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NASA NTRS1991

Electronic neural network for dynamic resource allocation

A VLSI implementable neural network architecture for dynamic assignment is presented. The resource allocation problems involve assigning members of one set (e.g. resources) to those of another (e.g. consumers) such that the global 'cost' of the associations is minimized. The network consists of a matrix of sigmoidal processing elements (neurons), where the rows of the matrix represent resources and columns represent consumers. Unlike previous neural implementations, however, association costs are applied directly to the neurons, reducing connectivity of the network to VLSI-compatible 0 (number of neurons). Each row (and column) has an additional neuron associated with it to independently oversee activations of all the neurons in each row (and each column), providing a programmable 'k-winner-take-all' function. This function simultaneously enforces blocking (excitatory/inhibitory) constraints during convergence to control the number of active elements in each row and column within desired boundary conditions. Simulations show that the network, when implemented in fully parallel VLSI hardware, offers optimal (or near-optimal) solutions within only a fraction of a millisecond, for problems up to 128 resources and 128 consumers, orders of magnitude faster than conventional computing or heuristic search methods.

Thakoor, A. P.↗

NASA NTRS1990

Combined design of structures and controllers for optimal maneuverability

Approaches to the combined design of structures and controllers for achieving optimal maneuverability are presented. A maneuverability index which directly reflects the minimum time required to perform a given set of maneuvers is introduced. By designing the flexible appendages, the maneuver time of the spacecraft is minimized under the constraints of structural properties, and post maneuver spillover is kept within a specified bound. The spillover reduction is achieved by making use of an appropriate reduced order model. The distributed parameter design problem is approached using assumed shape functions, and finite element analysis with dynamic reduction. Solution procedures have been investigated. Approximate design methods have been developed to overcome the computational difficulties. Some new constraints on the modal frequencies of the spacecraft are introduced in the original optimization problem to facilitate the solution process. It is shown that the global optimal design may be obtained by tuning the natural frequencies to satisfy specific constraints. Researchers quantify the difference between a lower bound to the solution for maneuver time associated with the original problem and the estimate obtained from the modified problem, for a specified application requirement. Numerical examples are presented to demonstrate the capability of this approach.

Ling, Jer↗

NASA NTRS2022

Earth System Model Parameter Adjustment Using a Green's Functions Approach

We demonstrate the practicality and effectiveness of using a Green's functions estimation approach for adjusting uncertain parameters in an Earth system model (ESM). This estimation approach has previously been applied to an intermediate-complexity climate model and to individual ESM components, e.g., ocean, sea ice, or carbon cycle components. Here, the Green's functions approach is applied to a state-of-the-art ESM that comprises a global atmosphere/land configuration of the Goddard Earth Observing System (GEOS) coupled to an ocean and sea ice configuration of the Massachusetts Institute of Technology general circulation model (MITgcm). Horizontal grid spacing is approximately 110 km for GEOS and 37–110 km for MITgcm. In addition to the reference GEOS-MITgcm simulation, we carried out a series of model sensitivity experiments, in which 20 uncertain parameters are perturbed. These “control” parameters can be used to adjust sea ice, microphysics, turbulence, radiation, and surface schemes in the coupled simulation. We defined eight observational targets: sea ice fraction, net surface shortwave radiation, downward longwave radiation, near-surface temperature, sea surface temperature, sea surface salinity, and ocean temperature and salinity at 300 m. We applied the Green's functions approach to optimize the values of the 20 control parameters so as to minimize a weighted least-squares distance between the model and the eight observational targets. The new experiment with the optimized parameters resulted in a total cost reduction of 9 % relative to a simulation that had already been adjusted using other methods. The optimized experiment attained a balanced cost reduction over most of the observational targets. We also report on results from a set of sensitivity experiments that are not used in the final optimized simulation but helped explore options and guided the optimization process. These experiments include an assessment of sensitivity to the number of control parameters and to the selection of observational targets and weights in the cost function. Based on these sensitivity experiments, we selected a specific definition for the cost function. The sensitivity experiments also revealed a decreasing overall cost as the number of control variables was increased. In summary, we recommend using the Green's functions estimation approach as an additional fine-tuning step in the model development process. The method is not a replacement for modelers' experience in choosing and adjusting sensitive model parameters. Instead, it is an additional practical and effective tool for carrying out final adjustments of uncertain ESM parameters.

