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DOE OSTI2024

Symbolic diagnostics to interpret and analyze neural network models

Embedded machine-learned models (EMLMs) have the promise to improve the predictive accuracy of engineering simulators in environments of national interest. EMLMs often comprise complex input-output maps (e.g., neural networks), which make them unamenable to rigorous analysis and generally difficult to interpret. In the face of decades of theory, this lack of interpretability is a significant barrier to building confidence in these models. This work outlines an approach to interpret EMLMs using sparse polynomial regression for comparison with theoretical understanding. To do so, we build on the concept of Locally Interpretable Model-agnostic Explanations (LIME) using physics-informed clustering, prototype selection, and library construction. While general, we demonstrate our method on tensor-basis neural networks used in Reynolds-Averaged Navier-Stokes simulations of hypersonic fluid flows. Results are presented for a simulated toy model and for direct numerical simulations (DNS) of turbulent flows over a flat plate.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Hierarchically Informed Engineering Models for Predictive Modeling of Turbulent Premixed Flame Propagation in Pre- chamber Turbulent Jet Ignition

The goal of the project is to improve the predictive accuracy and efficiency of turbulent combustion sub-models for pre-chamber turbulent jet ignition (TJI). This goal is achieved through the development of a hierarchically informed engineering model for turbulent combustion in TJI. The model development starts with the highest level of model description of turbulent combustion with direct numerical simulation (DNS) from which fundamental characteristics and scaling properties of turbulent premixed flame propagation under TJI relevant conditions are obtained.

42 ENGINEERING↗

DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Challenge Problem 1: Preliminary Results of the Direct Numerical Simulation of Transient Flows

This report presents the first direct numerical simulations (DNS) of transient mixed convection in an idealized downcomer-like channel (Challenge Problem 1, Phase II). Using the GPU-accelerated NekRS solver, we modeled a sudden decay in driving pressure, mimicking loss-of-flow events, and tracked the resulting evolution of Reynolds number, boundary-layer structure, turbulence statistics, and heat-transfer metrics. Key findings include the systematic thickening and eventual asymmetry of velocity and thermal boundary layers under buoyant deceleration; minimal “memory” lag in Reynolds shear stress and TKE profiles when sampled at matching Re, yet clear shifts of peak locations toward the cooled wall; overshoots in transient eddy-viscosity and eddy-diffusivity (and corresponding sub-unity turbulent Prandtl numbers) on the cooled side; and a pronounced transient Nusselt-number enhancement driven by wall-temperature inertia and residual eddy mixing. These effects combined to offer a temporary cooling margin above steady-state predictions during reactor LOF transients. Future work will extend this work to a more complex “Case II” geometry (90° turn + lower plenum) and generate multi-Re/Pr datasets for data-driven turbulence closures.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

As a Matter of Dynamical Range – Scale Dependent Energy Dynamics in MHD Turbulence

Abstract Magnetized turbulence is ubiquitous in many astrophysical and terrestrial plasmas but no universal theory exists. Even the detailed energy dynamics in magnetohydrodynamic (MHD) turbulence are still not well understood. We present a suite of subsonic, super-Alfvénic, high plasma beta MHD turbulence simulations that only vary in their dynamical range, i.e., in their separation between the large-scale forcing and dissipation scales, and their dissipation mechanism (implicit large eddy simulation, ILES, and direct numerical simulation (DNS)). Using an energy transfer analysis framework we calculate the effective numerical viscosities and resistivities, and demonstrate that all ILES calculations of MHD turbulence are resolved and correspond to an equivalent visco-resistive MHD turbulence calculation. Increasing the number of grid points used in an ILES corresponds to lowering the dissipation coefficients, i.e., larger (kinetic and magnetic) Reynolds numbers for a constant forcing scale. Independently, we use this same framework to demonstrate that—contrary to hydrodynamic turbulence—the cross-scale energy fluxes are not constant in MHD turbulence. This applies both to different mediators (such as cascade processes or magnetic tension) for a given dynamical range as well as to a dependence on the dynamical range itself, which determines the physical properties of the flow. We do not observe any indication of convergence even at the highest resolution (largest Reynolds numbers) simulation at 2048 3 cells, calling into question whether an asymptotic regime in MHD turbulence exists, and, if so, what it looks like.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Cloud droplet diffusional growth in homogeneous isotropic turbulence: bin microphysics versus Lagrangian super-droplet simulations

