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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

THM: the MOOSE thermal hydraulics module

The MOOSE Thermal Hydraulics Module (THM) is designed to facilitate the development of thermal hydraulic system models. It provides the capability to assemble networks of coupled components such as pipes, junctions, valves, turbomachinery, and heat exchangers. Its library of components supports a single-phase, compressible flow model based on a variable-area formulation of the Euler equations of gas dynamics and discretized using a finite volume scheme. THM offers a flexible system for specifying closures such as friction factors or heat transfer coefficients, allowing the user to choose from built-in correlations or define their own in the input file. A control logic system can be used to control input parameters, necessary for implementing transient scenarios and mirroring real control systems in thermal hydraulic systems. THM can be coupled with other MOOSE-based applications for multiphysics calculations. This talk will give an introduction to the capabilities of THM and provide some examples of its usage and validation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

MOOSE Thermal-Hydraulics Module - MOOSE workshop

The MOOSE Thermal Hydraulics Module (THM) is designed to facilitate the development of thermal hydraulic system models. It provides the capability to assemble networks of coupled components such as pipes, junctions, valves, turbomachinery, and heat exchangers. Its library of components supports a single-phase, compressible flow model based on a variable-area formulation of the Euler equations of gas dynamics and discretized using a finite volume scheme. THM offers a flexible system for specifying closures such as friction factors or heat transfer coefficients, allowing the user to choose from built-in correlations or define their own in the input file. A control logic system can be used to control input parameters, necessary for implementing transient scenarios and mirroring real control systems in thermal hydraulic systems. THM can be coupled with other MOOSE-based applications for multiphysics calculations. This training will give an introduction to the capabilities of THM and provide some examples of its usage and validation.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2024

50 Years of metabolic control analysis

It has been 50 years since the publication of the seminal works by Savageau, Kacser & Burns and Heinrich & Rapoport, on the control of biochemical networks. What is remarkable about these three publications (especially the two papers by Kacser et al. and Rapoport et al.) is that they independently developed almost the same approach and came to the same conclusions. This approach is today called metabolic control analysis (MCA), and is a body of work that uses mathematics to reason about the properties of biochemical pathways in a deductive manner. Although originally focused on metabolic pathways, it was realized early on that it could be equally applied to genetic and signalling networks. In fact anything that one could associate a stoichiometry matrix with. In recent years, others have reinvented MCA, using different notation, highlighting the fact that there has been a good deal of conceptual convergence in this area.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2014

Analyzing Risks and Vulnerabilities of Various Computer Systems and Undergoing Exploitation using Embedded Devices

Security is one of the most if not the most important areas today. After the several attacks on the United States, security everywhere has heightened from airports to communication among the military branches legionnaires. With advanced persistent threats (APTs) on the rise following Stuxnet, government branches and agencies are required, more than ever, to follow several standards, policies and procedures to reduce the likelihood of a breach. Attack vectors today are very advanced and are going to continue to get more and more advanced as security controls advance. This creates a need for networks and systems to be in an updated, patched and secured state in a launch control system environment. Attacks on critical systems are becoming more and more relevant and frequent. Nation states are hacking into critical networks that might control electrical power grids or water dams as well as carrying out advanced persistent threat (APTs) attacks on government entities. NASA, as an organization, must protect its self from attacks from all different types of attackers with different motives. Although the International Space Station was created, there is still competition between the different space programs. With that in mind, NASA might get attacked and breached for various reasons such as espionage or sabotage. My project will provide a way for NASA to complete an in house penetration test which includes: asset discovery, vulnerability scans, exploit vulnerabilities and also provide forensic information to harden systems. Completing penetration testing is a part of the compliance requirements of the Federal Information Security Act (FISMA) and NASA NPR 2810.1 and related NASA Handbooks. This project is to demonstrate how in house penetration testing can be conducted that will satisfy all of the compliance requirements of the National Institute of Standards and Technology (NIST), as outlined in FISMA. By the end of this project, I hope to have carried out the tasks stated above as well as gain an immense knowledge about compliance, security tools, networks and network devices, as well as policies and procedures.

