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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

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

The 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. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing 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 microstructural variability 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 models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s 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 additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation 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 helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
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↗
DOE OSTI2022

A Multiscale Deep Learning Model for Soil Moisture Integrating Satellite and In Situ Data

Deep learning (DL) models trained on hydrologic observations can perform extraordinarily well, but they can inherit deficiencies of the training data, such as limited coverage of in situ data or low resolution/accuracy of satellite data. In this work, we propose a novel multiscale DL scheme learning simultaneously from satellite and in situ data to predict 9 km daily soil moisture (5 cm depth). Based on spatial cross-validation over sites in the conterminous United States, the multiscale scheme obtained a median correlation of 0.901 and root-mean-square error of 0.034 m 3 /m 3 . It outperformed the Soil Moisture Active Passive satellite mission's 9 km product, DL models trained on in situ data alone, and land surface models. Our 9 km product showed better accuracy than previous 1 km satellite downscaling products, highlighting limited impacts of improving resolution. Not only is our product useful for planning against floods, droughts, and pests, our scheme is generically applicable to geoscientific domains with data on multiple scales, breaking the confines of individual data sets.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2014

Development of Dynamic Sub-Grid Models for Variational Multiscale Methods

A dynamic Variational Multiscale Method (Hughes et al. 1998) is developed by leveraging the Germano procedure from classical Large-eddy Simulations (LES). The similarity between the classical and variational approaches is analyzed in the context of incompressible flow. This analysis leads to a consistent modeling approach for both incompressible and compressible flows, the latter being demonstrated in a priori testing for low-speed attached and separated boundary layers. Similar to the classical LES procedure from which it is derived, the variational dynamic procedure does not guarantee a positive semi-definite coefficient in the general case. However, reproducing the behavior of the classical LES dynamic approach is seen as a necessary first step to develop a VMM that automatically adjusts to the local resolution and flow physics.

Variational multiscale↗
NASA NTRSDate not supplied

Thermoviscoelastic modelling of high strain thin-ply composites by means of multiscale plate and beam model

High strain thin-ply (HS-TPC) technology is being increasingly adopted for high-performanceaerospace applications. Albeit many of these structures such as deployable booms can bemodeled as one-dimensional beam problems, there is a lack of themoviscoelastic beam mod-els to efficiently and accurately simulate HS-TPC. This work will use mechanics of struc-ture genome (MSG) to construct linear thermoviscoelastic beam models that can homogenizethree-dimensional heterogeneous materials made of constituents with time- and temperature-dependent behavior. The formulation derives the transient strain energy based on integralformulation for thermorheologically simple materials subject to finite temperature changeswith the restriction that the strain is small. A lenticular boom is used as a numerical exampleto verify the MSG-based linear thermoviscoelastic beam model against MSG-based shell/platemodel, which has already been validated against experimental data provided by NASA, anddirect numerical simulations performed in a finite element commercial package.

Orzuri Rique Garaizar↗
NASA NTRS1997

Environmental Assessment and Monitoring with ICAMS (Image Characterization and Modeling System) Using Multiscale Remote-Sensing Data

With the rapid increase in spatial data, especially in the NASA-EOS (Earth Observing System) era, it is necessary to develop efficient and innovative tools to handle and analyze these data so that environmental conditions can be assessed and monitored. A main difficulty facing geographers and environmental scientists in environmental assessment and measurement is that spatial analytical tools are not easily accessible. We have recently developed a remote sensing/GIS software module called Image Characterization and Modeling System (ICAMS) to provide specialized spatial analytical tools for the measurement and characterization of satellite and other forms of spatial data. ICAMS runs on both the Intergraph-MGE and Arc/info UNIX and Windows-NT platforms. The main techniques in ICAMS include fractal measurement methods, variogram analysis, spatial autocorrelation statistics, textural measures, aggregation techniques, normalized difference vegetation index (NDVI), and delineation of land/water and vegetated/non-vegetated boundaries. In this paper, we demonstrate the main applications of ICAMS on the Intergraph-MGE platform using Landsat Thematic Mapper images from the city of Lake Charles, Louisiana. While the utilities of ICAMS' spatial measurement methods (e.g., fractal indices) in assessing environmental conditions remain to be researched, making the software available to a wider scientific community can permit the techniques in ICAMS to be evaluated and used for a diversity of applications. The findings from these various studies should lead to improved algorithms and more reliable models for environmental assessment and monitoring.

