Publications

This paper presents a die-embedded glass interposer with minimum warpage for 5G/6G applications. The interposer performs high integration with low-loss interconnects by embedding multiple chips in the same glass substrate and interconnecting the chips through redistributive layers (RDL). Novel processes for cavity creation, multi-die embedding, carrier- less RDL build up and heat spreader attachment are proposed and demonstrated in this work. Performance of the interposer from 1 GHz to 110 GHz are evaluated. This work provides an advanced packaging solution for low-loss die-to-die and die-to-package interconnects, which is essential to high performance wireless system integration.

Unlike traditional base excitation vibration qualification testing, multi-axis vibration testing methods can be significantly faster and more accurate. Here, a 12-shaker multiple-input/multiple-output (MIMO) test method called intrinsic connection excitation (ICE) is developed and assessed for use on an example aerospace component. In this study, the ICE technique utilizes 12 shakers, 1 for each boundary condition attachment degree of freedom to the component, specially designed fixtures, and MIMO control to provide an accurate set of loads and boundary conditions during the test. Acceleration, force, and voltage control provide insight into the viability of this testing method. System field test and ICE test results are compared to traditional single degree of freedom specification development and testing. Results indicate the multi-shaker ICE test provided a much more accurate replication of system field test response compared with single degree of freedom testing.

Modern Industrial Control Systems (ICS) attacks evade existing tools by using knowledge of ICS processes to blend their activities with benign Supervisory Control and Data Acquisition (SCADA) operation, causing physical world damages. We present Scaphy to detect ICS attacks in SCADA by leveraging the unique execution phases of SCADA to identify the limited set of legitimate behaviors to control the physical world in different phases, which differentiates from attacker's activities. For example, it is typical for SCADA to setup ICS device objects during initialization, but anomalous during process-control. To extract unique behaviors of SCADA execution phases, Scaphy first leverages open ICS conventions to generate a novel physical process dependency and impact graph (PDIG) to identify disruptive physical states. Scaphy then uses PDIG to inform a physical process-aware dynamic analysis, whereby code paths of SCADA process-control execution is induced to reveal API call behaviors unique to legitimate process-control phases. Using this established behavior, Scaphy selectively monitors attacker's physical world-targeted activities that violates legitimate process-control behaviors. We evaluated Scaphy at a U.S. national lab ICS testbed environment. Using diverse ICS deployment scenarios and attacks across 4 ICS industries, Scaphy achieved 95% accuracy & 3.5% false positives (FP), compared to 47.5% accuracy and 25% FP of existing work. We analyze Scaphy's resilience to futuristic attacks where attacker knows our approach.

Phosphor thermometry has become an established remote sensing technique for acquiring the temperature of surfaces and gas-phase flows. Often, phosphors are excited by a light source (typically emitting in the UV region), and their temperature-sensitive emission is captured. Temperature can be inferred from shifts in the emission spectra or the radiative decay lifetime during relaxation. While recent work has shown that the emission of several phosphors remains thermographic during x-ray excitation, the radiative decay lifetime was not investigated. The focus of the present study is to characterize the lifetime decay of the phosphor Gd2O2S:Tb for temperature sensitivity after excitation from a pulsed x-ray source. These results are compared to the lifetime decays found for this phosphor when excited using a pulsed UV laser. Results show that the lifetime of this phosphor exhibits comparable sensitivity to temperature between both excitation sources for a temperature range between 21 °C to 140 °C in increments of 20 °C. This work introduces a novel method of thermometry for researchers to implement when employing x-rays for diagnostics.

The Information Harm Triangle (IHT) is a novel approach that aims to adapt intuitive engineering concepts to simplify defense in depth for instrumentation and control (I&C) systems at nuclear power plants. This approach combines digital harm, real-world harm, and unsafe control actions (UCAs) into a single graph named “Information Harm Triangle.” The IHT is based on the postulation that the consequences of cyberattacks targeting I&C systems can be expressed in terms of two orthogonal components: a component representing the magnitude of data harm (DH) (i.e., digital information harm) and a component representing physical information harm (PIH) (i.e., real-world harm, e.g., an inadvertent plant trip). The magnitude of the severity of the physical consequence is the aspect of risk that is of concern. The sum of these two components represents the total information harm. The IHT intuitively informs risk-informed cybersecurity strategies that employ independent measures that either act to prevent, reduce, or mitigate DH or PIH. Another aspect of the IHT is that the DH can result in cyber-initiated UCAs that result in severe physical consequences. The orthogonality of DH and PIH provides insights into designing effective defense in depth. The IHT can also represent cyberattacks that have the potential to impede, evade, or compromise countermeasures from taking appropriate action to reduce, stop, or mitigate the harm caused by such UCAs. Cyber-initiated UCAs transform DH to PIH.

