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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Automatic Segmentation of Building Envelope Point Cloud Data Using Machine Learning

About 50% of buildings in the US were constructed before energy codes were introduced. Modular overclad panel retrofits, in which a new envelope is constructed over the existing building, are a promising solution given that it minimizes occupant disruption and shortens construction time at the jobsite. Current state-of-the-art retrofit panel layout and dimensioning consists of three steps: 1) 3D point cloud data generation of the building envelope using commonly available surveying equipment, 2) manual segmentation of 3D point cloud data by a trained professional to identify and dimension window openings, door openings, and other architectural features, and 3) modular panel layout optimization and dimensioning by an architect or engineer. Among these steps, the second one remains the most difficult and costly because it is very labor-intensive. We propose a methodology to automatically label 3D point cloud data to reduce the time and expense spent in manual segmentation. Machine learning methods were employed to classify the point cloud data into distinct groups, each of which corresponds to different features of the building envelope. After classification, a segmentation algorithm was developed to perform boundary detection and separate the components of the façade. Finally, the algorithm returns the relative positions and dimensions of the features in the building envelope. The measurements obtained with the proposed automated method were compared against the actual dimensions to determine the overall algorithm accuracy. The proposed algorithm can then be used to reduce manual efforts for 3D point cloud labeling before modular panel layout optimization is performed.

Maldonado Puente, Bryan↗
DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Indicator-directed Dynamic Power Management for Iterative Workloads on GPU-Accelerated Systems

Modern high-performance and warehouse computing centers show strong interest in minimizing system power consumption while satisfying customers’ quality of service (QoS). Dynamic voltage and frequency scaling (DVFS) is effective for achieving this goal. Nevertheless, automating the process online and making it transparent to users must address three major challenges: (1) Complexity — today’s hardware components (e.g., CPUs, GPUs, memory, network, etc.) can be configured in several or dozens of frequency/voltage states for satisfying divergent system demands. Given their combination and the emergence of heterogeneity, searching the optimal configuration in the design space online can be timing consuming. (2) QoS guarantee — user-defined objectives such as power constraint and performance target must be monitored, predicted and ensured at the best effort. (3) Adaptability — various known and unknown workloads run on systems. Workloads characteristics should be quickly determined and configurations dynamically adjusted in accord with workloads and QoS. In this work, we focus on applications exhibiting an interesting feature – iterative or periodic, which is common among conventional HPC and emerging machine learning workloads. We propose an online dynamic power-performance (ODPP) management framework to dynamically adjust GPU DVFS configurations to meet performance and power objectives and constraints, without any code annotation or intrusion. Particularly, ODPP extracts the performance and power indicators for applications from their resources utilization profiles in a short episode. It further automatically constructs an accurate model that infers from the indicators how the application's performance and power vary with GPU core and memory frequencies. Aided with the model, for both seen and unseen applications, ODPP can quickly determine the most appropriate DVFS configuration for their execution. We evaluate ODPP on an NVIDIA GPU using multiple exascale computing (ECP) and deep learning applications.

Zou, Pengfei↗
DOE OSTI2025

A Behavioral Robotics Approach to Radiation Mapping Using Adaptive Sampling

Radiation mapping is a desirable task to automate because of the inherent risks involved and its tedious nature. A novel system was designed to address this by combining various existing technologies, utilizing behavior-based robotics and Bayesian optimization. The system uses a quadruped robot equipped with a manipulator and gamma detector to take measurements at locations that are selected based on the uncertainty of a surrogate model used to estimate the true radiation field. The robot uses input from the world with depth cameras to avoid collisions with the robot’s body, and unreachable points for the end effector are addressed by both allowing for a soft collision with the environment to occur, prompting the system to abandon that point, and varying the exploration tendency of the optimization based on consecutive collisions. This approach provides unique traversability and adaptability over other strategies in the literature. Experiments were performed by placing a Cesium-137 source on the ground and varying geometric setups and an optimization parameter demonstrating the adaptability to diverse environments and the increased robustness resulting from the designed behavior. The results additionally demonstrate that dynamically adjusting the optimization algorithm’s exploration tendency based on the arm’s collision history improves the system’s ability to navigate cluttered environments and construct accurate radiation maps without getting stuck in unreachable areas.

