to characterize the AM process quality or the interrogating UT technique. The larger block in this series was scanned from multiple faces, using multiple UT methods (conventional UT and FMC/TFM) and X-ray computed tomography for comparative purposes. The performance of each method was quantified by a metric corresponding to the detection limit of each feature, and the quantitative results are discussed.

36 MATERIALS SCIENCE↗

Multiple Scattering Effects of Trees on L-band Microwave Using a Hybrid Method

The multiple scattering of electromagnetic waves in forests is studied using a two-step hybrid method. First, the T-matrix of a single tree is calculated based on its far-field computed with the full-wave simulations of the FEKO software. The T-matrix captures the multiple scattering caused by the tree structure. Second, the the interactions among different trees are considered using the T-matrices of the individual trees and the Foldy-Lax equations. The result of the two-step hybrid method is validated with FEKO by solving scattering from two trees directly. The multiple scattering effects are illustrated by the field solutions.

Yueh, Simon↗

Multi-Frequency NMM3D Simulations of Wave Propagation in Vegetation for Remote Sensing of Soil Moisture

To investigate the feasibility of using multi-frequencies to fur- ther improve the soil moisture retrieval, the recently devel- oped hybrid method is used to perform full-wave scattering simulations of a wheat field at three different frequencies of L-, S- and C- bands. In the hybrid method, the multiple scattering within a single wheat plant is first captured using the T-matrix of vec- tor cylindrical waves calculated from the full-wave solutions of HFSS. In the second step, the scattering among different plants is considered using the Foldy-Lax equations of multiple scattering theory (MST) and the extracted T-matrix. The transmission of microwaves through wheat field at the L-, S- and C-bands are calculated using the hybrid method. Results show that: (1) the transmission obtained from the full-wave simulations is much larger than those computed from the radiative transfer equations (RTE) model, (2) the hybrid method transmission has a weaker frequency dependence than those of the RTE, and (3) the attenuation caused by the vegetation layer would saturate with an increase in frequency.

Yueh, Simon↗

A Framework for Propagation of Uncertainties in the Kepler Data Analysis Pipeline

The Kepler space telescope is designed to detect Earth-like planets around Sun-like stars using transit photometry by simultaneously observing 100,000 stellar targets nearly continuously over a three and a half year period. The 96-megapixel focal plane consists of 42 charge-coupled devices (CCD) each containing two 1024 x 1100 pixel arrays. Cross-correlations between calibrated pixels are introduced by common calibrations performed on each CCD requiring downstream data products access to the calibrated pixel covariance matrix in order to properly estimate uncertainties. The prohibitively large covariance matrices corresponding to the ~75,000 calibrated pixels per CCD preclude calculating and storing the covariance in standard lock-step fashion. We present a novel framework used to implement standard propagation of uncertainties (POU) in the Kepler Science Operations Center (SOC) data processing pipeline. The POU framework captures the variance of the raw pixel data and the kernel of each subsequent calibration transformation allowing the full covariance matrix of any subset of calibrated pixels to be recalled on-the-fly at any step in the calibration process. Singular value decomposition (SVD) is used to compress and low-pass filter the raw uncertainty data as well as any data dependent kernels. The combination of POU framework and SVD compression provide downstream consumers of the calibrated pixel data access to the full covariance matrix of any subset of the calibrated pixels traceable to pixel level measurement uncertainties without having to store, retrieve and operate on prohibitively large covariance matrices. We describe the POU Framework and SVD compression scheme and its implementation in the Kepler SOC pipeline.

Clarke, Bruce D.↗

Fracture of Carbon Nanotube - Amorphous Carbon Composites: Molecular Modeling

Carbon nanotubes (CNTs) are promising candidates for use as reinforcements in next generation structural composite materials because of their extremely high specific stiffness and strength. They cannot, however, be viewed as simple replacements for carbon fibers because there are key differences between these materials in areas such as handling, processing, and matrix design. It is impossible to know for certain that CNT composites will represent a significant advance over carbon fiber composites before these various factors have been optimized, which is an extremely costly and time intensive process. This work attempts to place an upper bound on CNT composite mechanical properties by performing molecular dynamics simulations on idealized model systems with a reactive forcefield that permits modeling of both elastic deformations and fracture. Amorphous carbon (AC) was chosen for the matrix material in this work because of its structural simplicity and physical compatibility with the CNT fillers. It is also much stiffer and stronger than typical engineering polymer matrices. Three different arrangements of CNTs in the simulation cell have been investigated: a single-wall nanotube (SWNT) array, a multi-wall nanotube (MWNT) array, and a SWNT bundle system. The SWNT and MWNT array systems are clearly idealizations, but the SWNT bundle system is a step closer to real systems in which individual tubes aggregate into large assemblies. The effect of chemical crosslinking on composite properties is modeled by adding bonds between the CNTs and AC. The balance between weakening the CNTs and improving fiber-matrix load transfer is explored by systematically varying the extent of crosslinking. It is, of course, impossible to capture the full range of deformation and fracture processes that occur in real materials with even the largest atomistic molecular dynamics simulations. With this limitation in mind, the simulation results reported here provide a plausible upper limit on achievable CNT composite properties and yield some insight on the influence of processing conditions on the mechanical properties of CNT composites.