Green's Function↗

DOE OSTI2024

Advances in Solutions to Improve the Energy Performance of Agricultural Greenhouses: A Comprehensive Review

The increasing global population and the challenges faced by the food production sector, including urbanization, reduction of arable land, and climatic extremes, necessitate innovative solutions for sustainable agriculture. This comprehensive review examines advancements in improving the energy performance of agricultural greenhouses, highlighting innovations in thermal and energy efficiency, particularly in heating and cooling systems. The methods include a systematic analysis of current technologies and their applications in optimizing greenhouse design and functionality. Key findings reveal significant progress in materials and techniques that enhance energy efficiency and operational sustainability. The review identifies gaps in the current knowledge, such as the need for more research on the economic viability of new materials and the development of predictive models for various climatic conditions. The conclusions emphasize the importance of integrating renewable energy technologies and advanced control systems to achieve energy-efficient and sustainable agricultural practices

Castro, Rodrigues Pascoal↗

NASA NTRS2016

Model Order Reduction of Aeroservoelastic Model of Flexible Aircraft

This paper presents a holistic model order reduction (MOR) methodology and framework that integrates key technological elements of sequential model reduction, consistent model representation, and model interpolation for constructing high-quality linear parameter-varying (LPV) aeroservoelastic (ASE) reduced order models (ROMs) of flexible aircraft. The sequential MOR encapsulates a suite of reduction techniques, such as truncation and residualization, modal reduction, and balanced realization and truncation to achieve optimal ROMs at grid points across the flight envelope. The consistence in state representation among local ROMs is obtained by the novel method of common subspace reprojection. Model interpolation is then exploited to stitch ROMs at grid points to build a global LPV ASE ROM feasible to arbitrary flight condition. The MOR method is applied to the X-56A MUTT vehicle with flexible wing being tested at NASA/AFRC for flutter suppression and gust load alleviation. Our studies demonstrated that relative to the fullorder model, our X-56A ROM can accurately and reliably capture vehicles dynamics at various flight conditions in the target frequency regime while the number of states in ROM can be reduced by 10X (from 180 to 19), and hence, holds great promise for robust ASE controller synthesis and novel vehicle design.

aeroelasticity↗

DOE OSTI2022

Biopolymer Concrete

Cement production for concrete has been responsible for ~7–8% of global greenhouse gas (GHG) emissions, and nearly equally contribution for steel production processes (EPA, 2020). In order to achieve carbon neutrality by 2050, a novel solution has to be investigated. This project aims to develop fundamental mechanistic understanding and experimental characterization to create a 3D printable biopolymer concrete using plant-based polyurethane as an innovative and sustainable alternative for Portland cement concrete, with significantly low carbon footprint. Future construction will utilize the advances in digital additive manufacturing (3D printing) to produce optimal geometries with a minimum waste of materials. Understanding the polymerization process, factors impacting the composite rheology, and the structural behavior of this biopolymer concrete will enable us to engineer the next generation of concrete structures with low carbon footprint. This project aims to improve the nation’s ability to control Greenhouse Gas emission neutrality for the set goal of 2050 via introducing a structurally viable bio-based polymer concrete.