Adams, Joel↗
DOE OSTI2024

SPARTA: High-Level Synthesis of Parallel Multi-Threaded Accelerators

This article presents a methodology for the Synthesis of PARallel multi-Threaded Accelerators (SPARTA) from OpenMP annotated C/C++ specifications. SPARTA extends an open-source HLS tool, enabling the generation of accelerators that provide latency tolerance for irregular memory accesses through multithreading, support fine-grained memory-level parallelism through a hot-potato deflection-based network-on-chip (NoC), support synchronization constructs, and can instantiate memory-side caches. Our approach is based on a custom runtime OpenMP library, providing flexibility and extensibility. Experimental results show high scalability when synthesizing irregular graph kernels. The accelerators generated with our approach are, on average, 2.29x faster than state-of-the-art HLS methodologies.

Design automation↗
DOE OSTI2022

Deploying Traffic Smoothing Cruise Controllers Learned from Trajectory Data

Autonomous vehicle-based traffic smoothing con- trollers are often not transferred to real-world use due to challenges in calibrating many-agent traffic simulators. We show a pipeline to sidestep such calibration issues by collecting trajectory data and learning controllers directly from trajectory data that are then deployed zero-shot onto the highway. We construct a dataset of 772.3 kilometers of recorded drives on the I-24. We then construct a simple simulator using the recorded drives as the lead vehicle in front of a simulated platoon consisting of one autonomous vehicle and five human followers. Using policy-gradient methods with an asymmetric critic to learn the controller, we show that we are able to improve average MPG by 11% in simulation on congested trajectories. We deploy this controller to a mixed platoon of 4 autonomous Toyota RAV-4’s and 7 human drivers in a validation experiment and demonstrate that the expected time-gap of the controller is maintained in the real world test. Finally, we release the driving dataset [1], the simulator, and the trained controller at https://github.com/nathanlct/trajectory-training-icra.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Low-Cost Preform and Molding Processes

The entry cost for prototyping a composite component for manufacture using automated, high rate processes is prohibitively expensive in many cases, especially for small business, where tooling costs may be several $100k. Discussions with industry also indicate that many small companies, tier 1 and 2 suppliers, have an interest to mold composite parts but do not want to deal with the capital cost, material handling issues, and labor associated with dry fiber preforming operations. While the molders may locate near the end user for logistics reasons, it may be more cost effective for the performer to remain regional and invest in capital equipment to support preform automation, thus keeping costs to a minimum. This project was designed to explore and demonstrate several options to meet these industry needs. Dry fiber preforming approaches were evaluated which allow for low pressure resin infusion, single sided tooling options such a vacuum assisted resin transfer molding (VARTM) or low pressure resin transfer molding (RTM-light). Unlike sheet molding compound, SMC compression molding where typical molding pressures of 1000 psi are required to push material into the desired location; positioning of a dry fiber preform into the desired location on the tool allows for low molding pressures of 10-50 psi. Lower molding pressures allow for use of low cost, additive fabrication of polymeric tooling. Polymeric tooling is suitable for rapid part prototyping and limited production. Dry fiber preforming approaches evaluated included use of commercial chopped strand mat, robotic chopper gun deposition, and continuous fiber preform augmentation using tailored fiber placement (TFP). Use of chopped strand mat does not require a robotic deposition method, however a cutting table is generally required and there is typically 20-30% scrap generation. While various fiber areal weights are available, the preform is not readily optimized for minimal fiber use or weight savings. In contrast, a robotic chopper gun approach allows for localized deposition where fiber is required to meet structural requirements. The robotic method is highly automated and minimizes fiber scrap, however the capital cost of the equipment and engineering labor for programming can result in higher preform cost compared to chopped strand mat in certain cases depending on preform complexity. Dry fiber preforming using the robotic chopper gun method allows for creation of three dimensional forms. This approach may be ideal for molding in-house, or if the preforms stack together densely to allow for efficient shipping. Applications evaluated for this program considered trade-off between fabrication of a fully 3D preform versus production of a flat preform which is designed to readily drape into the final desired shape. Such a preform design greatly simplifies robotic programming and requires no specialized tooling. The flat preforms are easily stacked and shipped to the final molding location. Flat preforms are much easier to augment with TFP continuous fiber to provide local reinforcement. The demonstration and evaluation of these preforming and tooling methods were completed on three component applications. The first application was a battery box cover for an electric vehicle which was highly three dimensional. The second demonstrator article was comprised of complex contours and was used to demonstrate the use of TFP and RTM-light molding process. The third demonstration article was the roof of an operator’s cab for large construction equipment. The roof is relatively flat however it is comprised of complex changes in thickness which clearly demonstrate the advantage of robotic chopper gun approach as compared to using numerous preform layers of chopped strand mat. The cost trades for the various preforming methods are summarized to help guide the reader as to preforming method considerations. Finally, these demonstrations all used glass fiber roving. A fourth, exploratory task was added to evaluate the ability to make preforms using Zoltek’s carbon fiber split tow roving. We were able to adapt the chopper gun to make flat preforms for laminate testing, but further development effort would be required to make suitable preforms.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bench-Scale Development of a Novel Direct Air Capture Technology Using High-Capacity Structured Sorbents