Jensen, Benjamin D.↗

Capturing electronic decoherence in quantum-classical dynamics using the ring-polymer-surface-hopping–density-matrix approach

Simulations of coupled electronic and nuclear dynamics in molecules can be quite challenging due to the involved interplay of the many degrees of freedom. Because a full quantum treatment of both electrons and nuclei is computationally very demanding, it is generally restricted to model systems or rather small molecules and short timescales. Mixed quantum-classical dynamics methods such as Tully's fewest switches surface hopping (FSSH) can be used to overcome this limitation. However, FSSH is known to poorly describe electronic coherences and decoherence phenomena. Here, we present an approach that combines FSSH with ring-polymer molecular dynamics (RPMD) in a specific way that aims to alleviate the coherence problem. Termed the ring-polymer-surface-hopping–density-matrix approach, this method uses an electronic density-matrix formulation to calculate surface hopping rates. Additionally, this incorporates decoherence effects into FSSH in a natural way by taking into account the spatial spreading of the ring polymer that mimics the width of a nuclear wave packet in each RPMD trajectory. By applying our method to Tully's one-dimensional model system, we demonstrate that this method captures a crucial decoherence mechanism that is missing in FSSH. Furthermore, our method turns out to be superior at describing electronic coherences compared with earlier attempts at combining RPMD and FSSH.

74 ATOMIC AND MOLECULAR PHYSICS↗

Wide Range SET Pulse Measurement

A method for measuring a wide range of SET pulses is demonstrated. Use of dynamic logic, faster than ordinary CMOS, allows capture of short pulses. A weighted binning of SET lengths allows measurement of a wide range of pulse lengths with compact circuitry. A pulse-length-conservative pulse combiner tree routes SETs from combinational logic to the measurement circuit, allowing SET measurements in circuits that cannot easily be arranged in long chains. The method is applied to add-multiplex combinational logic, and to an array of NFET routing switches, at .35 micron. Pulses are captured in a chain of Domino Logic AND gates. Propagation through the chain is frozen on the trailing edge by dropping low the second "enable" input to the AND gates. Capacitive loading is increased in the latter stages to create an approximately logarithmic weighted binning, so that a broad range of pulse lengths can be captured with a 10 stage capture chain. Simulations show pulses can be captured which are 1/5th the length of those typically captured with leading edge triggered latch methods, and less than the length of those captured with a trailing edge latch method. After capture, the pulse pattern is transferred to an SEU protected shift register for readout. 64 instances of each of two types of logic are used as targets. One is a full adder with a 4 to 1 mux on its inputs. The other is a 4 x 4 NFET routing matrix. The outputs are passed through buffered XNOR comparators to identify pulses, which are merged in a buffered not-nand (OR) tree designed to avoid pulse absorption as much as possible. The output from each of the two test circuits are input into separate pulse measurement circuits. Test inputs were provided so that the circuit could be bench tested and calibrated. A third SET measurement circuit with no inputs was used to judge the contribution from direct hits on the measurement circuit. Heavy ions were used with an LET range from 12 to 176. At LET of 21 and below, the very small number of SETs were not significantly higher in the test over the control circuits. At higher LET the test circuit SETs are one or two orders of magnitude greater than for the control circuit. The NFET circuit produces more and slightly longer SETs as expected. But the differences do not appear to be significant enough to modify strategies now used to avoid capture of SETs in chips such as FPGAs. Complete data and graphs will be in the full paper / presentation. In the summary figure below left, NOCL is the reference circuit without any input, and number of stages triggered is plotted. Simulation at right shows the smallest pulse captured (stage 2) at about 300 ps. Our conclusion is that the method is promising, but that improvements in the merge network are desirable before applying in a deep submicron process

Shuler, Robert L.↗

Improved Subcell Model for the Prediction of Braided Composite Response

In this work, the modeling of triaxially braided composites was explored through a semi-analytical discretization. Four unique subcells, each approximated by a "mosaic" stacking of unidirectional composite plies, were modeled through the use of layered-shell elements within the explicit finite element code LS-DYNA. Two subcell discretizations were investigated: a model explicitly capturing pure matrix regions, and a novel model which absorbed pure matrix pockets into neighboring tow plies. The in-plane stiffness properties of both models, computed using bottom-up micromechanics, correlated well to experimental data. The absorbed matrix model, however, was found to best capture out-of- plane flexural properties by comparing numerical simulations of the out-of-plane displacements from single-ply tension tests to experimental full field data. This strong correlation of out-of-plane characteristics supports the current modeling approach as a viable candidate for future work involving impact simulations.

