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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Process and feedstock driven microstructure for laser powder bed fusion of 316L stainless steel

Here in the pursuit of improving additively manufactured (AM) component quality and reliability, fine-tuning critical process parameters such as laser power and scan speed is a great first step toward limiting defect formation and optimizing the microstructure. However, the synergistic effects between these process parameters, layer thickness, and feedstock attributes (e.g. powder size distribution) on part characteristics such as microstructure, density, hardness, and surface roughness are not as well-studied. In this work, we investigate 316L stainless steel density cubes built via laser powder bed fusion (L-PBF), emphasizing the significant microstructural changes that occur due to altering the volumetric energy density (VED) via laser power, scan speed, and layer thickness changes, coupled with different starting powder size distributions. This study demonstrates that there is not one ideal process set and powder size distribution for each machine. Instead, there are several combinations or feedstock/process parameter ‘recipes’ to achieve similar goals. This study also establishes that for equivalent VEDs, changing powder size can significantly alter part density, GND density, and hardness. Through proper parameter and feedstock control, part attributes such as density, grain size, texture, dislocation density, hardness, and surface roughness can be customized, thereby creating multiple high-performance regions in the AM process space.

316L stainless steel↗
DOE OSTI2020

Cognition at the Point of Sensing

Over the last 15 years, compressive sensing techniques have been developed which have the potential to greatly reduce the amount of data collected by systems while preserving the amount of information obtained. A cost of this efficiency is that a computationally-intensive optimization routine must be used to put the sensed data into a form that a person can interpret. At the same time, machine learning techniques have experienced tremendous growth as well. Machines have demonstrated the ability learn how to effectively perform tasks such as detection and classification at speeds much faster than humanly possible. Our goal in this project was to study the feasibility of using compressive sensing systems "at the edge." That is, how can compressive sensing sensors be deployed such that information is created at the remote sensor rather than sending raw data to a central processing location? Studies were performed to analyze whether machine learning could be done on the compressively sensed data in its raw form. If a machine is performing the task, is it possible to do so without putting the data into a human interpretable form? We show that this is possible for some systems, in particular a compressive sensing snapshot imaging spectrometer. Machine learning tasks were demonstrated to be more effective and more robust to noise when the machine learning algorithm worked on data in its raw form. This system is shown to outperform a traditional spectrometer. Techniques for reducing the complexity of the reconstruction routine were also analyzed. Techniques for such as data regularization, deep neural networks, and matrix completion were studied and shown to have benefits over traditional reconstruction techniques. In this project we showed that compressive sensing sensors are indeed feasible at the edge. As always, sensors and algorithms must be carefully tuned to work in the constrained environment. In this project we developed tools and techniques to enable those analyses.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Portable Acceleration of CMS Computing Workflows with Coprocessors as a Service

Computing demands for large scientific experiments, such as the CMS experiment at the CERN LHC, will increase dramatically in the next decades. To complement the future performance increases of software running on central processing units (CPUs), explorations of coprocessor usage in data processing hold great potential and interest. Coprocessors are a class of computer processors that supplement CPUs, often improving the execution of certain functions due to architectural design choices. We explore the approach of Services for Optimized Network Inference on Coprocessors (SONIC) and study the deployment of this as-a-service approach in large-scale data processing. In the studies, we take a data processing workflow of the CMS experiment and run the main workflow on CPUs, while offloading several machine learning (ML) inference tasks onto either remote or local coprocessors, specifically graphics processing units (GPUs). With experiments performed at Google Cloud, the Purdue Tier-2 computing center, and combinations of the two, we demonstrate the acceleration of these ML algorithms individually on coprocessors and the corresponding throughput improvement for the entire workflow. This approach can be easily generalized to different types of coprocessors and deployed on local CPUs without decreasing the throughput performance. We emphasize that the SONIC approach enables high coprocessor usage and enables the portability to run workflows on different types of coprocessors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Star–Galaxy Image Separation with Computationally Efficient Gaussian Process Classification

