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DOE OSTI2026

TANTE: Time-adaptive operator learning via neural Taylor expansion

Operator learning for time-dependent partial differential equations (PDEs) has seen rapid progress in recent years, enabling efficient approximation of complex spatiotemporal dynamics. However, most existing methods rely on fixed time step sizes during rollout, which limits their ability to adapt to varying temporal complexity and often leads to error accumulation. In this work, we propose the Time-Adaptive Transformer with Neural Taylor Expansion (TANTE), a novel operator-learning framework that produces continuous-time predictions with adaptive step sizes. TANTE predicts future states by performing a Taylor expansion at the current state, where neural networks learn both the higher-order temporal derivatives and the local radius of convergence. This allows the model to dynamically adjust its rollout based on the local behavior of the solution, thereby reducing cumulative error and improving computational efficiency. We demonstrate the effectiveness of TANTE across a wide range of PDE benchmarks, achieving superior accuracy and adaptability compared to fixed-step baselines, delivering accuracy gains of 60-80 % and speed-ups of 30-40 % at inference time.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Phase-based velocity extraction method for photonic Doppler velocimetry with potential higher time resolution

We present an extension of the [Takeda et al., J. Opt. Soc. Am. 72, 156 (1982)] phase extraction method to heterodyne photonic Doppler velocimetry applications. The method yields results equivalent to those obtained by the short-time Fourier transform (STFT), while offering potential improvements in time resolution. Unlike STFT, which relies on window functions, such as the Hamming window, that emphasize central data points and diminish the influence of edges, the extended Takeda method utilizes all data uniformly. This uniform treatment allows for the derivation of empirical equations that directly relate velocity error to the actual time resolution rather than to the local analysis duration. The established equation provides a useful metric for both optimizing hardware configuration and guiding data analysis. Simulation and experimental results confirm that, for a given dataset, specifying a target time resolution yields consistent velocity errors for both methods. These findings underscore the Takeda method’s advantages, particularly its potential higher time resolution and reduced computational burden, making it a valuable tool for high-throughput applications such as laser dynamic compression experiments.

Computer simulation↗

DOE OSTI2026

Citizen science coupled with machine learning to quantify green-blue infrastructure cooling potential in Maricopa County, Arizona

Here, this study investigates the spatiotemporal cooling performance of green and blue infrastructure (GBI) in the Dobson Ranch urban neighborhood in Phoenix, Arizona. We leveraged citizen science near-surface (2 m) air temperature (Tair) measurements to train a highly accurate Tair predicting LightGBM machine learning model (R 2 : 0.986, MAE: 0.251 °C, RMSE: 0.585 °C). On June 16, 2024, the park area exhibited approximately 1 °C cooling effect (relative to the neighborhood mean) during both day and night. In contrast, the nearby artificial lake exhibited a stronger cooling effect of 2.4 °C during the day but a slight warming of 0.3 °C at night. At 00:00, locations 50 m downwind of the park were 0.3 °C warmer than the park, while locations 50 m upwind were 0.8 °C warmer. At 11:00, we observed that the downwind area is 0.8 °C cooler and the upwind area is 0.6 °C warmer—at the same 50 m distances relative to the park. We also observed 1 °C cooler and warmer effects respectively at the same 50 m downwind and upwind locations at 19:00 on June 17, 2024. Our data-driven analysis highlights potential limitations of car-traverse measurements, showing that failure to account for temporal variations during the traverse can lead to overestimation of Tair at night and underestimation during the day. Our analysis also showed only a weak correlation (coefficient: 0.48) between Landsat-derived land surface temperature (LST) and model predicted Tair at the time of the local Landsat overpass (∼11.00). This highlights the potential error of relying solely on LST for human thermal exposure analysis—particularly within the heterogenous built-environment.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Designing open quantum systems with known steady states: Davies generators and beyond

We provide a systematic framework for constructing generic models of nonequilibrium quantum dynamics with a target stationary (mixed) state. Our framework identifies (almost) all combinations of Hamiltonian and dissipative dynamics that relax to a steady state of interest, generalizing the Davies’ generator for dissipative relaxation at finite temperature to nonequilibrium dynamics targeting arbitrary stationary states. We focus on Gibbs states of stabilizer Hamiltonians, identifying local Lindbladians compatible therewith by constraining the rates of dissipative and unitary processes. Moreover, given terms in the Lindbladian not compatible with the target state, our formalism identifies the operations – including syndrome measurements and local feedback – one must apply to correct these errors. Our methods also reveal new models of quantum dynamics: for example, we provide a “measurement-induced phase transition” in which measurable two-point functions exhibit critical (power-law) scaling with distance at a critical ratio of the transverse field and rate of measurement and feedback. Time-reversal symmetry – defined naturally within our formalism – can be broken both in effectively classical and intrinsically quantum ways. Our framework provides a systematic starting point for exploring the landscape of dynamical universality classes in open quantum systems, as well as identifying new protocols for quantum error correction.

