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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Towards developing multiscale-multiphysics models and their surrogates for digital twins of metal additive manufacturing

Artificial intelligence (AI) embedded within digital models of manufacturing processes can be used to improve process productivity and product quality significantly. The application of such advanced capabilities particularly to highly digitalized processes such as metal additive manufacturing (AM) is likely to make those processes commercially more attractive. AI capabilities will reside within Digital Twins (DTs) which are living virtual replicas of the physical processes. DTs will be empowered to operate autonomously in a diagnostic control capacity to supervise processes and can be interrogated by the practitioner to inform the optimal processing route for any given product. The utility of the information gained from the DTs would depend on the quality of the digital models and, more importantly, their faster-solving surrogates which dwell within DTs for consultation during rapid decision-making. In this article, we point out the exceptional value of DTs in AM and focus on the need to create high-fidelity multiscale-multiphysics models for AM processes to feed the AI capabilities. We identify technical hurdles for their development, including those arising from the multiscale and multiphysics characteristics of the models, the difficulties in linking models of the subprocesses across scales and physics, and the scarcity of experimental data. We discuss the need for creating surrogate models using machine learning approaches for real-time problem-solving. We further identify non-technical barriers, such as the need for standardization and difficulties in collaborating across different types of institutions. We offer potential solutions for all these challenges, after reflecting on and researching discussions held at an international symposium on the subject in 2019. Here, we argue that a collaborative approach can not only help accelerate their development compared with disparate efforts, but also enhance the quality of the models by allowing modular development and linkages that account for interactions between the various sub-processes in AM. A high-level roadmap is suggested for starting such a collaboration.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Photodiode-based machine learning for optimization of laser powder bed fusion parameters in complex geometries

We report the quality of parts produced through laser powder bed fusion additive manufacturing can be irregular, with complex geometries sometimes exhibiting dimensional inaccuracies and defects. For optimal part quality, laser process parameters should be selected carefully prior to printing and adjusted during the print if necessary. This is challenging since approaches to control and optimize the build parameters need to take into account the part geometry, the material, and the complex physics of laser powder bed fusion. This work describes a data-driven approach using experimental diagnostics for the optimization of laser process parameters prior to printing. A training dataset is generated by collecting high speed photodiode signal data while printing simple parts containing key geometry features with various process parameter strategies. Supervised learning approaches are employed to train both a forward model and an inverse model. The forward model takes as inputs track-wise geometry features and laser parameters and outputs the photodiode signal along the scan path. The inverse model takes as inputs the geometry features and photodiode signal and predicts the laser parameters. Given the part geometry and a desired photodiode signal, the inverse model can thus determine the required laser parameters. Two test parts which contain defect-prone features are used to assess the validity of the inverse model. The use of the model leads to improved part quality (higher dimensional accuracy, reduced dross, reduced distortion) for both test geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Deep learning to estimate permeability using geophysical data