The structure-property linkage is one of the two most important relationships in materials science besides the process-structure linkage, especially for metals and polycrystalline alloys. The stochastic nature of microstructures begs for a robust approach to reliably address the linkage. As such, uncertainty quantification (UQ) plays an important role in this regard and cannot be ignored. To probe the structure-property linkage, many multi-scale integrated computational materials engineering (ICME) tools have been proposed and developed over the last decade to accelerate the material design process in the spirit of Material Genome Initiative (MGI), notably crystal plasticity finite element model (CPFEM) and phase-field simulations. Machine learning (ML) methods, including deep learning and physics-informed/-constrained approaches, can also be conveniently applied to approximate the computationally expensive ICME models, allowing one to efficiently navigate in both structure and property spaces effortlessly. Since UQ also plays a crucial role in verification and validation for both ICME and ML models, it is important to include UQ in the picture. In this paper, we summarize a few of our recent research efforts addressing UQ aspects of homogenized properties using CPFEM in a big picture context.

Machining-based deformation processing is used to produce metal foil and flat wire (strip) with suitable properties and quality for electrical power and renewable energy applications. In contrast to conventional multistage rolling, the strip is produced in a single-step and with much less process energy. Examples are presented from metal systems of varied workability, and strip product scale in terms of size and production rate. By utilizing the large-strain deformation intrinsic to cutting, bulk strip with ultrafine-grained microstructure, and crystallographic shear-texture favourable for formability, are achieved. Implications for production of commercial strip for electric motor applications and battery electrodes are discussed.

Multiple Input Multiple Output (MIMO) vibration testing provides the capability to expose a system to a field environment in a laboratory setting, saving both time and money by mitigating the need to perform multiple and costly large-scale field tests. However, MIMO vibration test design is not straightforward oftentimes relying on engineering judgment and multiple test iterations to determine the proper selection of response Degree of Freedom (DOF) and input locations that yield a successful test. This work investigates two DOF selection techniques for MIMO vibration testing to assist with test design, an iterative algorithm introduced in previous work and an Optimal Experiment Design (OED) approach. The iterative-based approach downselects the control set by removing DOF that have the smallest impact on overall error given a target Cross Power Spectral Density matrix and laboratory Frequency Response Function (FRF) matrix. The Optimal Experiment Design (OED) approach is formulated with the laboratory FRF matrix as a convex optimization problem and solved with a gradient-based optimization algorithm that seeks a set of weighted measurement DOF that minimize a measure of model prediction uncertainty. The DOF selection approaches are used to design MIMO vibration tests using candidate finite element models and simulated target environments. The results are generalized and compared to exemplify the quality of the MIMO test using the selected DOF.

Creation of a Sandia internally developed, shock-hardened Recoverable Data Recorder (RDR) necessitated experimentation by ballistically-firing the device into water targets at velocities up to 5,000 ft/s. The resultant mechanical environments were very severe—routinely achieving peak accelerations in excess of 200 kG and changes in pseudo-velocity greater than 38,000 inch/s. High-quality projectile deceleration datasets were obtained though high-speed imaging during the impact events. The datasets were then used to calibrate and validate computational models in both CTH and EPIC. Hydrodynamic stability in these environments was confirmed to differ from aerodynamic stability; projectile stability is maintained through a phenomenon known as “tail-slapping” or impingement of the rear of the projectile on the cavitation vapor-water interface which envelopes the projectile. As the projectile slows the predominate forces undergo a transition which is outside the codes’ capabilities to calculate accurately, however, CTH and EPIC both predict the projectile trajectory well in the initial hypervelocity regime. Stable projectile designs and the achievable acceleration space are explored through a large parameter sweep of CTH simulations. Front face chamfer angle has the largest influence on stability with low angles being more stable.

