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All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Reduced order component models for flexible multibody dynamics simulations

Many flexible multibody dynamics simulation codes require some form of component description that properly characterizes the dynamic behavior of the system. A model reduction procedure for producing low order component models for flexible multibody simulation is described. Referred to as projection and assembly, the method is a Rayleigh-Ritz approach that uses partitions of the system modal matrix as component Ritz transformation matrices. It is shown that the projection and assembly method yields a reduced system model that preserves a specified set of the full order system modes. Unlike classical component mode synthesis methods, the exactness of the method described is obtained at the expense of having to compute the full order system modes. The paper provides a comprehensive description of the method, a proof of exactness, and numerical results demonstrating the method's effectiveness.

Tsuha, Walter S.↗
NASA NTRS1978

Procedures for generation and reduction of linear models of a turbofan engine

A real time hybrid simulation of the Pratt & Whitney F100-PW-F100 turbofan engine was used for linear-model generation. The linear models were used to analyze the effect of disturbances about an operating point on the dynamic performance of the engine. A procedure that disturbs, samples, and records the state and control variables was developed. For large systems, such as the F100 engine, the state vector is large and may contain high-frequency information not required for control. This, reducing the full-state to a reduced-order model may be a practicable approach to simplifying the control design. A reduction technique was developed to generate reduced-order models. Selected linear and nonlinear output responses to exhaust-nozzle area and main-burner fuel flow disturbances are presented for comparison.

Seldner, K.↗
DOE OSTI2024

Performance characterization and modeling of an oscillating surge wave energy converter

Abstract Testing wave energy converters in the ocean could be expensive and complex, which necessitates the use of numerical modeling. However, accurately modeling the response of wave energy converters with high-fidelity simulations can be computationally intensive in the design stage where different configurations must be considered. Reduced-order models based on simplified equations of motion can be very useful in the design, optimization, or control of wave energy converters. Given the complex dynamics of wave energy converters, accurate representation, and evaluation of relative contributions by different forces are required. This effort is concerned with a performance characterization of the hydrodynamic response of an oscillating surge wave energy converter that is based on a reduced-order model. A state-space model is used to represent the radiation damping term. Morison’s representation of unsteady forces is used to account for the nonlinear damping. Wave tank tests are performed to validate simulations. A free response simulation is used to determine the coefficients of the state-space model. Torque-forced simulations are used to identify the coefficients of the nonlinear damping term for different amplitudes and wave frequencies. The impact of varying these coefficients on the response is investigated. An assessment of the capability of the model in predicting the hydrodynamic response under irregular forcing is performed. The results show that the maximum error is 3% when compared with high-fidelity simulations. It is determined that the nonlinear damping is proportional to the torque amplitude and its effects are more pronounced as the amplitude of the flap oscillations increases.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Micro–macro finite element modeling method for rub response in abradable coating materials

Gas turbine engines experience “rub” when the rotating blades come in contact with a static abradable coating. This results in extreme strain rates and dynamics inside a high-temperature/high-pressure environment. Current rub models are phenomenological and do not reflect the underlying microstructures, thus limiting their prediction accuracy. In this work, a microstructure-informed, reduced order modeling framework is introduced for simulating abradable coating “rub" behavior. This framework comprises a microscale model constructed based on digitized abradable microstructure and explicitly simulates the mechanical behavior of each constituent phases and their interactions. After calibration and validation with experiment data, the calibrated microscale model is used to generate data across a vast range of applied strain rates and temperature with various load paths. Then, the virtually generated data are used to fit the macroscopic-reduced order model, which enables fast component scale rub simulation without compromising the integrity of the complex material behavior. In conclusion, the proposed effort will address the technical challenge of predicting abradable material behavior during rub through the application of multiscale modeling from microstructure to engines behavior, effectively reducing the development costs and time of new abradable material for better “rub” properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Physics-Informed Machine Learning Models for Predicting the Progress of Reactive-Mixing