Time-lapse electrical resistivity tomography (ERT) is a popular geophysical method to estimate three-dimensional (3D) permeability fields from electrical potential difference measurements. Traditional inversion and data assimilation methods are used to ingest this ERT data into hydrogeophysical models to estimate permeability. Due to ill-posedness and the curse of dimensionality, existing inversion strategies provide poor estimates and low resolution of the 3D permeability field. Recent advances in deep learning provide us with powerful algorithms to overcome this challenge. This paper presents a deep learning (DL) framework to estimate the 3D subsurface permeability from time-lapse ERT data. To test the feasibility of the proposed framework, we train DL-enabled inverse models on simulation data. Each measurement in both synthetic and field data is standardized by removing the mean and scaling the time-series to unit variance. This pre-processing step is necessary to bring simulation data closer to field observations. Subsurface process models based on hydrogeophysics are used to generate this synthetic data. Training performed on limited simulation data resulted in the DL model over-fitting. An advanced data augmentation based on mixup is implemented to generate additional training samples to overcome this issue. This mixup technique creates weakly labeled (low-fidelity) samples from strongly labeled (high-fidelity) data. The weakly labeled training data is then used to develop DL-enabled inverse models and reduce over-fitting. As both time-lapse ERT (1133048 features/realization) and 3D permeability (585453 features/realization) data samples are from a high-dimensional space, principal component analysis (PCA) is employed to reduce dimensionality. Encoded ERT and encoded permeability are generated using the trained PCA estimators. A deep neural network is then trained to map the encoded ERT to encoded permeability. This mixup training and unsupervised learning allowed us to build a fast and reasonably accurate DL-based inverse model under limited simulation data. Results show that proposed weak supervised learning can capture salient spatial features in the 3D permeability field. Quantitatively, the average mean squared error (in terms of the natural log) on the strongly labeled training, validation, and test datasets is less than 0.5. The R 2 -score (global metric) is greater than 0.75, and the percent error in each cell (local metric) is less than 10%. Finally, an added benefit in terms of computational cost is that the proposed DL-based inverse model is at least O(10 4 ) times faster than running a forward model once it is trained. Data generation, DL model training, and hyperparameter tuning to identify optimal neural network architectures utilized high-performance computing resources while the DL inference is performed on a standard laptop. Approximately, O(10 5 ) processor hours are used for generating data and DL tuning and training. We acknowledge that the data generation and DL model development are expensive. But once a DL model is trained, it can be re-used for inversion rapidly for the given system, with set physics and domain. Note that traditional inversion may require multiple forward model simulations (e.g., in the order of 10 to 1000), which are very expensive. This computational savings ≈ O(10 5 ) – O(10 7 )) makes the proposed DL-based inverse model attractive for subsurface imaging and real-time ERT monitoring applications due to fast and yet reasonably accurate estimations of permeability field.

58 GEOSCIENCES↗
DOE OSTI2023

Deep reinforcement learning for class imbalance fault diagnosis of equipment in nuclear power plants

In equipment fault diagnosis in nuclear power plants, there may be far more samples in one class (e.g., a health state) than in another class (e.g., a fault state). The distribution of data in each class is highly skewed. Most machine learning algorithms are suitable for balanced training datasets. When faced with imbalanced samples, these algorithms tend to provide good identification for the majority classes and bias for the minority classes. However, the misclassification of minority classes can lead to high costs. To address the above problem, this paper develops a deep reinforcement learning-based diagnosis method that models fault diagnosis as a sequential decision-making process. At each time step, the agent receives the state of the environment represented by the training samples and then takes a diagnosis action guided by a policy. If the action is correct/incorrect, the agent receives a positive/negative reward. The reward for minority classes is higher than that for majority classes. The agent’s goal is to obtain as many cumulative rewards as possible in the process, i.e., to identify the sample as correctly as possible. Six demonstration scenarios are constructed, depending on the selected fault datasets and the designed model structures. Experiments show that the proposed method achieves a higher weighted-averaged F1 score than the classical supervised learning method in most cases of class imbalance. Finally, the proposed method has potential applications in the field of class imbalance fault diagnosis of equipment in nuclear power plants.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Machine learning the dynamics of quantum kicked rotor

Highlights: • Quantum kicked rotor. • Quantum phase transition. • Machine learning. • LSTM network. • Convolutional neural network. Using the multilayer convolutional neural network (CNN), we can detect the quantum phases in random electron systems, and phase diagrams of two and higher dimensional Anderson transitions and quantum percolations as well as disordered topological systems have been obtained. Here, instead of using CNN to analyze the wave functions, we analyze the dynamics of wave packets via long short-term memory network (LSTM). We adopt the quasi-periodic quantum kicked rotors, which simulate the three and four dimensional Anderson transitions. By supervised training, we let LSTM extract the features of the time series of wave packet displacements in localized and delocalized phases. We then simulate the wave packets in unknown phases and let LSTM classify the time series to localized and delocalized phases. We compare the phase diagrams obtained by LSTM and those obtained by CNN.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