The increase in the spectral width of an initially monodisperse population of cloud droplets in homogeneous isotropic turbulence is investigated by applying a finite-difference fluid flow model combined with either Eulerian bin microphysics or a Lagrangian particle-based scheme. The turbulence is forced applying a variant of the so-called linear forcing method that maintains the mean turbulent kinetic energy (TKE) and the TKE partitioning between velocity components. The latter is important for maintaining the quasi-steady forcing of the supersaturation fluctuations that drive the increase in the spectral width. We apply a large computational domain (64 3 m 3 ), one of the domains considered in Thomas et al. (2020). The simulations apply 1 m grid length and are in the spirit of the implicit large eddy simulation (ILES), that is, with small-scale dissipation provided by the model numerics. This is in contrast to the scaled-up direct numerical simulation (DNS) applied in Thomas et al. (2020). Two TKE intensities and three different droplet concentrations are considered. Analytic solutions derived in Sardina et al. (2015), valid for the case when the turbulence integral timescale is much larger than the droplet phase relaxation timescale, are used to guide the comparison between the two microphysics simulation techniques. The Lagrangian approach reproduces the scalings relatively well. Representing the spectral width increase in time is more challenging for the bin microphysics because appropriately high resolution in the bin space is needed. The bin width of 0.5 µm is only sufficient for the lowest droplet concentration (26 cm -3 ). For the highest droplet concentration (650 cm -3 ), an order of magnitude smaller bin size is barely sufficient. The scalings are not expected to be valid for the lowest droplet concentration and the high-TKE case, and the two microphysics schemes represent similar departures. Finally, because the fluid flow is the same for all simulations featuring either low or high TKE, one can compare point-by-point simulation results. Such a comparison shows very close temperature and water vapor point-by-point values across the computational domain and larger differences between simulated mean droplet radii and spectral width. The latter are explained by fundamental differences in the two simulation methodologies, numerical diffusion in the Eulerian bin approach and a relatively small number of Lagrangian particles that are used in the particle-based microphysics.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

JHTDB-wind: a web-accessible large-eddy simulation database of a wind farm with virtual sensor querying

This paper introduces JHTDB-wind (https://turbulence.idies.jhu.edu/datasets/windfarms, last access: 11 November 2025), a publicly accessible database containing large-eddy simulation (LES) data from wind farms. Building on the framework of the Johns Hopkins Turbulence Database (JHTDB), which hosts direct numerical simulation (DNS) and some LES datasets of canonical turbulent flows, JHTDB-wind stores the 4D space–time history of the flow and provides users the ability to access and query the data via a web-based virtual sensor interface. The initial dataset comprises LES results from a large wind farm with 10×6 turbines, modeled using a filtered actuator line method, under conventionally neutral atmospheric conditions. These data comprise 1 h (hour) of flow field data (velocity, pressure, potential temperature deviation, subgrid-scale (SGS) eddy viscosity, and turbine forces, approximately 15 TB (terabytes) and wind turbine data – including both turbine-level operational quantities and blade-level aerodynamic quantities (approximately 1.3 TB) – stored in Zarr and Parquet formats, respectively. Data retrieval is facilitated by the giverny Python package, allowing remote users to query the database in Python or MATLAB (C and Fortran support are available for flow field data). This paper details the simulation setup and demonstrates data access through examples that analyze wind farm flow structures and turbine performance. The framework is extensible to future datasets, including the JHTDB-wind diurnal cycle simulation analyzed in Xiao et al. (2025).

17 WIND ENERGY↗

DOE OSTI2020

Development of a Physics-Based Combustion Model for Engine Knock Prediction

The objective of this project is to improve the prediction of engine knock by developing a new combustion modeling framework. Engine knock is a limiting factor to constrain the increase of fuel efficiency for spark ignition (SI) engines in most passenger cars. Efforts to increase fuel efficiency, increasing the compression ratio or downsizing, lead to the increase in the tendency of the knock occurrence. The knock is an undesired ignition of the end-gas, unburned fuel/air mixture ahead of the spark-ignited premixed flame, resulting in rapid in-cylinder pressure rises and engine damages. The combustion modeling framework developed in this project can consider turbulence-chemistry interactions during end-gas ignition, while using a reasonably detailed chemical mechanism developed for ignition and combustion reactions under engine relevant conditions, and the subtle characteristics of spark-ignited flame propagation. It is developed in the context of large eddy simulation (LES), which can capture stochastic in-cylinder processes. The developed model is incorporated into a commercial software for engine simulation, CONVERGE CFD, as a user defined function, and validated. Engine knock and knock-free experiments as well as direct numerical simulation (DNS) of end-gas ignition in homogeneous turbulence are performed to help model development and provide data sets for model validation. With further validation, the developed model is expected to advance the predictive capability for engine knock simulations and thus contribute to improving the fuel efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Hypernetwork Science: From Multidimensional Networks to Computational Topology

