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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.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Characterizing Mesoscale Cellular Convection in Marine Cold Air Outbreaks With a Machine Learning Approach

Abstract During marine cold‐air outbreaks (MCAOs), when cold polar air moves over warmer ocean, a well‐recognized cloud pattern develops, with open or closed mesoscale cellular convection (MCC) at larger fetch over open water. The Cold‐Air Outbreaks in the Marine Boundary Layer Experiment provided a comprehensive set of ground‐based in situ and remote sensing observations of MCAOs at a coastal location in northern Norway. MCAO periods that unambiguously exhibit open or closed MCC are determined. Individual cells observed with a profiling Ka‐band radar are identified using a watershed segmentation method. Using self‐organizing maps (SOMs), these cells are then objectively classified based on the variability in their vertical structure. The SOM nodes contain some information about the location of the cell transect relative to the center of the MCC. This adds classification noise, requiring numerous cell transects to isolate cell dynamical information. The SOM‐based classification shows that comparatively intense convection occurs only in open MCC. This convection undergoes an apparent lifecycle. Developing cells are associated with stronger updrafts, large spectrum width, larger amounts of liquid water, lower surface precipitation rates, and lower cloud tops than mature and weakening cells. The weakening of these cells is associated with the development of precipitation‐induced cold pools. The SOM classification also reveals less intense convection, with a similar lifecycle. More stratiform vertical cloud structures with weak vertical motions are common during closed MCC periods and are separated into precipitating and non‐precipitating stratiform cores. Convection is observed only occasionally in the closed MCC environment.

Meteorology & Atmospheric Sciences↗
DOE OSTI2025

OpenCRUMS USA: An Open Machine Learning Framework for Characterizing Variability in Aerosol Reanalysis Data

Advances in artificial intelligence (AI) have called for exploring how these techniques can be used for exploring patterns in large climate datasets. To that regard, the U.S. Department of Energy AI for Earth System Predictability (AI4ESP) supported a pilot initiative called the Open Classification of Regimes in the Southeast USA (OpenCRUMS USA) project to explore how AI can be used to characterize modes of spatial variability in large climate datasets. For this study, we focus on comparing two methods for characterizing the modes of spatial variability of surface aerosol concentration over the Houston region: empirical orthogonal functions (EOFs) and layerwise relevance propagation (LRP) applied to a convolutional neural network (CNN) classifier. We show that EOF analysis typically attributes spatial variability modes that span all of southeast Texas, prohibiting the attribution of spatial variability to localized regions. However, using LRP on the CNN classifier resolves the explanatory parameters at a finer spatial resolution than EOFs. This allows for the attribution of the spatial variability of surface aerosols to local regions of organic carbon which was not possible using EOFs. In addition, the LRP analysis also suggests that synoptic-scale transport of dust is most prevalent during anticyclonic and pretrough synoptic conditions as categorized by self-organizing maps.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Servomotor-driven leveling elements for machine tool frame-to-floor alignment

This paper presents the results of aligning the frame to concrete floor of a large 5-axis machine tool by leveling element adjustments using servomotors instead of manual operation. The machine tool leveling elements used in this study are mechanical devices that attach the machine tool frame to the concrete foundation. These leveling elements are also adjustable so that each location along the machine tool can be uniquely adjusted such that the geometric errors of the frame are minimized, and the accuracy of the machine tool is improved. Off-the-shelf servomotors and connection equipment were installed at each of 12 leveling element locations for a precision 5-axis machine tool at Oak Ridge National Laboratory. The servomotors allow a technician to align the machine tool frame remotely, instead of crawling under the machine tool to iteratively manually adjust each of the 12 leveling elements. The open-loop servomotor-leveling element system design is presented in this paper as well as machine tool frame alignment results. The servomotor system significantly reduces leveling element adjustment time, eliminates the need for under-machine access, reduces technician physical strain, and significantly improves the adjustment repeatability.

