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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Experimental characterization and modeling of thermal resistance of electric machine lamination stacks

There is lack of information in the open literature on thermal properties of electric machine lamination stacks such as contact resistance and effective thermal conductivity, yet this information is critical for researchers and engineers in electric machine design and development. The thermal conductivity of electromagnetic steel lamination materials was measured, and the thermal contact resistance between laminations in a stack, as well as factors affecting contact resistance between laminations - such as the contact pressure and surface finish - were investigated. A model was also developed to estimate the through-stack thermal conductivity for materials beyond those that were directly tested in this work. Four lamination materials were investigated, including the commonly-used 26-gauge and 29-gauge M19 materials, the HF10, and Arnon 7 materials. Although this paper focuses on electric machines for automotive applications, the information is potentially applicable to any component utilizing electromagnetic steel laminations.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Underground hydrogen storage leakage detection and characterization based on machine learning of sparse seismic data

Underground hydrogen storage (UHS) is considered as a scalable approach for massive storage and seasonal extraction of hydrogen (H 2 ). Although conventional leakage detection and characterization methods based on time-lapse seismic imaging and inversion generally apply to H 2 leakage detection problem, a high-fidelity yet cost effective geophysics approach is still missing to reliably inform leakage location and properties based on very sparse data. In response, we develop a novel supervised machine learning method to detect and characterize H 2 leakage from UHS. The input to our neural network are sparse time-lapse seismic waveforms, while the output from the neural network includes the spatial location and physical properties of a H 2 leakage. Here, we generate high-quality time-lapse waveforms using the elastic-wave equations to train the neural network. We train and validate our machine learning model and find that it attains high accuracy in using extremely sparse time-lapse seismic data to detect and characterize H 2 leakage. Our investigation is the first systematic study that focuses on applying machine learning to subsurface H 2 leakage detection and characterization and could potentially serve as a cost-effective geophysical tool for underground hydrogen leakage detection and characterization with high fidelity.

08 HYDROGEN↗
DOE OSTI2020

Mesoscale informed parameter estimation through machine learning: A case-study in fracture modeling

Scale bridging is a critical need in computational sciences, where the modeling community has developed accurate physics models from first principles, of processes at lower length and time scales that influence the behavior at the higher scales of interest. However, it is not computationally feasible to incorporate all of the lower length scale physics directly into upscaled models. This is an area where machine learning has shown promise in building emulators of the lower length scale models, which incur a mere fraction of the computational cost of the original higher fidelity models. We demonstrate the use of machine learning using an example in materials science estimating continuum scale parameters by emulating, with uncertainties, complicated mesoscale physics. Additionally, we describe a new framework to emulate the fine scale physics, especially in the presence of microstructures, using machine learning, and showcase its usefulness by providing an example from modeling fracture propagation. Our approach can be thought of as a data-driven dimension reduction technique that yields probabilistic emulators. Our results show well-calibrated predictions for the quantities of interests in a low-strain simulation of fracture propagation at the mesoscale level. Furthermore, on average, we achieve ~10% relative errors on time-varying quantities like total damage and maximum stresses. Successfully replicating mesoscale scale physics within the continuum models is a crucial step towards predictive capability in multi-scale problems.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A hybrid Penman-Monteith and machine learning model for simulating evapotranspiration and its components