This paper presents a physics-informed machine learning (ML) framework to construct reduced-order models (ROMs) for reactive-transport quantities of interest (QoIs) based on high-fidelity numerical simu-lations. QoIs include species decay, product yield, and degree of mixing. The ROMs for QoIs are applied to quantify and understand how the chemical species evolve over time. First, high-resolution datasets for constructing ROMs are generated by solving anisotropic reaction-di?usion equations using a non-negative finite element formulation for di?erent input parameters. The reactive-mixing model input parameters are: time-scale associated with flipping of velocity, spatial-scale controlling small/large vortex structures of velocity, perturbation parameter of the vortex-based velocity, anisotropic dispersion strength/contrast, and molecular diffusion. Second, random forests, F-test, and mutual information criterion are used to evaluate the importance of model inputs/features with respect to QoIs. We observed that anisotropic dispersion strength/contrast is the most important feature and time-scale associated with flipping of velocity is the least important feature. Third, Support Vector Machines (SVM) and Support Vector Regression (SVR) are used to construct ROMs based on the model inputs. The constructed SVR-ROMs are then used to predict scaling of QoIs. We also present estimates and inequalities on the QoIs, which inform that the species decay, mix, and produce in an exponential fashion. These inequalities also inform that a radial basis function is the most suitable kernel for the SVM/SVR models for QoIs. It is observed that R2-score for SVR-ROMs on unseen data is greater than 0.9, implying that the SVR-ROMs are able to predict the reaction-diffusion system state reasonably well. Finally, in terms of the computational cost, the proposed SVM-ROMs are O(107) times faster than running a high-fidelity finite element simulation for evaluating QoIs. This makes the proposed ML-based ROMs attractive for reactive-transport sensing and real-time monitoring applications as they are significantly faster yet reasonably accurate.

Mudunuru, Maruti K.↗
DOE OSTI2025

Develop a new integrated macro→micro←nano (MMN) multiscale modeling framework to optimize high strength aluminum alloys and processes for vehicle light-weighting​

Bending tests provide a means to study plane strain fracture performance of 6000 series aluminum alloys. Metrics from bending tests have been correlated with self-pierce riveting (SPR) performance of a high strength AA6111 automotive aluminum alloy in previous works. Using the ORNL HPC resources, this project developed an innovative macro→micro←nano (MMN) multiscale microstructure-based finite element (FE) code to further understanding of the relationship between microstructure and fracture properties of high-strength 6000-series alloys. This work started with microstructural characterization in both mesoscale and nanoscale and bending performance characterization of AA6111 HS2-T6 alloy at Ford, the MMN framework was applied to this alloy to simulate 3-point VDA bending. From the results of the macro-modeling of 3-point VDA bending, the critical region of fracture was identified, and the region geometry was used to construct the micro-model. The fracture criterion of micron-scale precipitates and aluminum matrix which contains submicron and nano particles (AL-SMP-NP) in the micro-model was calibrated and validated by comparing simulated and measured bending results. With the AL-SMP-NP fracture strain obtained, the fracture strain of Al-matrix containing nano particles (ALNP) will similarly be determined by a submicron scale-model using an edge-constrained FE modeling approach developed by Hu et al. With the ALNP fracture strain obtained, the fracture strain of Al-matrix containing no particles will similarly be determined by a nano scale-model using an edge-constrained FE modeling approach. After the MMN framework is built and fracture criterion calibrated, nano-model FE simulations with virtual microstructures was performed to obtain a reduced order model (ROM) of the fracture criterion of the ALNP as a function of volume fraction, size, and distribution of the nanoparticle. This nano→submicron→micro modeling part allows exploration of the influence of different material nanostructures from different process conditions on the bending properties within the multiscale bending simulation framework and the ROM of material bendability as a function of nanoparticle size and shape was established. This obtained reduced order model (ROM) could help guide the design and selection of materials to improve existing SPR process models that could replace trial-and-error rivet/die selection and help to design new rivet/die combinations capable of robustly joining new higher strength 6000 5 series alloys in automotive body structures. This would enable lightweighting of Ford vehicles leading to greater fuel efficiency and reduce manufacturing time and energy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Validation and parameterization of a novel physics-constrained neural dynamics model applied to turbulent fluid flow