The work performed under this project has resulted into development of a DAC technology utilizing a structured sorbent to capture CO 2 from ambient air with a key innovation of direct Joule heating of the sorbent for CO 2 desorption. A working SMA, fully integrated with an electrically resistive heating layer, high surface area support, and high CO 2 capacity sorbent coated onto a commercial ceramic monolithic substrate, was successfully developed and demonstrated over >200 adsorption-desorption cycles in a high-fidelity bench test unit directly using ambient air. A cordierite-based monolith was selected as a substrate owing to its high surface area, low bulk density, low heat capacity, and commercial availability. Reaction kinetics study conducted during this project led to development of a promoter for the base Na 2 CO 3 sorbent that could be incorporated into the sorbent to enhance to achieve higher CO 2 adsorption/desorption rates, greater working capacity, and reduced regeneration temperature. An accelerated aging study was conducted in a TGA to determine sorbent stability and no degradation in the sorbent performance was observed even after 250 adsorption-desorption cycles. An electrically resistive heating layer was developed with tunable electrical properties. The heating layer was coated onto the selected cordierite substrate. Aging studies performed showed the electrical properties and heating performance was stable after 500 heating and cooling cycles. The collective findings on the selected cordierite substrate, robust heating layer, promoter and sorbent selection were used to synthesize a full, 6”x6” SMA for bench-scale testing. The bench-scale DAC system was constructed to test full size SMAs using real ambient air for adsorption and joule heating for regeneration. After completing shakedown and commissioning of the 1 kg/day of CO 2 capacity DAC bench unit, an extended operation was performed to complete over 230 cycles with the full size SMA. This testing showed no observable degradation in sorbent performance. A detailed process model, TEA and LCA were developed for a conceptual 100,000 TPY CO 2 removal DAC facility. The LCA results show the net CO 2 e emissions from the DAC system are highly dependent on the electricity source. All other factors, including SMA manufacturing, materials for facility enclosure, etc., are minor cost contributors compared to the energy consumption required for CO 2 removal. With the successful development and validation of the SMA for the sustained performance for CO 2 removal from ambient air with joule heated regeneration in this project, a fully integrated 1 TPY bench-scale DAC system is currently in development with the support of DOE/FECM (DE-FE0032243). The project objective is to demonstrate the engineering design of the DAC system to produce a continuous, high purity CO 2 stream from ambient air. This project will address and validate key engineering features of the DAC system including the gas sealing mechanism and panels, enclosure and air contactor design, and automation sequence to achieve continuous CO 2 production.

42 ENGINEERING↗
DOE OSTI2020

AI-optimized detector design for the future Electron-Ion Collider: the dual-radiator RICH case

Advanced detector R&D requires performing computationally intensive and detailed simulations as part of the detector-design optimization process. Here, we propose a general approach to this process based on Bayesian optimization and machine learning that encodes detector requirements. As a case study, we focus on the design of the dual-radiator Ring Imaging Cherenkov (dRICH) detector under development as a potential component of the particle-identification system at the future Electron-Ion Collider (EIC). The EIC is a US-led frontier accelerator project for nuclear physics, which has been proposed to further explore the structure and interactions of nuclear matter at the scale of sea quarks and gluons. We show that the detector design obtained with our automated and highly parallelized framework outperforms the baseline dRICH design within the assumptions of the current model. Our technique can be applied to any detector R&D, provided that realistic simulations are available.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Final Technical Report)