Penetration Testing↗
NASA NTRS2021

A Mathematical Analysis of an Example Delay Tolerant Network using the Theory of Sheaves

NASA’s High-Data Rate Architecture (HiDRA) project is working towards a general yet practical toolkit and knowledge base to help usher in the era of new technologies for space systems communications, such as optical links. The High-Rate Delay Tolerant Networking (HDTN) implementation falls under the umbrellas of both the toolkit and the knowledge base, as its advancements illuminate more general areas of Delay Tolerant Networking (DTN) that need growth. The goal of this paper is to explore the usage of particular mathematical machineries, namely temporal flow networks and sheaves, to identify fundamental, underlying structures in DTN for space systems. Satellites, space assets, ground stations, etc. give rise to a disconnected network, and it is the goal of DTN to glue disparate links together into a cohesive system, that is, a network. Depending on a given link, the latencies might be beyond that which the Transmission Control Protocol (TCP) can handle, and contact times might have one-way light times in excess of minute (sometimes significantly longer). Some links might be periodic (say, due to orbital mechanics) or they might not be. This diversity has made it difficult to probe the underlying structure. An immediate consequence is that DTNs in practice today are controlled by globally distributed contact plans (schedules), which are the input to the contact graph routing (CGR) algorithm. While this is effective for smaller networks, it will be very difficult to scale for future networks. Deeper and more rigorous theory is needed to bring DTN to the next evolutionary step. To this end, this paper introduces and suggests a mathematical framework for DTN, and applies it to a space network that is simulated using an orbital analysis toolkit. The tag-line for the structure known as sheaves is that they are the mathematically precise way of gluing local data together into unique, global data. If we consider routing, we see that networking is a “sheafy” science. We then discuss a simplified sheaf model, known as the cellular sheaf. The sheaf-theoretic analysis is presented and discussed, as it is hoped that this and related papers will help form the primordial ooze of DTN theory. Finally there is a section of future work suggesting follow-on research.

Delay Tolerant Networking↗
NASA NTRS2008

System Engineering on the Use for Ares I,V - the Simpler, the Better

The Ares I and Ares V Vehicles will utilize the J-2X rocket engine developed for NASA by the Pratt & Whitney Rocketdyne Company. The J-2X is an improved higher power version of the original J-2 engine used during the Apollo program. With higher power and updated requirements for safety and performance, the J-2X becomes a new engine using state-of-the-art design methodology, materials and manufacturing processes. The implementation of Systems Engineering (SE) principles enables the rapid J-2X development program to remain aligned with the ARES I and V vehicle programs, Meeting the aggressive development schedule is a challenge. Coordinating the best expertise thai NASA and PWR have to offer requires effectively utilizing resources at multiple sites. This presents formidable communication challenges. SE allows honest and open discussions of issues and problems. This simple idea is often overlooked in large and complex SE programs. Regular and effective meetings linking SE objectives to component designs are used to voice differences of opinions with customer and contractor in attendance so that the best mutual decisions can be made on the shortest possible schedule. Regular technical interchange meetings on secure program wide computer networks and CM processes are effective,in the "Controlled Change" process that exemplifies good SE. Good communication is a key effective SE implementation. The System of Systems approach is the vision of the Orion program which facilitates the establishment of dynamic SE processes at all levels including the engine. SE enables requirements evolution by facilitating organizational and process agility. Flow down and distribution of requirements is controlled by Allocation Reports which breakdown numerical design objectives (weight, reliability, etc.) into quanta goals for each component area. Linked databases of design and verification requirements helps eliminate redundancy and potential mistakes inherent m separated systems. Another tool, the Architecture Design Description, is being used to control J-2X system architecture and effectively communicate configuration changes to those involved in the design process. But the proof is in successful program accomplishment. The SE is the methodology being used to meet the challenge of completing J-2X engine certification 2 years ahead of any engine program ever developed at PWR. The Ares I SE system of systems has delivered according to expectations thus far. All major design reviews (SRR. PDR, CDR) have been successfully conducted to satisfy overall program objectives using SE as the basis for accomplishment. The paper describes SE tools and techniques utilized to achieve this success.