Integrating physical processes with machine learning has advanced evapotranspiration (ET) simulation, yet most hybrid models fail to partition total ET into its components: soil evaporation (E) and vegetation transpiration (T). This study introduces Residual Neural Network–Penman–Monteith (RNN-PM), a novel hybrid dual-source ET model designed to overcome this limitation. The model synergizes the physically-based Penman–Monteith framework with three specialized residual neural networks trained to estimate key conductance parameters (canopy conductance, soil surface conductance, and aerodynamic conductance). Furthermore this explicit parameterization allows for the direct partitioning of total ET. Validation at National Ecological Observatory Network (NEON) flux sites using high-frequency partitioned E and T shows that RNN-PM reliably reproduces ET and the transpiration fraction (T/ET). For ET, the model achieves an average Kling–Gupta efficiency (KGE) of 0.89 and a root-mean-square error (RMSE) of 0.55 mm/day; for T/ET, the KGE is 0.87 with an RMSE of 0.06. Furthermore, RNN-PM demonstrates robust generalization, accurately simulating ET and its components well beyond the initial training dataset, even under extreme climatic conditions. This study extended the analysis by comparing the RNN-PM model with seven established dual-source ET models. The results indicate that RNN-PM outperforms both conventional machine learning models and purely physical process-based models in simulating ET components in most cases. Among the purely physical process-based dual-source models, those based on surface temperature decomposition showed improved performance as the leaf area index (LAI) decreased when evaluated against high-frequency ET component datasets. In contrast, the performance of conductance-based dual-source models declined with decreasing LAI. Although purely machine learning-based models can produce relatively accurate simulations of ET components, they often exhibit limited generalization capability, an issue that the RNN-PM model effectively overcomes. Ultimately, the RNN-PM model represents a significant advance in simulating ET components, offering a novel and scalable approach for improving the representation of land–atmosphere interactions in Earth system models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Process–structure–property relationships in bimodal machined microstructures using robust structure descriptors

Machining is a severe plastic deformation process that subjects materials to high rates of deformation and elevated temperatures. Dynamic recrystallization during severe plastic deformation drives grain refinement into the sub-micron range but the ductility and thermal stability of these structures is poor. In contrast, bimodal microstructures consisting of both fine and coarse grains have been shown to exhibit attractive strength and ductility properties at these temperatures. In this paper, we study the process–structure–property relationships for pure copper subject to a machining process where the cutting speeds are varied. Further, we investigate the role of thermal effects by varying the post-deformation cooling rates. Microstructures generated under these deformation conditions are quantified using angularly resolved chord length statistics. The derived metrics are found to be robust descriptors of the studied microstructures as they automatically capture complex features such as unimodal and bimodal distributions of grain structure, grain constituent length scales, and morphological anisotropy induced by shear deformation. The uniaxial equivalent yield strength of the generated structures are estimated using spherical nanoindentation and inverse modeling techniques. Lastly, we present a methodology for identifying the constrained property-process inverse mapping for machining using a Bayesian framework and the established forward process–structure–property mapping.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Machine learning based algorithms for uncertainty quantification in numerical weather prediction models

Complex numerical weather prediction models incorporate a variety of physical processes, each described by multiple alternative physical schemes with specific parameters. The selection of the physical schemes and the choice of the corresponding physical parameters during model configuration can significantly impact the accuracy of model forecasts. There is no combination of physical schemes that works best for all times, at all locations, and under all conditions. It is therefore of considerable interest to understand the interplay between the choice of physics and the accuracy of the resulting forecasts under different conditions. This paper demonstrates the use of machine learning techniques to study the uncertainty in numerical weather prediction models due to the interaction of multiple physical processes. The first problem addressed herein is the estimation of systematic model errors in output quantities of interest at future times, and the use of this information to improve the model forecasts. The second problem considered is the identification of those specific physical processes that contribute most to the forecast uncertainty in the quantity of interest under specified meteorological conditions. In order to address these questions we employ two machine learning approaches, random forests and artificial neural networks. The discrepancies between model results and observations at past times are used to learn the relationships between the choice of physical processes and the resulting forecast errors. Numerical experiments are carried out with the Weather Research and Forecasting (WRF) model. The output quantity of interest is the model precipitation, a variable that is both extremely important and very challenging to forecast. The physical processes under consideration include various micro-physics schemes, cumulus parameterizations, short wave, and long wave radiation schemes. The experiments demonstrate the strong potential of machine learning approaches to aid the study of model errors.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Dynamic machine learning-based optimization algorithm to improve boiler efficiency