Lam, N.↗
DOE OSTI2022

LDRD-DR: Accelerating Nuclear Fuel Qualification through Integrated Multiscale and Multiphysics Models [Slides]

Nuclear fuel qualification implies ensuring that a new fuel can safely operate in a reactor under both normal and accident conditions. Historically, extensive irradiation campaigns probe fuel performance relationships and interconnections in an integral sense, which is very time-consuming and costly. The presentation focus is on introducing advanced modeling and simulation into the qualification process in order to reduce the qualification timeline by targeting fewer integral tests

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2005

Multiscale Experiments and Models for Polymer Nanocomposites

This report summarizes our research activities at the University of Virginia conducted under the support of this NASA research grant from March 2004 to October 2004 and provides a summary of the research to be conducted in the remaining period of the project at the University of Illinois at Urbana-Champaign (UIUC). The original research objectives will remain the same after our transition to UIUC. In the beginning of this program we completed the analysis on the graphite polymer micro and nanocomposites that were studied at NASA Langley and UVa in the summer of 2003. A publication summarizing this work was submitted in the fall of 2004 to the journal of Experimental Mechanics and the reviewer comments are currently addressed. The research program aims at understanding the local interactions between the polymer matrix and hard reinforcement in polymer nanocomposites (PNCs). The materials selected for this study were PNCs with different fillers (14nm silica nanospheres or nanoclays) and volume fractions (0.5%, 1%, 2% and 5%).

Chasiotis, Ioannis↗
DOE OSTI2023

A multiscale recurrent neural network model for predicting energy production from geothermal reservoirs

Optimization of energy production from geothermal reservoirs requires reliable prediction of energy production performance under alternative operation and development scenarios. Traditionally, reservoir simulation models are used for the evaluation and screening of alternative production and development plans. However, simulation models require extensive data collection and modeling efforts and are time-consuming to build, run, and update. Data-driven predictive models, on the other hand, can serve as efficient prediction tools that can be used for decision support and management of daily operations and surveillance activities. Data-driven models become particularly attractive when a reservoir simulation model for a field does not exist and/or is difficult to build. Machine learning (ML)-based data-driven models that have recently become popular in several fields exploit statistical patterns and relations in training data to generate predictions. As such, they tend to perform better in interpolation problems (that is, prediction within the training data range) than when they are used to extrapolate beyond the training data. Production data from geothermal reservoirs tend to exhibit short-term variabilities as well as long-term trends, such as monotonically declining production temperatures. Capturing both short-term features and long-term trends with ML-based models is not trivial. We evaluate the use of recurrent neural networks (RNN) for the prediction of energy production from geothermal reservoirs. RNN is a class of ML architectures that are used to represent and predict sequential/dynamic data. Thus, it can be challenging to apply RNN to problems where long-term trends must be captured and extrapolation beyond the training data range is needed. We introduce the multiscale RNN architecture to extend the application of RNN to detect and predict both short-term variabilities and long-term trends in geothermal data. The developed architecture consists of a long-term component to only capture low-frequency data patterns, and a short-term component to detect features with higher frequency and more nonlinearity. The final prediction is obtained by combining the long-term and short-term predictions. Both synthetic and field data are used to evaluate the presented multiscale RNN model. The prediction performance of the multiscale RNN is compared against those obtained from the regular RNN and the autoregressive (AR) model. The results suggest that the multiscale architecture improves the long-term prediction performance of the regular RNN and enhances its robustness against noise.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