Kelly, William↗
NASA NTRS2013

IT Security Support for the Spaceport Command Control Systems Development Ground Support Development Operations

Security is one of the most if not the most important areas today. After the several attacks on the United States, security everywhere was heightened from Airports to the communication among the military branches legionnaires. With advanced persistent threats (APTs) on the rise following Stuxnet, government branches and agencies are required, more than ever, to follow several standards, policies and procedures to reduce the likelihood of a breach. Attack vectors today are very advanced and are going to continue to get more and more advanced as security controls advance. This creates a need for networks and systems to be in an updated and secured state in a launch control system environment. FISMA is a law that is mandated by the government to follow when government agencies secure networks and devices. My role on this project is to ensure network devices and systems are in compliance with NIST, as outlined in FISMA. I will achieve this by providing assistance with security plan documentation and collection, system hardware and software inventory, malicious code and malware scanning and configuration of network devices i.e. routers and IDSsIPSs. In addition I will be completing security assessments on software and hardware, vulnerability assessments and reporting, conducting patch management and risk assessments. A guideline that will help with compliance with NIST is the SANS Top 20 Critical Controls. SANS Top 20 Critical Controls as well as numerous security tools, security software and the conduction of research will be used to successfully complete the tasks given to me. This will ensure compliance with FISMA and NIST, secure systems and a secured network. By the end of this project, I hope to have carried out stated above as well as gain an immense knowledge about compliance, security tools, networks and network devices, policies and procedures.

computer information security↗
DOE OSTI2020

Smart-DS: Synthetic Models for Advanced, Realistic Testing: Distribution Systems and Scenarios

The explosion of new ideas for distributed energy resources and advanced distribution grid algorithms faces a critical challenge: how can one effectively develop and evaluate these breakthrough technologies without an adequate set of power systems network, load, and resource data to test against? Today's open test systems, particularly for distribution systems, are tiny and incomplete; and though with enough effort, obtaining utility data under NDA can overcome scale challenges, the results can't be openly shared, preventing fair comparison. The Smart-DS project-led by NREL in partnership with MIT, Universidad Pontificia Comillas, CYME, and EDD-is working to overcome this gap by generating multiple large-scale, open, synthetic, distribution systems that are realistic but not real. These datasets go beyond a single medium voltage feeder (~1000 customers) to cover entire metropolitan areas and their surrounds with up to hundreds of feeders and millions of customers, complete with low voltage customer connections and high voltage sub-transmission. This scale allows adequate testing and analysis of not just local controls and advanced DERs, but also multiple substation interactions, optimized switching, full-scale distribution-OPF, and more. To accompany these datasets, the project is also building a rich set of scenario generation tools that can be used for distribution and transmission systems alike. This includes automated, spatially aware access to world-class, high-resolution solar, wind, and weather data: forward looking generation mixes: and highly configurable DER, load, climate, outage, control-scheme, and other scenarios. We will also highlight DiTTo, an exciting open-source, multi-way distribution dataset transformation tool for many-to-many format translation with scenario, merge/split, and many other manipulation capabilities.

DERs↗
NASA NTRS1984

The control network of Iapetus

A control network of the Saturnian satellite Iapetus has been established photogrammetrically from pictures taken by the two Voyager spacecraft. Coordinates of 62 control points have been computed and listed; pixel measurements of these points were made on 14 Voyager 1 and 66 Voyager 2 pictures. Some of these points are identified on the preliminary U.S. Geological Survey map of Iapetus and many are identified by name. The Voyager 1 and Voyager 2 pictures covered limited regions of the satellite's surface and contained no overlapping areas. The longitude system on Iapetus is defined by the crater Almeric; the 276 deg meridian passes through the center of this crater. The obliquity of Iapetus has been measured as 0.4 deg + or - 1.6 deg. The mean radius of Iapetus has been determined at 718 + or - 8 km.

