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DOE OSTI2026

Distributed quantum approximate optimization algorithm on a quantum-centric supercomputing architecture

Quantum approximate optimization algorithm (QAOA) has shown promise in solving combinatorial optimization problems by providing quantum speedup on near-term gate-based quantum computing systems. However, QAOA faces challenges for high-dimensional problems due to the large number of qubits required and the complexity of deep circuits, limiting its scalability for real-world applications. In this study, we present a distributed QAOA (DQAOA), which leverages distributed computing strategies to decompose a large computational workload into smaller tasks that require fewer qubits and shallower circuits than are necessary to solve the original problem. These sub-problems are processed using a combination of high-performance and quantum computing resources. The global solution is iteratively updated by aggregating sub-solutions, allowing convergence toward the optimal solution. We demonstrate that DQAOA can handle considerably large-scale optimization problems (e.g., 1000-bit problem), achieving a high solution quality and short time-to-solution, outperforming existing strategies. Furthermore, we realize DQAOA on a quantum-centric supercomputing architecture, paving the way for practical applications of gate-based quantum computers in real-world optimization tasks. To extend DQAOA’s applicability to materials science, we further develop an active learning algorithm integrated with our DQAOA (AL-DQAOA), which involves machine learning, DQAOA, and active data production in an iterative loop. We successfully optimize photonic structures using AL-DQAOA, indicating that solving real-world optimization problems using gate-based quantum computing is feasible. We expect the proposed DQAOA to be applicable to a wide range of optimization problems and AL-DQAOA to find broader applications in material design.

Kim, Seongmin [ORNL] (ORCID:0000000159063004)↗

DOE OSTI2021

Data-driven optimized control of the COVID-19 epidemics

Optimizing the impact on the economy of control strategies aiming at containing the spread of COVID-19 is a critical challenge. We use daily new case counts of COVID-19 patients reported by local health administrations from different Metropolitan Statistical Areas (MSAs) within the US to parametrize a model that well describes the propagation of the disease in each area. We then introduce a time-varying control input that represents the level of social distancing imposed on the population of a given area and solve an optimal control problem with the goal of minimizing the impact of social distancing on the economy in the presence of relevant constraints, such as a desired level of suppression for the epidemics at a terminal time. We find that with the exception of the initial time and of the final time, the optimal control input is well approximated by a constant, specific to each area, which contrasts with the implemented system of reopening ‘in phases’. For all the areas considered, this optimal level corresponds to stricter social distancing than the level estimated from data. Proper selection of the time period for application of the control action optimally is important: depending on the particular MSA this period should be either short or long or intermediate. We also consider the case that the transmissibility increases in time (due e.g. to increasingly colder weather), for which we find that the optimal control solution yields progressively stricter measures of social distancing. We finally compute the optimal control solution for a model modified to incorporate the effects of vaccinations on the population and we see that depending on a number of factors, social distancing measures could be optimally reduced during the period over which vaccines are administered to the population.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

Fully localised nonlinear energy growth optimals in pipe flow

A new, fully localised, energy growth optimal is found over large times and in long pipe domains at a given mass flow rate. This optimal emerges at a threshold disturbance energy below which a nonlinear version of the known (streamwise-independent) linear optimal [P. J. Schmid and D. S. Henningson, “Optimal energy density growth in Hagen-Poiseuille flow,” J. Fluid Mech. 277, 192–225 (1994)] is selected and appears to remain the optimal up until the critical energy at which transition is triggered. The form of this optimal is similar to that found in short pipes [Pringle et al., “Minimal seeds for shear flow turbulence: Using nonlinear transient growth to touch the edge of chaos,” J. Fluid Mech. 702, 415–443 (2012)], but now with full localisation in the streamwise direction. This fully localised optimal perturbation represents the best approximation yet of the minimal seed (the smallest perturbation which is arbitrarily close to states capable of triggering a turbulent episode) for “real” (laboratory) pipe flows. Dependence of the optimal with respect to several parameters has been computed and establishes that the structure is robust.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

Automated property optimization via ab initio O(N) elongation method: Application to (hyper-)polarizability in DNA