Abstract We introduce a novel method for discerning optical telescope images of stars from those of galaxies using Gaussian processes (GPs). Although applications of GPs often struggle in high-dimensional data modalities such as optical image classification, we show that a low-dimensional embedding of images into a metric space defined by the principal components of the data suffices to produce high-quality predictions from real large-scale survey data. We develop a novel method of GP classification hyperparameter training that scales approximately linearly in the number of image observations, which allows for application of GP models to large-size Hyper Suprime-Cam Subaru Strategic Program data. In our experiments, we evaluate the performance of a principal component analysis embedded GP predictive model against other machine-learning algorithms, including a convolutional neural network and an image photometric morphology discriminator. Our analysis shows that our methods compare favorably with current methods in optical image classification while producing posterior distributions from the GP regression that can be used to quantify object classification uncertainty. We further describe how classification uncertainty can be used to efficiently parse large-scale survey imaging data to produce high-confidence object catalogs.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Low latency optical-based mode tracking with machine learning deployed on FPGAs on a tokamak

Active feedback control in magnetic confinement fusion devices is desirable to mitigate plasma instabilities and enable robust operation. Optical high-speed cameras provide a powerful, non-invasive diagnostic and can be suitable for these applications. Here, in this study, we process high-speed camera data, at rates exceeding 100 kfps, on in situ field-programmable gate array (FPGA) hardware to track magnetohydrodynamic (MHD) mode evolution and generate control signals in real time. Our system utilizes a convolutional neural network (CNN) model, which predicts the n = 1 MHD mode amplitude and phase using camera images with better accuracy than other tested non-deep-learning-based methods. By implementing this model directly within the standard FPGA readout hardware of the high-speed camera diagnostic, our mode tracking system achieves a total trigger-to-output latency of 17.6 μs and a throughput of up to 120 kfps. This study at the High Beta Tokamak-Extended Pulse (HBT-EP) experiment demonstrates an FPGA-based high-speed camera data acquisition and processing system, enabling application in real-time machine-learning-based tokamak diagnostic and control as well as potential applications in other scientific domains.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Machine learning enables interpretable discovery of innovative polymers for gas separation membranes

Polymer membranes perform innumerable separations with far-reaching environmental implications. Despite decades of research, design of new membrane materials remains a largely Edisonian process. To address this shortcoming, we demonstrate a generalizable, accurate machine learning (ML) implementation for the discovery of innovative polymers with ideal performance. Specifically, multitask ML models are trained on experimental data to link polymer chemistry to gas permeabilities of He, H 2 , O 2 , N 2 , CO 2 , and CH 4 . We interpret the ML models and extract valuable insights into the contributions of different chemical moieties to permeability and selectivity. We then screen over 9 million hypothetical polymers and identify thousands that lie well above current performance upper bounds, including hundreds of never-before-seen ultrapermeable polymer membranes with O 2 and CO 2 permeability greater than 10 4 and 10 5 Barrers, respectively. High-fidelity molecular dynamics simulations confirm the ML-predicted gas permeabilities of the promising candidates, which suggests that many can be translated to reality.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Leveraging unlabeled SEM datasets with self-supervised learning for enhanced particle segmentation

Scanning Electron Microscopes (SEMs) are widely used in experimental science laboratories, often requiring cumbersome and repetitive user analysis. Automating SEM image analysis processes is highly desirable to address this challenge. In particle sample analysis, Machine Learning (ML) has emerged as the most effective approach for particle segmentation. However, the time-intensive process of manually annotating thousands of SEM images limits the applicability of supervised learning approaches. Self-Supervised Learning (SSL) offers a promising alternative by enabling knowledge extraction from raw, unlabeled data. This study presents a framework for evaluating SSL techniques in SEM image analysis, focusing on novel methods leveraging the ConvNeXtV2 architecture for particle detection. A dataset comprising 25,000 SEM images is curated to benchmark these proposed SSL methods. The results demonstrate that ConvNeXtV2 models, with varying parameter counts, consistently outperform other techniques in particle detection across different length scales, achieving up to a 34% reduction in relative error compared to established SSL methods. Furthermore, an ablation study explores the relationship between dataset size and SSL performance, providing actionable insights for practitioners regarding model selection and resource efficiency. This research advances the integration of SSL into autonomous analysis pipelines and supports its application in accelerating materials science discovery.