Guo, Jinkang [Department of Physics and Center for↗

DOE OSTI2026

Using Density-Corrected DFT to Understand Density-Driven and Functional-Dependent Errors in Ab Initio Simulations of the Hydrated Electron

The hydrated electron, an excess electron in liquid water, plays a crucial role in a plethora of chemical processes, motivating extensive research efforts to characterize its structure, dynamics, and reactivity in solution. Recent theoretical approaches to understanding this intriguing object have involved ab initio simulations based on density functional theory (DFT). Although DFT allows for the study of hydrated electron reactivity and quantum mechanical behavior, it is well-known that anionic systems can suffer from significant density-driven errors (DDEs). Density-corrected DFT (DC-DFT) provides a framework to mitigate such errors; the method reduces DDEs by replacing the self-consistent (SC) density associated with a given density functional with the Hartree–Fock (HF) density. Since HF densities tend to be more localized than DFT SC densities, the DC-DFT scheme significantly improves errors in calculations where the SC density is spuriously delocalized. Here, we investigate how the use of density correction affects the calculated properties of the DFT-simulated (PBEh) hydrated electron, a particularly challenging diffuse anionic system to simulate. First, we analyze charge delocalization in a system consisting of a model octahedral hydrated electron water cluster (the so-called Kevan structure) along with a spatially separated sulfur atom. We show that the use of density correction indeed reduces DDEs in comparison to a standard DFT global hybrid functional. We then propagate molecular dynamics trajectories of the hydrated electron using DC-DFT, where we find that DC further localizes electron density in the cavity region, a signature of reduced charge delocalization. Unfortunately, the decreased radius of gyration of the spin density and corresponding tightening of the local solvation structure from density correction causes predicted observables to deviate further from experimental measurements than when density correction is not employed. Here, we argue that DC’s worse agreement with experiment results from the removal of a fortuitous cancellation of errors that is intrinsic to the PBEh functional. This indicates that the difficulties with DFT to simulate hydrated electrons are primarily due to the inherent approximations in DFT rather than to density-driven errors.

Density functional theory↗

DOE OSTI2026

Local Spin Density Approximation Strongly Improved by a Better-Informed Local Scaling of Its Self-Interaction Correction

The Perdew−Zunger self-interaction correction (PZSIC) makes density functional approximations (DFAs) exact for all one-electron densities. However, it overcorrects in manyelectron regions, introducing errors for the uniform-density limit, where uncorrected DFAs are exact. The locally scaled PZSIC (LSIC), based on the iso-orbital indicator zσ [which distinguishes single-orbital and slowly varying density regions and is used with the local spin density approximation (LSDA)], restores the uniform-density limit and significantly improves results for many properties, including chemical reaction barrier heights, atomization energies, and ionization potentials. Yet, LSIC performs poorly for weakly bonded systems, leaving many unbound, due to limitations of its iso-orbital indicator. To correct this, in this work we propose a new local scaling, LSIC-α, based on the iso-orbital indicator ασ (which additionally identifies regions of overlapping density tails). A two-parameter scaling function of ασ is fitted to a subset of the nonbonded appropriate norms for the SCAN and r2SCAN meta- GGAs, and tested on many properties of main-group atoms, molecules, and molecular complexes. LSIC-α greatly improves the interaction energies of weakly bonded systems in the S22 data set while retaining LSIC’s accuracy for other properties. This work shows that the errors of LSDA (and presumably of higher-level DFAs) can be largely but not entirely repaired by a proper “do no harm” self-interaction correction.