A multiscale anisotropic polymer network model coupled with phase field fracture

The study of polymers has continued to gain substantial attention due to their expanding range of applications, spanning essential engineering fields to emerging domains like stretchable electronics, soft robotics, and implantable sensors. These materials exhibit remarkable properties, primarily stemming from their intricate polymer chain network, which, in turn, increases the complexity of precisely modeling their behavior. Especially for modeling elastomers and their fracture behavior, accurately accounting for the deformations of the polymer chains is vital for predicting the rupture in highly stretched chains. Despite the importance, many robust multiscale continuum frameworks for modeling elastomer fracture tend to simplify network deformations by assuming uniform behavior among chains in all directions. Recognizing this limitation, our study proposes a multiscale fracture model that accounts for the anisotropic nature of elastomer network responses. At the microscale, damage in the chains is assumed to be driven by both the chain's entropy and the internal energy due to molecular bond distortions. In order to bridge the stretching in the chains to the macroscale deformation, we employ the maximal advance path constraint network model, inherently accommodating anisotropic network responses. As a result, chains oriented differently can be predicted to exhibit varying stretch and, consequently, different damage levels. To drive macroscale fracture based on damages in these chains, we utilize the micromorphic regularization theory, which involves the introduction of dual local-global damage variables at the macroscale. The macroscale local damage variable is obtained through the homogenization of the chain damage values, resulting in the prediction of an isotropic material response. The macroscale global damage variable is subjected to nonlocal effects and boundary conditions in a thermodynamically consistent phase field continuum formulation. Moreover, the total dissipation in the system is considered to be mainly due to the breaking of the molecular bonds at the microscale. To validate our model, we employ the double-edge notched tensile test as a benchmark, comparing simulation predictions with existing experimental data. Additionally, to enhance our understanding of the fracturing process, we conduct uniaxial tensile experiments on a square film made up of polydimethylsiloxane (PDMS) rubber embedded with a hole and notches and then compare our simulation predictions with the experimental observations. Furthermore, we visualize the evolution of stretch and damage values in chains oriented along different directions to assess the predictive capacity of the model. In conclusion, the results are also compared with another existing model to evaluate the utility of our model in accurately simulating the fracture behavior of rubber-like materials.

42 ENGINEERING↗
DOE OSTI2021

Multiscale Machine-Learned Modeling Infrastructure Core

MuMMI Core is the central component of the Multiscale Machine-Learned Modeling Infrastructure (MuMMI), a scalable and generalizable framework that couples pairs of models using machine learning and in situ feedback across three scales of resolution.

Bhatia, Harsh↗
DOE OSTI2021

Multiscale Machine-Learned Modeling Infrastructure RAS

MuMMI RAS is the application component of the Multiscale Machine-Learned Modeling Infrastructure (MuMMI). It simulates RAS protein interactions at three scales of resolution coupled with ML-based selection and in-situ feedback. MuMMI RAS is particularly configured for massive scale, running thousands of simultaneous jobs with several terabytes of data on Lassen and Summit.

Moon, JosephY.↗
DOE OSTI2019

Modeling framework for multiphysics-multiscale behavior of Si–C composite anode

To achieve the urgent requirement for high energy density in lithium-ion batteries, Si-C composite anode has been spotlighted as one of the most promising alternatives for next-generation batteries. Additionally, a comprehensive computational model is indispensable in the developing process of the excellent performance of anode material due to the low-realizability, inconvenience, and high-cost of experiments. Herein, a simultaneous multiphysics-multiscale model aiming at the Si-C composite anode was developed. This model was then used to study the effects of Si percentage, mechanical constraint and charging rate in terms of electrochemical and mechanical performances. A better design to achieve high capacity was proposed based on the computational results. Results provide a powerful tool in the design, development, and evaluation of high energy density lithium-ion batteries.

25 ENERGY STORAGE↗