Rettenberger, Luca↗
DOE OSTI2021

Expansion of Machine-Learning Method for Classifying Neutron Resonances

The understanding of astrophysics processes and the performance of nuclear reactors and other nuclear systems depend on a precise description of the neutron interaction cross sections for materials and nuclei present in these environments. At low neutron energies, these cross sections exhibit resonance structure represented by sharp enhancements when the neutron energy is sufficiently close to excited levels in a compound nucleus. Such resonances can be characterized by their quantum numbers relative to angular momenta, which are often deduced in an ad hoc and irreproducible manner from the shape of the cross sections. The correct assignment of the quantum numbers of neutron resonances is therefore of paramount importance. To address this we have developed a machine-learning method to automate the identification and correction of these spin assignments. The algorithm is trained from simulated data, generated from statistical properties of resonance data for a given nucleus, to mimic the errors found in real data. In this project we describe five independent approaches to further develop and expand the applicability of the machine-learning spin classifier: i) Feature impact; ii) Integration with the Atlas; iii) Training optimization; iv) Spacings systematics; and v) Validation with polarized data. The premises, methods, results, and future perspectives are discussed.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Sub-pilot-scale Production of High-Value Products from U.S. Coals

Investigators from the University of Utah, University of Wyoming and Marshall University pursued a program to study the conversion of raw coal to high-value products of carbon fiber and silicon carbide. Team members also developed an initial framework for a data portal that can incorporate laboratory data on coal processing and product quality, and also work with tools for machine learning for data analysis, data visualization and economic assessment. Experimental R&D efforts focused on the conversion of raw coal to coal tar and other byproducts, and the resulting tar intermediates were upgraded to form anisotropic and isotropic pitch materials. These pitch materials were produced from coal using both thermal (pyrolysis) and chemical (mild solvolysis liquefaction) decomposition of raw coal. Four different coals were studied: Utah bituminous coal (Sufco), Wyoming PRB coal (Black Thunder), Illinois bituminous coal (Illinois #6), and West Virginia bituminous coal (Flying Eagle). Both metallurgical-grade coking coals and lower-grade steam coals were investigated, and controlled secondary gas-phase reactions were used during a two-stage pyrolysis process to induce cracking and condensation reactions among the pyrolytic tar species. This approach successfully improved the performance of the lower grade coals for yielding pitch materials, with properties more consistent with a commercial-grade pitch that had previously demonstrated success for quality carbon fiber production. The use of waste plastic materials was also studied, to help improve physical and chemical characteristics of the intermediate tars and final pitch product; in particular, for lowering the pitch softening point to an acceptable level for melt spinning carbon fiber. Mild solvolysis liquefaction was also used as a method for producing pitch for carbon fiber production. As expected, significantly higher pitch yields were obtained using this approach, and waste plastic materials were also successfully used to reduce pitch softening point to an acceptable level. The plastic materials were also utilized to create a solvent for the mild solvolysis process, and this plastic-derived solvent was shown to provide results consistent with more expensive commercial chemical solvents, and could thus avoid the need for costly recovery and recycle of a liquefaction solvent. Additional experimental R&D focused on the production of silicon carbide (β-SiC) from the residual char byproduct from pitch production, and also on the production of carbon fiber from the anisotropic pitch. SiC was successfully synthesized using a mixture of residual char and sandstone at a ratio of 1:1. Reaction temperature and residence time were optimized and yielded a product purity of 81%. For carbon fiber production, the most successful pitch samples were obtained from the mild solvolysis liquefaction approach, combined with the use of a plastic (HDPE)-derived solvent. Fiber properties improved over time as laboratory fiber production methodologies improved, and final yields of carbon fiber were obtained with a diameter of 12.14 ± 1.10 um, Modulus of 173.73 ± 15.25 GPa, and Tensile Strength of 1.04 ± 0.10 GPa. A proof-of-concept Modern Community Research Data Portal (MCRDP) was developed and deployed for coal and coal-derived pitch characterization, with the full support of (i) remote web-based access, (ii) distributed analysis, (iii) interactive visualization and exploration, (iv) shared and long-term data access, (v) advanced query capabilities and (vi) real-time collaboration. The Coal to Products Data Portal “coaltoproducts.org” provides researchers with space to store and share data within a project, tools for analyzing and understanding data for scientific investigation, and the ability to publish data to the broader community for reproducibility. The portal leverages the Material Commons 2.0 (MC) platform developed by the Center for PRedictive Integrated Structural Materials Science (PRISMS) of the University of Michigan, to achieve long-term longevity of data collections and, more importantly, collaborative science. A number of data visualization tools were also assessed and implemented for interrogating the experimental and modeling data. The machine learning portion of this project analyzed datasets from two different coal conversion processes performed on a diverse set of coal samples from both the coal pyrolysis experiments and the solvent liquefaction experiments. The work was initiated by exploring standard regression models on the pyrolysis data, aiming to understand the impact of sample characteristics and processing conditions on key product metrics. Over the course of the project, the focus expanded to include a variety of machine learning tools, delving into both supervised and unsupervised learning methods. Models tested on the pyrolysis data included linear, ridge, lasso, elastic-net, Gaussian process, random forest regression, and AutoSklearn, and the approach was continually refined to enhance predictive accuracy and model interpretability. Similar techniques were applied to the liquefaction data with an additional focus on feature engineering. Along with mesophase content, additional outputs of interest were the pitch yield, softening point, and QI content. Insights derived from these analyses are crucial in determining the factors influencing the quality and yield of coal-derived products. As the work progressed, the research evolved from foundational model comparisons to analyses of random forests, decision paths, and feature importance scores. A thorough market analysis was performed to examine the prospects of coal-based carbon fibers. The best opportunities for coal come from its lower and more stable price relative to petroleum, particularly for subbituminous coals, which is the primary advantage that a coal refinery may have over a petroleum refinery. Before a commercial CTP production facility can be modeled, however, several things need to be understood regarding the nature of the would-be coal refinery. These include the technology to be deployed, the size of facility, the volume(s) of co-product(s), and the waste and emissions profile of the plant. The volume of co-products and waste may be substantial and will require separate market analysis to ensure viability. In the near-term, the importance of coal tar pitch, in the form of carbon pitch, to the aluminum and steel industries is likely to overshadow the alternative use of this material as an input for carbon fiber. The importance of steel and aluminum in building materials, and the need for carbon materials in their manufacturing, will ensure that demand for these products remains for the long run. In addition, carbon fiber may also be the best substitute for steel and aluminum well into the future. While society will eventually be able to shift production of much of its electricity needs to renewables, it will not be able to shift away from fossil fuels for production of high-strength construction and vehicular materials. Demand for carbon fiber is expected to increase quickly, but the volume of carbon fiber and the amount of coal that would be needed to produce even a sizeable share of this market may still be relatively small compared to current coal production. Thus, other coal-based products like graphene, graphite, carbon foams, resins, and carbon-based building products will play important roles in sustaining coal production as coal-fired power generation continues to decline.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Application of Data Science and Engineering