42 ENGINEERING↗

NASA NTRS2014

Use of MODIS Cloud Top Pressure to Improve Assimilation Yields of AIRS Radiances in GSI

Radiances from hyperspectral sounders such as the Atmospheric Infrared Sounder (AIRS) are routinely assimilated both globally and regionally in operational numerical weather prediction (NWP) systems using the Gridpoint Statistical Interpolation (GSI) data assimilation system. However, only thinned, cloud-free radiances from a 281-channel subset are used, so the overall percentage of these observations that are assimilated is somewhere on the order of 5%. Cloud checks are performed within GSI to determine which channels peak above cloud top; inaccuracies may lead to less assimilated radiances or introduction of biases from cloud-contaminated radiances.Relatively large footprint from AIRS may not optimally represent small-scale cloud features that might be better resolved by higher-resolution imagers like the Moderate Resolution Imaging Spectroradiometer (MODIS). Objective of this project is to "swap" the MODIS-derived cloud top pressure (CTP) for that designated by the AIRS-only quality control within GSI to test the hypothesis that better representation of cloud features will result in higher assimilated radiance yields and improved forecasts.

Zavodsky, Bradley↗

DOE OSTI2021

Physics-constrained, low-dimensional models for magnetohydrodynamics: First-principles and data-driven approaches

Plasmas are highly nonlinear and multiscale, motivating a hierarchy of models to understand and describe their behavior. However, there is a scarcity of plasma models of lower fidelity than magnetohydrodynamics (MHD), although these reduced models hold promise for understanding key physical mechanisms, efficient computation, and real-time optimization and control. Galerkin models, obtained by projection of the MHD equations onto a truncated modal basis, and data-driven models, obtained by modern machine learning and system identification, can furnish this gap in the lower levels of the model hierarchy. This work develops a reduced-order modeling framework for compressible plasmas, leveraging decades of progress in projection-based and data-driven modeling of fluids. We begin by formalizing projection-based model reduction for nonlinear MHD systems. To avoid separate modal decompositions for the magnetic, velocity, and pressure fields, we introduce an energy inner product to synthesize all of the fields into a dimensionally consistent, reduced-order basis. Next, we obtain an analytic model by Galerkin projection of the Hall-MHD equations onto these modes. We illustrate how global conservation laws constrain the model parameters, revealing symmetries that can be enforced in data-driven models, directly connecting these models to the underlying physics. We demonstrate the effectiveness of this approach on data from high-fidelity numerical simulations of a three-dimensional spheromak experiment. Finally, this manuscript builds a bridge to the extensive Galerkin literature in fluid mechanics and facilitates future principled development of projection-based and data-driven models for plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2005

Modular Software Interfaces for Revolutionary Flexibility in Space Operations

To make revolutionary improvements in exploration, space systems need to be flexible, realtime reconfigurable, and able to trade data transparently among themselves and mission operations. Onboard operations systems, space assembly coordination and EVA systems in exploration and construction all require real-time modular reconfigurability and data sharing. But NASA's current exploration systems are still largely legacies from hastily-developed, one-off Apollo-era practices. Today's rovers, vehicles, spacesuits, space stations, and instruments are not able to plug-and-play, Lego-like: into different combinations. Point-to-point dominates - individual suit to individual vehicle, individual instrument to rover. All are locally optimized, all unique, each of the data interfaces has been recoded for each possible combination. This will be an operations and maintenance nightmare in the much larger Project Constellation system of systems. This legacy approach does not scale to the hundreds of networked space components needed for space construction and for new, space-based approaches to Earth-Moon operations. By comparison, battlefield information management systems, which are considered critical to military force projection, have long since abandoned a point-to-point approach to systems integration. From a system-of-systems viewpoint, a clean-sheet redesign of the interfaces of all exploration systems is a necessary prerequisite before designing the interfaces of the individual exploration systems. Existing communications and Global Information Grid and middleware technologies are probably sufficient for command and control and information interfaces, with some hardware and time-delay modifications for space environments. NASA's future advanced space operations must also be information and data compatible with aerospace operations and surveillance systems being developed by other US Government agencies such as the Department of Homeland Security, Federal Aviation Administration and Department of Defense. This paper discusses fundamental system-of-systems infrastructure: approaches and architectures for modular plug-and-play software interfaces for revolutionary improvements in flexibility, modularity, robustness, ease of maintenance, reconfigurability, safety and productivity. Starting with middleware, databases, and mobile communications technologies, our technical challenges will be to apply these ideas to the requirements of constellations of space systems and to implement them initially on prototype space hardware. This is necessary to demonstrate an integrated information sharing architecture and services. It is a bottom-up approach, one that solves the problem of space operations data integration. Exploration demands uniform software mechanisms for application information interchange, and the corresponding uniformly available software services to enhance these mechanisms. We will examine the issues in plug-and-play, real-time-configurable systems, including common definition and management and tracking of data and information among many different space systems. Different field test approaches are discussed, including the use of the International Space Station and terrestrial analog mission operations at field sites.