Approximation↗

DOE OSTI2026

Explainable machine learning reveals that local structural motifs encode the thermodynamic state across the CuZr metallic glass-forming range

Metallic glasses derive their properties from the statistics of local atomic motifs rather than from long-range order, yet a quantitative, chemistry-specific link between motif populations and the underlying glassy state has remained elusive. In this work we combine large-scale molecular dynamics, Voronoi tessellation, deep neural networks, and SHapley Additive exPlanations (SHAP) to identify which local structural motifs define the glassy state of Cu—Zr metallic glasses. A dataset of 17,180 atomistic configurations spanning ten compositions (Cu 20 Zr 80 –Cu 80 Zr 20 ) and four quench rates (10 9 –10 12 K/s) is used to train a feed-forward neural network that regresses temperature across the 50–2000 K liquid–supercooled–glass range, achieving a mean absolute error of 19.89 K and R 2 = 0.9974, confirming that the local structural state is faithfully encoded in motif-level structure. SHAP analysis then reveals that a tightly coupled near-icosahedral family of motifs (coordination numbers (CN) 11–13, including the full icosahedron 001200 and its single-atom-perturbation sibling 10930) collectively encodes the thermodynamic state of the system across the full glass-forming range. The CN = 11–13 ordered members carry negative SHAP values at high populations, tracking the most deeply-quenched configurations, while 10930 shows the reversed signature consistent with its role as a soft-spot host whose population shrinks as the icosahedral network deepens. The analysis demonstrates that explainable machine learning can isolate the minimal motif vocabulary defining the glassy state and recovers the near-icosahedral building blocks previously identified by data-driven analyses of Cu—Zr. The approach provides a general, chemistry-specific route for characterizing the structural state of disordered materials.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Diabatic error and propagation of Majorana zero modes in interacting quantum dots systems

Motivated by recent experimental progress in realizing Majorana zero modes (MZMs) using quantum dot systems, we investigate the diabatic errors associated with the movement of those MZMs. The movement is achieved by tuning time-dependent gate potentials applied to individual quantum dots, effectively creating a moving potential wall. To probe the optimized movement of MZMs, we calculate the experimentally accessible time-dependent fidelity and local density-of-states using many-body time-dependent numerical methods. Furthermore, our analysis reveals that an optimal potential wall height is crucial to preserve the well-localized nature of the MZM during its movement. Moreover, we analyze diabatic errors in realistic quantum-dot systems, incorporating the effects of repulsive Coulomb interactions and disorder in both hopping and pairing terms. Additionally, we provide a comparative study of diabatic errors arising from the simultaneous versus sequential tuning of multiple gates during the MZMs movement. Finally, we estimate the timescale required for MZM transfer in a six-quantum-dot system, demonstrating that MZM movement is feasible and can be completed well within the qubit's operational lifetime in practical quantum-dot setups.

Density of states↗

DOE OSTI2024

Adaptive immersed isogeometric level-set topology optimization

Here, this paper presents for the first time an adaptive immersed approach for level-set topology optimization using higher-order truncated hierarchical B-spline discretizations for design and state variable fields. Boundaries and interfaces are represented implicitly by the iso-contour of one or multiple level-set functions. An immersed finite element method, the eXtended IsoGeometric Analysis, is used to predict the physical response. The proposed optimization framework affords different adaptively refined higher-order B-spline discretizations for individual design and state variable fields. The increased continuity of higher-order B-spline discretizations together with local refinement enables direct control over the accuracy of the representation of each field while simultaneously reducing computational cost compared to uniformly refined discretizations. A flexible mesh adaptation strategy enables local refinement based on geometric measures or physics-based error indicators. These adaptive discretization and analysis approaches are integrated into gradient-based optimization schemes, evaluating the design sensitivities using the adjoint method. Numerical studies illustrate the features of the proposed framework with static, linear elastic, multi-material, two- and three-dimensional problems. The examples provide insight into the effect of refining the design variable field on the optimization result and the convergence rate of the optimization process. Using coarse higher-order B-spline discretizations for level-set fields promotes the development of smooth designs and suppresses the emergence of small features. Moreover, adaptive mesh refinement for state variable fields results in a reduction of overall computational cost. Higher-order B-spline discretizations are especially interesting when evaluating gradients of state variable fields due to their higher inter-element continuity.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Modeling and Experimental Demonstration of Flux Spreading in Light Trapping Planar-Cavity Solar Enclosed Particle Receivers

This study experimentally validates and numerically models the flux-spreading effect in a light-trapping planar-cavity solar receiver) for particle-based concentrating solar power systems. The receiver's shallow cavity with vertical planar walls redistributes concentrated solar flux, reducing peak intensity and achieving uniform heat flux. On-sun tests at National Renewable Energy Laboratory's High-Flux Solar Furnace under flux up to 1500 kW/m2 measured cavity wall temperatures, which were compared with Monte Carlo ray-tracing (SolTrace) and computational numerical simulations. Three angular absorptance models were evaluated: constant absorptance, a Pyromark-based directional model, and a Fresnel-based Cr2O3 model. The Fresnel-derived model showed the best agreement with experiments, achieving high correlation (PC > 0.85), structural similarity (SSIM > 0.98), and signal-to-noise ratios (PSNR > 40 dB), with temperature prediction errors of 1-11%. Results confirm that flux spreading mitigates local overheating and validate the integrated modeling approach, supporting the solar receiver scalability for high-efficiency, high-temperature concentrating solar power applications.