Honeycutt, Andrew [ORNL]↗
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 OSTI2024

Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

A205 aluminum is one of the few high-strength aluminum alloys discovered for additive manufacturing (AM). The microstructure and heat treatment effects of AM A205 vary from those of its cast form, indicating possible differences in machinability during post-processing. Here, the objective of this research is to determine these variations of AM A205 and their effects on machinability using the cast condition as the baseline. As built and two heat-treated conditions (solution treatment and age hardening) were applied and compared in terms of their microstructures, micro-hardness, and machinability including vibration, specific cutting energy, chip morphology, and surface finish. The effects of print orientations on machinability were tested as well and found to be insignificant. AM as built had a higher hardness and slightly better machinability than its cast as built cast counterpart due to a smaller grain size (1 µm vs. 15 µm), eutectic θ-Al 2 Cu lattice and a fine, homogeneous TiB 2 distribution. The solution treatment dissolved this θ-Al 2 Cu lattice and increased the grain size (3 µm) which decreased the hardness, increased the ductility seen in the chips, and reduced the overall machinability. The presence of θ’-Al 2 Cu precipitates improved the machinability of aged AM A205. In addition, it was found that A205 exhibited both ductile and brittle behavior depending on the cutting speed, thus producing different machinability. The speed dependency is related to the material condition and heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rapid Commissioning of Large Machine Tools Using Finite Element-Based Correction of Geometric Errors

Large computer numerical control (CNC) machine tools derive their stiffness from monolithic cast iron bases or weldments that are sometimes integral to machine motion systems like box ways or guideways. However, the sheer size of castings and even floor flatness deviations result in dimensional errors in these systems, which manifest as machine motion errors. Typical geometric alignment processes rely on an iterative approach, where measurements are taken to assess alignment (straightness, squareness, and parallelism), followed by adjustment of the machine supports (fixators or leveling pads), which can take weeks even for an experienced operator. Conversely, a novel method is proposed to shorten the correction time by eliminating the trial-and-error process in favor of a more deterministic approach guided by a finite element (FE) method. A feasibility study is conducted on a CNC polymer hybrid machine, with a steel weldment frame, supported by six leveling pads. An FE model of the frame is utilized to obtain recommended leveling pad adjustments, based on measurement of machine errors taken using a laser tracker. After a single adjustment cycle, measurements reveal that geometric errors of the machine tool are reduced from 2.22 mm of flatness deviation to 0.32 mm, achieving an 85.6% reduction. Furthermore, the entire process including measurement, adjustment, and assessment is completed in just 6 h by two operators who are not professional service engineers. In conclusion, this methodology demonstrates feasibility for scaling up, especially to large, high-precision CNC machine tools with bases mounted by fixators, offering the capability for bidirectional adjustment.

42 ENGINEERING↗
DOE OSTI2024

A data-driven framework for predicting machining stability: employing simulated data, operational modal analysis, and enhanced transfer learning

Chatter, a self-excited vibration phenomenon, presents a significant challenge in machining operations, particularly in high-speed milling, where it can degrade tool life, reduce material removal efficiency, and compromise workpiece quality. Addressing this challenge requires a reliable predictive model that can accommodate the complex dynamics of various machining scenarios. This study introduces a novel, data-driven approach to predicting machining stability, leveraging over 140,000 simulated datasets and employing advanced techniques such as operational modal analysis (OMA), enhanced transfer learning (TL), and receptance coupling substructure analysis (RCSA). By integrating these methodologies, the framework effectively classifies and predicts chatter across diverse operational modes, achieving robust and accurate outcomes. Our model utilizes a Random Forest (RF) classifier trained with the comprehensive dataset, which demonstrates substantial improvements in both predictive accuracy and robustness. Specifically, the RF model achieved an accuracy rate of 85%, an area under the curve (AUC) of 0.90, and an F1 score of 0.88, underscoring its capability to adapt to varying machining configurations. These results highlight the framework’s potential to enhance operational efficiency and machining quality by providing reliable chatter predictions across a broad range of machining parameters. In conclusion, this research thus offers a significant advancement in predictive maintenance for machining processes, enabling more stable and efficient manufacturing operations.