Cater, Christopher R.↗

Component modes damping assignment methodology for articulated, multiflexible body structures

To simulate the dynamical motion of articulated, multiflexible body structures, one can use multibody simulation packages such as DISCOS. To this end, one must supply appropriate reduced-order models for all of the flexible components involved. The component modes projection and assembly model reduction (COMPARE) methodology is one way to construct these reduced-order component models, which when reassembled capture important system input-to-output mapping of the full-order model at multiple system configurations of interest. In conjunction, we must also supply component damping matrices which when reassembled generate a system damping matrix that has certain desirable properties. The problem of determining the damping factors of components' modes to achieve a given system damping matrix is addressed here. To this end, we must establish from first principles a matrix-algebraic relation between the system's modal damping matrix and the components' modal damping matrices. An unconstrained/constrained optimization problem can then be formulated to determine the component modes' damping factors that best satisfy that matrix-algebraic relation. The effectiveness of the developed methodology, called ModeDamp, has been successfully demonstrated on a high-order, finite element model of the Galileo spacecraft.

Lee, Allan Y.↗

G-DYN Multibody Dynamics Engine

G-DYN is a multi-body dynamic simulation software engine that automatically assembles and integrates equations of motion for arbitrarily connected multibody dynamic systems. The algorithm behind G-DYN is based on a primal-dual formulation of the dynamics that captures the position and velocity vectors (primal variables) of each body and the interaction forces (dual variables) between bodies, which are particularly useful for control and estimation analysis and synthesis. It also takes full advantage of the spare matrix structure resulting from the system dynamics to numerically integrate the equations of motion efficiently. Furthermore, the dynamic model for each body can easily be replaced without re-deriving the overall equations of motion, and the assembly of the equations of motion is done automatically. G-DYN proved an essential software tool in the simulation of spacecraft systems used for small celestial body surface sampling, specifically in simulating touch-and-go (TAG) maneuvers of a robotic sampling system from a comet and asteroid. It is used extensively in validating mission concepts for small body sample return, such as Comet Odyssey and Galahad New Frontiers proposals.

Acikmese, Behcet↗

Power capture and power take-off load of a self-balanced dual-flap oscillating surge wave energy converter

Wave energy converters are an important part of future renewable energy infrastructure. Predicting their power matrix, capture width ratio, and power take-off loads at a targeted site is required for performance assessment before deployment. Because their testing is very expensive, numerical modeling and simulations play a significant role in those assessments. Linear potential flow theory has limited accuracy under large amplitude wave forcing. More accurate predictions can be obtained by using higher-fidelity models, which are computationally expensive. We present a framework for multi-fidelity numerical simulations to determine the hydrodynamic response, wave capture capability, and power take-off load of a full-scale dual-flap oscillating surge wave energy converter. This design exploits out-of-phase motion by setting the distance between the flaps to half the wavelength of the most occurring wave. The simulations are validated using a 1:10 model experiments in a wave tank. Based on these validations, it was determined that Euler simulations provide an acceptable prediction with 90% reduction in computational time with only 11% error. Utilizing Euler simulations at full-scale, the results demonstrate that the annual electrical energy output is 1.79 GWh under regular wave conditions. Here, one significant improvement over single-flap designs is the capture width ratio which exceeds unity.

16 TIDAL AND WAVE POWER↗

3D TRISO particle-explicit compact meshing

The TRI-structural ISOtropic (TRISO) layered fuel particle is a robust nuclear fuel form offering enhanced safety and performance for advanced reactor concepts, including high-temperature gas-cooled reactors and other Generation IV designs. These poppy-seed-sized particles are embedded in a graphite matrix to form fuel elements that must withstand elevated temperatures and high burn-up levels. The heterogeneous nature of these fuel elements — comprising thousands of randomly distributed TRISO particles — produces complex stress fields and thermal gradients that one- and two-dimensional models cannot accurately capture. While three-dimensional modeling has improved predictions of dimensional changes, internal pressure buildup, and fission product transport under irradiation, current approaches rely on homogenized material properties that are known to have considerable divergence from experimental observations. This work presents a methodology for optimized random packing of TRISO fuel compacts and full three-dimensional mesh generation within the BISON fuel performance code, with each particle coating layer individually discretized. The resulting mesh was demonstrated through heat conduction simulations under representative in-reactor operating conditions, showing strong agreement with expected behavior. This capability enables detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating layer failures — all of which directly govern fuel performance and safety margins.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Equation-Free Coarse Control of Distributed Parameter Systems via Local Neural Operators