With decreasing computational costs, improvement in algorithms, and the aggregation of large industrial and commercial datasets, machine learning is becoming a ubiquitous tool for process and business innovations. Machine learning is still lacking applications in the field of dynamic optimization for real-time control. This work presents a novel framework for performing constrained dynamic optimization using a recurrent neural network model combined with a metaheuristic optimizer. The framework is designed to augment an existing control system and is purely data-driven, like most industrial Model Predictive Control applications. Several recurrent neural network models are compared as well as several metaheuristic optimizers. Hyperparameters and optimizer parameters are tuned with parameter sweeps, and the resulting values are reported. Further, the best parameters for each optimizer and model combination are demonstrated in closed-loop control of a dynamic simulation, and several recommendations are made for generalizing this framework to other systems. Up to 0.953% improvement is realized over the non-optimized case for a simulated coal-fired boiler. While this is not a large improvement in percentage, the total economic impact is $991,000 per year, and this study builds a foundation for future machine learning with dynamic optimization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Machine learning-enabled multiscale modeling of mechanical deformation of aluminum and Al-SiC nanocomposites

A machine learning-enabled multiscale framework is developed for modeling the mechanical response of both pure metal and nanoparticle-reinforced metal matrix nanocomposites (MMNCs). Using aluminum–silicon carbide (Al-SiC) as an example MMNC, atomistic simulations reveal three distinct deformation mechanisms (i.e., defect-free, dislocation-based, and interface separation) governed by the interfaces between the Al matrix and SiC nanoparticles. As compared with single crystal Al, the lattice undergoes a more abrupt failure once the dislocation network becomes extensive and void nucleation initiates, whereas in Al-SiC, nanoparticle interfaces enable a more gradual progression of damage. These mechanisms are captured through a combined classification-regression neural network surrogate model that bridges atomic-scale insights with continuum-scale finite element analysis. Machine learning-enabled multiscale modeling of pure Al accurately predicted strain localization and confirmed by in-situ scanning electron microscopic tensile testing on perforated Al specimens. This study underscores the promise of integrating physics-informed machine learning with hierarchical modeling to capture the interface dominated phenomena and guide the design of advanced MMNCs.

Al-SiC↗
DOE OSTI2017

A microstructure sensitive grain boundary sliding and slip based constitutive model for machining of $\mathrm{Ti}$-$\mathrm{6Al}$-$\mathrm{4V}$

We report a composite dual phase internal state variable constitutive model was developed for Ti-6Al-4V. The proposed model includes diffusion assisted grain boundary sliding based physics in addition to a traditional slip-based plasticity. Influence of microstructure on the flow stress is introduced via dislocation density and mean grain size internal state variables. The dislocation density evolves according to a physics based law that considers dislocation nucleation and annihilation processes. Grain refinement is driven by dynamic recrystallization, which is modeled phenomenologically. The model is calibrated with uniaxial stress–strain data that ranges between quasi-static and dynamic rates across a wide range of temperatures. Validation against machining data shows that the model predicts chip segmentation frequency, machining forces, and tool temperatures reasonably well. The newly introduced grain boundary sliding physics was found to dominate deformation following sufficient grain refinement. This deformation mode provides softening at the constitutive level without the need for invoking damage based softening mechanisms. This physical interpretation is something that has not previously been explored in the machining literature.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Rethinking production of machine tool bases: Polymer additive manufacturing and concrete

Cast iron and steel weldments are the most common machine tool base elements. However, both construction methods have associated disadvantages for domestic machine tool manufacturers. Here, this paper documents the investigation of an alternative method for machine tool base production using concrete to fill an additively manufactured polymer mold, where the motion components are attached to the concrete base after the initial concrete curing. Modal testing results for a three-axis, vertical spindle prototype indicate high damping and stiffness can be achieved using the concrete base construction. Advantages are reduced cost and lead time compared to traditional methods.

Additive manufacturing↗
DOE OSTI2024

A machine learning approach for particle accelerator errant beam prediction using spatial phase deviation

Particle accelerators are extremely complex systems that are expected to operate on high availability. Predicting impending failures only by utilizing data collected from diagnostic equipment already on board can help operators to avoid installing expensive sensors, unscheduled downtime and associated costs. For this purpose we explore the predictive power of Machine Learning algorithms to detect faulty beams prior to the failure. In this study, we propose a Machine Learning approach to model mapping from a pair of sensors located across the accelerator. While the model is trained to represent normal operation, we evaluate the predictive performance on known faulty beam pulses. We also investigate the model performance on unseen data through k-fold cross-validation. Then we recap the analysis with a neural architecture search and hyperparameter optimization study to fine tune our initial model. In conclusion, this paper will also introduce a sustainable framework that can standardize Machine Learning workflow applied to particle accelerators.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Expanded analysis of machine learning models for nuclear transient identification using TPOT