An automated property optimization method was developed based on the ab initio O(N) elongation (ELG) method and applied to the optimization of nonlinear optical (NLO) properties in DNA as a first test. The ELG method mimics a polymerization reaction on a computer, and the reaction terminal of a starting cluster is attacked by monomers sequentially to elongate the electronic structure of the system by solving in each step a limited space including the terminal (localized molecular orbitals at the terminal) and monomer. The ELG-finite field (ELG-FF) method for calculating (hyper-)polarizabilities was used as the engine program of the optimization method, and it was found to show linear scaling efficiency while maintaining high computational accuracy for a random sequenced DNA model. Furthermore, the self-consistent field convergence was significantly improved by using the ELG-FF method compared with a conventional method, and it can lead to more feasible NLO property values in the FF treatment. The automated optimization method successfully chose an appropriate base pair from four base pairs (A, T, G, and C) for each elongation step according to an evaluation function. From test optimizations for the first order hyper-polarizability (β) in DNA, a substantial difference was observed depending on optimization conditions between “choose-maximum” (choose a base pair giving the maximum β for each step) and “choose-minimum” (choose a base pair giving the minimum β). In contrast, there was an ambiguous difference between these conditions for optimizing the second order hyper-polarizability (γ) because of the small absolute value of γ and the limitation of numerical differential calculations in the FF method. It can be concluded that the ab initio level property optimization method introduced here can be an effective step towards an advanced computer aided material design method as long as the numerical limitation of the FF method is taken into account.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Coupling multi-fidelity xRAGE with machine learning for graded inner shell design optimization in double shell capsules

Bayesian optimization has shown promise for the design optimization of inertial confinement fusion targets. Specifically, in Vazirani et al. [Phys. Plasmas 28 , 122709 (2021)], optimal designs for double shell capsules with graded inner shells were identified using one-dimensional xRAGE simulation yield calculations. While the machine learning models were able to accurately learn and predict one-dimensional simulation target performance, using simulations with higher fidelity would improve design optimization and better match with the expected experimental performance. However, higher fidelity physics modeling, i.e., two-dimensional xRAGE simulations, requires significantly larger computational time/cost, usually at least an order of magnitude, in comparison with one-dimensional simulations. This study presents a multi-fidelity Bayesian optimization, in which the machine learning model leverages low-fidelity (one-dimensional xRAGE) and high-fidelity (two-dimensional xRAGE) simulations to more accurately predict “pre-shot” target performance with respect to the expected experimental performance. By building a multi-fidelity Bayesian optimization framework coupled with xRAGE, the low-fidelity and high-fidelity simulations are able to inform one another, such that we have: (1) improved physics modeling in comparison with using low-fidelity simulations alone, (2) reduced computational time/cost in comparison with using high-fidelity simulations alone, and (3) more confidence in the expected performance of optimized targets during real-world experiments. In the future, we plan to use this robust multi-fidelity Bayesian optimization methodology to expedite the design of graded inner shells further and eventually full capsules as a part of the current double shell campaign at the National Ignition Facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

ParaOpt: Automated Application Parameterization and Optimization for the Cloud

The variety of instance types available on cloud platforms offers enormous flexibility to match the requirements of applications with available resources. However, selecting the most suitable instance type and configuring an application to optimally execute on that instance type can be complicated and time-consuming. For example, application parallelism flags must match available cores and problem sizes must be tuned to match available memory. As the search space of application configurations can be enormous, we propose an automated approach, called ParaOpt, to automatically explore and tune application configurations on arbitrary cloud instances. ParaOpt supports arbitrary applications, enables use of custom optimization methods, and can be configured with different optimization targets such as runtime and cost. We evaluate ParaOpt by optimizing genomics, molecular dynamics, and machine learning applications with four types of optimizers. We show with as few as 15 parameterized executions of an application, representing between 1.2%-26.7% of the search space, that ParaOpt is able to identify the optimal configuration in 32.7% of experiments and a near-optimal configuration in 83.2% of cases. As a result of using near-optimal configurations, ParaOpt reduces overall execution time by up to 85.8% when compared with using the default configuration.