A novel machine learning based identification of potential adopter of rooftop solar photovoltaics

With the proliferation of rooftop solar photovoltaic installations, there is a need to proactively predict consumer potential for solar photovoltaic adoption, for improved electric utility planning and operation. Traditional analytical modeling approaches are limited to a few survey features and a larger part of the survey would remain untouched by the decision model. This article presents a novel, data-driven modeling approach that strategically prunes a large set of consumer profile features using a machine learning framework to train a model for predicting potential solar adoption. The approach utilizes the Gradient Boosting Decision Tree model through a Light Gradient Boosting framework that improves significantly over the poor prediction accuracy of the existing approaches. Model training using focal-loss based supervision is used to overcome the difficulty in identifying the potential adopters that is inherent in conventional data-driven models. In addition, to overcome possible data sparsity in a limited survey sample, a Generative Adversarial Network is presented to create synthetic user samples and its effectiveness on model performance is assessed. A Bayesian optimization approach is used to systematically arrive at the hyperparameters of the proposed model. Validation of the presented approach on a survey data collected by the National Rural Electric Cooperative Association in Virginia in 2018 demonstrates the excellent predictive capability of the machine learning based approach to modeling solar adoption reliably.

14 SOLAR ENERGY↗
DOE OSTI2021

Model-Free Voltage Control of Active Distribution System with PVs Using Surrogate Model-Based Deep Reinforcement Learning

Accurate knowledge of the distribution system topology and parameters is required to achieve good voltage control performance, but this is difficult to obtain in practice. This paper proposes a physical-model-free voltage control method based on a surrogate-model-enabled deep reinforcement learning approach. Specifically, a surrogate model is trained in a supervised manner using the recorded limited number of historical data to learn the relationship between the power injections and voltage fluctuations of each node. Then, the deep reinforcement learning algorithm is applied to learn an optimal control strategy from the experiences obtained by continuous interactions with the surrogate model. The proposed method can achieve physical-model-free control of unbalanced distribution network and inform real-time decisions to deal with fast voltage fluctuations caused by the rapid variation of PV generation. Simulation results on an unbalance IEEE 123-bus system show that the proposed method can achieve similar performance as that of perfect physical-model-based approaches while being advantageous over other traditional methods.

active distribution network↗
DOE OSTI2021

ResNet and CycleGAN for pulse shape discrimination of He-4 detector pulses: Recovering pulses conventional algorithms fail to label unanimously

Pulse shape discrimination (PSD) capable detectors, such as He-4, that respond to neutron and gamma-ray 7 interactions have a threshold deposited energy value below which n/γ discrimination vanishes when using 8 conventional PSD algorithms. Recent attempts in applying supervised learning based artificial neural 9 networks for PSD use the pulses in the separated regions to train the networks so they can be used to classify 10 another set of separated pulses. In doing so, pulses previously indistinguishable are not recovered for 11 classification, which would have increased the number of neutron and gamma-ray pulses that could be used 12 for further analysis. Assuming the reason why conventional PSD algorithms have unseparated regions is 13 because the parameter space of the algorithms fail to capture the intrinsic (but subtle) distinguishing 14 behavior of some of the neutron and gamma-ray pulses, a cycle-consistent generative adversarial network 15 (CycleGAN) was trained to amplify those differences and extract well separated neutron and gamma-ray 16 clusters. Results show that, once the network is trained with pulses from separated and unseparated regions, 17 it was able to transform the pulses in the unseparated region to improve the PSD. Subsequent n/γ 18 classification was performed using deep residual network (ResNet) that takes pulses with 512 data points 19 as an input. Two different ResNets were explored – simple ResNet and modified ResNet which takes 20 segmented pulse inputs in the first layer and the corresponding time axis values in the last hidden layer. 21 The later approach enables the network to extract time correlated pulse features to enhance its ability to 22 capture the pulse behaviors relevant for PSD. Although it achieves slightly lower accuracy, 99.41% versus 23 99.89%, based on simply counting the number of correct n/γ labels assigned, compared to the simple 24 ResNet, the modified ResNets architecture was able to decreases the cross-entropy loss function by half, 25 which implies that the correct n/γ labels assigned are less likely to be accidental. PSD parameter 26 distributions based on n/γ classification by ResNet before and after transforming unseparated pulses using 27 CycleGAN show that by enhancing the separation between neutrons and gamma-rays, the transformation 28 helps improve the performance of classifier networks that are trained using labeled dataset. The 29 enhancement of neutron and gamma-ray separation by the CycleGAN increased the PSD figure of merit 30 (FOM) by up to 70% in some regions. Here, the results show that, if a given detector achieves clear separation 31 between neutron and gamma-ray pulses in any energy region, such neural network approaches can help 32 lower the energy threshold for the separation and increasing the number of neutron and gamma-ray pulses 33 that can be used for further analysis.