Collision of birds and bats with wind turbines is a conservation concern for both land-based and offshore wind projects. The fatality rates of birds and bats at land-based turbines are well documented. The measurement strategies on land focus on finding carcasses following collision, estimating the number of carcasses missed through searcher efficiency, carcass persistence trials and carcass fall distributions, and modeling statistically robust fatality rates. Few technologies have been developed to monitor offshore bird and bat collisions, and many that have been developed focused on detecting collisions with large birds. The few studies that have attempted to document collisions at offshore turbines do not account for smaller bodied animals or for collisions that might be missed, which prevents the calculation of statistically robust fatality rates. The overall goal of this report, A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Project), was to develop an effective multi-sensor system for quantifying bird and bat collision rates, specifically for offshore wind facilities. The Project goal and resulting automated collision detection system was achieved through two major technological advancements: 1) refining The Netherlands Organisation for Applied Scientific Research’s (TNO’s) existing WT-Bird® vibration sensing system, that had successfully detected large bird collisions during daytime, to allow for improved detection of smaller birds and bats during both daytime and nighttime hours and 2) improving image processing systems and developing and integrating machine learning algorithms to automatically detect and classify small and large bird and bat collisions with offshore turbines. This final technical report (FTR) summarizes Methods , Results , Conclusions , and Lessons Learned during each of the five Tasks identified for this research and development effort. This FTR includes summaries of the following: Task 1. Initial Engineering Tests to Improve WT-Bird® Task 2. Installation of WT‐Bird® on a Utility-scale Turbine at the National Wind Technology Center – National Renewable Energy Laboratory Task 3. Field Tests and Refinement of the Object Detection System Task 4. Validation of WT-Bird® on a Land-based Turbine Task 5. Preparation for the Implementation of WT-Bird® on an Offshore Turbine. This research and development effort documented successful improvement of the WT Bird® collision detection system to detect small birds and bats, and WT-Bird® is the first collision detection system to validate results compared to land-based post-construction monitoring. The collision trials provide estimates of missed targets that can be used to estimate fatality rates, a significant improvement relative to other offshore collision monitoring systems. Advances were made in developing an edge-processing solution to reduce data storage requirements, which is important if the system is deployed for long periods of time at offshore turbines. The improved WT-Bird® system also provides an important option for wind operators on land or offshore who need to document specific details about when collisions occur, particularly efforts to further research on bat impact minimization, or when standard fatality searches are impractical (e.g. offshore) or inadequate (e.g. challenging locations on land).

17 WIND ENERGY↗
DOE OSTI2024

Innovating the next generation of commercial smart building software

Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.

Casillas, Armando↗
DOE OSTI2021

Deep active learning for classifying cancer pathology reports

Abstract Background Automated text classification has many important applications in the clinical setting; however, obtaining labelled data for training machine learning and deep learning models is often difficult and expensive. Active learning techniques may mitigate this challenge by reducing the amount of labelled data required to effectively train a model. In this study, we analyze the effectiveness of 11 active learning algorithms on classifying subsite and histology from cancer pathology reports using a Convolutional Neural Network as the text classification model. Results We compare the performance of each active learning strategy using two differently sized datasets and two different classification tasks. Our results show that on all tasks and dataset sizes, all active learning strategies except diversity-sampling strategies outperformed random sampling, i.e., no active learning. On our large dataset (15K initial labelled samples, adding 15K additional labelled samples each iteration of active learning), there was no clear winner between the different active learning strategies. On our small dataset (1K initial labelled samples, adding 1K additional labelled samples each iteration of active learning), marginal and ratio uncertainty sampling performed better than all other active learning techniques. We found that compared to random sampling, active learning strongly helps performance on rare classes by focusing on underrepresented classes. Conclusions Active learning can save annotation cost by helping human annotators efficiently and intelligently select which samples to label. Our results show that a dataset constructed using effective active learning techniques requires less than half the amount of labelled data to achieve the same performance as a dataset constructed using random sampling.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Optimized Carbon Fiber Intermediate Development to Enable High-Volume Manufacturing of Lightweight Automotive Composites