Wu, Chaofeng↗

DOE OSTI2019

Economic Optimal Control for Minimizing Fuel Consumption of Heavy-Duty Trucks in a Highway Environment

This paper provides a comparative assessment of three economic optimal control strategies, aimed at minimizing the fuel consumption of heavy-duty trucks in a highway environment, under a representative lead vehicle model informed by traffic data. These strategies fuse a global, offline dynamic programming (DP) optimization with online model predictive control (MPC). We then show how two of the three strategies can be adapted to accommodate the presence of traffic and optimally navigate signalized intersections using infrastructure-to-vehicular (I2V) communication. The MPC optimization, which is local in nature, makes refinements to a coarsely (but globally, subject to grid resolution) optimized target velocity profile from the DP optimization. The three candidate economic MPC formulations that are evaluated include: a nonlinear time-based formulation that directly penalizes predicted fuel consumption, a nonlinear time-based formulation that penalizes braking effort as a surrogate for fuel consumption, and a linear distance-based convex formulation that maintains a tradeoff between energy expenditure and tracking of the coarsely optimized velocity profile obtained from DP. Using a medium-fidelity Simulink model, based on a Volvo truck's longitudinal and engine dynamics, we analyze the optimization's performance on four highway routes under various traffic scenarios. Results demonstrate 3.7-8.3% fuel economy improvement on highway routes without traffic and 6.5-10% on the same routes with traffic included. Furthermore, we present a detailed analysis of energy usage by "type" (aerodynamic losses, braking losses, and comparison of brake-specific fuel consumption), under each candidate control strategy.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

STUDY OF THE DESIGN REPRESENTATION METHODS FOR THE OPTIMIZATION OF MULTI-LAYER COMPOSITE STRUCTURES

The purpose of multi-layer composite structure optimization is to find the optimal composite layout, such that superior structure performances and lightweight can be achieved. However, the existing optimization methods have a low efficiency when applied to the multi-component, multi-layer composite structure. Such low efficiency is caused by the high dimensionality and the inherent shortcomings of the existing design representation methods. In this work, two composite layout representation methods are compared to better understand their impacts on optimization. The root cause of the low efficiency is identified, and its influences are also quantified using three metrics. Furthermore, a new Representation-Switch Optimization (RSO) strategy is proposed. This strategy improves the search efficiency by switching the design representation methods during the optimization process. Three benchmark studies, two mathematical examples and one real engineering example, are conducted to demonstrate the impact of design representation methods on the optimization results, as well as the effectiveness of the proposed optimization strategy.

Xu, Hongyi↗

DOE OSTI2013

Simultaneous optimization of dose distributions and fractionation schemes in particle radiotherapy

Purpose: The paper considers the fractionation problem in intensity modulated proton therapy (IMPT). Conventionally, IMPT fields are optimized independently of the fractionation scheme. In this work, we discuss the simultaneous optimization of fractionation scheme and pencil beam intensities.Methods: This is performed by allowing for distinct pencil beam intensities in each fraction, which are optimized using objective and constraint functions based on biologically equivalent dose (BED). The paper presents a model that mimics an IMPT treatment with a single incident beam direction for which the optimal fractionation scheme can be determined despite the nonconvexity of the BED-based treatment planning problem.Results: For this model, it is shown that a small α/β ratio in the tumor gives rise to a hypofractionated treatment, whereas a large α/β ratio gives rise to hyperfractionation. It is further demonstrated that, for intermediate α/β ratios in the tumor, a nonuniform fractionation scheme emerges, in which it is optimal to deliver different dose distributions in subsequent fractions. The intuitive explanation for this phenomenon is as follows: By varying the dose distribution in the tumor between fractions, the same total BED can be achieved with a lower physical dose. If it is possible to achieve this dose variation in the tumor without varying the dose in the normal tissue (which would have an adverse effect), the reduction in physical dose may lead to a net reduction of the normal tissue BED. For proton therapy, this is indeed possible to some degree because the entrance dose is mostly independent of the range of the proton pencil beam.Conclusions: The paper provides conceptual insight into the interdependence of optimal fractionation schemes and the spatial optimization of dose distributions. It demonstrates the emergence of nonuniform fractionation schemes that arise from the standard BED model when IMPT fields and fractionation scheme are optimized simultaneously. Although the projected benefits are likely to be small, the approach may give rise to an improved therapeutic ratio for tumors treated with stereotactic techniques to high doses per fraction.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2015

Optimization of the fractionated irradiation scheme considering physical doses to tumor and organ at risk based on dose–volume histograms