42 ENGINEERING↗
DOE OSTI2024

Transitioning from Simulation to Reality: Applying Chatter Detection Models to Real-World Machining Data

Chatter, a self-excited vibration phenomenon, is a critical challenge in high-speed machining operations, affecting tool life, product surface quality, and overall process efficiency. While machine learning models trained on simulated data have shown promise in detecting chatter, their real-world applicability remains uncertain due to discrepancies between simulated and actual machining environments. The primary goal of this study is to bridge the gap between simulation-based machine learning models and real-world applications by developing and validating a Random Forest-based chatter detection system. This research focuses on improving manufacturing efficiency through reliable chatter detection by integrating Operational Modal Analysis (OMA), Receptance Coupling Substructure Analysis (RCSA), and Transfer Learning (TL). The study applies a Random Forest classification model trained on over 140,000 simulated machining datasets, incorporating techniques like Operational Modal Analysis (OMA), Receptance Coupling Substructure Analysis (RCSA), and Transfer Learning (TL) to adapt the model for real-world operational data. The model is validated against 1600 real-world machining datasets, achieving an accuracy of 86.1%, with strong precision and recall scores. The results demonstrate the model’s robustness and potential for practical implementation in industrial settings, highlighting challenges such as sensor noise and variability in machining conditions. This work advances the use of predictive analytics in machining processes, offering a data-driven solution to improve manufacturing efficiency through more reliable chatter detection.

42 ENGINEERING↗
DOE OSTI2024

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing

The Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing project objective is to automatically tune machining parameter predictions from physics-based models using process data and Bayesian machine learning. The intent is to enable a step change in aerospace manufacturing by combining machine learning, physics-based process models, and sensors/data in a comprehensive digital environment that simultaneously considers the computer numerically controlled (CNC) machining center capabilities, the workpiece material and geometry, and the workpiece support (fixturing). The project hypothesis is that this combination will enable improved performance in machining operations.

42 ENGINEERING↗
DOE OSTI2025

Security Assessment of an LBP16-Protocol-Based Computer Numerical Control Machine

Subtractive manufacturing systems, specifically, computer numerical control machines, have revolutionized the manufacturing industry. Computer numerical control machining is the preferred method for producing finished parts due to its efficiency, speed and suitability for high-volume production. Securing computer numerical control machines is a priority. Compromises or disruptions of these machines can result in significant downtime, loss of productivity and financial loss. This study examines the vulnerabilities and risks associated with computer numerical control machines, in particular, systems utilizing the LBP16 protocol for controller-machine communications. The study reveals that an adversary can execute cyber-physical attacks such as sabotage and denial of service. The potential security threats emphasize the importance of implementing robust security measures to mitigate the cyber risks to computer numerical control machines.

Forihat, Yahya [Virginia Commonwealth University, ↗
DOE OSTI2026

Thermal Management for a Novel Non-Heavy Rare-Earth Interior Permanent Magnet Machine

The work presents a thermal management solution for a novel non-heavy rare-earth permanent magnet machine being developed at Oak Ridge National Laboratory. The motor has been designed to minimize losses while maximizing performance for a range of speeds and power ratings. The novel motor design reduces rare-earth magnet usage, thereby avoiding supply chain issues. The motor component heat losses are established for operating windows and desired performance. These heat losses, along with windage losses, are being used to develop cooling solutions for different components of this machine. A novel thermal management solution for stators and rotors has been developed, and progress is presented in this paper. The stator cooling is achieved with the help of water-ethylene glycol flowing over the finned aluminum stator jacket, and rotor cooling with automatic transmission fluid passing through novel channels designed in the rotor laminations. The attempt is to establish effective cooling of the stator winding, laminations, and rotor magnets. A 3D conjugate heat transfer model has been developed for overall thermal analysis to establish a down- selected thermal management solution for the machine. The model, in addition to estimated component heat losses, includes windage losses and its impact on rotor and stator cooling. Overall, the work presents a workable thermal solution for the interior permanent magnet machine with potential for further improvements. Future work will involve establishing end winding and refinement of other end parts of the machine with the aim of establishing a robust thermal management solution. The work will also focus on different shapes (e.g., round, non-round, presence of wedges) of rotor-stator gaps and investigate windage losses and their impact on thermal management for higher rotational speeds for the machine.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Subseasonal Forecasting and MJO Teleconnections in Machine Learning Weather Prediction Models