Glass, Brian↗

DOE OSTI2025

Photon–photon chemical thermodynamics of frequency conversion processes in highly multimode systems

Abstract Frequency generation in highly multimode nonlinear optical systems is inherently a complex process, giving rise to an exceedingly convoluted landscape of evolution dynamics. While predicting and controlling the global conversion efficiencies in such nonlinear environments has long been considered impossible, here, we formally address this challenge even in scenarios involving a very large number of spatial modes. By utilizing fundamental notions from optical statistical mechanics, we develop a universal theoretical framework that effectively treats all frequency components as chemical reactants/products, capable of undergoing optical thermodynamic reactions facilitated by a variety of multi-wave mixing effects. These photon–photon reactions are governed by conservation laws that directly determine the optical temperatures and chemical potentials of the ensued chemical equilibria for each frequency species. In this context, we develop a comprehensive stoichiometric model and formally derive an expression that relates the chemical potentials to the optical stoichiometric coefficients, in a manner akin to atomic/molecular chemical reactions. This advancement unlocks new predictive capabilities that can facilitate the optimization of frequency generation in highly multimode photonic arrangements, surpassing the limitations of conventional schemes that rely exclusively on nonlinear optical dynamics. Notably, we identify a universal regime of Rayleigh–Jeans thermalization where an optical reaction at near-zero optical temperatures can promote the complete and entropically irreversible conversion of light to the fundamental mode at a target frequency. Our theoretical results are corroborated by numerical simulations in settings where second-harmonic generation, sum-frequency generation and four-wave mixing processes can manifest.

Optics↗

NASA NTRS2007

Estimating the Inertia Matrix of a Spacecraft

A paper presents a method of utilizing some flight data, aboard a spacecraft that includes reaction wheels for attitude control, to estimate the inertia matrix of the spacecraft. The required data are digitized samples of (1) the spacecraft attitude in an inertial reference frame as measured, for example, by use of a star tracker and (2) speeds of rotation of the reaction wheels, the moments of inertia of which are deemed to be known. Starting from the classical equations for conservation of angular momentum of a rigid body, the inertia-matrix-estimation problem is formulated as a constrained least-squares minimization problem with explicit bounds on the inertia matrix incorporated as linear matrix inequalities. The explicit bounds reflect physical bounds on the inertia matrix and reduce the volume of data that must be processed to obtain a solution. The resulting minimization problem is a semidefinite optimization problem that can be solved efficiently, with guaranteed convergence to the global optimum, by use of readily available algorithms. In a test case involving a model attitude platform rotating on an air bearing, it is shown that, relative to a prior method, the present method produces better estimates from few data.

Acikmese, Behcet↗

DOE OSTI2021

Deep Reinforcement Learning Enabled Physical-Model-Free Two-Timescale Voltage Control Method for Active Distribution Systems

