Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “machining processes”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

New Extrusion Method is Taking ShAPE

PNNL’s patented Shear Assisted Processing and Extrusion (ShAPE™) includes a novel extrusion machine, tooling, and associated processing techniques that delivers high-performance metal alloys for a wide range of market needs. ShAPE is a technique for manufacturing wire, bar, and tubular extrusions with unprecedented properties and manufacturing advantages compared to conventional extrusion. In a single step, ShAPE extrudes metal powder, flake, chip, and ingot directly into products with properties that cannot be achieved by conventional means. ShAPE delivers better products, because it uniquely mixes and deforms the metal feedstocks in their solid form without melting them, dramatically improving product properties and the energy efficiency of production.

Joshi, Vineet V.↗
DOE OSTI2025

Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components

The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Process damping identification using Bayesian learning and time domain simulation

Process damping can provide improved machining productivity by increasing the stability limit at low spindle speeds. However, existing methods for identifying process damping models experimentally require specialized setups and/or multiple cutting tests. While the phenomenon is well known, the modeling challenges limit pre-process parameter selection that leverages the potential increases in material removal rates. This paper proposes a physics-informed Bayesian method that can identify the cutting force and process damping models from a limited set of test cuts without requiring direct measurements of cutting force or vibration. The method uses time domain simulation to incorporate process damping and provide a basis for test selection. Here, new strategies for efficient sampling and dimensionality reduction are applied to lower computation time and minimize the effect of model error. The proposed method is demonstrated and the identified cutting and damping force coefficients are compared to values obtained using machining tests and least-squares fitting.

42 ENGINEERING↗
DOE OSTI2022

An Overview in the Development of a Multi-Sensor Data Science System for Monitoring a Solvent Extraction Process

To enhance nuclear nonproliferation stewardship, Idaho National Laboratory is building the Beartooth nuclear fuel cycle processing test bed. The Beartooth test bed will allow researchers the opportunity to study nuclear fuel processing operations including the use of centrifugal contactors in solvent extraction processes. The test bed is designed to support data collection and machine learning to monitor process operations. As part of this project, researchers will study data collected from a host of sensors that have not been typically used to monitor solvent extraction processes such as vibration, acoustic, colormetric, and thermal measurement data. The goal of this research is to employ machine learning and data analytics to study the confluence of signals collected from both traditionally and non-traditionally used sensors to provide operator process awareness and discover process anomalies. An overview of planned sensors and experiments that will focus on signal discovery will be presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

An Overview in the Development of a Multi-Sensor Data Science System for Monitoring a Solvent Extraction Process

To enhance nuclear nonproliferation stewardship, Idaho National Laboratory is building the Beartooth nuclear fuel cycle processing test bed. The Beartooth test bed will allow researchers the opportunity to study nuclear fuel processing operations including the use of centrifugal contactors in solvent extraction processes. The test bed is designed to support data collection and machine learning to monitor process operations. As part of this project, researchers will study data collected from a host of sensors that have not been typically used to monitor solvent extraction processes such as vibration, acoustic, colormetric, and thermal measurement data. The goal of this research is to employ machine learning and data analytics to study the confluence of signals collected from both traditionally and non-traditionally used sensors to provide operator process awareness and discover process anomalies. An overview of planned sensors and experiments that will focus on signal discovery will be presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Process window estimation in manufacturing through Entropy-Sigma active learning

In manufacturing, there exist boundary identification problems for defining parameter spaces that meet desired thresholds on outcomes. This paper presents an Entropy-Sigma acquisition function for active learning of the process window/map in manufacturing using a Gaussian Process surrogate. Here, the method is applied to identify the stability boundary for the stability process map in machining using time-domain simulations with a periodic sampling stability metric. Results show that the proposed Entropy-Sigma method significantly outperforms Latin hypercube sampling or grid-based methods. The described method can be applied to identify the process window/map for any manufacturing application using a quantitative process outcome metric.