Abstract In recent years, machine‐learning (ML) models trained on reanalysis data have rivaled physics‐based forecast models in terms of performance skill for global weather forecasting. With increased rollout stability, the question of how these models perform for subseasonal to seasonal (S2S, week 3–8) forecasting has emerged. In this study we run a large set of subseasonal hindcasts over 2004–2023 to evaluate two ML weather forecast models at the S2S time scale, SFNO‐HENS (Nvidia, fully ML) and NeuralGCM (Google Research, hybrid). Corresponding hindcasts from the European Centre for Medium‐Range Weather Forecasts (ECMWF) are used as a baseline for comparison to a physics‐based model. Because our focus is on predicting moisture transport over the Western United States between October and March, we evaluate the models' prediction skill for the Madden‐Julian Oscillation (MJO) and its associated teleconnections in the North Pacific. We find that both ML models are competitive with the ECWMF model, with comparable skill in predicting the North Pacific large‐scale circulation and the MJO at week 3 and beyond. Even though overall the mid‐latitude subseasonal prediction skill remains low, the ML models exhibit interesting behavior such as a realistic propagation of the MJO across the Maritime Continent and realistic teleconnections. A SFNO‐HENS sensitivity experiment with altered initial conditions in the tropics demonstrates the stability of the model, and it illustrates the capability of ML models to represent important physical processes of the atmosphere at the S2S time scale. Plain Language Summary Predicting weather patterns and precipitation a few weeks in advance (subseasonal time scale) is of great interest for stakeholders such as water managers in the Southwest United States (US), where arid conditions prevail. Subseasonal forecasts from traditional weather forecast models exhibit low skill in the region, limiting their applicability. Here we examine whether the recent breakthrough in weather forecasting made with machine learning/artificial intelligence models can translate to improved subseasonal forecasts. Recently‐developed machine learning models exhibit comparable skill to a state‐of‐the‐art physics‐based model for predicting weather patterns in the North Pacific/North America region, and associated moisture transport. The same applies to their skill in predicting the tropical pattern, the Madden‐Julian Oscillation, and its important remote perturbations over the midlatitude East Pacific and Southwest US. Additionally, a perturbation experiment carried out with one of the machine learning models illustrates their ability to not only predict the evolution of atmospheric fields, but also to learn and represent physical processes such as tropics‐extratropics Rossby wave propagation. Key Points Two machine learning weather forecast models exhibit state‐of‐the‐art prediction skill at the subseasonal time scale in the Pacific sector The models equal ECWMF in terms of Madden‐Julian oscillation (MJO) prediction skill, and they accurately predict the MJO propagation and associated teleconnections The two machine‐learning models represent key physical processes for subseasonal prediction, despite being trained for weather forecasting

Peings, Yannick↗
DOE OSTI2024

Quantum Annealing for Real-World Machine Learning Applications

Optimizing the training of a machine learning pipeline is important for reducing training costs and improving model performance. One such optimizing strategy is quantum annealing, which is an emerging computing paradigm that has shown potential in optimizing the training of a machine learning model. The implementation of a physical quantum annealer has been realized by D-Wave systems and is available to the research community for experiments. Recent experimental results on a variety of machine learning applications have shown interesting results especially under the conditions where the performance of classical machine learning techniques are limited such as limited training data and high dimensional features. This chapter explores the application of D-Wave’s quantum annealer for optimizing machine learning pipelines for real-world classification problems. We review the application domains on which a physical quantum annealer has been used to train machine learning classifiers. We discuss and analyze the experiments performed on the D-Wave quantum annealer for applications such as image recognition, remote sensing imagery, security, computational biology, biomedical sciences, and physics. We discuss the possible advantages and the problems for which quantum annealing is likely to be advantageous over classical computation.

