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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Local prediction of Laser Powder Bed Fusion porosity by short-wave infrared imaging thermal feature porosity probability maps

We report that local thermal history can significantly vary in parts during metal Additive Manufacturing (AM), leading to local defects. However, the sequential layer-by-layer nature of AM facilitates in-situ part voxelmetric observations that can be used to detect and correct these defects for part qualification and quality control. The challenge is to relate this local radiometric data with local defect information to estimate process error likelihood in future builds. This paper uses a Short-Wave Infrared (SWIR) camera to record the temperature history for parts manufactured with Laser Powder Bed Fusion (LPBF) processes. The porosity from a cylindrical specimen is measured by ex-situ micro-computed tomography (μCT). Specimen data from the SWIR camera, combined with the μCT data, are used to generate thermal feature-based porosity probability maps. The porosity predictions made by various SWIR thermal feature-porosity probability maps of a specimen with a complex geometry are scored against the true porosity obtained via μCT. The receiver operating characteristic curves constructed from the predictions for the complex sample demonstrate the porosity probability mapping methodology’s potential for in-situ based porosity detection.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Nondestructive Modular Leak Detection in 3D Printed 316L Stainless Steel Pipes via Laser Powder Bed Fusion

This research investigates the leak detection features of 316L Stainless Steel pipe structures manufactured via Laser Powder Bed Fusion (LPBF). This work involves the design of a modular sensor system integrating nondestructive evaluation (NDE) methods, including thermal imaging and ultrasonic frequency detection to detect and characterize leaks in components. This aims to improve leak detection sensitivity within medium-pressure gas systems, during continuous operation without halting flow or introducing safety risks. The system could be adaptable for use on unmanned aerial vehicles (UAVs), enabling remote leak detection in active environments. A custom pneumatic system incorporating temperature and pressure sensors was assembled to detect leaks in LPBF-printed 316L SS tee pipes. Experimental results and simulations confirm the system’s effectiveness in leak detection and material evaluation. This research program also integrated a Python-based image recognition platform based on a metallography and optical microscopy to assess the porosity and complement the leak detection data on the printed structures. This allows a detailed analysis of pore distribution and internal leak paths, which could compromise structural integrity, critical for quality control during manufacturing. Findings suggest that the investigated approach holds potential for enhancing leak detection technologies and adapt them for advanced manufactured parts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Seismicity-constrained fault detection and characterization with a multitask machine learning model

Geological fault detection and characterization are crucial for understanding subsurface dynamics across scales. While methods for fault delineation based on either seismicity location analysis or seismic image reflector discontinuity are well-established, a systematic approach that integrates both data types remains absent. We develop a novel machine learning model that unifies seismic reflector images and seismicity location information to automatically identify geological faults and characterize their geometrical properties. The model encodes a seismic image and a seismicity location image separately, and fuses the encoded features with a spatial-channel attention fusion module to improve the learning of important features in both inputs. We design an automated strategy to generate high-quality synthetic training data and labels. To improve the realism of the seismicity location image, we include random seismicity noise and missing seismicity location associated with some of the faults. We validate the model’s efficacy and accuracy using synthetic data examples and two field data examples. Moreover, we show that fine-tuning the trained model with a small, domain-specific dataset enhances its fidelity for field data applications. The results demonstrate that integrating seismicity location and seismic images into a unified framework allows the end-to-end neural network to achieve higher fidelity and accuracy in delineating subsurface faults and their geometrical properties compared with image-only fault detection methods. Our approach offers an adaptive data-driven tool for geological fault characterization and seismic hazard mitigation, bridging the gap between seismicity location and image-based fault detection methods.

58 GEOSCIENCES↗
DOE OSTI2024

The Updated Case for a National Stellarator Program

The stellarator concept provides a compelling path to a Fusion Pilot Plant that features steady state, disruption free operation with low recirculating power. The need for a national stellarator program and a new stellarator experiment have been highlighted previously in the FESAC Long-Range Plan (LRP) and the APS Community Planning Process (CPP). There have been many advances in the stellarator field since those reports were drafted, both theoretically and experimentally, that provide an even stronger motivation for an expanded stellarator program within the US. In addition, in recent years a number of private companies have been founded (and funded) to pursue the stellarator concept, two of which are FES Milestone Program award recipients. An expanded stellarator program is needed to fully support these companies and their goals. This whitepaper aims to briefly provide an updated outlook on the need for a national stellator program including benefits to private industry and opportunities for Public Private Partnerships (PPP).