42 ENGINEERING↗
DOE OSTI2025

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the tool position and cutting power were monitored using the machine controller and an external power transducer, respectively. Results show that the power transducer is sensitive to machining porosities. A novel approach using the standard deviation of cutting power was developed to determine the location of porosities along the length of the machining pass. Test cuts were completed at different machining process parameters. Results showed that the probability of detection was one for pore volume greater than 0.3 mm 3 at different machining parameters. In conclusion, although the detection of porosity using machining is a destructive method for evaluation, it offers a low-cost and fast approach for monitoring porosity in additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Minimizing total energy cost and tardiness penalty for a scheduling-layout problem in a flexible job shop system: A comparison of four metaheuristic algorithms

Job scheduling and machine layout are interrelated in improving energy consumption (EC) and productivity measures such as tardiness and represent two important decisions that must be made by manufacturers. This interdependency can be explained by transportation time, which connects scheduling and layout. Scheduling and layout, however, have not been thoroughly studied in conjunction using an integrated model in the context of sustainable manufacturing. Hence, we propose an energy-aware optimization model in which scheduling is integrated with layout in a single-level framework. More specifically, a single objective function is defined to minimize the facility energy cost and the job tardiness penalty, which control EC and tardiness respectively in a flexible job shop system. In order to model machine EC more accurately, we also consider three different machine states: a processing state and two idle states. Our case studies show that the integrated model exhibits better performance in controlling manufacturing EC and job tardiness than a non-integrated model in which machine locations are uncontrollable and transportation times between machines are unchangeable. To deal with large-sized problems, we also introduce four new metaheuristics. The performances of these new metaheuristics are compared in terms of objective function values and CPU times using various case studies. The results indicate that a hybrid ant colony optimization and simulated annealing (ACO-SA) algorithm provides better performance than the other algorithms. Specifically, our case studies show that the integrated model using ACO-SA can improve the objective function value by around 5% when compared to the non-integrated model.

42 ENGINEERING↗
DOE OSTI2021

A systematic comparison of machine learning methods for modeling of dynamic processes applied to combustion emission rate modeling

Ten established, data-driven dynamic algorithms are surveyed and a practical guide for understanding these methods generated. Existing Python programming packages for implementing each algorithm are acknowledged, and the model equations necessary for prediction are presented. A case study on a coal-fired power plant’s NO x emission rates is performed, directly comparing each modeling method’s performance on a mutual system. Each model is evaluated by its root mean squared error (RMSE) on out-of-sample future horizon predictions. Optimal hyperparameters are identified using either an exhaustive search or genetic algorithm. The top five model structures of each method are used to recursively predict future NO x emission rates over a 60-step time horizon. The RMSE at each future timestep is determined, and the recursive output prediction trends compared against measurements in time. The GRU neural network is identified as the best candidate for representing the system, demonstrating accurate and stable predictions across the future horizon by all considered models, while satisfactory performance was observed in several of the ARX/NARX formulations. Finally, these efforts have contributed 1) a concise resource of multiple proven dynamic machine learning methods, 2) a practical guide explaining the use of these methods, effectively lowering the “barrier-to-entry” of deploying such models in control systems, 3) a comparison study evaluating each method’s performance on a mutual system, 4) demonstration of accurate multi-timestep emissions modeling suitable for systems-level control, and 5) generalizable results demonstrating the suitability of each method for prediction over a multi-step future horizon to other complex dynamic systems.