4He↗
DOE OSTI2021

Multi-channel Imager Algorithm (MIA): A novel cloud-top phase classification algorithm

The current Geostationary Operational Environmental Satellites (GOES-16 and 17) cloud-top phase classification algorithm is based primarily on empirical thresholds at multiple wavelengths that have varying absorption capabilities for water and ice. The performance of current GOES-16 cloud-top phase product largely depends on the accuracy of the selection of reflectance ratios. Here this study aims at presenting a novel cloud-top phase classification algorithm (the Multi-channel Imager Algorithm, MIA) that provides a more judicious selection of relationships between channels using a supervised K-mean clustering method on multi-channel Red-Green-Blue images. The K-mean clustering method works analogously to how human eyes separate different colors in a microphysical color rendering set of satellite images, which differentiates water, ice and unclassified thin clouds. For water phase, cloud-top temperature information is used to further distinguish supercooled water. To evaluate the performance of the MIA, an extensive comparison with Cloud-Aerosol Lidar with Orthogonal Polarization (CALIOP), Moderate Resolution Imaging Spectroradiometer, and current GOES-16 cloud-top phase products is conducted, using CALIOP as the benchmark. Compared to the current GOES-16 cloud-top phase product, MIA demonstrates a substantial improvement in phase classification, where hit rate increases from 69% to 76% over the Continental United States and 58% to 66% over the full disk domain.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Unified architecture for data-driven metadata tagging of building automation systems

This article presents a Unified Architecture (UA) for automated point tagging of Building Automation System (BAS) data, based on a combination of data-driven approaches. Advanced energy analytics applications—including fault detection and diagnostics and supervisory control—have emerged as a significant opportunity for improving the performance of our built environment. Effective application of these analytics depends on harnessing structured data from the various building control and monitoring systems, but typical BAS implementations do not employ any standardized metadata schema. While standards such as Project Haystack and Brick Schema have been developed to address this issue, the process of structuring the data, i.e., tagging the points to apply a standard metadata schema, has, to date, been a manual process. This process is typically costly, labor-intensive, and error-prone. In this work we address this gap by proposing a UA that automates the process of point tagging by leveraging the data accessible through connection to the BAS, including time-series data and the raw point names. The UA intertwines supervised classification and unsupervised clustering techniques from machine learning and leverages both their deterministic and probabilistic outputs to inform the point tagging process. Furthermore, we extend the UA to embed additional input and output data-processing modules that are designed to address the challenges associated with the real-time deployment of this automation solution. We test the UA on two datasets for real-life buildings: (i) commercial retail buildings and (ii) office buildings from the National Renewable Energy Laboratory (NREL) campus. We report the proposed methodology correctly applied 85–90% and 70–75% of the tags in each of these test scenarios, respectively for two significantly different building types used for testing UA's fully-functional prototype. The proposed UA, therefore, offers promising approach for automatically tagging BAS data as it reaches close to 90% accuracy. Further building upon this framework to algorithmically identify the equipment type and their relationships is an apt future research direction to pursue.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Allosteric prediction via convolutional neural networks and protein structural and dynamical features