Metal additive manufacturing (AM) processes exhibit significant variability in the quality and properties of components that are produced. This variability has prevented the widespread adoption of AM in industry. The need for more advanced and descriptive process monitoring, part qualification, and process control has led to an increasing number of sensors on machines and subsequent data to analyze. Increasingly, data science principles are being leveraged in each of these domains in order to process this data and better understand the causes of variability and the corresponding quality inconsistencies that occur in additive manufacturing.

Halsey, William↗
DOE OSTI2025

Machine learning approaches for intentional materials engineering

In this article, the development of nanoporous metals and metallic composites through dealloying processes presents significant opportunities in materials engineering. However, designing multicomponent precursor alloys and establishing corresponding processing methods that yield predictable compositions and nanostructures remain a complex challenge. This article explores how machine learning (ML)-augmented computational and experimental methodologies can tackle these challenges by predicting precursor alloy compositions, final nanoporous structures, and mechanical properties, while integrating ML-enabled autonomous experimentation for material design and quantification. We highlight recent advancements in applying ML to nanostructured materials design via dealloying and discuss how techniques from other nanomaterial designs can be adapted for improved control over morphological and compositional outcomes in nanoporous and nanocomposite materials. Furthermore, we explore the role of ML in autonomous synchrotron x-ray experimentation, enabling real-time feedback between modeling and experimental setups. ML-driven approaches to microstructure characterization and mechanical property prediction are also examined, with a focus on modeling and advanced imaging techniques such as three-dimensional nanotomography. Finally, this article outlines future directions for ML-enhanced materials science, emphasizing the exploration of high-dimensional parameter spaces and the incorporation of materials kinetics into processing and property evaluation, ultimately advancing the design of nanoporous structures and materials science.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Machine Learning for Automated Weld Quality Monitoring and Control (CRADA 461)