42 ENGINEERING↗
DOE OSTI2024

Navigating high-dimensional process-structure–property relations in nanocrystalline Pt-Au alloys with machine learning

For decades, materials scientists have relied on the process-structure–property paradigm to guide investigations into material behaviors. Traditional studies often examine a limited number of process-structure–property variables, striving to elucidate mechanisms governing material response. However, this approach is time consuming and can limit exploration, as well as the discovery of process-structure–property relations in novel materials. In this paper, we combined combinatorial sputter deposition and multi-modal high-throughput materials characterization with feedforward neural networks to establish high-dimensional process-structure–property relations in Pt-Au alloys, yielding nanocrystalline alloys with high hardness and low resistivity relevant to electrical contact switch applications. We mapped three indicators of process conditions (composition and two atomic deposition characteristics) onto four indicators of material structure (X-ray diffraction, film thickness, density, and surface roughness) and two indicators of material properties (hardness and resistivity), resulting in 784 unique combinations evaluated over a 13-dimensional space. The neural networks predicted Pt-Au alloys with 18–24 at.% Au, when deposited at specific conditions, to have a nanoindentation hardness up to 7.2 GPa. This high hardness value, comparable to some steels, represents a 3-fold improvement in hardness over “hard gold”, a commonly used electrical contact alloy, while maintaining requisite electrical conductivity. The neural network models provide an avenue to identify expected process windows capable of maximizing material performance.

Electrical contact materials↗
DOE OSTI2024

Leveraging Multitime Hamilton–Jacobi PDEs for Certain Scientific Machine Learning Problems

Hamilton-Jacobi partial differential equations (HJ PDEs) have deep connections with a wide range of fields, including optimal control, differential games, and imaging sciences. By considering the time variable to be a higher dimensional quantity, HJ PDEs can be extended to the multi-time case. In this paper, we establish a novel theoretical connection between specific optimization problems arising in machine learning and the multi-time Hopf formula, which corresponds to a representation of the solution to certain multi-time HJ PDEs. Through this connection, we increase the interpretability of the training process of certain machine learning applications by showing that when we solve these learning problems, we also solve a multi-time HJ PDE and, by extension, its corresponding optimal control problem. As a first exploration of this connection, we develop the relation between the regularized linear regression problem and the Linear Quadratic Regulator (LQR). We then leverage our theoretical connection to adapt standard LQR solvers (namely, those based on the Riccati ordinary differential equations) to design new training approaches for machine learning. Lastly, we provide some numerical examples that demonstrate the versatility and possible computational advantages of our Riccati-based approach in the context of continual learning, post-training calibration, transfer learning, and sparse dynamics identification.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Using Machine Learning to Predict Cloud Turbulent Entrainment–Mixing Processes

Different turbulent entrainment–mixing mechanisms between clouds and environment are essential to cloud–related processes; however, accurate representation of entrainment–mixing in weather/climate models still poses a challenge. This study exploits the use of machine learning (ML) to address this challenge. Four ML (Light Gradient Boosting Machine [LGB], eXtreme Gradient Boosting, Random Forest, and Support Vector Regression) are examined and compared. It is found that LGB performs best, and thus is selected to understand the impact of entrainment–mixing on microphysics using simulation data from Explicit Mixing Parcel Model. Compared with traditional parameterizations, the trained LGB provides more accurate microphysical properties (number concentration and cloud droplet spectral dispersion). The partial dependences of predicted microphysics on features exhibit a strong alignment with physical mechanisms and expectations, as determined by the interpreting method, thus overcoming the limitations of the “black box” scheme. The underlying mechanisms are that the smaller number concentration and larger spectral dispersion correspond to more inhomogeneous entrainment–mixing. Specifically, number concentration after entrainment–mixing is positively correlated with adiabatic number concentration and liquid water content affected by entrainment–mixing, and inversely correlated with adiabatic volume mean radius. Spectral dispersion after entrainment–mixing is negatively correlated with liquid water content affected by entrainment–mixing, turbulent dissipation rate and relative humidity of entrained air. Sensitivity analysis further suggests that number concentration is mainly determined by cloud microphysical properties whereas spectral dispersion is influenced by both cloud microphysical properties and environmental variables. The results indicate that the LGB scheme has the potential to enhance the representation of entrainment–mixing in weather/climate models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Combining Machine Learning and Comparative Effectiveness Methodology to Study Primary Care Pharmacotherapy Pathways for Veterans With Depression