The ongoing pursuit of improved fuel economy and reduced greenhouse gas emissions has resulted in sustained interest for lightweight materials technologies. In this context, carbon fiber composites have captured the imagination of automotive engineers due to the potential to achieve substantial mass reduction when compared to traditional steel construction. That stated, the use of carbon fiber composites in automotive has been limited for the most part to premium supercars and other derivative platforms. In these cases, manufacturing costs are less of an obstacle to implementation, and the performance benefits of carbon fiber have enabled production of structures offering more than 50% weight savings. In practice, translating these low-volume demonstrations onto high-volume vehicle platforms has remained challenging. This can be attributed to several factors, with the absence of suitable high throughput production methodologies being a key impediment. To date, structural, crash critical components have relied upon manufacturing techniques born out of the aerospace industry. This has created a disconnect between automotive production systems that are accustomed to manufacturing multiple parts per minute and the aerospace technologies that have cycle times in the order of hours. Consequently, the focus of this project is the development of manufacturing process technology for carbon fiber composites that can support a mainstream vehicle program at an assumed throughput of 100,000 vehicles per year. In practice, this translates to a part-to-part cycle time of less than 3 minutes. Project participation included contributions from a broad range of academic, industrial and national lab partners. The primary scope of work, being the development of new carbon fiber epoxy compounds that are stable at room temperature and suited to high throughput automated processing. For project management, the work streams were divided into six key areas, with the lead organization in parentheses. • Carbon fiber/epoxy materials formulation development and scale up (Dow) • Simulation of discontinuous near isotropic meso-structure intermediates (Purdue) • Simulation of mechanical performance of compression molded components (Purdue) • Meso-Scale morphological analysis and correlation with structural performance (UTK) • Paint and adhesion durability analysis (MSU) • Demonstrator part design, prototype production, and validation testing (Ford). The primary goal at the commencement of the project was development of a chopped carbon fiber sheet molding compound (SMC) that offered a three times improvement in tensile modulus over a comparable glass-based SMC. In addition to meeting mechanical performance targets, the resin kinetics were modified to achieve a processing cycle time of less than 3 minutes. Other critical-to-quality (CTQ) specifications were also stipulated to account for a broad range of materials and processing characteristics. To achieve the above, staff scientists at Dow Chemical created an extensive series of new epoxy blends for testing and validation. Throughout this development, a key challenge was attaining material performance goals without impacting processing behavior and paintability of finished components. The latter required a new internal mold release system being developed by Dow that was designed to complement the kinetics of the rapid cure epoxy. As a complement to work studies at the industrial partners, the teams from academia executed a series of analytical and experimental studies to investigate potential factors influencing CF-SMC performance. Unit cell models were developed to capture the meso-scale representations of the fiber matrix architecture. Results of this analysis and subsequent morphological investigations led to the design of a novel composite derivative comprising carbon fiber platelets embedded in an epoxy matrix; the platelet size and aspect ratio playing significant role in final composite properties. This approach was a departure from previous research in CF-SMC development whereby bulk filamentization or disassembly of the carbon fiber rovings had been considered the most effective means of achieving both fiber wet through and wet-out. As the course of the academia studies progressed, the aspect ratio of the fiber constituents was further optimized before finalizing material attributes and processing conditions. For the purposes of technology validation, the Ford team led a work stream devoted to the design, fabrication and testing of demonstration components. The carbon fiber SMC material has the potential to displace numerous stampings and castings on an automotive structure but ultimately vehicle closure applications were selected to showcase the abilities of the CF-SMC to achieve both mass reduction and business case for large complex structures. Using target properties established by the Dow staff scientists, the complete closure system for a full-size sedan decklid and a mid-size wagon liftgate were engineered. Prototypes for both applications were fabricated using production representative processing methods to allow for physical testing and performance validation of the CF-SMC structures. Following completion of a testing program that concluded with a FMVSS301 55 mph offset rear crash, the CF-SMC formulation was declared by the Ford team to have met all engineering requirements. To summarize, the joint development activities during this project led to significant technical breakthroughs and achievement of all milestones. The result was the development of a novel, tack-free carbon fiber molding compound that is suited to automated processing. This combined room temperature stability, fast cure kinetics, and internal mold release system facilitates cycle times that are conducive to high-volume production. The VORAFUSE M6400 successfully passed technology validation at Ford and is now eligible for consideration on future production commercial vehicle programs.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Digital Safety Analysis for Small Modular Nuclear Reactors (SMRs)