Active distribution networks are being challenged by frequent and rapid voltage violations due to renewable energy integration. Conventional model-based voltage control methods rely on accurate parameters of the distribution networks, which are difficult to achieve in practice. This paper proposes a novel physical-model-free two-timescale voltage control framework for active distribution systems. To achieve fast control of PV inverters, the whole network is first partitioned into several subnetworks using voltage-reactive power sensitivity. Then, the scheduling of PV inverters in the multiple sub-networks is formulated as Markov games and solved by a multi-agent soft actor-critic (MASAC) algorithm, where each subnetwork is modeled as an intelligent agent. All agents are trained in a centralized manner to learn a coordinated strategy while being executed based on only local information for fast response. For the slower time-scale control, OLTCs and switched capacitors are coordinated by a single agent-based SAC algorithm using the global information with considering control behaviors of the inverters. Particularly, the two-level agents are trained concurrently with information exchange according to the reward signal calculated from the data-driven surrogate model. Comparative tests with different benchmark methods on IEEE 33-and 123-bus systems and 342-node low voltage distribution system demonstrate that the proposed method can effectively mitigate the fast voltage violations and achieve systematical coordination of different voltage regulation assets without the knowledge of accurate system model.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2002

Reliable Real-Time Solution of Parametrized Partial Differential Equations: Reduced-Basis Output Bound Methods

We present a technique for the rapid and reliable prediction of linear-functional outputs of elliptic (and parabolic) partial differential equations with affine parameter dependence. The essential components are (i) (provably) rapidly convergent global reduced basis approximations, Galerkin projection onto a space W(sub N) spanned by solutions of the governing partial differential equation at N selected points in parameter space; (ii) a posteriori error estimation, relaxations of the error-residual equation that provide inexpensive yet sharp and rigorous bounds for the error in the outputs of interest; and (iii) off-line/on-line computational procedures, methods which decouple the generation and projection stages of the approximation process. The operation count for the on-line stage, in which, given a new parameter value, we calculate the output of interest and associated error bound, depends only on N (typically very small) and the parametric complexity of the problem; the method is thus ideally suited for the repeated and rapid evaluations required in the context of parameter estimation, design, optimization, and real-time control.

Prudhomme, C.↗

NASA NTRS2024

Georgia’s Potentials for Sustainable Intensification, Increasing Food Security and Rural Incomes

Increasing global demand for agricultural commodities spurs conversions of natural ecosystems. Sustainable intensification in areas of high yield gaps can contribute to reducing the impact of commodity production, while also supporting development, food security, and livelihoods. Following the dissolution of the Union of Soviet Socialist Republics (USSR), Georgia experienced one the highest losses of agricultural productivity among all former USSR countries and is now highly dependent on food imports. Closing yield gaps in Georgia through sustainable intensification has the potential to increase food self-sufficiency, support rural livelihoods, and strengthen food security and sovereignty. We estimated it’s potential for sustainable intensification on current agricultural areas to achieve self-sufficiency for wheat, maize, and barley. We found that crop yields can be doubled to tripled under high input production systems, using high-yielding varieties, optimized inputs, fertilizers, and pest control. Yet, self-sufficiency in wheat can only be reached if at least 60-80% of the potentially attainable yields are achieved and if land is optimally allocated between crops. To achieve such increases, farmers need access to and training for using different crop varieties, fertilizers, and pest and disease control practices and products. Intensification increases the risks to ecosystem services health and livelihoods, particularly raising equity concern. Yet, intensifying very low input systems is often found to be more sustainable, with high yield increases compared to limited impacts on the environment. The high employment in the agricultural sector in Georgia particularly provides opportunities to reduce poverty and increase livelihoods through increasing incomes and food security.

Florian Gollnow↗

DOE OSTI2022

Co-optimized Mixed-Mode Engine and Fuel Demonstrator for Improved Fuel Economy while Meeting Emissions Requirements

Progressively increasing regulatory demands on fuel economy and future global emission standards have led to a focus on advanced engine development to improve overall engine efficiency and fulfill emission requirements. Low temperature combustion (LTC) and gasoline compression ignition (GCI) are promising technologies to achieve these goals and have the advantage of using existing refinery infrastructure and subsequent economies of scale for a robust energy supply. By applying spark ignition (SI) for cold start, LTC for low load operations, and GCI for medium to high load operations, a multimode GCI engine concept was proposed and the fuel formation was co-optimized to maximize fuel economy improvement potential while maintaining ULEV 70 emissions standards. HATCI has successfully demonstrated the feasibility of this multimode GCI engine concept, and confirmed the fuel economy improvement over the baseline SI engine by simulating the FTP75 vehicle drive cycle. In this report, the technical approaches, multimode engine control, and engine test results of both steady state and transitions, CFD modeling, fuel testing, and FTP75 drive cycle simulation results are summarized, followed with technical challenges observed, and recommendations for possible follow-up studies.