As data structures and mathematical objects used for complex systems modeling, hypergraphs sit nicely poised between on the one hand the world of network models, and on the other that of higher-order mathematical abstractions from algebra, lattice theory, and topology. They are able to represent complex systems interactions more faithfully than graphs and networks, while also being some of the simplest classes of systems representing topological structures as collections of multidimensional objects connected in a particular pattern. In this paper we discuss the role of (undirected) hypergraphs in the science of complex networks, and provide a mathematical overview of the core concepts needed for hypernetwork modeling, including duality and the relationship to bicolored graphs, quantitative adjacency and incidence, the nature of walks in hypergraphs, and available topological relationships and properties. We close with a brief discussion of two example applications: biomedical databases for disease analysis, and domain-name system (DNS) analysis of cyber data.

Joslyn, Cliff A.↗

DOE OSTI2024

Unsupervised Learning for Equitable DER Control: Preprint

In the context of managing distributed energy resources (DERs) within distribution networks (DNs), this work focuses on the task of developing local controllers. We propose an unsupervised learning framework to train functions that can closely approximate optimal power flow (OPF) solutions. The primary aim is to establish specific conditions under which these learned functions can collectively guide the network towards desired configurations asymptotically, leveraging an incremental control approach. The flexibility of the proposed methodology allows to integrate fairness-driven components into the cost function associated with the OPF problem. This addition seeks to mitigate power curtailment disparities among DERs, thereby promoting equitable power injections across the network. To demonstrate the effectiveness of the proposed approach, power flow simulations are conducted using the IEEE 37-bus feeder. The findings not only showcase the guaranteed system stability but also underscore its improved overall performance.

asymptotic stability↗

DOE OSTI2024

Verifying Cyber Implementation Best Practices With Malcolm

Network traffic analysis can reveal a lot about what's right or wrong with a network's cybersecurity footing. Using Malcolm, a powerful open-source network traffic analysis tool suite for network security monitoring, cyber analysts and asset owners can validate cybersecurity best practices and uncover red flags in network configuration, including: proper network segmentation east-west (cross-segment) and north-south traffic unsecure or outdated network protocols authentication using clear text credentials rogue devices and services unexpected protocols (e.g., IPv6, DNS, DHCP, update checks, etc.) suspicious file transfers

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Digital Assurance Checklist for Homeowners and Installers

This document provides a comprehensive Digital Assurance Checklist for securing behind-the-meter energy assets, focusing on both installers and homeowners. As distributed energy resources (DERs) such as solar PV and battery storage become integral to residential energy systems, cybersecurity emerges as a critical component of reliability and safety. The guide outlines actionable steps for installers during pre-installation, commissioning, and post-installation phases, emphasizing practices like network segmentation, credential management, firmware validation, and homeowner education. For homeowners, the document introduces a tiered approach to cyber hygiene—from essential measures like strong Wi-Fi credentials and automatic updates to advanced strategies such as network segmentation, DNS filtering, and intrusion detection. By adopting these practices, stakeholders can mitigate cyber risks, safeguard energy infrastructure, and ensure resilient, secure operation of DER systems. Additional resources and references to industry standards are included to support implementation.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Digital Assurance Checklist for Homeowners and Installers

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

A direct numerical simulation of Jet A flame kernel quenching

The safe operation of aeronautical engines requires an understanding of flame ignition, propagation and extinction. In this study, direct numerical simulations are performed using a 29 species reduced chemical mechanism for jet fuel surrogate Jet A to understand the flame quenching process. Here, initially laminar spherical flames of varying sizes and equivalence ratios are subject to an identical periodic domain of decaying and isotropic high intensity turbulence with a turbulent Reynolds number of 2400. All cases become quenched, except for the larger kernel with lower Karlovitz number. An analysis of the flame structure shows broadened preheat zone, flame shortening on the product side, differential species diffusion and partial fuel pyrolysis in the fresh mixture. Two extinction mechanisms are identified arising from flame shortening and high flame stretch. Flame shortening occurs due to turbulence-chemistry interactions that resemble the flame–flame interaction in a laminar counterflow reactant-to-reactant configuration, which contorts and breaks up the ignition kernel. Flame stretch is a local effect that attenuates the heat release rate and causes the flame to retreat towards the product mixtures, similar to what has been observed for reactant-to-product laminar counterflow flames. Chemical explosive mode analysis was also performed to quantify the flame structure and local combustion mode. The diffusion–reaction balance in pinched-off flame islands favors extinction of these smaller structures, while auto-ignition modes are observed within the flame kernel after fresh mixture is engulfed and preheated in the product kernel. Statistics of the density-weighted displacement speed conditional on local combustion mode indicates strong correlation between the local extinction mode and negative displacement speed. The local balance between diffusion and reaction ultimately determines the propensity for local extinction in both laminar and turbulent flames, the extent of which has an impact on global flame propagation.