We report, in fluid physics, data-driven models to enhance or accelerate time to solution are becoming increasingly popular for many application domains, such as alternatives to turbulence closures, system surrogates, or for new physics discovery. In the context of reduced order models of high-dimensional time-dependent fluid systems, machine learning methods grant the benefit of automated learning from data, but the burden of a model lies on its reduced-order representation of both the fluid state and physical dynamics. In this work, we build a physics-constrained, data-driven reduced order model for Navier–Stokes equations to approximate spatiotemporal fluid dynamics in the canonical case of isotropic turbulence in a triply periodic box. The model design choices mimic numerical and physical constraints by, for example, implicitly enforcing the incompressibility constraint and utilizing continuous neural ordinary differential equations for tracking the evolution of the governing differential equation. We demonstrate this technique on a three-dimensional, moderate Reynolds number turbulent fluid flow. In assessing the statistical quality and characteristics of the machine-learned model through rigorous diagnostic tests, we find that our model is capable of reconstructing the dynamics of the flow over large integral timescales, favoring accuracy at the larger length scales. More significantly, comprehensive diagnostics suggest that physically interpretable model parameters, corresponding to the representations of the fluid state and dynamics, have attributable and quantifiable impact on the quality of the model predictions and computational complexity.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Scientific Discovery with Physics-Informed System Identification (Abbreviated Report)

My fellowship research focused on making physics-based simulations faster and more useful through machine learning. Many problems in science and engineering are governed by partial differential equations, but high-fidelity simulations are often too expensive to run repeatedly. I worked on improving Latent Space Dynamics Identification (LaSDI), a reduced-order modeling framework that compresses large simulation data sets into a smaller representation and then learns how that representation evolves over time. The motivation was to develop reduced models that remain accurate for more challenging systems, especially when predictions must remain reliable over long time intervals or when the underlying dynamics are more complicated than standard methods can easily handle. I also contributed to related work on Quandary, a high-performance software effort for simulation and control of open quantum systems, before focusing primarily on Latent Space Dynamics Identification methods. The main outcomes of the fellowship were two new algorithms (both of which were published), Rollout-LaSDI and Higher-Order LaSDI, together with supporting work on multi-stage Latent Space Dynamics Identification. Rollout-LaSDI improved long-term prediction by training the model to stay accurate over extended time horizons, and Higher-Order LaSDI broadened the method so it could model systems with higher-order time dynamics. My contributions to multistage Latent Space Dynamics Identification also helped show that its later training stages could be simplified without losing effectiveness, and that this behavior held across different model architectures and training strategies. Taken together, these advances improved the accuracy, flexibility, and practical value of reduced-order modeling tools for computational science.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Enabling Dynamic Probabilistic Risk Assessment of Physical Security Using EMRALD and MAAP

The optimization of physical security in nuclear power plants requires sophisticated methodologies that integrate operator actions and plant behavior through advanced simulation tools. To address this, Idaho National Laboratory [JL2.1]has developed the Modeling and Analysis for Safety and Security using the Dynamic EMRALD Framework (MASS-DEF) methodology, an approach that integrates force-on-force simulations, dynamic probabilistic risk assessment, and thermal-hydraulics modeling [JL3.1]to enhance security planning while reducing costs. We developed a tool that produces reduced order models using thermal hydraulic simulations from the Modular Accident Analysis Program (MAAP) [1]. These models can quickly evaluate reactor core behavior during attack simulations, and in so doing, address two barriers of traditional methods: (1) MAAP simulations are computationally intensive, and (2) attack scenarios must be run in a secure environment, which complicates analysis and validation. By precomputing scenario outcomes for a small number of modified parameters, the reduced order model significantly decreases the computational cost and enables offsite review of the results.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Parametric model-order reduction for radiation transport using multi-resolution proper orthogonal decomposition

For parametric high-fidelity simulations, it is often desirable to utilize a reduced-order model (ROM) to emulate, at a reduced computational cost, parametric solutions of the governing partial differential equations (PDEs) for unseen parameter values. One commonly employed option is to utilize a data-driven, projection-based ROM supplemented with subspace identification via proper orthogonal decomposition (POD). POD discovers the ROM subspace by computing the singular value decomposition (SVD) of a set of training data from the full-order model (FOM). In streaming-dominated radiation transport simulations with localized sources, solutions often greatly vary over the spatial domain by many orders of magnitude. In such cases, machine-precision arithmetic can be insufficient to obtain an accurate SVD, resulting in a poorly performing ROM. We present a method called multiresolution POD (mrPOD) that mitigates these inaccuracies. The mrPOD method works by decomposing the spatial domain into regions and performing proper orthogonal decomposition on the training dataset separately in each region. In conclusion, mrPOD is tested on single energy group and multigroup atmospheric shielding transport problems and is shown to outperform classic POD.