02 PETROLEUM↗

NASA NTRS2010

NASA Tech Briefs, November 2010

Topics covered include: Portable Handheld Optical Window Inspection Device; Salience Assignment for Multiple-Instance Data and Its Application to Crop Yield Prediction; Speech Acquisition and Automatic Speech Recognition for Integrated Spacesuit Audio Systems ; Predicting Long-Range Traversability from Short-Range Stereo-Derived Geometry; Browser-Based Application for Telemetry Monitoring of Robotic Assets; Miniature Low-Noise G-Band I-Q Receiver; Methods of Using a Magnetic Field Response Sensor Within Closed, Electrically Conductive Containers; Differential Resonant Ring YIG Tuned Oscillator; Microfabricated Segmented-Involute-Foil Regenerator for Stirling Engines; Reducing Seal Adhesion in Low Impact Docking Systems; Optimal Flow Control Design; Corrosion-Resistant Container for Molten-Material Processing; Reusable Hot-Wire Cable Cutter; Deployment of a Curved Truss; High-Volume Airborne Fluids Handling Technologies to Fight Wildfires; Modeling of Alkane Oxidation Using Constituents and Species; Fabrication of Lanthanum Telluride 14-1-11 Zintl High-Temperature Thermoelectric Couple; A Computer Model for Analyzing Volatile Removal Assembly; Analysis of Nozzle Jet Plume Effects on Sonic Boom Signature; Optical Sidebands Multiplier; Single Spatial-Mode Room-Temperature-Operated 3.0 to 3.4 micrometer Diode Lasers; Self-Nulling Beam Combiner Using No External Phase Inverter; Portable Dew Point Mass Spectrometry System for Real-Time Gas and Moisture Analysis; Maximum Likelihood Time-of-Arrival Estimation of Optical Pulses via Photon-Counting Photodetectors; Handheld White Light Interferometer for Measuring Defect Depth in Windows; Decomposition Algorithm for Global Reachability on a Time-Varying Graph; Autonomous GN and C for Spacecraft Exploration of Comets and Asteroids; Efficient Web Services Policy Combination; Using CTX Image Features to Predict HiRISE-Equivalent Rock Density; Isolation of the Paenibacillus phoenicis, a Spore-Forming Bacterium; Monolithically Integrated, Mechanically Resilient Carbon-Based Probes for Scanning Probe Microscopy; Cell Radiation Experiment System; Process to Produce Iron Nanoparticle Lunar Dust Simulant Composite; Inversion Method for Early Detection of ARES-1 Case Breach Failure; Use of ILTV Control Laws for LaNCETS Flight Research;and Evaluating Descent and Ascent Trajectories Near Non-Spherical Bodies.

Source record↗

DOE OSTI2020

A machine learning approach to emulation and biophysical parameter estimation with the Community Land Model, version 5