42 ENGINEERING↗

DOE OSTI2020

A crisis for the verification and validation of turbulence simulations

Three algorithms have been proposed for solution of the Rayleigh–Taylor turbulent mixing problem. They are based upon three different physical principles governing the Euler equations for fluid flow. The principles serve to select the physically relevant solution from among many nonunique solutions. The admissibility principle is in dispute. The three different algorithms, expressing the three physical admissibility principles can be formulated in terms of the three energy dissipation rates or the entropy production rates, as selected by the size of the sub grid scale coefficients. These have maximal values or less than maximal values. The resulting solutions are markedly different. We find strong validation evidence that supports the maximum rate principle, based on a review of prior results and on new results presented here. We review experimental data used for validation and sufficient to discriminate among the three. We present a new analysis of this data. We show that the hypothesized long wave length perturbations in the initial conditions are not significant, so that validation can be based on this data in a straight forward manner. One of the algorithms is labeled direct numerical simulation, but is not, and as a consequence, the two algorithms with less than maximal SGS coefficients are variants of one another. Finally recommendations for the numerical modeling of the deflagration to detonation transition in type Ia supernova are discussed.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Chemical vapor infiltration of additively manufactured preforms: Pore-resolved simulations and experimental validation

The densification of additively manufactured porous preforms by chemical vapor infiltration (CVI) is studied using pore-resolved simulations and experiments. Experimentally, 3D printed silicon carbide (SiC) preforms are subject to CVI synthesis using methyltrichlorosilane (MTS) precursor to obtain high purity SiC/SiC composites. Optical images of the cross sections of the processed preforms are analyzed to obtain the spatial porosity distribution. The numerical method is based on a level set formulation to capture the spatial distribution and time evolution of the pore scale microstructural characteristics. The coupled transport and kinetic effects are represented using a dimensionless Thiele modulus. Simulations are initialized using representative synthetic preform geometries comprising of packed particles based on the size distribution of the powder used for 3D printing. The simulation results are validated against the experimental observations in terms of total density and the distribution of residual porosity. The densification characteristics, porosity classification, concentration profiles, and structure functions are analyzed as functions of processing temperature and Thiele modulus.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Evaporation Submodel Development for Volume of Fluid (eVOF) Method Applicable to Spray-Wall Interaction Including Film Characteristics with Validation at High Pressure and Temperature Conditions

Internal combustion engines have seen a great evolution over the last several decades through application of high pressure direct injection, multiple injections, and other technologies to reduced fuel consumption, NOx, and PM. Although combustion systems with advanced injection strategies have been studied extensively, there exists a significant fundamental knowledge gap on the fuel-spray interactions with the piston surface and chamber walls. Advanced computational codes validated with experimental techniques have to be developed for accurate representation of the drop impingement, fuel film formation, and vaporization. Current engine CFD (Computational Fluid Dynamics) spray models utilize a Lagrangian framework for modeling which lacks critical considerations of the physics pertaining to these interactions and thus requiring extensive parameterization, tuning and validation. The team from Michigan Technological University, University of Massachusetts Dartmouth, and Argonne National Laboratory is composed of experts in sprays, combustion, engines and CFD with a wide spectrum of knowledge including specific expertise in the area under consideration. In the proposed work, a VOF (Volume of Fluid) modeling approach has been adopted for the spray-wall interaction, film formation and spreading, and vaporization. With the inclusion of a vaporization submodel, a more predictive and accurate simulation of the spray-film was performed without extensive need of parameterization and tuning. Extensive experimentation of the spray-wall interaction under the range of conditions matching the thermodynamic and surface temperatures that occur in diesel and gasoline engines were conducted to validate the SWI submodels and for development of the evaporation submodel, which has been implemented in the flow solver.

42 ENGINEERING↗