The control of high-dimensional distributed parameter systems (DPS) remains a challenge when explicit coarse-grained equations are unavailable. Classical equation-free (EF) approaches rely on fine-scale simulators treated as black-box timesteppers. However, repeated simulations for steady-state computation, linearization, and control design are often computationally prohibitive, or the microscopic timestepper may not even be available, leaving us with data as the only resource. We propose a data-driven alternative that uses local neural operators, trained on spatiotemporal microscopic/mesoscopic data, to obtain efficient short-time solution operators. These surrogates are employed within Krylov subspace methods to compute coarse steady and unsteady-states, while also providing Jacobian information in a matrix-free manner. Krylov-Arnoldi iterations then approximate the dominant eigenspectrum, yielding reduced models that capture the open-loop slow dynamics without explicit Jacobian assembly. Both discrete-time Linear Quadratic Regulator (dLQR) and pole-placement (PP) controllers are based on this reduced system and lifted back to the full nonlinear dynamics, thereby closing the feedback loop.

93B52, 93C20, 47N70, 65J15, 65M32, 68T07, 68T20, 6↗

Neutron Capture and Transmission Measurements and Evaluation of 54 Fe at the RPI LINAC [Slides]

This presentation covers neutron capture and transmission measurements and evaluation of 54 Fe (Iron) at the Rensselaer Polytechnic Insitute (RPI) Linear Accelerator (LINAC). Presentation conclusions find that 54 Fe is near its conclusion, covariance matrix generation is needed for both experiments before data is made available and released (Completion by April 2023). RPI will be conducting a full Resolved Resonance Region (RRR) evaluation following release of data (Completion by September 2023). Additionally, the neutron beam imager shows promise in providing an easy way to align samples in the most intense part of the neutron beam and there will be a new evaluation that will offer improvements in crit safety, shielding, and stellar applications.

07 ISOTOPE AND RADIATION SOURCES↗

Assessing the National Off-Cycle Benefits of 2-Layer HVAC Technology Using Dynamometer Testing and a National Simulation Framework

Some CO2-reducing technologies have real-world benefits not captured by regulatory testing methods. This paper documents a two-layer heating, ventilation, and air-conditioning (HVAC) system that facilitates faster engine warmup through strategic increased air recirculation. The performance of this technology was assessed on a 2020 Hyundai Sonata. Empirical performance of the technology was obtained through dynamometer tests at Argonne National Laboratory. Performance of the vehicle across multiple cycles and cell ambient temperatures with the two-layer technology active and inactive indicated fuel consumption reduction in nearly all cases. A thermally sensitive powertrain model, the National Renewable Energy Laboratory's FASTSim Hot, was calibrated and validated against vehicle testing data. The developed model included the engine, cabin, and HVAC system controls. Validation of component thermal models and engine efficiency ensured accurate thermal dynamics, fuel consumption, and two-layer benefit. The real-world benefit of the two-layer technology was calculated by simulating the validated powertrain model across a representative test matrix comparing performance with and without the two-layer system. Simulation across the test matrix revealed a real-world representative benefit of 0.0835%. Analysis of test matrix results at the regional level revealed the most benefit in cold climates and rural regions. Mean results across cycle length sensitivity simulations revealed a larger real-world benefit of 0.0872%. These benefit values can be considered a more accurate assessment of real-world technology performance. Future work is planned to explore the requisite number of drive cycles to ensure the full technology benefit is captured.

2-layer↗

FEED Study of CarbonCapture Inc DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat (Final Report)