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Experimental and theoretical study of weakly coherent mode in I-mode edge plasmas in the EAST tokamak

The I-mode is a promising operation mode for fusion in the future, featuring high-temperature and low-density confinement, but the reason why the temperature and density are decoupled remains an important aspect to be explored. The experimental results from the experimental advanced superconducting tokamak (EAST) showed that the weakly coherent mode (WCM) is directly related to sustaining the I-mode and that the peak amplitude of the WCM is proportional to the temperature in the pedestal. Here, simulating the experimental data from EAST with the six-field model of BOUT++, we find a density perturbation close to the frequency of the WCM observed in the experiment. By testing all the physical terms in this model, we find that the density perturbation and particle transport are directly related to the drift Alfvén wave (DAW) mode. Additionally we use the SymPIC program (Xiao et al Plasma Sci. Technol. 20 110501; Phys. Plasmas 22 112504; Plasma Sci. Technol. 23 055102) to simulate the same experimental data and find that the frequency range of the WCM is close to both experimental and BOUT++ results. Therefore, the WCM of the I-mode can be considered to be driven by the DAW, which helps improve the transport of the I-mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Faster ablative Kelvin–Helmholtz instability growth in a magnetic field

Shear flows along a plasma interface will quickly grow unstable due to the Kelvin–Helmholtz instability. If there is a concurrent temperature gradient across the interface, higher modes are stabilized by the thermal diffusion. These ablative effects must be considered in, for example, jet features in inertial confinement fusion hot-spots, or plasma plumes in young supernovae. We show that magnetization of the plasma can greatly affect the instability, even if magnetic pressure is small. This is because electrons are localized by their gyromotion, reducing the heat flux and material ablation. We use a two-dimensional numerical extended-magnetohydrodynamics approach to assess this effect for dense fusion conditions. In comparison with the unmagnetized case, self-generated Biermann fields make only a minor difference to growth rates. However, simulations with a large 50 kT external field found that the growth rate of the least stable mode increased by 40%. In conclusion, this has implications for mix processes in Z-pinches and magnetized inertial confinement fusion concepts.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Introducing SpaceNet 9 - Cross-Modal Satellite Imagery Registration for Natural Disaster Responses

Computer vision algorithms are increasingly leveraged to accelerate geospatial analysis for disaster response and recovery. As the diversity of remote sensing imagery grows with optical, SAR, and other modalities, a perquisite for analytics is cross-modal image registration. There is a high potential to harness computer vision for this pre-processing requirement toward enabling downstream analytics such as heterogeneous change detection, automated feature extraction, and data fusion. Advancement in these areas has the potential to simplify data wrangling tasks and further accelerate disaster response timelines. The SpaceNet 9 challenge (launching in mid-2024) focuses on addressing the cross-modal image registration problem and demonstrating the utility of such modules on earthquake impacted scenarios. This paper describes the motivation for the SpaceNet 9 and provides a first overview of the dataset, the baseline algorithm, and implications for seeking cross-modal image registration in Earth observation. Code is available at https://github.com/SpaceNetChallenge/SpaceNet9.

Hansch, Ronny↗
DOE OSTI2020

CHAI and RAJA Extensions

CHAI and RAJA provide an excellent base on which to build portable codes. CARE expands that functionality, adding new features such as loop fusion capability and a portable interface for many numerical algorithms. It provides all the basics for anyone wanting to write portable code.