The widespread adoption of residential solar PV requires distribution system studies to ensure the addition of solar PV at a customer location does not violate the system constraints, which can be referred to as locational hosting capacity (HC). These model-based analyses are prone to error due to their dependencies on the accuracy of the system information. Model-free approaches to estimate the solar PV hosting capacity for a customer can be a good alternative to this approach as their accuracies do not depend on detailed system information. In this paper, an Adaptive Boosting (AdaBoost) algorithm is deployed to utilize the statistical properties (mean, minimum, maximum, and standard deviation) of the customer's historical data (real power, reactive power, voltage) as inputs to estimate the voltage-constrained PV HC for the customer. A baseline comparison approach is also built that utilizes just the maximum voltage of the customer to predict PV HC. The results show that the ensemble-based AdaBoost algorithm outperformed the proposed baseline approach. The developed methods are also compared and validated by existing state-of-the-art model-free PV HC estimation methods.

Experiments were conducted on a wave tank model of a bottom raised oscillating surge wave energy converter (OSWEC) model in regular waves. The OSWEC model shape was a thin rectangular flap, which was allowed to pitch in response to incident waves about a hinge located at the intersection of the flap and the top of the supporting foundation. Torsion springs were added to the hinge in order to position the pitch natural frequency at the center of the wave frequency range of the wave maker. The flap motion as well as the loads at the base of the foundation were measured. The OSWEC was modeled analytically using elliptic functions in order to obtain closed form expressions for added mass and radiation damping coefficients, along with the excitation force and torque. These formulations were derived and reported in a previous publication by the authors. While analytical predictions of the foundation loads agree very well with experiments, large discrepancies are seen in the pitch response close to resonance. These differences are analyzed by conducting a sensitivity study, in which system parameters, including damping and added mass values, are varied. The likely contributors to the differences between predictions and experiments are attributed to tank reflections, standing waves that can occur in long, narrow wave tanks, as well as the thin plate assumption employed in the analytical approach.

Computational simulation allows scientists to explore, observe, and test physical regimes thought to be unattainable. Validation and uncertainty quantification play crucial roles in extrapolating the use of physics-based models. Bayesian analysis provides a natural framework for incorporating the uncertainties that undeniably exist in computational modeling. However, the ability to perform quality Bayesian and uncertainty analyses is often limited by the computational expense of first-principles physics models. In the absence of a reliable low-fidelity physics model, phenomenological surrogate or machine learned models can be used to mitigate this expense; however, these data-driven models may not adhere to known physics or properties. Furthermore, the interactions of complex physics in high-fidelity codes lead to dependencies between quantities of interest (QoIs) that are difficult to quantify and capture when individual surrogates are used for each observable. Although this is not always problematic, predicting multiple QoIs with a single surrogate preserves valuable insights regarding the correlated behavior of the target observables and maximizes the information gained from available data. A method of constructing a Gaussian Process (GP) that emulates multiple QoIs simultaneously is presented. As an exemplar, we consider Magnetized Liner Inertial Fusion, a fusion concept that relies on the direct compression of magnetized, laser-heated fuel by a metal liner to achieve thermonuclear ignition. Magneto-hydrodynamics (MHD) codes calculate diagnostics to infer the state of the fuel during experiments, which cannot be measured directly. The calibration of these diagnostic metrics is complicated by sparse experimental data and the expense of high-fidelity neutron transport models. The development of an appropriate surrogate raises long-standing issues in modeling and simulation, including calibration, validation, and uncertainty quantification. The performance of the proposed multi-output GP surrogate model, which preserves correlations between QoIs, is compared to the standard single-output GP for a 1D realization of the MagLIF experiment.

This paper describes the methodology of designing a replacement blade tip and winglet for a wind turbine blade to demonstrate the potential of additive-manufacturing for wind energy. The team will later field-demonstrate this additive-manufactured, system-integrated tip (AMSIT) on a wind turbine. The blade tip aims to reduce the cost of wind energy by improving aerodynamic performance and reliability, while reducing transportation costs. This paper focuses on the design and modeling of a winglet for increased power production while maintaining acceptable structural loads of the original Vestas V27 blade design. A free-wake vortex model, WindDVE, was used for the winglet design analysis. A summary of the aerodynamic design process is presented along with a case study of a specific design.

This presentation describes a new effort to better understand insulator flashover in high current, high voltage pulsed power systems. Both experimental and modeling investigations are described. Particular emphasis is put upon understand flashover that initiate in the anode triple junction (anode-vacuum-dielectric).

A high altitude electromagnetic pulse (HEMP) or other similar geomagnetic disturbance (GMD) has the potential to severely impact the operation of large-scale electric power grids. By introducing low-frequency common-mode (CM) currents, these events can impact the performance of key system components such as large power transformers. In this work, a solid-state transformer (SST) that can replace susceptible equipment and improve grid resiliency by safely absorbing these CM insults is described. An overview of the proposed SST power electronics and controls architecture is provided, a system model is developed, and the performance of the SST in response to a simulated CM insult is evaluated. Compared to a conventional magnetic transformer, the SST is found to recover quickly from the insult while maintaining nominal ac input/output behavior.