Industries around the world are becoming more and more data driven. The nuclear field is no exception with several different applications being proposed. One popular area of research is the use of machine learning in transient detection. This paper seeks to build upon a previous study which made use of the AutoML package TPOT to train traditional machine learning models to classify transient events occurring with a reactor. Synthetic data was once again collected using a GPWR reactor simulator. Data on 12 different events was collected using 15 different initial conditions. Here, a dataset consisting of over 100,000 data points was compiled and used to train 7 different machine learning models using a pre-defined TPOT dictionary with 12 different preprocessing techniques. Three of the trained models were able to produce validation results in the 90s with the expanded dataset. Once the models were trained, it was possible to look into where during the simulation, misclassifications occurred. Using these three models, analysis was done to determine if TPOT could be used to train models that were effective if important features were missing. The results from this were positive with the newly trained models scoring close to the original models. Finally, to conclude this study, the three high performing models were retrained using different random states to see if there was any major variation when different states were used.

42 ENGINEERING↗
DOE OSTI2025

Confidence-weighted integration of human and machine judgments for superior decision-making

Large language models (LLMs) can surpass humans in certain forecasting tasks. What role does this leave for humans in the overall decision process? One possibility is that humans, despite performing worse than LLMs, can still add value when teamed with them. A human and machine team can surpass each individual teammate when team members’ confidence is well calibrated and team members diverge in which tasks they find difficult (i.e., calibration and diversity are needed). We simplified and extended a Bayesian approach to combining judgments using a logistic regression framework that integrates confidence-weighted judgments for any number of team members. Using this straightforward method, we demonstrated its effectiveness in both image classification and neuroscience forecasting tasks. Combining human judgments with one or more machines consistently improved overall team performance. Our hope is that this simple and effective strategy for integrating the judgments of humans and machines will lead to productive collaborations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Predicting the superconducting critical temperature in transition metal carbides and nitrides using machine learning

Transition metal carbides and nitrides have unique mechanical and chemical characteristics. At low temperatures many of them also exhibit superconductivity, which can be controlled by substitutions into both the transition metal and carbon/nitrogen sites. To investigate the factors governing the superconducting state, we apply machine learning methods. Here we collected a dataset containing 147 materials, which was used to create a pipeline for predicting their superconducting critical temperature. When this pipeline is applied to a randomly selected test set, it shows a good performance, with of 0.82 and RMSE of 1.9 K. To explore the limits of the machine learning approach, we also use it to predict entire substitution series within the dataset. This represents a realistic test for the predictive models, which can be extremely useful when applied to new substitutions in materials systems. The performance of the pipeline in this case is much more uneven, with good predictions for some series, while for others the model shows minimal predictive power. We discuss possible reasons for these results, as well as methods to estimate the performance of machine learning on new substitution series.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Vehicle energy consumption estimation using large scale simulations and machine learning methods

Vehicle energy consumption and powertrain operations for future vehicle powertrain technologies are predicted through full-vehicle simulations using Autonomie, a simulation tool developed at Argonne National Laboratory. Over 1 million vehicles, with different powertrain types (conventional and numerous electrified powertrains) and component technologies (advanced engines, batteries, electrical machines, light weighting) are simulated for outputs including vehicle fuel economy and cost. Despite the ability of Autonomic to predict fuel economy given various combination of vehicle inputs, the full-vehicle simulation is very time-consuming. It takes approximately 84 h to simulate for 33,060 vehicles even using distributed computing on a cluster of 128 worker nodes. Moreover, Autonomic is unable to populate a continuous output space through simulation since it only yields outputs with discrete values instead of an input-output relation. This paper proposes a novel large-scale learning and prediction process (LSLPP) via machine learning approaches to answer the need for a continuous space of vehicle fuel economy and a more efficient simulation process. By learning in a supervised fashion to discover structures in data, the machine learning approaches seek to train a model that can explain the data with which we can perform prediction over unseen data. As such, we are able to accomplish analytic continuation on the current discrete space of simulation results. In addition, we present a random sampling -based numerosity reduction algorithm incorporated in LSLPP that reduces simulation runs and improves efficiency of data procurement. We analytically derive a theoretical bound in order to guarantee the effectiveness of our algorithm. We also compare random sampling to stratified sampling and suggest sampling strategies. A user-friendly tool is developed to support the process. Our experimental results confirm that the proposed LSLPP is able to greatly accelerate prediction and analysis of vehicle fuel economy. The output of this study is used by the US government to evaluate the impact of its R&D funding on energy security and CO 2 emission as well as for the setting of Corporate Average Fuel Economy (CAFE) standards.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Machine Learning for Materials Scientists: An Introductory Guide toward Best Practices