Our objective is to demonstrate an innovative method combining machine learning with comparative effectiveness research techniques and to investigate a hitherto unstudied question about the effectiveness of common prescribing patterns. For Operation Enduring Freedom/Operation Iraqi Freedom veterans with major depressive disorder, we generate pharmacotherapy pathways (of antidepressants) using process mining and machine learning. We select the medication episodes that were started at subtherapeutic doses by the first assigned primary care physician and observe the paths that those medication episodes follow. Using 2-stage least squares, we test the effectiveness of starting at a low dose and staying low for longer versus ramping up fast while balancing observable and unobservable characteristics of patients and providers through instrumental variables. We leverage predetermined provider practice patterns as instruments. We collected outpatient pharmacy data for selective serotonin reuptake inhibitors and selective norepinephrine reuptake inhibitors, patient and provider characteristics (as control variables), and the instruments for our cohort. All data were extracted for the period between 2006 and 2020. There is a statistically significant positive effect (0.68, 95% CI 0.11–1.25) of “ramping up fast” on engagement in care. When we examine the effect of “ramping up slow”, we see an insignificant negative impact on engagement in care (−0.82, 95% CI −1.89 to 0.25). As expected, the probability of drop-out also seems to have a negative effect on engagement in care (−0.39, 95% CI −0.94 to 0.17). We further validate these results by testing with medication possession ratios calculated periodically as an alternative engagement in care metric. Our findings contradict the “Start low, go slow” adage, indicating that ramping up the dose of an antidepressant faster has a significantly positive effect on engagement in care for our population.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Advancing river corridor science beyond disciplinary boundaries with an inductive approach to catalyse hypothesis generation

Abstract A unified conceptual framework for river corridors requires synthesis of diverse site‐, method‐ and discipline‐specific findings. The river research community has developed a substantial body of observations and process‐specific interpretations, but we are still lacking a comprehensive model to distill this knowledge into fundamental transferable concepts. We confront the challenge of how a discipline classically organized around the deductive model of systematically collecting of site‐, scale‐, and mechanism‐specific observations begins the process of synthesis. Machine learning is particularly well‐suited to inductive generation of hypotheses. In this study, we prototype an inductive approach to holistic synthesis of river corridor observations, using support vector machine regression to identify potential couplings or feedbacks that would not necessarily arise from classical approaches. This approach generated 672 relationships linking a suite of 157 variables each measured at 62 locations in a fifth order river network. Eighty four percent of these relationships have not been previously investigated, and representing potential (hypothetical) process connections. We document relationships consistent with current understanding including hydrologic exchange processes, microbial ecology, and the River Continuum Concept, supporting that the approach can identify meaningful relationships in the data. Moreover, we highlight examples of two novel research questions that stem from interpretation of inductively‐generated relationships. This study demonstrates the implementation of machine learning to sieve complex data sets and identify a small set of candidate relationships that warrant further study, including data types not commonly measured together. This structured approach complements traditional modes of inquiry, which are often limited by disciplinary perspectives and favour the careful pursuit of parsimony. Finally, we emphasize that this approach should be viewed as a complement to, rather than in place of, more traditional, deductive approaches to scientific discovery.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Machine learning on FPGA for event selection

Real-time data processing is a frontier field in experimental particle physics. The application of FPGAs at the trigger level is used by many current and planned experiments (CMS, LHCb, Belle2, PANDA). Usually they use conventional processing algorithms. LHCb has implemented Machine Learning (ML) elements for real-time data processing with a triggered readout system that runs most of the ML algorithms on a computer farm. The work described in this article aims to test the ML-FPGA algorithms for streaming data acquisition. Herein, there are many experiments working in this area and they have a lot in common, but there are many specific solutions for detector and accelerator parameters that are worth exploring further. This report describes the purpose of the work and progress in evaluating the ML-FPGA application.

47 OTHER INSTRUMENTATION↗