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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 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Attack-resilient algorithms and testbed federation for wide-area protection and control in smart grid

Today’s energy infrastructure is undergoing a massive transformation across all generation, transmission, and distribution systems to provide reliability, efficiency, and sustainability to the power system network. During the past 10 years, there has been a remarkable enhancement in developing close-loop wide-area protection and control (WAPAC) applications, such as automatic generation control (AGC), wide-area protection scheme (WAPS), synchrophasor-based wide-area voltage control system (WAVCS), etc., in the energy management system (EMS) to provide an adequate situational awareness to control center operators during physical disturbances and natural events. The rapid digitalization, unencrypted communication, and numerous data-sharing devices have increased digital access points that have exposed the grid network to countless cyberattacks pertinent to the WAPAC cybersecurity. Given the amount of complex grid network coupled with legacy infrastructures, it is untrustworthy to completely rely on information technology (IT)-based conventional security measures to defend against evolving cyberattacks. Hence, there is a compelling need to go beyond the traditional paradigm of ‘security by obscurity’ and ‘bolt-on’ security measures, and develop a suite of innovative security solutions at multiple layers to transform the current “fault-resilient” grid into “fault and attack-resilient” grid of the future. This dissertation specifically focuses on developing application-specific attack-resilient solutions for critical WAPAC applications in the smart grid. The first part of the study, Attack-Resilient Wide-Area Protection Scheme, presents a cyber-physical attack-resilient system (CPARS) for WAPS, where two anomaly detection methods are proposed to detect multi-level cyberattacks followed by the rules-based intrusion mitigation system (RIMS) to initiate effective mitigation strategies, tailored to these attacks, to restore the normal grid operation after disturbances. The first anomaly detection component, Machine learning-based Anomaly Detection for Centralized WAPS, discusses a novel architecture and methodology for developing a machine-learning-based anomaly detection system (ADS) for the centralized wide-area protection system (CWAPS) by applying the variational mode decomposition (VMD) technique and decision tree (DT) algorithms using cyber logs and synchrophasor measurements. The second component, Multi-Agent-based Anomaly Detection for Decentralized WAPS, presents a two-level hierarchical multi-agent-based decentralized WAPS against the system-aware stealthy cyber-attacks. Finally, for the RIMS, the state transition diagram-based mitigation measures are defined based on the grid operation states and experimental testing and evaluation are presented in a cyber-physical testbed environment. The second part of the study, Attack-Resilient Wide-Area Voltage Control System, addresses the existing vulnerabilities in the wide-area voltage control system (WAVCS), presents the methodology for performing an impact analysis during data integrity attacks, and proposes a data-driven attackresilient system (DARS) by incorporating machine learning-based ADS and rules-based anomaly mitigation system (RAMS) to detect these attacks and provide necessary mitigation actions to maintain the transient voltage stability after disturbances. Finally, the third part, Networked Federation Testbed (NEFTSec) for Smart Grid Cybersecurity, focuses on developing an interconnected federated testbed through a common network like the internet, describes its conceptual architectures, and also presents its design components for experimental testing, validation, and evaluation. Further, it presents the co-simulation interface algorithm (CIA) to facilitate the geographically-dispersed real-time distributed simulation (GD-RTDS) during the cyber-physical federation. In general, this dissertation presents innovative attack-resilient solutions for WAPAC applications that are experimentally tested and evaluated using the PowerCyber testbed and NEFTSec platform to accelerate the transition of state-of-the-art research works to the real-field deployments.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Optical neural engine for solving scientific partial differential equations

Abstract Solving partial differential equations (PDEs) is the cornerstone of scientific research and development. Data-driven machine learning (ML) approaches are emerging to accelerate time-consuming and computation-intensive numerical simulations of PDEs. Although optical systems offer high-throughput and energy-efficient ML hardware, their demonstration for solving PDEs is limited. Here, we present an optical neural engine (ONE) architecture combining diffractive optical neural networks for Fourier space processing and optical crossbar structures for real space processing to solve time-dependent and time-independent PDEs in diverse disciplines, including Darcy flow equation, the magnetostatic Poisson’s equation in demagnetization, the Navier-Stokes equation in incompressible fluid, Maxwell’s equations in nanophotonic metasurfaces, and coupled PDEs in a multiphysics system. We numerically and experimentally demonstrate the capability of the ONE architecture, which not only leverages the advantages of high-performance dual-space processing for outperforming traditional PDE solvers and being comparable with state-of-the-art ML models but also can be implemented using optical computing hardware with unique features of low-energy and highly parallel constant-time processing irrespective of model scales and real-time reconfigurability for tackling multiple tasks with the same architecture. The demonstrated architecture offers a versatile and powerful platform for large-scale scientific and engineering computations.