ROBINSON, PeterB↗
DOE OSTI2021

Localized Defect Detection from Spatially Mapped, In-Situ Process Data With Machine Learning

In powder bed fusion additive manufacturing, machines are often equipped with in-situ sensors to monitor the build environment as well as machine actuators and subsystems. The data from these sensors offer rich information about the consistency of the fabrication process within a build and across builds. This information may be used for process monitoring and defect detection; however, little has been done to leverage this data from the machines for more than just coarse-grained process monitoring. In this work we demonstrate how these inherently temporal data may be mapped spatially by leveraging scan path information. We then train a XGBoost machine learning model to predict localized defects—specifically soot–using only the mapped process data of builds from a laser powder bed fusion process as input features. The XGBoost model offers a feature importance metric that will help to elucidate possible relationships between the process data and observed defects. Finally, we analyze the model performance spatially and rationalize areas of greater and lesser performance.

3D printing↗
DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Predicting High‐Resolution Spatial and Spectral Features in Mass Spectrometry Imaging with Machine Learning and Multimodal Data Fusion

Recent advancements in molecular Mass Spectrometry Imaging have sparked interest in integrating high spatial resolution methods with molecular mass-spectrometry-based chemical imaging. Fusion-based algorithms have proven effective in generating high spatial-resolution molecular mass spectra. However, a significant challenge stems from the differing physical mechanisms underlying image generation and data upsampling techniques, potentially leading to discrepancies in integrated information channels. Integrating physical constraints into data processing workflows is essential to tackle this issue. In this study, we propose an innovative approach that merges data from Fourier transform ion cyclotron resonance (FTICR), time-of-flight matrix-assisted laser desorption/ionization, and time-of-flight secondary ion mass spectrometry imaging techniques. By leveraging FT-ICR's unparalleled spectral resolution and ToF-SIMS's exceptional spatial resolution, we achieve submicron spatial resolution, enabling the observation of intact molecular species with remarkable spectral precision. Canonical correlation analysis is employed to incorporate physical constraints. Through sophisticated image processing and machine learning techniques, the results of this fusion hold significant promise for advancing our comprehension of complex systems and unveiling concealed molecular intricacies.

canonical correlation analysis↗
DOE OSTI2022

Multimodal sensor fusion framework for residential building occupancy detection

For several years now, smart building energy systems have been a research area of intensive activity. In light of the increasing need for sustainable buildings and energy systems, this trend motivates an increasing need for a solution to reduce carbon dioxide emissions and improve energy efficiency. This work proposes a high-performing and transferable occupancy detection framework that combines sensor data from different data modalities, including time series environmental data (temperature, humidity, and illuminance), image data, and acoustic energy data using ensemble method. To draw out the best prediction performance in each modality, the proposed framework was developed, including various models that were designed to learn the occupancy patterns reflected in the physical data streams. To tackle the time series environmental data, we designed two variants of an occupancy detection spatiotemporal pattern network (Occ-STPN) that performs both feature level and decision level fusion, respectively. We also propose a new metric; the fading memory mean square error (FMMSE), that provides a fair evaluation and penalization of delayed occupancy predictions. Multiple open-sourced datasets, including the Electricity Consumption and Occupancy and the University of California, Irvine's (UCI) building occupancy detection dataset, along with our own real data collected from six different houses, were used to validate the algorithms' performance. The experimental results presented herein break down the performance for each sensing modality, and a detailed analysis of the performance is also discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

OpenEdge: A collaborative, open-source, multi-purpose direct simulation Monte Carlo for plasma simulation in magnetic fusion environments

OpenEdge is a collaborative, open-source, object-oriented Direct Simulation Monte Carlo (DSMC) code, designed specifically for plasma simulations in magnetic fusion environments. Here, the code features include advanced structures, robust capabilities, and an effective parallelization strategy, all of which significantly enhance performance. It includes specialized modules for managing complex particle interactions, including collisions, ionization/recombination, and reflection/sputtering. Benchmarks and performance analyses have confirmed its efficiency and scalability. Versatile and adaptable, OpenEdge is applied across a broad spectrum of plasma-material interaction studies and charged particle transport in various fusion research settings.