This Methods/Protocols article is intended for materials scientists interested in performing machine learning-centered research. Herein, we cover broad guidelines and best practices regarding the obtaining and treatment of data, feature engineering, model training, validation, evaluation and comparison, popular repositories for materials data and benchmarking data sets, model and architecture sharing, and finally publication. In addition, we include interactive Jupyter notebooks with example Python code to demonstrate some of the concepts, workflows, and best practices discussed. Overall, the data-driven methods and machine learning workflows and considerations are presented in a simple way, allowing interested readers to more intelligently guide their machine learning research using the suggested references, best practices, and their own materials domain expertise.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Machine Learning Analysis of Direct Dynamics Trajectory Outcomes for Thermal Deazetization of 2,3-Diazabicyclo[2.2.1]hept-2-ene

Experimentally, the thermal gas-phase deazetization of 2,3-diazabicyclo[2.2.1]hept-2-ene (1) results in the loss of N2 and the formation of bicyclo products 3 (exo) and 4 (endo) in a nonstatistical ratio, with preference for the exo product. Here, we report unrestricted M06-2X quasiclassical trajectories initialized from the concerted N2 ejection transition state that were able to replicate the experimental preference to form 3. We found that the 3:4 ratio results from the relative amounts of very fast (ballistic) exotype trajectories versus trajectories that lead to the 1,3-diradical intermediate 2. These quasiclassical trajectories provided a set of transition-state vibrational, velocity, momenta, and geometric features for the machine learning analysis. Additionally, a selection of popular supervised classification algorithms (e.g., random forest) provided poor prediction of trajectory outcomes based on only transition-state vibrational quanta and energy features. However, these machine learning models provided more accurate predictions using atomic velocities and atomic positions, attaining ~70% accuracy using initial conditions and between 85 and 95% accuracy at later reaction time steps. This increased accuracy allowed the feature importance analysis to reveal that, at the later-time analysis, the methylene bridge out-of-plane bending is correlated with trajectory outcomes for the formation of either the exo product or toward the diradical intermediate. Possible reasons for the struggle of machine learning algorithms to classify trajectories based on transition-state features is the heavily overlapping feature values, the finite but very large possible vibrational mode combinations, and the possibility of chaos as trajectories propagate. We examined this chaos by comparing a set of nearly identical trajectories that differed by only a very small scaling of the kinetic energies resulting from the transition-state reaction coordinate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Machine Learning Screening of Metal-Ion Battery Electrode Materials

Here, in this work we present deep neural network regression machine learning models (ML) for predicting the average voltage and the percentage change in volume of battery electrodes upon charging and discharging with metal ions. Our models exhibit good performance as measured by the average mean absolute error obtained from a 10-fold cross-validation as well as on independent test sets. We further assess the robustness our ML models by investigating their screening potential beyond the training database. We produce novel Na-ion electrodes by systematically replacing Li-ions in the original database by Na-ions, and then selecting a set of 22 electrodes that exhibit a good performance in energy density as well as small volume variations upon charging and discharging, as predicted by the machine learning model. The ML predictions for these new materials are then compared to quantum-mechanics based calculations. Our results reaffirm the significant role of machine learning techniques in the exploration of materials for battery applications.

,electrode volume change↗