A Documented Safety Analysis (DSA) is a Department of Energy (DOE) construct that defines the extent to which a nuclear facility can be operated safely. It includes a description of hazards, safe boundaries, and hazard controls. The authors assert that a Digital Safety Analysis (DgSA) is far superior to a legacy DSA for several reasons: • The underling database is structured such that it is possible to perform a comprehensive design review and safety analysis by iterating systematically across a hierarchy of linked objects versus a redundant and spotty review by entities of various abilities under unknown resource and schedule constraints. • The analysis of a new design can discover elements that are similar to elements in previous designs. The discovery of similarities is made possible by using the same structure for the underlying database for each new DgSA. The “prior learning” from previous designs is then applied automatically to new designs. • Outputs from the DgSA are from a single source to ensure consistency among various views of the same information. After the DgSA is released, the continued use of a single source implements a configuration management program to ensure consistency between the design basis, the design, the built system, and system procedures. • The development of the DgSA is agile in that any change in a linked object triggers an analysis of impacts on other linked objects and updates of linked objects are made accordingly. After the DgSA is released, the continued maintenance of these links and objects automates the “unreviewed safety question” process.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

GeoThermalCloud: Cloud Fusion of Big Data and Multi-Physics Models using Machine Learning for Discovery, Exploration, and Development of Hidden Geothermal Resources

The primary goals of this project are exploring hidden geothermal resources in the U.S.A. and designing profitable enhanced geothermal systems (EGS). Many processes and parameters control geothermal exploration and energy production from geothermal fields. Diverse datasets (e.g., geology, geochemistry, geophysics, satellite, airborne geophysics) are available to help characterize subsurface geothermal conditions. Sparse and multi-scale characteristics of these datasets prohibit properly leveraging these datasets for geothermal exploration and profitable EGS design. Recent advancements in machine learning (ML) promise to resolve these issues. The tremendous challenges and risks of geothermal exploration and production bring the demand for novel ML methods and tools that can (1) analyze large field datasets, (2) assimilate model simulations (large inputs and outputs), (3) process sparse datasets, (4) perform transfer learning (between sites with different exploratory levels), (5) extract hidden geothermal signatures in the field and simulation data, (6) label geothermal resources and processes, (7) identify high-value data acquisition targets, and (8) guide geothermal exploration and production by selecting optimal exploration, production, and drilling strategies. To address these necessities, ML-based geothermal resources exploration and enhanced geothermal systems (EGS) design tools have been developed. The exploration tool is called GeoThermalCloud and EGS design tool is called GeoDT-ML. GeoThermalCloud (https://github.com/SmartTensors/GeoThermalCloud.jl) utilizes a LANL unsupervised ML platform called SmartTensors (https://tensors.lanl.gov/) to automate data analyses and interpretations by extracting hidden signatures to identify geothermal prospects. Also, it enables the identification of critical measurements needed to identify geothermal resource signatures. Alternatively, GeoDT-ML (https://github.com/SmartTensors/GeoThermalCloud.jl/tree/master/EGS) is an ML-based alternative to GeoDT (https://github.com/GeoDesignTool/GeoDT.git), a fast, simplified multi-physics solver to evaluate EGS project designs in uncertain geologic systems. GeoDT-ML leverages recent advances in deep learning and high-performance computing. It is a faster and simpler version of GeoDT. To make this project a success, we used capabilities of LANL, PNNL, Google, Stanford, and Julia Computing. We analyzed eight datasets of the U.S.A. using GeothermalCloud and demonstrated potential highly prospective geothermal resources and identified key factors defining highly prospective sites. The first data set includes 44 locations in southwest New Mexico and 18 geological, hydrogeological, geophysical, geothermal, geochemical attributes. We defined low- and medium-temperature hydrothermal systems and discovered a new highly prospective site. The second data set analyzed 18 shallow water chemistry attributes at 14,342 locations in the Great Basin. It demarcated modestly, moderately, and highly prospective sites including key attributes for each type of prospectivity. The third data set analyzed Utah FORGE data including satellite (InSAR), geophysical (gravity, seismic), geochemical, and geothermal attributes. Here, we performed prospectivity analysis to identify future drilling locations using geological, geochemical, and geophysical attributes. Maps of temperature at depth and heat flow are constructed based on the available data. Prospectivity maps were generated, and drilling locations were proposed for future geothermal field exploration. The fourth data set analyzed 21 attributes at 120 locations in Tularosa Basin, New Mexico; data comes from past play fairway analyses in this region. ML analyses identified geothermal signatures associated with modestly, moderately, and highly hydrothermal systems. We also defined dominant attributes and spatial distribution of the geothermal signatures. The fifth, sixth, seventh, and eighth datasets include Tohatchi Springs, New Mexico, Hawaii, Brady site, Nevada, and EGS Collab, respectively. Moreover, we coupled GeothermalCloud and magnetotellurics data to pinpoint drilling locations for developing geothermal projects in the Tularosa Basin, New Mexico. GeothermalCloud found potential prospective locations for geothermal resources near White Sands Missile Range and McGregor Range at Fort Bliss. Magnetotellurics data determined the potential depth (~1800m) of geothermal prospects at McGregor Range based on apparent resistivity structures/layers in the subsurface. The McGregor Range consists of three resistivity layers and two resistivity structures. Magnetotellurics data also helps identify that the western portion of the McGregor Range has thick and low-resistivity earth materials. The low resistivity to the west is most likely for a fault system. Assuming temperature is consistent with a geothermal reservoir, the west-central part of the McGregor Range has the highest geothermal potential because of the increase in porosity and associated permeability attributed to the interpreted fault system. Also, we devised a coupling strategy between a process model and GeothermalCloud to characterize hydrogeological conditions and geothermal conditions, respectively. The process model characterizes hydrogeological and geothermal conditions on highly prospective geothermal sites provided by GeothermalCloud. We developed a physics-informed neural network (PINN) version of the Burns equation that can be easily coupled with GeothermalCloud. Furthermore, we performed an optimal design decision maximizing the economic value of an EGS power plant. This study optimized the range of well spacing between injection and production wells maximizing net present value in dollars (NPV). For this task, we used the GeoDT to simulate the Utah FORGE EGS development cycle from the initial well design to the end of production. Next, we accomplished another crucial task, which is predicting permeability of geothermal reservoirs. Predicting permeability of geothermal reservoirs is a non-trivial task because of huge computational runtime of simulation and lack of measurements. To avoid these limitations, we used easy-to-measure chemical concentrations in the subsurface as measurement data and convolutional neural network based ML model of a high-fidelity model. Next, we predicted permeability using Markov chain Monte Carlo simulation. We found that Markov chain Monte Carlo simulation predicts permeability with a high certainty if the prediction zone in the simulation area has chemical concentration data. Finally, we analyzed the DOE funded INGENIOUS and GeoDAWN projects data. For discovering hidden geothermal systems in the Great Basin, the INGENIOUS project accumulated old data, collected new data, and released them in 2022. The dataset includes a total of 24 geological, geophysical, and geochemical attributes. Data resolution and scale significantly vary prohibiting an appropriate usage. To avoid such limitations, we brought all data in the same resolution and scale by applying the inverse distance weighting interpolation technique for predicting data in unsampled locations. Subsequently, we analyzed LiDAR data of the GeoDAWN project. We received data in tiles format. The DOE’s overarching goal is to use ML on LiDAR data for finding favorable geological structures (e.g., step up faults in Brady, Nevada). To serve the purpose, we need to label favorable geologic structures that correspond to LiDAR data. We wrote an algorithm to label the LiDAR data with the favorable geologic structures.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Integrative Modeling and Analysis of Fungal Central Carbon Metabolism