Davies, M. E.↗
NASA NTRS1998

An Evaluation of TCP with Larger Initial Windows

Transmission Control Protocol (TCP's) slow start algorithm gradually increases the amount of data a sender injects into the network, which prevents the sender from overwhelming the network with an inappropriately large burst of traffic. However, the slow start algorithm can make poor use of the available band-width for transfers which are small compared to the bandwidth-delay product of the link, such as file transfers up to few thousand characters over satellite links or even transfers of several hundred bytes over local area networks. This paper evaluates a proposed performance enhancement that raises the initial window used by TCP from 1 MSS-sized segment to roughly 4 KB. The paper evaluates the impact of using larger initial windows on TCP transfers over both the shared Internet and dialup modem links.

Allman, Mark↗
NASA NTRS2012

NASA Tech Briefs, January 2012

Contents of this issue are: (1) Energy-Based Tetrahedron Sensor for High-Temperature, High-Pressure Environments (2) Handheld Universal Diagnostic Sensor (3) Large-Area Vacuum Ultraviolet Sensors (4) Fiber Bragg Grating Sensor System for Monitoring Smart Composite Aerospace Structures (5) Health-Enabled Smart Sensor Fusion Technology (6) Extended-Range Passive RFID and Sensor Tags (7) Hybrid Collaborative Learning for Classification and Clustering in Sensor Networks (8) Self-Healing, Inflatable, Rigidizable Shelter (9) Improvements in Cold-Plate Fabrication (10) Technique for Radiometer and Antenna Array Calibration - TRAAC (11) Real-Time Cognitive Computing Architecture for Data Fusion in a Dynamic Environment (12) Programmable Digital Controller (13) Use of CCSDS Packets Over SpaceWire to Control Hardware (14) Key Decision Record Creation and Approval Module (15) Enhanced Graphics for Extended Scale Range (16) Debris Examination Using Ballistic and Radar Integrated Software (17) Data Distribution System (DDS) and Solar Dynamic Observatory Ground Station (SDOGS) (18) Integration Manager (19) Eclipse-Free-Time Assessment Tool for IRIS (20) Automated and Manual Rocket Crater Measurement Software (21) MATLAB Stability and Control Toolbox Trim and Static Stability Module (22) Patched Conic Trajectory Code (23) Ring Image Analyzer (24) SureTrak Probability of Impact Display (25) Implementation of a Non-Metallic Barrier in an Electric Motor (26) Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover (27) Uniform Dust Distributor for Testing Radiative Emittance of Dust-Coated Surfaces (28) MicroProbe Small Unmanned Aerial System (29) Highly Stable and Active Catalyst for Sabatier Reactions (30) Better Proton-Conducting Polymers for Fuel-Cell Membranes (31) CCD Camera Lens Interface for Real-Time Theodolite Alignment (32) Peregrine 100-km Sounding Rocket Project (33) SOFIA Closed- and Open-Door Aerodynamic Analyses (34) Sonic Thermometer for High-Altitude Balloons (35) Near-Infrared Photon-Counting Camera for High-Sensitivity Observations (36) Integrated Optics Achromatic Nuller for Stellar Interferometry (37) High-Speed Digital Interferometry (38) Ultra-Miniature Lidar Scanner for Launch Range Data Collection (39) Shape and Color Features for Object Recognition Search (40) Explanation Capabilities for Behavior-Based Robot Control (41) A DNA-Inspired Encryption Methodology for Secure, Mobile Ad Hoc Networks (42) Quality Control Method for a Micro-Nano-Channel Microfabricated Device (43) Corner-Cube Retroreflector Instrument for Advanced Lunar Laser Ranging (44) Electrospray Collection of Lunar Dust (45) Fabrication of a Kilopixel Array of Superconducting Microcalorimeters with Microstripline Wiring Spacecraft Attitude Tracking and Maneuver Using Combined Magnetic Actuators (46) Coherent Detector for Near-Angle Scattering and Polarization Characterization of Telescope Mirror Coatings

Source record↗
NASA NTRS2014

IT Security Support for the Spaceport Command Control Systems Development Ground Support Development Operations