Allostery is the phenomenon whereby a binding event or covalent modification at one site in a protein modulates function at a distal site, thus changing a protein’s functional state. As such, it is a ubiquitous aspect of protein functional regulation. Computationally predicting allosteric states is important as part of the broader challenge of functional annotation, but it also has practical implications for drug development, as targeting an allosteric site often affords greater specificity compared with targeting an orthosteric site. This study introduces a machine learning approach to predict the allosteric functional state using the small G-protein KRas as the model system, due to its implication in many types of cancer and being well studied as a result with many x-ray crystallographic structures of KRas available with different mutations and ligands bound. Using structural and dynamical features that can be cast as images, namely interatomic distances, contact maps, covariance, and mutual information, supervised learning was performed using convolutional neural networks. Two pretrained convolutional neural network architectures, GoogLeNet and ResNet18, were fine-tuned to classify KRas into active or inactive states based on these features. Across training regimes, atomic contact maps emerged as the most effective structural feature, whereas linearized mutual information outperformed covariance in capturing dynamical correlations relevant to allostery. Models achieved significant validation accuracy, with atomic contact maps yielding up to 90% accuracy. In conclusion, the findings suggest that integrating global structural rearrangements and correlated motion patterns with deep learning can reliably predict protein allosteric states, offering a promising framework for understanding allosteric regulation and developing targeted therapeutics.

Rajeshwar T., Rajitha [Oak Ridge National Laborato↗
DOE OSTI2020

Advanced data science toolkit for non-data scientists – A user guide

Emerging modern data analytics attracts much attention in materials research and shows great potential for enabling data-driven design. Data populated from the high-throughput CALPHAD approach enables researchers to better understand underlying mechanisms and to facilitate novel hypotheses generation, but the increasing volume of data makes the analysis extremely challenging. Here in this paper, we introduce an easy-to-use, versatile, and open-source data analytics frontend, ASCENDS (Advanced data SCiENce toolkit for Non-Data Scientists), designed with the intent of accelerating data-driven materials research and development. The toolkit is also of value beyond materials science as it can analyze the correlation between input features and target values, train machine learning models, and make predictions from the trained surrogate models of any scientific dataset. Various algorithms implemented in ASCENDS allow users performing quantified correlation analyses and supervised machine learning to explore any datasets of interest without extensive computing and data science background. The detailed usage of ASCENDS is introduced with an example of experimental high-temperature alloy data.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2020

Inverse design of two-dimensional graphene/h-BN hybrids by a regressional and conditional GAN

Design of materials with desired properties is currently laborious and heavily relies on intuition of researchers through a trial-and-error process. To tackle this challenge, in this work we propose a novel regressional and conditional generative adversarial network (RCGAN) for inverse design of representative two-dimensional materials, the graphene and boron-nitride (BN) hybrids. RCGAN incorporates a supervised regressor network, thus overcoming the common technical barrier in the traditional unsupervised GANs, which cannot generate data when fed with continuous and quantitative labels. RCGAN can autonomously generate graphene/BN hybrids given any target bandgap values. These structures are distinguished from the ones used for training and exhibit high diversity for a given bandgap. Moreover, they exhibit high fidelity, yielding bandgaps within ~10% MAE F of the desired bandgaps as validated by density functional theory (DFT) calculations. Analysis by the principle component analysis (PCA) and modified locally linear embedding (MLLE) reveals that the generator has successfully generated structures following the statistical distribution of the real structures. It implies the possibility of the RCGAN in recognizing physical rules hidden in the high-dimensional data. The novel strategy for designing regressional GAN architecture together with the successful application to inverse design of materials would inspire further exploration in research fields beyond materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

NanoPSD: A software for automatic detection of Nano-Particle Shape Distribution in electron microscopy images