Over a thousand fungal genomes have been sequenced, yet manually curated genome-scale metabolic models (GEMs) are available for only a limited number of species. Moreover, these models have often been developed independently, leading to inconsistencies in namespaces, compartment definitions, and pathway representations that hinder comparative analysis, the systematic reuse of prior curation efforts, and the integration of consolidated metabolic knowledge. Here, we present the Consolidated Fungal Core Metabolism Model (CFCMM), constructed by integrating thirteen published fungal models spanning Ascomycota, Mucoromycota, and both Crabtree-positive and Crabtree-negative yeasts. We harmonized metabolites and reactions into a non-redundant shared ModelSEED ontological space, standardized compartmentalization, and refined gene–protein–reaction (GPR) rules. Using pathway-level visualization and systematic gap detection, we further improved the integrated network through literature-guided curation to correct stoichiometry, stereospecificity, and pathway architecture. Orthologous protein family reconstruction and functional annotation workflows were used to validate and inform GPR associations, with particular emphasis on ambiguous enzyme superfamilies and membrane-associated components. Using the resulting CFCMM, we built high-quality central carbon core models for each fungus and performed flux balance analysis to quantify ATP-yield variation under aerobic and anaerobic conditions, explicitly evaluating scenarios driven by differences in electron transport chain (ETC) composition. Simulations reproduced the expected fermentative yield of approximately 2 mmol ATP per mmol glucose under anaerobic conditions and separated the thirteen fungi into two bioenergetic groups under aerobic respiration based on Complex I status, with predicted yields of approximately 30 versus 22 mmol ATP per mmol glucose. Forcing flux through the alternative oxidase bypass further reduced ATP yields to approximately 12 and 4 mmol ATP per mmol glucose in Complex I-containing and Complex I-lacking fungi, respectively. Collectively, this work provides a manually curated, ModelSEED-consistent, and extensible fungal core metabolic template, deployed in DOE KBase as a resource for automated reconstruction of central carbon core models from any sequenced fungal genome. In addition, the CFCMM provides modular components for developing GEMs with more accurate energy predictions and enables robust comparative analyses of fungal bioenergetics and core metabolic diversity