Security is one of the most if not the most important areas today. After the several attacks on the United States, security everywhere has heightened from airports to the communication among the military branches legionnaires. With advanced persistent threats (APT's) on the rise following Stuxnet, government branches and agencies are required, more than ever, to follow several standards, policies and procedures to reduce the likelihood of a breach. Attack vectors today are very advanced and are going to continue to get more and more advanced as security controls advance. This creates a need for networks and systems to be in an updated and secured state in a launch control system environment. FISMA is a law that is mandated by the government to follow when government agencies secure networks and devices. My role on this project is to ensure network devices and systems are in compliance with NIST, as outlined in FISMA. I will achieve this by providing assistance with security plan documentation and collection, system hardware and software inventory, malicious code and malware scanning, and configuration of network devices i.e. routers and IDS's/IPS's. In addition, I will be completing security assessments on software and hardware, vulnerability assessments and reporting, and conducting patch management and risk assessments. A guideline that will help with compliance with NIST is the SANS Top 20 Critical Controls. SANS Top 20 Critical Controls as well as numerous security tools, security software and the conduction of research will be used to successfully complete the tasks given to me. This will ensure compliance with FISMA and NIST, secure systems and a secured network. By the end of this project, I hope to have carried out the tasks stated above as well as gain an immense knowledge about compliance, security tools, networks and network devices, as well as policies and procedures.

security↗
NASA NTRS2017

UAV Trajectory Modeling Using Neural Networks

Large amount of small Unmanned Aerial Vehicles (sUAVs) are projected to operate in the near future. Potential sUAV applications include, but not limited to, search and rescue, inspection and surveillance, aerial photography and video, precision agriculture, and parcel delivery. sUAVs are expected to operate in the uncontrolled Class G airspace, which is at or below 500 feet above ground level (AGL), where many static and dynamic constraints exist, such as ground properties and terrains, restricted areas, various winds, manned helicopters, and conflict avoidance among sUAVs. How to enable safe, efficient, and massive sUAV operations at the low altitude airspace remains a great challenge. NASA's Unmanned aircraft system Traffic Management (UTM) research initiative works on establishing infrastructure and developing policies, requirement, and rules to enable safe and efficient sUAVs' operations. To achieve this goal, it is important to gain insights of future UTM traffic operations through simulations, where the accurate trajectory model plays an extremely important role. On the other hand, like what happens in current aviation development, trajectory modeling should also serve as the foundation for any advanced concepts and tools in UTM. Accurate models of sUAV dynamics and control systems are very important considering the requirement of the meter level precision in UTM operations. The vehicle dynamics are relatively easy to derive and model, however, vehicle control systems remain unknown as they are usually kept by manufactures as a part of intellectual properties. That brings challenges to trajectory modeling for sUAVs. How to model the vehicle's trajectories with unknown control system? This work proposes to use a neural network to model a vehicle's trajectory. The neural network is first trained to learn the vehicle's responses at numerous conditions. Once being fully trained, given current vehicle states, winds, and desired future trajectory, the neural network should be able to predict the vehicle's future states at next time step. A complete 4-D trajectory are then generated step by step using the trained neural network. Experiments in this work show that the neural network can approximate the sUAV's model and predict the trajectory accurately.

Neural Networks↗
DOE OSTI2023

Predicting future well performance for environmental remediation design using deep learning