42 ENGINEERING↗
DOE OSTI2022

Equation‐Free Surrogate Modeling of Geophysical Flows at the Intersection of Machine Learning and Data Assimilation

Abstract There is a growing interest in developing data‐driven reduced‐order models for atmospheric and oceanic flows that are trained on data obtained either from high‐resolution simulations or satellite observations. The data‐driven models are non‐intrusive in nature and offer significant computational savings compared to large‐scale numerical models. These low‐dimensional models can be utilized to reduce the computational burden of generating forecasts and estimating model uncertainty without losing the key information needed for data assimilation (DA) to produce accurate state estimates. This paper aims at exploring an equation‐free surrogate modeling approach at the intersection of machine learning and DA in Earth system modeling. With this objective, we introduce an end‐to‐end non‐intrusive reduced‐order modeling (NIROM) framework equipped with contributions in modal decomposition, time series prediction, optimal sensor placement, and sequential DA. Specifically, we use proper orthogonal decomposition (POD) to identify the dominant structures of the flow, and a long short‐term memory network to model the dynamics of the POD modes. The NIROM is integrated within the deterministic ensemble Kalman filter (DEnKF) to incorporate sparse and noisy observations at optimal sensor locations obtained through QR pivoting. The feasibility and the benefit of the proposed framework are demonstrated for the NOAA Optimum Interpolation Sea Surface Temperature (SST) V2 data set. Our results indicate that the NIROM is stable for long‐term forecasting and can model dynamics of SST with a reasonable level of accuracy. Furthermore, the prediction accuracy of the NIROM gets improved by almost one order of magnitude by the DEnKF algorithm.

Pawar, Suraj↗
NASA NTRS2010

Final Plenary Session Transcript

Let s start with the report - as you know - when we are talking about flow control it is a multi-disciplinary type of work. So it involves many people and disciplines. This group first discussed the important issues associated with flow control. As you start doing flow control what are the issues to which you really have to start paying attention? That is the first part I am going to present. Then in the second part I will present some challenges - problems that we should really be looking at. So as far as the issues - if you want to control a flow, you really need to understand the flow physics, because anything that you do comes from the flow physics. The design of the controllers, your decisions on the actuators, sensors, reduced order modeling and all of that, would be helped if you understand flow physics. And you have to have a specific objective - what exactly are you controlling? Are you trying to reduce drag, eliminate separation, reduce noise, enhance mixing? So you have to have very specific control objectives. From all the talks we have seen here actuation is extremely important and it is very problem specific. It depends on what problem you are dealing with so you have to design and build actuators for that specific problem. Sensors obviously are very important, especially when you are dealing with feedback control. Consensus was that when you dealing with flow control, you must take an integrated approach; from the beginning you have to take into account every aspect of it and even maybe to modify your experiment, your geometry, to go along with the actuation, sensors and control models. Development of tools is very important in this multi-disciplinary problem. The tools include CFD, reduced order modeling, controller design, understanding and utilizing the instabilities of the flow, etc. So, in order to have success in flow control, we really need to develop these tools.

Gostelow, Paul↗
DOE OSTI2023

DT-HYDRO

The software solves the time dependent, one dimensional (1D) coupled mass and momentum balance equations governing the elastic flow of water through the penstock, turbine and draft tube in a hydroelectric facility using a high order finite volume based method. The numerical method is based on the Kurganov-Tadmor central method paired with the Monotonic Upstream-centered Scheme for Conservation Laws (MUSCL). This solution method accurately resolves the fast transient behavior of the flow, including water hammer. Additionally, the software estimates the full 3D flow field within the turbine chamber in real time, a feat that is made possible by leveraging pre-computed CFD results by utilizing a reduced order modeling method based on an efficient randomized singular value decomposition (SVD) driven proper orthogonal decomposition (POD) with POD-mode weight regression. The reduced order model of the 3D flow is directly coupled to the 1D elastic flow model so the entire flow field through the penstock and turbine system is resolved quickly and with high fidelity.