When exposed to mechanical environments such as shock and vibration, electrical connections may experience increased levels of contact resistance associated with the physical characteristics of the electrical interface. A phenomenon known as electrical chatter occurs when these vibrations are large enough to interrupt the electric signals. It is critical to understand the root causes behind these events because electrical chatter may result in unexpected performance or failure of the system. The root causes span a variety of fields, such as structural dynamics, contact mechanics, and tribology. Therefore, a wide range of analyses are required to fully explore the physical phenomenon. This paper intends to provide a better understanding of the relationship between structural dynamics and electrical chatter events. Specifically, electrical contact assembly composed of a cylindrical pin and bifurcated structure were studied using high fidelity simulations. Structural dynamic simulations will be performed with both linear and nonlinear reduced-order models (ROM) to replicate the relevant structural dynamics. Subsequent multi-physics simulations will be discussed to relate the contact mechanics associated with the dynamic interactions between the pin and receptacle to the chatter. Each simulation method was parametrized by data from a variety of dynamic experiments. Both structural dynamics and electrical continuity were observed in both the simulation and experimental approaches, so that the relationship between the two can be established.

Prescriptive approaches for the cybersecurity of digital nuclear instrumentation and control (I&C) systems can be cumbersome and costly. These considerations are of particular concern for advanced reactors that implement digital technologies for monitoring, diagnostics, and control. A risk-informed performance-based approach is needed to enable the efficient design of secure digital I&C systems for nuclear power plants. This paper presents a tiered cybersecurity analysis (TCA) methodology as a graded approach for cybersecurity design. The TCA is a sequence of analyses that align with the plant, system, and component stages of design. Earlier application of the TCA in the design process provides greater opportunity for an efficient graded approach and defense-in-depth. The TCA consists of three tiers. Tier 1 is design and impact analysis. In Tier 1 it is assumed that the adversary has control over all digital systems, components, and networks in the plant, and that the adversary is only constrained by the physical limitations of the plant design. The plant's safety design features are examined to determine whether the consequences of an attack by this cyber-enabled adversary are eliminated or mitigated. Accident sequences that are not eliminated or mitigated by security by design features are examined in Tier 2 analysis. In Tier 2, adversary access pathways are identified for the unmitigated accident sequences, and passive measures are implemented to deny system and network access to those pathways wherever feasible. Any systems with remaining susceptible access pathways are then examined in Tier 3. In Tier 3, active defensive cybersecurity architecture features and cybersecurity plan controls are applied to deny the adversary the ability to conduct the tasks needed to cause a severe consequence. Tier 3 is not performed in this analysis because of the design maturity required for this tier of analysis.

A quantum-cascade-laser-absorption-spectroscopy (QCLAS) diagnostic was used to characterize post-detonation fireballs of RP-80 detonators via measurements of temperature, pressure, and CO column pressure at a repetition rate of 1 MHz. Scanned-wavelength direct-absorption spectroscopy was used to measure CO absorbance spectra near 2008.5 cm−1 which are dominated by the P(0,31), P(2,20), and P(3,14) transitions. Line-of-sight (LOS) measurements were acquired 51 and 91 mm above the detonator surface. Three strategies were employed to facilitate interpretation of the LAS measurements in this highly nonuniform environment and to evaluate the accuracy of four post-detonation fireball models: (1) High-energy transitions were used to deliberately bias the measurements to the high-temperature outer shell, (2) a novel dual-zone absorption model was used to extract temperature, pressure, and CO measurements in two distinct regions of the fireball at times where pressure variations along the LOS were pronounced, and (3) the LAS measurements were compared with synthetic LAS measurements produced using the simulated distributions of temperature, pressure, and gas composition predicted by reactive CFD modeling. The results indicate that the QCLAS diagnostic provides high-fidelity data for evaluating post-detonation fireball models, and that assumptions regarding thermochemical equilibrium and carbon freeze-out during expansion of detonation gases have a large impact on the predicted chemical composition of the fireball.