14 SOLAR ENERGY↗

DOE OSTI2025

Toward a 2D Local Implementation of Quantum Low-Density Parity-Check Codes

Geometric locality is an important theoretical and practical factor for quantum low-density parity-check (qLDPC) codes that affects code performance and ease of physical realization. For device architectures restricted to two-dimensional (2D) local gates, naively implementing the high-rate codes suitable for low-overhead fault-tolerant quantum computing incurs prohibitive overhead. In this work, we present an error-correction protocol built on a bilayer architecture that aims to reduce operational overheads when restricted to 2D local gates by measuring some generators less frequently than others. We investigate the family of bivariate-bicycle qLDPC codes and show that they are well suited for a parallel syndrome-measurement scheme using fast routing with local operations and classical communication (LOCC). Through circuit-level simulations, we find that in some parameter regimes, bivariate-bicycle codes implemented with this protocol have logical error rates comparable to the surface code while using fewer physical qubits. Published by the American Physical Society 2025

Berthusen, Noah (ORCID:0000000275862786)↗

DOE OSTI2025

Accuracy Guarantees and Quantum Advantage in Analog Open Quantum Simulation with and without Noise

Many-body open quantum systems, described by Lindbladian master equations, are a rich class of physical models that display complex equilibrium and out-of-equilibrium phenomena which remain to be understood. In this paper, we theoretically analyze noisy analog quantum simulation of geometrically local open quantum systems and provide evidence that this problem both is hard to simulate on classical computers and could be approximately solved on near-term quantum devices. First, given a noiseless quantum simulator, we show that the dynamics of local observables and the fixed-point expectation values of rapidly mixing local observables in geometrically local Lindbladians can be obtained to a precision of ϵ in time that is poly ( ϵ − 1 ) and uniform in system size. Furthermore, we establish that the quantum simulator would provide a superpolynomial advantage, in run-time scaling with respect to the target precision and either the evolution time (when simulating dynamics) or the Lindbladian’s decay rate (when simulating fixed points), over any classical algorithm for these problems, assuming BQP ≠ BPP . We then consider the presence of noise in the quantum simulator in the form of additional geometrically local Lindbladian terms. We show that the simulation tasks considered in this paper are stable to errors; i.e., they can be solved to a noise-limited, but system-size independent, precision. Finally, we establish that, assuming BQP ≠ BPP , there are stable geometrically local Lindbladian simulation problems such that, as the noise rate on the simulator is reduced, classical algorithms must take time superpolynomially longer in the inverse noise rate to attain the same precision as the analog quantum simulator. Published by the American Physical Society 2025

Kashyap, Vikram (ORCID:0000000208195207)↗

DOE OSTI2025

Optimising the processing and storage of visibilities using lossy compression

The next-generation radio astronomy instruments are providing a massive increase in sensitivity and coverage, largely through increasing the number of stations in the array and the frequency span sampled. The two primary problems encountered when processing the resultant avalanche of data are the need for abundant storage and the constraints imposed by I/O, as I/O bandwidths drop significantly on cold storage. An example of this is the data deluge expected from the SKA Telescopes of more than 60 PB per day, all to be stored on the buffer filesystem. While compressing the data is an obvious solution, the impacts on the final data products are hard to predict. In this paper, we chose an error-controlled compressor – MGARD – and applied it to simulated SKA-Mid and real pathfinder visibility data, in noise-free and noise-dominated regimes. As the data have an implicit error level in the system temperature, using an error bound in compression provides a natural metric for compression. MGARD ensures the compression incurred errors adhere to the user-prescribed tolerance. To measure the degradation of images reconstructed using the lossy compressed data, we proposed a list of diagnostic measures, exploring the trade-off between these error bounds and the corresponding compression ratios, as well as the impact on science quality derived from the lossy compressed data products through a series of experiments. We studied the global and local impacts on the output images for continuum and spectral line examples. We found relative error bounds of as much as 10%, which provide compression ratios of about 20, have a limited impact on the continuum imaging as the increased noise is less than the image RMS, whereas a 1% error bound (compression ratio of 8) introduces an increase in noise of about an order of magnitude less than the image RMS. For extremely sensitive observations and for very precious data, we would recommend a 0.1% error bound with compression ratios of about 4. These have noise impacts two orders of magnitude less than the image RMS levels. At these levels, the limits are due to instabilities in the deconvolution methods. We compared the results to the alternative compression tool DYSCO, in both the impacts on the images and in the relative flexibility. MGARD provides better compression for similar error bounds and has a host of potentially powerful additional features.