Purpose: Radiotherapy of solid tumors has been performed with various fractionation regimens such as multi- and hypofractionations. However, the ability to optimize the fractionation regimen considering the physical dose distribution remains insufficient. This study aims to optimize the fractionation regimen, in which the authors propose a graphical method for selecting the optimal number of fractions (n) and dose per fraction (d) based on dose–volume histograms for tumor and normal tissues of organs around the tumor. Methods: Modified linear-quadratic models were employed to estimate the radiation effects on the tumor and an organ at risk (OAR), where the repopulation of the tumor cells and the linearity of the dose-response curve in the high dose range of the surviving fraction were considered. The minimization problem for the damage effect on the OAR was solved under the constraint that the radiation effect on the tumor is fixed by a graphical method. Here, the damage effect on the OAR was estimated based on the dose–volume histogram. Results: It was found that the optimization of fractionation scheme incorporating the dose–volume histogram is possible by employing appropriate cell surviving models. The graphical method considering the repopulation of tumor cells and a rectilinear response in the high dose range enables them to derive the optimal number of fractions and dose per fraction. For example, in the treatment of prostate cancer, the optimal fractionation was suggested to lie in the range of 8–32 fractions with a daily dose of 2.2–6.3 Gy. Conclusions: It is possible to optimize the number of fractions and dose per fraction based on the physical dose distribution (i.e., dose–volume histogram) by the graphical method considering the effects on tumor and OARs around the tumor. This method may stipulate a new guideline to optimize the fractionation regimen for physics-guided fractionation.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

SU-F-T-497: Spatiotemporally Optimal, Personalized Prescription Scheme for Glioblastoma Patients Using the Proliferation and Invasion Glioma Model

Purpose: To investigate a spatiotemporally optimal radiotherapy prescription scheme and its potential benefit for glioblastoma (GBM) patients using the proliferation and invasion (PI) glioma model. Methods: Standard prescription for GBM was assumed to deliver 46Gy in 23 fractions to GTV1+2cm margin and additional 14Gy in 7 fractions to GTV2+2cm margin. We simulated the tumor proliferation and invasion in 2D according to the PI glioma model with a moving velocity of 0.029(slow-move), 0.079(average-move), and 0.13(fast-move) mm/day for GTV2 with a radius of 1 and 2cm. For each tumor, the margin around GTV1 and GTV2 was varied to 0–6 cm and 1–3 cm respectively. Total dose to GTV1 was constrained such that the equivalent uniform dose (EUD) to normal brain equals EUD with the standard prescription. A non-stationary dose policy, where the fractional dose varies, was investigated to estimate the temporal effect of the radiation dose. The efficacy of an optimal prescription scheme was evaluated by tumor cell-surviving fraction (SF), EUD, and the expected survival time. Results: Optimal prescription for the slow-move tumors was to use 3.0(small)-3.5(large) cm margins to GTV1, and 1.5cm margin to GTV2. For the average- and fast-move tumors, it was optimal to use 6.0cm margin for GTV1 suggesting that whole brain therapy is optimal, and then 1.5cm (average-move) and 1.5–3.0cm (fast-move, small-large) margins for GTV2. It was optimal to deliver the boost sequentially using a linearly decreasing fractional dose for all tumors. Optimal prescription led to 0.001–0.465% of the tumor SF resulted from using the standard prescription, and increased tumor EUD by 25.3–49.3% and the estimated survival time by 7.6–22.2 months. Conclusion: It is feasible to optimize a prescription scheme depending on the individual tumor characteristics. A personalized prescription scheme could potentially increase tumor EUD and the expected survival time significantly without increasing EUD to normal brain.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

A Data Driven Pre-cooling Framework for Energy Cost Optimization in Commercial Buildings

Commercial buildings consume significant amount of energy. Facility managers are increasingly grappling with the problem of reducing their buildings’ peak power, overall energy consumption and energy bills. In this paper, we first develop an optimization framework – based on a gray box model for zone thermal dynamics – to determine a pre-cooling strategy that simultaneously shifts the peak power to low energy tariff regimes, and reduces both the peak power and overall energy consumption by exploiting the flexibility in a building’s thermal comfort range. We then evaluate the efficacy of the pre-cooling optimization framework by applying it to building management system data, spanning several days, obtained from a large commercial building located in a tropical region of the world. The results from simulations show that optimal pre-cooling reduces peak power by over 50%, energy consumption by up to 30% and energy bills by up to 37%. Next, to enable ease of use of our framework, we also propose a shortest path based heuristic algorithmfor solving the optimization problemand show that it has comparable erformance with the optimal solution. Finally, we describe an application of the proposed optimization framework for developing countries to reduce the dependency on expensive fossil fuels, which are often used as a source for energy backup.We conclude by highlighting our real world deployment of the optimal pre-cooling framework via a software service on the cloud platform of a major provider. Our pre-cooling methodology, based on the gray box optimization framework, incurs no capital expense and relies on data readily available from a building management system, thus enabling facility managers to take informed decisions for improving the energy and cost footprints of their buildings