Gurecky, William [Oak Ridge National Laboratory (O↗
DOE OSTI2022

Technoeconomics of Particle-based CSP Featuring Falling Particle Receivers with and without Active Heliostat Control

This report documents the results and conclusions of a recent project to understand the technoeconomics of utility-scale, particle-based concentrating solar power (CSP) facilities leveraging unique operational strategies. This project included two primary objectives. The first project objective was to build confidence in the modeling approaches applied to falling particle receivers (FPRs) including the effect s of wind. The second project objective was to create the necessary modeling capability to adequately predict and maximize the annual performance of utility-scale, particle-based CSP plants under anticipated conditions with and without active heliostat control. Results of an extensive model validation study provided the strongest evidence to date for the modeling strategies typically applied to FPRs, albeit at smaller receiver scales. This modeling strategy was then applied in a parametric study of candidate utility-scale FPRs, including both free-falling and multistage FPR concepts, to develop reduced order models for predicting the receiver thermal efficiency under anticipated environmental and operating conditions. Multistage FPRs were found to significantly improve receiver performance at utility-scales. These reduced order models were then leveraged in a sophisticated technoeconomic analysis to optimize utility-scale , particle-based CSP plants considering the potential of active heliostat control. In summary, active heliostat control did not show significant performance benefits to future utility-scale CSP systems though some benefit may still be realized in FPR designs with wide acceptance angles and/or with lower concentration ratios. Using the latest FPR technologies available, the levelized-cost of electricity was quantified for particle-based CSP facilities with nominal powers ranging from 5 MW e up to 100 MW e with many viable designs having costs < 0.06 $/kWh and local minimums occurring between ~25–35 MW e .

14 SOLAR ENERGY↗
DOE OSTI2026

Deposition Height Prediction in Directed Energy Deposition

Using 316L stainless steel as a model material, reduced-order models are developed to predict capture efficiency, deposition height, and site-specific hardness in directed energy deposition. Capture efficiency is predicted over a 15 to 55 pct range using a dimensionless number derived from processing conditions and thermophysical properties. Deposition height is predicted over a 0.3 to 1.3 mm range without in situ sensing or prior training data, using two models based on the same mass and energy-balance principles. Predictions are compared with machine learning approaches. A quantitative relationship links deposition height, primary dendrite arm spacing (PDAS), and hardness: heights of 0.3 to 1.1 mm correspond to PDAS values of 2.7 to 5.1 µm and Vickers hardness (HV) of 160 to 219. Thinner layers cool more rapidly, producing finer microstructures and higher hardness. Samples fabricated with in situ variations in deposition height exhibited up to 55 HV differences between thick and thin regions, demonstrating that local control of deposition height enables predictive, site-specific hardness within a single build. These results establish deposition height prediction as a pathway for a priori process design and property control in directed energy deposition for 316L stainless steel.

Kunkel, William [Univ. of Wisconsin, Madison, WI (↗
DOE OSTI2020

Southeast Regional CO 2 Utilization and Storage Acceleration Partnership (SECARB-USA): Preliminary Regional Assessment of Potential Storage Complexes, Including Capacities and Costs, Based on Application of NRAP and SCO2T (Deliverable 3.3) Storage Complexes

The Recipient will assist with the field validation of one or more risk assessment toolsets through: 1) collaborative research; 2) sharing of relevant datasets, information, and technical insights from field efforts; and 3) other modeling and simulation toolsets as they are developed. Collaborative research could include, but is not limited to: 1) demonstrating use of field data for improved leakage pathway characterization, uncertainty reduction, and risk management and uncertainty workflows; 2) testing and validation of a specific National Risk Assessment Partnership (NRAP) tool using site specific data; and 3) improved modeling or reduced-order modeling of geophysical monitoring.

42 ENGINEERING↗
NASA NTRS1994

Modeling the effect of shroud contact and friction dampers on the mistuned response of turbopumps

The contract has been revised. Under the revised scope of work a reduced order model has been developed that can be used to predict the steady-state response of mistuned bladed disks. The approach has been implemented in a computer code, LMCC. It is concluded that: the reduced order model displays structural fidelity comparable to that of a finite element model of an entire bladed disk system with significantly improved computational efficiency; and, when the disk is stiff, both the finite element model and LMCC predict significantly more amplitude variation than was predicted by earlier models. This second result may have important practical ramifications, especially in the case of integrally bladed disks.

Griffin, Jerry H.↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