Kumar nath, Rajdeep↗
DOE OSTI2026

Brushless Excitation for Wound-field Synchronous Machines using Multi-harmonic Windings

Wound-field synchronous machines (WFSM) are promising alternatives to electric machines with permanent magnets (PM). The ability to control the rotor field in these machines makes them well-suited to safety critical applications, while the absence of rare-earth permanent magnets makes these machines sustainable. The WFSM rotor excitation schemes have traditionally used carbon brushes, which significantly reduces the reliability of these machines, limiting their widespread adoption. To overcome this limitation and improve the reliability of WFSMs, several brushless rotor excitation schemes have been developed. However, most of these systems require additional windings or dedicated power electronics, making them expensive and limiting achievable power-density. In this paper a new brushless excitation scheme is proposed. In this scheme, a multiphase, multi-harmonic stator winding is designed. This winding can independently control two spatial harmonics in the airgap of the machine; the first to create torque and the second to wirelessly transfer power to the rotor to excite it.

Gadiyar, Nishanth [ORNL] (ORCID:0000000348267524)↗
DOE OSTI2024

Machine learning-guided design, synthesis, and characterization of atomically dispersed electrocatalysts

The recent integration of machine learning into materials design has revolutionized the understanding of structure–property relationships and optimization of material properties beyond the trial-and-error paradigm. On one hand, machine learning has significantly accelerated the development of atomically dispersed metal-nitrogen-carbon (M-N-C) electrocatalysts, which traditionally heavily relied on heuristic approaches. On the other hand, the primary challenge of leveraging machine learning to expedite M-N-C materials discovery lies in the cost associated with data collection. Here, we review recent machine learning integration strategies for M-N-C catalyst development, including discussions on the typical algorithms such as symbolic regression and convolutional neural networks employed for the theoretical design, synthesis optimization via active learning, and advanced microscopy characterization. Subsequently, we provide our perspective on potential near-future directions for furthering machine learning-assisted development of new M-N-C catalysts and elucidating the complex physicochemical mechanisms governing the selectivity, activity, and durability in this class of materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Leveraging large language models to address data scarcity in machine learning for graphene synthesis

Machine learning in experimental materials science faces significant challenges due to the scarcity of data, which are costly and time-consuming to generate, particularly when relying on in-house experiments. Literature data mining offers a potential solution but introduces issues like mixed data quality, inconsistent formats, and non-uniform reporting of synthesis parameters, resulting in partially missing and heterogeneous features across the dataset. Here, we propose data imputation and feature engineering methods that employ pre-trained large language models (LLMs) to enhance machine learning performance on scarce, heterogeneous datasets, demonstrated on graphene CVD synthesis data and the ML-HydPARK hydrogen storage dataset. GPT models perform data imputation via tailored prompting and semantic normalization of inconsistently reported features through embeddings, for example, to harmonize the complex nomenclature of CVD substrates. Beyond yielding more diverse and richer feature representations than traditional methods such as K-nearest neighbors (KNN) and Multivariate Imputation by Chained Equations (MICE), LLM-based data imputation is evaluated against dataset characteristics and prompting strategies. We vary the level of autonomy granted to the LLM, from generic prompting that leverages pre-trained knowledge for autonomous data generation to data-informed prompting that constrains outputs using target-specific information, and demonstrate which level of autonomy yields superior imputation performance across datasets and feature types. The proposed data engineering methods markedly improve downstream performance; for example, in graphene layer number classification using a support vector machine (SVM), binary accuracy increases from 39% to 65% and ternary accuracy from 52% to 72%. Fine-tuning experiments on both datasets show that combining our proposed LLM-based data imputation and feature encoding methods with numerical machine learning predictors outperforms standalone fine-tuned LLM predictors in data-scarce settings. The proposed strategies emphasize data enhancement techniques rather than refining learning architectures or regularizing loss functions, offering a broadly applicable framework for improving machine learning performance on scarce, inhomogeneous datasets.

Chemical vapor deposition↗