Vishwanath, Arun↗

DOE OSTI2020

A Framework for the Analysis of Compiler Optimizations

Compilers transform program source code to machine executable code. During this transformation, they perform a number of compiler optimizations to improve the performance of the generated executable code. Importantly, applying those optimizations depends on the source code structure, such as the parallel programming model used to parallelize an algorithm. Often, implementations of the same algorithm with different programming models have vastly different performance because the compiler optimized them differently. We create FAROS, a framework to structure and automate the analysis of compiler optimizations on programs. FAROS automates the building process, execution profiling, and analysis of compiler optimization of programs, through a configuration interface. It outputs compiler optimization reports to show which optimizations applied to which line of source code, leveraging compilation remarks output by the compiler. Also, FAROS supports benchmarking performance of different program versions by collecting execution time results. In this first release of FAROS, we provide a configuration file to analyze compiler optimization differences for sequential vs OpenMP compilation, including 38 programs consisting of HPC proxy/mini/large applications, and NAS and Rodina kernels for analysis.

Georgakoudis, Giorgis↗

DOE OSTI2024

Dose optimization of an adjuvanted peptide-based personalized neoantigen melanoma vaccine

The advancements in next-generation sequencing have made it possible to effectively detect somatic mutations, which has led to the development of personalized neoantigen cancer vaccines that are tailored to the unique variants found in a patient’s cancer. These vaccines can provide significant clinical benefit by leveraging the patient’s immune response to eliminate malignant cells. However, determining the optimal vaccine dose for each patient is a challenge due to the heterogeneity of tumors. To address this challenge, we formulate a mathematical dose optimization problem based on a previous mathematical model that encompasses the immune response cascade produced by the vaccine in a patient. We propose an optimization approach to identify the optimal personalized vaccine doses, considering a fixed vaccination schedule, while simultaneously minimizing the overall number of tumor and activated T cells. To validate our approach, we perform in silico experiments on six real-world clinical trial patients with advanced melanoma. We compare the results of applying an optimal vaccine dose to those of a suboptimal dose (the dose used in the clinical trial and its deviations). Our simulations reveal that an optimal vaccine regimen of higher initial doses and lower final doses may lead to a reduction in tumor size for certain patients. Our mathematical dose optimization offers a promising approach to determining an optimal vaccine dose for each patient and improving clinical outcomes.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2012

Model Based Optimal Sensor Network Design for Condition Monitoring in an IGCC Plant

This report summarizes the achievements and final results of this program. The objective of this program is to develop a general model-based sensor network design methodology and tools to address key issues in the design of an optimal sensor network configuration: the type, location and number of sensors used in a network, for online condition monitoring. In particular, the focus in this work is to develop software tools for optimal sensor placement (OSP) and use these tools to design optimal sensor network configuration for online condition monitoring of gasifier refractory wear and radiant syngas cooler (RSC) fouling. The methodology developed will be applicable to sensing system design for online condition monitoring for broad range of applications. The overall approach consists of (i) defining condition monitoring requirement in terms of OSP and mapping these requirements in mathematical terms for OSP algorithm, (ii) analyzing trade-off of alternate OSP algorithms, down selecting the most relevant ones and developing them for IGCC applications (iii) enhancing the gasifier and RSC models as required by OSP algorithms, (iv) applying the developed OSP algorithm to design the optimal sensor network required for the condition monitoring of an IGCC gasifier refractory and RSC fouling. Two key requirements for OSP for condition monitoring are desired precision for the monitoring variables (e.g. refractory wear) and reliability of the proposed sensor network in the presence of expected sensor failures. The OSP problem is naturally posed within a Kalman filtering approach as an integer programming problem where the key requirements of precision and reliability are imposed as constraints. The optimization is performed over the overall network cost. Based on extensive literature survey two formulations were identified as being relevant to OSP for condition monitoring; one based on LMI formulation and the other being standard INLP formulation. Various algorithms to solve these two formulations were developed and validated. For a given OSP problem the computation efficiency largely depends on the “size” of the problem. Initially a simplified 1-D gasifier model assuming axial and azimuthal symmetry was used to test out various OSP algorithms. Finally these algorithms were used to design the optimal sensor network for condition monitoring of IGCC gasifier refractory wear and RSC fouling. The sensors type and locations obtained as solution to the OSP problem were validated using model based sensing approach. The OSP algorithm has been developed in a modular form and has been packaged as a software tool for OSP design where a designer can explore various OSP design algorithm is a user friendly way. The OSP software tool is implemented in Matlab/Simulink© in-house. The tool also uses few optimization routines that are freely available on World Wide Web. In addition a modular Extended Kalman Filter (EKF) block has also been developed in Matlab/Simulink© which can be utilized for model based sensing of important process variables that are not directly measured through combining the online sensors with model based estimation once the hardware sensor and their locations has been finalized. The OSP algorithm details and the results of applying these algorithms to obtain optimal sensor location for condition monitoring of gasifier refractory wear and RSC fouling profile are summarized in this final report.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