Abstract. Land models are essential tools for understanding and predicting terrestrial processes and climate–carbon feedbacks in the Earth system, but uncertainties in their future projections are poorly understood. Improvements in physical process realism and the representation of human influence arguably make models more comparable to reality but also increase the degrees of freedom in model configuration, leading to increased parametric uncertainty in projections. In this work we design and implement a machine learning approach to globally calibrate a subset of the parameters of the Community Land Model, version 5 (CLM5) to observations of carbon and water fluxes. We focus on parameters controlling biophysical features such as surface energy balance, hydrology, and carbon uptake. We first use parameter sensitivity simulations and a combination of objective metrics including ranked global mean sensitivity to multiple output variables and non-overlapping spatial pattern responses between parameters to narrow the parameter space and determine a subset of important CLM5 biophysical parameters for further analysis. Using a perturbed parameter ensemble, we then train a series of artificial feed-forward neural networks to emulate CLM5 output given parameter values as input. We use annual mean globally aggregated spatial variability in carbon and water fluxes as our emulation and calibration targets. Validation and out-of-sample tests are used to assess the predictive skill of the networks, and we utilize permutation feature importance and partial dependence methods to better interpret the results. The trained networks are then used to estimate global optimal parameter values with greater computational efficiency than achieved by hand tuning efforts and increased spatial scale relative to previous studies optimizing at a single site. By developing this methodology, our framework can help quantify the contribution of parameter uncertainty to overall uncertainty in land model projections.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

A Multi-Scale Computational Platform for Predictive Modeling of Corrosion in Al-Steel Joints (Final Report)

The research team proposed to develop innovative multi-scale models to predict corrosion and the resulting mechanical performances in aluminum-steel joints. The methods of joining considered are resistance spot welding, self-piercing riveting, and rivet-welding, all suitable for mass production applications. The multi-scale models integrate high throughput first-principle calculations based on density functional theory (DFT), high throughput calculation of phase diagrams (CALPHAD) modeling, and finite element method (FEM) simulations. These models are to be validated through laboratory experiments. Furthermore, the models are available as open source so as to enable scientists and engineers in the community to adapt and contribute to the development and application. The approaches rely on the research team’s extensive experience on the prediction of properties of individual phases at finite temperatures and variable compositions through DFT calculations, and our broad expertise on dissimilar material joining and their corrosion. The proposed computational framework enables high throughput computations for improved predictions of corrosion and the associated mechanical performance in dissimilar material joints, resulting in significant reduction in computational time needed by the current state-of-the-art methods. With the participation of researchers from three universities, an auto manufacturer, two manufacturing technology/equipment suppliers, and a software developer/vendor, the interdisciplinary research team applies the technical development on both phase-based modeling and laboratory experiments into the automobile body joining processes for validation and technology demonstration. The global cost of corrosion was estimated at about 3.4% of the global GDP in 2013. By using available corrosion control practices, it is estimated a saving between 15-35% of the cost of corrosion. In the U.S., more than $276 billion is spent repairing corrosion damage. Prediction of the corrosion and its impact on performance of the dissimilar material joints is critical for reducing the massive number of the current corrosion-based recalls for automobiles. Thus, the project goal is to develop models to enable predictive maintenance and end-of-life planning of multi-metal joints with risk of corrosion under different conditions such as exposure to high temperatures in summer and salt solutions in winter, quantified through its pH. An academia-industry consortium led by the University of Michigan and including Pennsylvania State University, University of Illinois Urbana-Champaign, University of Georgia, General Motors Company, Livermore Software Technology Corporation, and Optimal Process Technologies, LLC. created multi-scale models for prediction of corrosion in aluminum-steel joint structures such of them used in vehicle subassemblies – chassis and transmission systems. Starting from the first principle calculations, the team developed mathematical and data-driven models to predict the metallic components, which are formed during joining of two metals, for example aluminum and steel - a lightweight multilateral system which is currently used in more than 60% car bodies. These models were used for simulating chemical reactions that are happening when the joining metallic components are exposed to high temperatures and different pH values. The team was able to predict how the corrosion installs on the metallic components and how they lead to a sudden failure of components in cars. Newly developed machine learning algorithms combining Science, Technology, Engineering and Math disciplines, advanced finite element simulation and experimental validations have been integrated in a platform for prediction of the corrosion evolution and prediction the failure of joints under mechanical loadings and fatigue. Moreover, based on machine learning and inverse analysis, the team proposed solutions for designing new metallic alloys less susceptible to corrosion when joining multi-material assembles. An average of 4% error compared with experiments was achieved for the most common joints that are used in vehicle subassemblies.

36 MATERIALS SCIENCE↗