The emergence of Artificial Intelligence (AI) and Machine Learning (ML) methods may provide an alternative pathway to elicit the desired process-structure-property relationship. To achieve such relationship at an accelerated pace the use of data driven machine learning techniques are employed. This CRADA investigates the use and effectiveness of applying AI/ML techniques to a large dataset with the intention of creating a data-driven model that will predict processing parameters required to join lightweight materials at optimal performance.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Understanding effects of printhead geometry in aerosol jet printing

Aerosol jet printing offers a versatile, high-resolution digital patterning capability broadly relevant to flexible and printed electronic systems. Despite its promise and numerous demonstrations, the theoretical principles driving process outputs have not been thoroughly explored. In this study, a custom-built, modular printing system is developed to provide a head-to-head comparison of two print nozzle geometries to better understand the technology. Print resolution data from a range of process parameters are analyzed using a support vector machine framework. The linear deposition rate is identified as a key variable, which can confound careful studies of printing performance. Taking this into account, a clear difference is observed between the printheads, corresponding to a difference in resolution of 57% ± 11% under typical conditions. Models to understand differences in aerodynamic and mass transport effects identify enhanced drying within the NanoJet printhead as a likely cause of this difference. Overall, this study provides improved understanding of the aerosol jet printing process, including valuable insight to inform process optimization, robust data analysis, ink formulation, and printer geometric design.

42 ENGINEERING↗
DOE OSTI2022

Developments in Online Monitoring Technologies for Autonomous Microreactor Operations

This report presents the results of an ongoing research and development (R&D) effort to develop an online monitoring (OLM) system to support autonomous microreactor operations. A key component of this work is an evaluation of Artificial Intelligence (AI) and Machine Learning (ML) techniques to identify, diagnose, and predict problems with sensors and processes of the reactor. As described herein, selected methods of AI/ML were used to identify and diagnose anomalous sensor and system behaviors using data from a thermal-hydraulic flow loop and from operating nuclear power plants. This work serves to further the state-of-the-art in OLM technologies for nuclear reactor applications and will ultimately result in a comprehensive system to enable OLM of critical structures, systems, components, and processes in microreactors.

Machine learning↗
DOE OSTI2021

Salton Sea Geodatabase for Geothermal Exploration Artificial Intelligence

These files contain the geodatabases related to Salton Sea Geothermal Field. It includes all input and output files used with the Geothermal Exploration Artificial Intelligence. Input and output files are sorted into three categories: raw data, pre-processed data, and analysis (post-processed data). In each of these categories there are six additional types of raster catalogs which are titled Radar, SWIR, Thermal, Geophysics, Geology, and Wells. The files are used with the Geothermal Exploration Artificial Intelligence for the Salton Sea Geothermal Site to identify indicators of blind geothermal systems. The included zip file is a geodatabase to be used with ArcGIS and the tar file is an inclusive database that encompasses the inputs and outputs for the Salton Sea Geothermal Site.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

A Machine Learning-Based Vulnerability Analysis for Cascading Failures of Integrated Power-Gas Systems

This article proposes a cascading failure simulation (CFS) method and a hybrid machine learning method for vulnerability analysis of integrated power-gas systems (IPGSs). The CFS method is designed to study the propagating process of cascading failures between the two systems, generating data for machine learning with initial states randomly sampled. The proposed method considers generator and gas well ramping, transmission line and gas pipeline tripping, island issue handling and load shedding strategies. Then, a hybrid machine learning model with a combined random forest (RF) classification and regression algorithms is proposed to investigate the impact of random initial states on the vulnerability metrics of IPGSs. Extensive case studies are carried out on three test IPGSs to verify the proposed models and algorithms. Simulation results show that the proposed models and algorithms can achieve high accuracy for the vulnerability analysis of IPGSs.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Systems and methods for liner braiding and resin application

A method of making a tank for storing fluid that includes generating a resinated braid layer on an elongated liner having a plurality of successively alternating rigid and flexible portions along the length of the liner. Generating the resinated braid layer on the liner includes feeding the liner into a braiding machine and applying resin to a plurality of fibers during a braiding process to generate a resinated plurality of fibers and generating, over a length of the liner, by the braiding machine, the resinated braid layer defined by the resinated plurality of fibers.

Wexler, Jason Stein↗