Boundary plasma↗
DOE OSTI2024

New Developments of MOOSE/FENIX Capabilities for Fusion Neutronics Calculations

This poster summarizes internship work to support new developments of MOOSE/FENIX Capabilities for fusion neutronics calculations. A new feature was added to allow coupling OpenMC models with thermomechanics models and was verified. Two coupled multiphysics models are demonstrated for a tokamak model and monoblock divertor model. Results show heating results, temperature distributions, tritium production and transport.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Visualization of conformational changes and membrane remodeling leading to genome delivery by viral class-II fusion machinery

Chikungunya virus (CHIKV) is a human pathogen that delivers its genome to the host cell cytoplasm through endocytic low pH-activated membrane fusion mediated by class-II fusion proteins. Though structures of prefusion, icosahedral CHIKV are available, structural characterization of virion interaction with membranes has been limited. Here, we have used cryo-electron tomography to visualize CHIKV’s complete membrane fusion pathway, identifying key intermediary glycoprotein conformations coupled to membrane remodeling events. Using sub-tomogram averaging, we elucidate features of the low pH-exposed virion, nucleocapsid and full-length E1-glycoprotein’s post-fusion structure. Contrary to class-I fusion systems, CHIKV achieves membrane apposition by protrusion of extended E1-glycoprotein homotrimers into the target membrane. The fusion process also features a large hemifusion diaphragm that transitions to a wide pore for intact nucleocapsid delivery. Our analyses provide comprehensive ultrastructural insights into the class-II virus fusion system function and direct mechanistic characterization of the fundamental process of protein-mediated membrane fusion.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Ultrasonic Testing (UT) and Computed Tomography (CT) Comparative Scanning of Proposed Additive Manufacturing Reference Standard

This report presents qualitative results of ultrasonic full matrix capture/total focusing method (FMC/TFM) scanning of two series of blocks, additively manufactured by powder bed fusion, containing a variety of internal features and structures that would not be achievable by conventional manufacturing techniques. The purpose of the first series of additively manufactured (AM) blocks was to explore the possibility of building calibration blocks for FMC/TFM ultrasonic testing (UT). It was confirmed that AM is a suitable candidate for generation of unusual and novel reflector forms, such as rotating slots, purposely embedded voids, and tapering holes, and that FMC/TFM was very capable of characterizing them. The intended use of the second series of AM blocks was as UT reference blocks to characterize the AM process quality or the interrogating UT technique. The larger block in this series was scanned from multiple faces, using multiple UT methods (conventional UT and FMC/TFM) and X-ray computed tomography for comparative purposes. The performance of each method was quantified by a metric corresponding to the detection limit of each feature, and the quantitative results are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Classification of Dissolution Events Using Fusion of Effluents Measurements and Classifiers

Classifiers for dissolution events at a radiochemical processing facility are studied using gamma spectra measurements of effluents collected by a high purity germanium detector located at its off-gas stack. Data sets collected at the Oak Ridge National Laboratory’s Radiochemical Engineering Development Center under a Pu dissolution campaign spanning a three months period are utilized. Features corresponding to the activity levels of 15 radionuclides, including isotopes of iodine, krypton, and xenon, that are indicated by the target decay chains, are computed from the spectra at 1 hour intervals. A conceptualization diagram is developed to reflect the steps from the source to measurement to feature computation that depend on fission products indicated by decay chains, chemical processing, and effluents transport to the off-gas stack. A diverse set of eight classifiers based on different design principles are trained using the ground truth data for this campaign, and the outputs of top three classifiers, namely, classification trees, Ensemble of Trees (EOT), and k-nearest neighbor, are combined using EOT classifier-fuser. Our results show that for 5-fold cross validation, features associated with isotopes of xenon provide the lowest classification error among the different elements across the classifiers; the classification error is furthered improved when all 15 isotope features are used by each classifier, and it is again improved by the fusion of three classifiers. Further reduction in classification error is achieved by using a measurement window of 1-2 days which is identified based on half-life time estimates of the isotopes; it is long enough for the stabilization of feature estimates while being short enough not to be affected by the follow on dissolution events. As a net result of feature and classifier fusion, combined with the incorporation of decay chain and isotope half-life information, this approach achieves 98% detection rate while maintaining a false alarm rate under 2% for this data set.

Rao, Nageswara↗