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Model predictive control of heating, ventilation, and air conditioning (HVAC) systems: A state-of-the-art review

Due to the fast advancement of communication and information technology, intelligent buildings have garnered great interest. These buildings can forecast weather, ambient temperature, and sun irradiation and can modify heating, ventilation, and air conditioning (HVAC) operations appropriately, based on current and previous data. This change is intended to reduce HVAC system energy usage while maintaining an appropriate degree of thermal comfort and indoor air quality. Since its inception, model predictive control (MPC) has been one of the prospective solutions for HVAC management systems to reduce both costs and energy usage. Additionally, MPC is becoming increasingly practical as the processing capacity of building automation systems increases and a large quantity of monitored building data becomes available. MPC also provides the potential to improve the energy efficiency of HVAC systems via its capacity to consider limitations, to predict disruptions, and to factor in multiple competing goals such as interior thermal comfort and building energy consumption. Although substantial research has been conducted on MPC in building HVAC systems, there is a shortage of critical reviews and a lack of a comprehensive framework that formulates and defines the applications. Here, this article provides a comprehensive state-of-the-art overview of MPC in HVAC systems. Detailed discussions of modeling approaches and optimization algorithms are included. Numerous design aspects such as prediction horizon, occupancy behavior, building type, and cost function, that impact MPC performance are discussed in detail. The technical characteristics, advantages, and disadvantages of various types of modeling software are discussed. The primary objective of this work is to highlight critical design characteristics for the MPC control scheme and to give improved suggestions for future research. Moreover, numerous prospective scenarios have been suggested that might provide future research direction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

ADEPT: a domain independent sequence alignment strategy for gpu architectures

Bioinformatic workflows frequently make use of automated genome assembly and protein clustering tools. At the core of most of these tools, a significant portion of execution time is spent in determining optimal local alignment between two sequences. This task is performed with the Smith-Waterman algorithm, which is a dynamic programming based method. With the advent of modern sequencing technologies and increasing size of both genome and protein databases, a need for faster Smith-Waterman implementations has emerged. Multiple SIMD strategies for the Smith-Waterman algorithm are available for CPUs. However, with the move of HPC facilities towards accelerator based architectures, a need for an efficient GPU accelerated strategy has emerged. Existing GPU based strategies have either been optimized for a specific type of characters (Nucleotides or Amino Acids) or for only a handful of application use-cases. In this paper, we present ADEPT, a new sequence alignment strategy for GPU architectures that is domain independent, supporting alignment of sequences from both genomes and proteins. Our proposed strategy uses GPU specific optimizations that do not rely on the nature of sequence. We demonstrate the feasibility of this strategy by implementing the Smith-Waterman algorithm and comparing it to similar CPU strategies as well as the fastest known GPU methods for each domain. ADEPT’s driver enables it to scale across multiple GPUs and allows easy integration into software pipelines which utilize large scale computational systems. We have shown that the ADEPT based Smith-Waterman algorithm demonstrates a peak performance of 360 GCUPS and 497 GCUPs for protein based and DNA based datasets respectively on a single GPU node (8 GPUs) of the Cori Supercomputer. Overall ADEPT shows 10x faster performance in a node-to-node comparison against a corresponding SIMD CPU implementation. ADEPT demonstrates a performance that is either comparable or better than existing GPU strategies. We demonstrated the efficacy of ADEPT in supporting existing bionformatics software pipelines by integrating ADEPT in MetaHipMer a high-performance denovo metagenome assembler and PASTIS a high-performance protein similarity graph construction pipeline. Our results show 10% and 30% boost of performance in MetaHipMer and PASTIS respectively.

59 BASIC BIOLOGICAL SCIENCES↗