Assessment of Model-Based Schemes for Accelerating Optimization by RAVEN

Nuclear-Renewable Hybrid Energy Systems (N-R HES) combine different energy technologies in a synergistic way with the objective of achieving a more economical energy production. In this report the particular hybrid system dealt with includes a PWR nuclear reactor, the associated Rankine-based energy conversion cycle (Balance of Plant, BOP), an Industrial Process (IP) for hydrogen production, a gas turbine (Second Energy Source, SES), and a battery (Energy Storage, ES). The RAVEN-based HYBRID framework is used to find the optimal installed capacity and the optimal economical dispatch of each component of the N-R HES. HYBRID solves the coupled capacity planning-economic and dispatch optimization problem with the objective of minimizing the Levelized Cost of Electricity (LCOE). In the optimization of the power dispatch strategy, the HYBRID framework takes into account the time-dependent dynamics of each subsystem by including a Dymola object-oriented model of the process dynamics. To ease the computational burden of the optimization process, an initial guess for the dispatch optimization problem is provided by a preconditioner. The solution guess is calculated by means of a least-marginal cost approach which applies the same criterion behind the screening curve method. Though this algorithm allows evaluating an economically adapted generation mix for a target load duration curve within a few seconds, it neglects the constraints due to the single component dynamics, and it is not able to adequately represent the ES. An improved treatment of the pre-conditioner problem was addressed by introducing a Monte Carlo based optimization algorithm. The new approach takes into account limits on power rates for the system subcomponents, which was not previously done. Additionally, this new Monte-Carlo based preconditioner addresses the problem with the ES component through improved modeling of that component. The new algorithm has been implemented in the HYBRID framework and tested to assess its performance. The results obtained with the new Monte Carlobased preconditioner were benchmarked against those obtained through the reference deterministic approach. The comparison shows that the Monte-Carlo based approach provides improved solution accuracy to the power dispatch optimization problem. Also in this report, the treatment of the penalty function on LCOE is discussed, and an improved penalty function for missed demand is suggested and tested.

Maronati, Giovanni↗

DOE OSTI2022

Learning Optimal Aerodynamic Designs

This project created a framework for efficient, accurate, and scalable deep neural network representations of design optimization problem solutions. The inputs to these DNN representations are the vector of design requirement parameters, the outputs are the optimal design variables, and the goal is to learn the map from inputs to outputs (i.e., inverse design). The team addressed the problem of the optimal shape design of aerodynamic lifting surfaces—in particular aircraft wings—using a Reynolds-Average Navier Stokes model to govern the CFD-based aerodynamic shape optimization. The inverse design map for such problems is very complex and high-dimensional, involving inputs and outputs on the order of 1000s. To approximate this inverse design map, the team developed algorithms to construct parsimonious DNN architectures, which automatically identify low-dimensional manifolds in which design requirements affect optimal shape parameters, and trained these architectures with multifidelity optimization methods. The resulting methodology accurately and automatically designs optimal aerodynamic lifting surfaces with very high accuracy (99%) at interactive speeds, of the order of milliseconds, resulting in factors of one million or more speedup relative to CFD-based design optimization.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