The University of Illinois at Urbana-Champaign (UIUC) led this project to produce a front-end engineering design (FEED) study of an advanced Direct Air Capture and Utilization System (DACUS) system that can remove a minimum of 5,000 tonnes/yr net of carbon dioxide from air (based on cradle-to-gate LCA) and utilizing the CO 2 to produce low carbon intensity ready mix concrete. The designed system, if built, would be larger than any currently existing Direct Air Capture (DAC) collector in the U.S. Such carbon capture technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. In addition to the power sector, industrial facilities for the manufacture of steel and cement/concrete are among the major sources of anthropogenic CO 2 . DAC is a promising new technology for reducing CO 2 , a potent greenhouse gas, in the atmosphere but is expensive, in part due to the energy required to adsorb and desorb captured CO 2 during cycles. By integrating CarbonCapture Inc. (CCI) DAC modules at United States Steel's Gary Works (USS) and utilizing the site's waste heat, energy, and location this project evaluates the feasibility of utilizing the captured CO 2 and the logistics of transportation. CarbonCapture Inc. has developed an innovative DAC system using novel adsorbents to cost-effectively capture CO 2 . The captured, liquified gas will be trucked to ready-mix concrete plants within the region, the closest of which is approximately 3.5 miles away, where CarbonCure will inject it into concrete during the mixing process at the facilities. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO 3 ), permanently locking the greenhouse gas into the matrix of the building material. This FEED study demonstrated a full CO 2 value chain for DACUS from industrial facilities. It also provided a means for Visage Energy Corp. (Visage) to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. The project team also included Sargent & Lundy (S&L) to provide the constructability review and costing of the integration of the DAC with the steel plant. Ecotek Engineering USA, LLC designed the outside battery limit (OSBL) infrastructure to connect the DAC and the plant. Activities performed during the project included: (1) Project Management Plan; (2) Technology Maturation Plan (TMP); (3) Initial Workforce Readiness Plan; (4) Workforce Readiness Plan; (5) Front-End Engineering Design (FEED) Study; (6) Project Design Basis; (7) Hazards and Operability (HAZOP) Study; (8) Constructability Review; (9) Project Cost Assessment; (10) Logistics Analysis of CO 2 Transportation to the Utilization Site; (11) Business Case Analysis; (12) Life Cycle Analysis (LCA); (13) Environmental Health and Safety (EH&S) Analysis; (14) Environmental Justice Analysis; and (15) Economic Revitalization and Job Creation Outcomes Analysis. This report provides a summary of the outcomes and results of the project, which was performed between Oct. 1, 2022, through Sept. 30, 2024.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Elastic Model Transitions: A Hybrid Approach Utilizing Quadratic Inequality Constrained Least Squares (LSQI) and Direct Shape Mapping (DSM)

A method for transitioning linear time invariant (LTI) models in time varying simulation is proposed that utilizes a hybrid approach for determining physical displacements by augmenting the original quadratically constrained least squares (LSQI) algorithm with Direct Shape Mapping (DSM) and modifying the energy constraints. The approach presented is applicable to simulation of the elastic behavior of launch vehicles and other structures that utilize discrete LTI finite element model (FEM) derived mode sets (eigenvalues and eigenvectors) that are propagated throughout time. The time invariant nature of the elastic data presents a problem of how to properly transition elastic states from the prior to the new model while preserving motion across the transition and ensuring there is no truncation or excitation of the system. A previous approach utilizes a LSQI algorithm with an energy constraint to effect smooth transitions between eigenvector sets with no requirement that the models be of similar dimension or have any correlation. This approach assumes energy is conserved across the transition, which results in significant non-physical transients due to changing quasi-steady state energy between mode sets, a phenomenon seen when utilizing a truncated mode set. The computational burden of simulating a full mode set is significant so a subset of modes is often selected to reduce run time. As a result of this truncation, energy between mode sets may not be constant and solutions across transitions could produce non-physical transients. In an effort to abate these transients an improved methodology was developed based on the aforementioned approach, but this new approach can handle significant changes in energy across mode set transitions. It is proposed that physical velocities due to elastic behavior be solved for using the LSQI algorithm, but solve for displacements using a two-step process that independently addresses the quasi-steady-state and non-steady-state contributions to the elastic displacement. For structures subject to large external forces, such as thrust or atmospheric drag, it is imperative to capture these forces when solving for elastic displacement. To simplify the mathematical formulation, assumptions are made regarding mass matrix normalization, constant external forcing, and constant viscous damping. These simplifications allow for direct solutions to the quasi-steady-state displacements through a process titled Direct Shape Mapping. DSM solves for the displacements using the eigenvalues of the elastic modes and the external forcing and returns a set of elastic displacements dictated by the eigenvectors of the post-transition mode set. For the non-steady-state contributions to displacement we formulate a LSQI problem that is constrained by energy of the non-steady state terms. The contributions from the quasi-steady-state and non-steady state solutions are then combined to obtain the physical displacements associated with the new set of eigenvectors. Results for the LSQI-DSM approach show significant reduction/complete removal of transients across mode set transitions while maintaining elastic motion from the prior state. For time propagation applications employing discrete elastic models that need to be transitioned in time and where running with full a full mode set is not feasible, the method developed offers a practical solution to simulating vehicle elasticity.

Hannan, Mike R.↗