Techniques: interferometric↗

DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A B-spline based gradient-enhanced micropolar implicit material point method for large localized inelastic deformations

The quasi-brittle response of cohesive-frictional materials in numerical simulations is commonly represented by softening plasticity or continuum damage models, either individually or in combination. However, classical models, particularly when coupled with non-associated plasticity, often suffer from ill-posedness and a lack of objectivity in numerical simulations. Moreover, the performance of the finite element method significantly degrades in simulations involving finite strains when mesh distortion reaches excessive levels. This represents a challenge for modeling cohesive-frictional materials, given their tendency to experience strongly localized deformations, such as those occurring during shear band dominated failure. Hence, accurate modeling of the response of cohesive-frictional solids is a demanding task. To address these challenges, we present an extension of the material point method (MPM) for the unified gradient-enhanced micropolar continuum, aiming at the analysis of finite localized inelastic deformations in cohesive-frictional materials. The generalized gradient-enhanced micropolar continuum formulation is employed to tackle challenges related to localization and softening material behavior, while the MPM addresses issues arising from excessive deformations. The method utilizes a B-spline formulation for the rigid background mesh to mitigate the well-known cell crossing errors of the MPM. To demonstrate the performance of the method, 2D and 3D numerical studies on localized failure in sandstone in plane strain compression and triaxial extension tests are presented. A comparison with finite element results confirms the suitability of the formulation. Moreover, an efficient numerical implementation of the formulation is presented, and it is demonstrated that the additional MPM specific overhead is negligible.

B-spline↗

DOE OSTI2025

Atomic ionization: sd energy imbalance and Perdew–Zunger self-interaction correction energy penalty in 3d atoms

To accurately describe the energetics of transition metal systems, density functional approximations (DFAs) must provide a balanced description of s- and d- electrons. One measure of this is the sd transfer error, which has previously been defined as E ( 3 d n − 1 4 s 1 ) − E ( 3 d n − 2 4 s 2 ) . Theoretical concerns have been raised about this definition due to its evaluation of excited-state energies using ground-state DFAs. A more serious concern appears to be strong correlation in the 4s 2 configuration. Here, we define a ground-state measure of the sd energy imbalance, based on the errors of s- and d-electron second ionization energies of the 3d atoms, that effectively circumvents the aforementioned problems. We find an improved performance as we move from the local spin density approximation (LSDA) to the Perdew-Burke-Ernzerhof (PBE) generalized gradient approximation (GGA) to the regularized and restored Strongly Constrained and Appropriately Normed (r 2 SCAN) meta-GGA for first-row transition metal atoms. However, we find large (∼2 eV) ground-state sd energy imbalances when applying a Perdew–Zunger 1981 self-interaction correction. This is attributed to an “energy penalty” associated with the noded 3d orbitals. A local scaling of the self-interaction correction to LSDA results in a balance of s- and d-errors.

Science & Technology - Other Topics↗

DOE OSTI2026

Computationally inexpensive part-scale thermal history of additive friction-stir deposition

This study presents an analytical model for steady-state power generation and tool heat loss in additive friction-stir deposition (AFSD), developed to enable part-scale thermal simulation while remaining computationally inexpensive. The model predicts total generated power, yielding 3.7–4.7 kW across deposition temperature setpoints of 400–460 °C for the deposition of AA6061 with a Be-Cu tool. This corresponds to 90–95% of the reported spindle power. Tool heat loss is experimentally determined by calibrating a steady-state energy balance between the generated power, the substrate-deposition thermal gradient, and a temperature dependent tool heat loss term: q tool (T) = a + b (T - 400°C) with a = 2.7 x 10 6 Wm -2 and b = 9.5 x 10 3 Wm -2 K -1 . The calibration indicates that about 69% of the generated heat is conducted into the tool for this configuration, which is much higher than previously reported. The calibrated heat-source is implemented in finite element software (Adamantine) to simulate the transient thermal history of a 100 cm 3 representative build in 8 min on a standard desktop (at 0.635 mm build-height resolution). For the first three layers, the substrate temperatures between simulation and experiment are within 10% mean absolute percentage error. Sensitivity analysis indicates that uncertainties in average deposition temperature and deformation localization (stir-zone geometry, depth, and spatial dependance of strain-rate and flow stress) dominate model variance, motivating additional experimental verification.

Additive Friction-Stir Deposition↗