Here in this study, we developed a deep learning (DL) framework with a multi-channel three-dimensional convolutional neural network (MC3D-CNN) to predict well performance and thereby assist future environmental remediation design. Such prediction of extraction well performance at designated locations is critical for configuring pump-and-treat (P&T) well network design and operation, setting reasonable target closure dates for overall remedying, and estimating remedy costs. The framework is developed with operational and monitoring data routinely collected during P&T remedy operations, including well extraction and injection rates as well as in situ contaminant concentrations. Traditionally, the collected data were rarely used for purposes other than assessing past well performance and the accuracy of the conceptual site model. However, recent advances in data-driven computational approaches enable better use of the large datasets to inform future well performance, enhance site characterization, and improve remediation planning. In this study, we established a DL framework to integrate transient three-dimensional contaminant plumes and multiple aquifer properties (e.g., hydraulic conductivity and hydrostratigraphic maps) to identify characteristic patterns controlling and representing extraction well mass recovery, aiming at providing future mass recovery estimates for existing wells and candidate wells at any proposed locations. We evaluated our framework by using a realistic synthetic dataset generated from a well-calibrated flow and transport model used in the 200 West Area of the U.S. Department of Energy’s Hanford Site in southeastern Washington state. The multi-channel feature in our framework allows integration of various types and temporal densities of training datasets for DL model development. Overall, we found that the trained DL model achieved an accuracy of over 90% in ranking extraction well performance in validation datasets, and over 80% in predicting high-performance-ranking well locations. This data-informed approach provides a flexible tool to support adaptive site management, streamline decision-making, and potentially reduce remediation time and costs. Our DL framework can be used as a filtering tool to improve the current P&T network optimization design by reducing the number of candidate well locations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Biodegradable transient battery built on core-double-shell zinc microparticle networks

A transient or biodegradable battery is provided having a filament structure that limits the speed of reaction allowing for a longer duration of battery power with a controlled current limit. In one embodiment, the filament may be constructed of zinc microparticles or nanoparticles having a thin outer insulation whereby a chemical reaction at the center core results in the progressive disintegration of the insulation revealing more core material. In one embodiment, microparticles or nanoparticles are coated with outer layers of chitosan and Al2O3 nanofilms, respectively, with designable discharge current and battery lifespan by controlling the exposed cross-sectional area of the zinc microparticle center core and the length of the filament, respectively. This novel structure of biodegradable battery provides improved control of battery life and power output, providing a promising solution to power transient medical implants.

Wang, Xudong↗
NASA NTRS1985

Studies of lightning data in conjunction with geostationary satellite data

Since January, work has been proceeding on the first phase of this project: the creation of an extensive real-time lightning data base accessible via the Space Science and Engineering Center McIdas system. The purpose of this endeavor is two-fold: to enhance the availability and ease of access to lightning data among the various networks, governmental and research agencies; and to test the feasiblity and desirability of such efforts in succeeding years. The final steps in the creation of the necessary communications links, hardware, and software are in the process of being completed. Operations ground rules for access among the various users have been discussed and are being refined. While the research planned for the last year of the project will rely for the most part on archived, quality-controlled data from the various networks, the real-time data will provide a valuable first-look at potentially interesting case studies. For this purpose, tools are being developed on McIdas for display and analysis of the data as they become available. In conjunction with concurrent GOES real-time imagery, strike locations can be plotted, gridded and contoured, or displayed in various statistical formats including frequency distributions, histograms, and scatter plots. The user may also perform these functions in relation to arbitrarily defined areas on the satellite image. By mid-May these preparations for the access and analysis of real-time lightning data are expected to be complete.

Auvine, B.↗
DOE OSTI2024

A Regional Phase Amplitude Model of 2-D Attenuation for North America

We analyzed seismic attenuation patterns across the North America using over 70,000,000 Lg wave amplitudes recorded by the various networks at frequencies of 0.1-32 Hz. Our inversion solved for laterally varying attenuation, site terms, moments, and apparent stress following Phillips et al., (2016). The inversion was anchored by independently constrained: corner frequencies (via coda spectral ratios) to control the attenuation-stress tradeoff and moment measurements of teleseismic (GCMT, USGS) and regional (St. Louis University and UC Berkeley) earthquakes to provided absolute scaling. The quality factor (Q) shows clear regional patterns: low values in coastal, volcanic, and tectonically active regions, and high values in stable areas like the Great Plains and major plateaus throughout North America. These 2-D Q models enable improved regional source characterization, magnitude estimation, and yield determination.

58 GEOSCIENCES↗
DOE OSTI2026

In-situ sensor monitoring of multi-class gas porosity formation in laser powder bed fusion using convolutional neural network

In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.

Laser powder bed fusion, Multi-class pores, In-sit↗