Accurate quantification of the size and morphology of nanoparticles from electron microscopy (EM) images is essential to understand growth mechanisms, surface reactivity, and functional behavior in nanoscale materials. Manual analysis remains slow, subjective, and difficult to reproduce in large datasets. We introduce NanoPSD (Nano-Particle Shape Distribution), an open-source and fully automated framework for quantitative particle detection and morphology analysis from EM images. NanoPSD integrates adaptive contrast enhancement, polarity-agnostic scale-bar detection, Optical Character Recognition (OCR)-based calibration, and classical segmentation via Otsu thresholding with morphological refinement. Particle contours are used to extract geometric descriptors, including equivalent circular diameter, aspect ratio, circularity, and solidity, enabling automated classification into spherical, rod-like, and aggregate morphologies. The framework supports both single-image and batch processing, generating publication-quality visualizations, LaTeX-ready tables, and structured comma-separated values (CSV) datasets. As a demonstration, we applied NanoPSD to plasma-synthesized nanoparticle samples diagnosed via transmission electron microscopy (TEM). The code produced statistically robust size and morphology distributions spanning a few to tens of nanometers with minimal user supervision. The pipeline demonstrates high reproducibility and scalability, processing large image collections with consistent calibration and output formatting. Its modular design enables seamless integration of future deep-learning-based segmentation models, providing a pathway toward intelligent, data-driven electron microscopy analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

From clutter to clarity: Emergent neural operators via questionnaire metrics

Real-world datasets in chemical engineering and bioengineering processes—such as those from catalytic reactors, multiphase flows, polymerization reactors, bioreactors, and clinical trials—can often be unlabeled or disorganized, rendering the training of existing supervised learning models ineffective at learning the underlying dynamics. To salvage these datasets for decision-making, we first seek to obtain clarity from the cluttered data. Here, we present a framework for developing “structural” generative models, discovering emergent equations, and constructing efficient emulators from scrambled datasets by integrating unsupervised organizational learning techniques (Questionnaires) with advanced deep learning architectures (Deep Hidden Physics Models and Deep Operator Networks). Our approach is demonstrated on two illustrative model systems: (a) a 1D advection–diffusion partial differential equation representing a winding underground pipe and (b) an ensemble of Stuart–Landau oscillators, an agent-based system of coupled ordinary differential equations. In both cases, we successfully reconstruct meaningful spatial, temporal, and parameter embeddings from scrambled data, enabling good predictions of system dynamics. As a result, we highlight the framework’s potential for broader applications, enabling data-driven system identification in fields with inherently disorganized or hidden parameter spaces.

42 ENGINEERING↗
DOE OSTI2025

Delamination-informed lifecycle decisions: A dielectric and machine learning framework for composite sorting and recycling

Composite materials are widely used in aerospace, marine, and automotive sectors due to their high strength-to-weight ratio and durability. However, their long-term reliability can be compromised by damage accumulation. Specifically, delamination initiation serves as a precursor to structural failure, which is often difficult to detect during damage inspection. Identifying and sorting delamination initiation in samples not only increases operational safety while providing critical information for end-of-life decisions, which influences both the service life extension value and the efficiency of fiber extraction during recycling. This research addresses two challenges: (1) developing a nondestructive, ex-situ framework to sort composite materials based on damage severity, particularly delamination, and (2) understanding how damage in composites influences resin removal during pyrolysis. Both experimental work and finite element analysis were performed to predict critical stress levels that are associated with delamination onset. Based on these results, three loading levels 50 %, 75 %, and 90 % of maximum stress, were selected for controlled experiments, generating composite samples with varying extents of damage for machine learning model training. Microscopic imaging of these samples confirmed the damage progression from matrix cracking to delamination, validating the computational predictions. We explored supervised machine learning using dielectric measurements to classify damage states. Preliminary results show an artificial neural network can identify early delamination which is a potential precursor to failure, with 94.44 % accuracy on our dataset. A parallel investigation into the effect of damage severity on pyrolysis recycling showed that heavily delaminated samples required significantly less energy for comparable matrix removal than undamaged samples.

dielectric variables↗