The DevOps movement, which aims to accelerate the continuous delivery of high-quality software, has taken a leading role in reshaping the software industry. Likewise, there is growing interest in applying DevOps tools and practices in the domains of computational science and engineering (CSE) to meet the ever-growing demand for scalable simulation and analysis. Translating insights from industry to research computing, however, remains an ongoing challenge; DevOps for science and engineering demands adaptation and innovation in those tools and practices. There is a need to better understand the challenges faced by DevOps practitioners in CSE contexts in bridging this divide. To that end, we conducted a participatory action research study to collect and analyze the experiences of DevOps practitioners at a major US national laboratory through the use of storytelling techniques. We share lessons learned and present opportunities for future investigation into DevOps practice in the CSE domain.

We present the SEU sensitivity and SEL results from proton and heavy ion testing performed on NVIDIA Xavier NX and AMD Ryzen V1605B GPU devices in both static and dynamic operation.

Subhourly changes in solar irradiance can lead to energy models being biased high if realistic distributions of irradiance values are not reflected in the resource data and model. This is particularly true in solar facility designs with high inverter loading ratios (ILRs). When resource data with sufficient temporal and spatial resolution is not available for a site, synthetic variability can be added to the data that is available in an attempt to address this issue. In this work, we demonstrate the use of anonymized commercial resource datasets with synthetic variability and compare results with previous estimates of model bias due to inverter clipping and increasing ILR.

Here we examine models for particle curtain dispersion using drag based formalisms and their connection to streamwise pressure difference closures. Focusing on drag models, we specifically demonstrate that scaling arguments developed in DeMauro et. al. [1] using early time drag modeling can be extended to include late time particle curtain dispersion behavior by weighting the dynamic portion of the drag relative velocity e.g. (Formula Presented) by the inverse of the particle volume fraction to the ¼th power. The additional parameter e.g. α introduced in this scaling is related to the model drag parameters by employing an early-time latetime matching argument. Comparison with the scaled measurements of DeMauro et. al. suggest that the proposed modification is an effective formalism. Next, the connection between drag-based models and streamwise pressure difference-based expressions is explored by formulating simple analytical models that verify an empirical (Daniel and Wagner [2]) upstream-downstream expression. Though simple, these models provide physics-based approached describing shock particle curtain interaction behavior.

Geomagnetic disturbances (GMDs) give rise to geomagnetically induced currents (GICs) on the earth's surface which find their way into power systems via grounded transformer neutrals. The quasi-dc nature of the GICs results in half-cycle saturation of the power grid transformers which in turn results in transformer failure, life reduction, and other adverse effects. Therefore, transformers need to be more resilient to dc excitation. This paper sets forth dc immunity metrics for transformers. Furthermore, this paper sets forth a novel transformer architecture and a design methodology which employs the dc immunity metrics to make it more resilient to dc excitation. This is demonstrated using a time-stepping 2D finite element analysis (FEA) simulation. It was found that a relatively small change in the core geometry significantly increases transformer resiliency with respect to dc excitation.

Spent nuclear fuel repository simulations are currently not able to incorporate detailed fuel matrix degradation (FMD) process models due to their computational cost, especially when large numbers of waste packages breach. The current paper uses machine learning to develop artificial neural network and k-nearest neighbor regression surrogate models that approximate the detailed FMD process model while being computationally much faster to evaluate. Using fuel cask temperature, dose rate, and the environmental concentrations of CO32−, O2, Fe2+, and H2 as inputs, these surrogates show good agreement with the FMD process model predictions of the UO2 degradation rate for conditions within the range of the training data. A demonstration in a full-scale shale repository reference case simulation shows that the incorporation of the surrogate models captures local and temporal environmental effects on fuel degradation rates while retaining good computational efficiency.

The design of thermal protection systems (TPS), including heat shields for reentry vehicles, rely more and more on computational simulation tools for design optimization and uncertainty quantification. Since high-fidelity simulations are computationally expensive for full vehicle geometries, analysts primarily use reduced-physics models instead. Recent work has shown that projection-based reduced-order models (ROMs) can provide accurate approximations of high-fidelity models at a lower computational cost. ROMs are preferable to alternative approximation approaches for high-consequence applications due to the presence of rigorous error bounds. The following paper extends our previous work on projection-based ROMs for ablative TPS by considering hyperreduction methods which yield further reductions in computational cost and demonstrating the approach for simulations of a three-dimensional flight vehicle. We compare the accuracy and potential performance of several different hyperreduction methods and mesh sampling strategies. This paper shows that with the correct implementation, hyperreduction can make ROMs up to 1-3 orders of magnitude faster than the full order model by evaluating the residual at only a small fraction of the mesh nodes.