Tang, Yingheng (ORCID:0009000153622546)↗
DOE OSTI2025

Enabling Efficient Sparse Computations using Linear Algebra Aware Compilers

This project developed the LAPIS compiler framework, built on the Multilevel Intermediate Representation (MLIR), to optimize sparse linear algebra operations and support performance portability across diverse architectures. The main innovation of LAPIS is the Kokkos dialect, which allows for lowering codes from a high productivity language to different architectures in an elegant way. The dialect also allows the conversion of lower-level MLIR code to C++ Kokkos code, facilitating the integration of scientific machine learning (SciML) models into applications. To extend LAPIS for distributed memory architectures, a new partition dialect was created to manage the distribution of sparse tensors and express communication patterns for sparse linear algebra operations. This dialect also supports the distributed execution of operators and includes algorithmic optimizations to minimize communication to improve performance. The project also demonstrates that MLIR can enable effective linear algebra-level optimizations, improving performance on different GPUs for both sparse and dense linear algebra kernels. Key applications of LAPIS include sparse linear algebra and graph kernels, TenSQL, a relational database management solution built on GraphBLAS, and the development of subgraph isomorphism and monomorphism kernels, showcasing performance portability. In summary, the LAPIS framework supports productivity, performance, portability, and distributed memory execution, while also enabling linear algebra-level optimizations that are challenging in traditional programming languages, with successful applications ranging from simple sparse linear algebra to complex graph kernels.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Toward designing effective exascale scientific computing workflows: experiences and best practices

Many fields within scientific computing have embraced advances in big-data analysis and machine learning, which often requires the deployment of large, distributed and complicated workflows that may combine training neural networks, performing simulations, running inference, and performing database queries and data analysis in asynchronous, parallel and pipelined execution frameworks. Such a shift has brought into focus the need for scalable, efficient workflow management solutions with reproducibility, error and provenance handling, traceability, and checkpoint-restart capabilities, among other needs. Here, we discuss challenges and best-practices for deploying exascale-generation computational science workflows on resources at the Oak Ridge Leadership Computing Facility (OLCF). We present our experiences with large-scale deployment of distributed workflows on the Summit supercomputer, including for bioinformatics and computational biophysics, materials science, and deep learning model optimization. We also present problems and solutions created by working within a Python-centric software base on traditional HPC systems, and discuss steps that will be required before the convergence of HPC, AI, and data science can be fully realized. Our results point to a wealth of exciting new possibilities for harnessing this convergence to tackle new scientific challenges.

Coletti, Mark↗
DOE OSTI2021

Class imbalance in out-of-distribution datasets: Improving the robustness of the TextCNN for the classification of rare cancer types

In the last decade, the widespread adoption of electronic health record documentation has created huge opportunities for information mining. Natural language processing (NLP) techniques using machine and deep learning are becoming increasingly widespread for information extraction tasks from unstructured clinical notes. Disparities in performance when deploying machine learning models in the real world have recently received considerable attention. In the clinical NLP domain, the robustness of convolutional neural networks (CNNs) for classifying cancer pathology reports under natural distribution shifts remains understudied. In this research, we aim to quantify and improve the performance of the CNN for text classification on out-of-distribution (OOD) datasets resulting from the natural evolution of clinical text in pathology reports. We identified class imbalance due to different prevalence of cancer types as one of the sources of performance drop and analyzed the impact of previous methods for addressing class imbalance when deploying models in real-world domains. Our results show that our novel class-specialized ensemble technique outperforms other methods for the classification of rare cancer types in terms of macro F1 scores. We also found that traditional ensemble methods perform better in top classes, leading to higher micro F1 scores. Based on our findings, we formulate a series of recommendations for other ML practitioners on how to build robust models with extremely imbalanced datasets in biomedical NLP applications.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Exploring PV Circularity by Modeling Socio-Technical Dynamics of Modules' End-of-Life Management: Preprint

The circular economy (CE) tackles environmental and resource scarcity issues by maximizing value retention in the economy. The concept implies design strategies such as reducing the use of materials or improving products’ durability and end-of-life (EOL) strategies such as reusing products and components and recycling materials. With an estimated 80 million tons of global cumulative EOL photovoltaic (PV) modules, applying CE principles to the PV industry could alleviate resource scarcity issues while also providing economic benefits. However, transitioning to a CE may imply changes in organizations and consumer behaviors. In this context, assessment of CE strategies may require accounting for behavioral change, a requirement that methods from complex system science such as agent-based modeling meet. Thus, this paper uses an agent-based modeling (ABM) approach to study circularity in the photovoltaics supply chain. Four types of agents are represented in the ABM: PV owners, installers, recyclers, and manufacturers. Moreover, five possible EOL options – including three CE strategies – are modeled. Departing from traditional techno-economic analysis, the model includes techno-economic factors as well as social factors to model EOL management decisions. Results show that each dollar decrease in the recycling fees improves the recycling rate by roughly 1.1%. However, excluding social factors underestimates the effect that lower recycling prices have on material circularity.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2022

Dynamic Earth Energy Storage: Terawatt-year, Grid-scale Energy Storage Using Planet Earth as a Thermal Battery (GeoTES): Phase I Project (Final Report)

Grid-scale energy storage has been identified by the U.S. Department of Energy’s (DOE) Energy Storage Grand Challenge as a necessary technology to support the continued build-out of intermittent renewable energy resources required to attain a carbon-free energy future. To meet this goal, the 2018 Department of Energy Research and Innovation Act mandated the creation of a comprehensive program to accelerate the development and commercialization of next-generation energy storage technologies. One of numerous energy storage technology options is the storage of excess energy as heated geothermal brine in suitable geologic formations. This concept, known as reservoir thermal energy storage (RTES), geologic thermal energy storage (GeoTES), aquifer thermal energy storage (ATES), etc., relies on the storage of thermal energy in geologic formations for recovery and use in large-scale direct use geothermal (e.g., district heating, industrial processes, etc.) and electrical power generation applications. This thermal energy is derived from excess or waste heat from any high-temperature heat source, such as concentrated solar or from conventional thermal/nuclear generation. As such, RTES can potentially play a significant role in meeting the energy storage shortfall in the coming decades. RTES can provide energy arbitrage through both the storage and production of thermal energy stored in geologic formations for direct use applications and can serve as a source of hot fluids that can be used to generate electricity to support peak demand ramping, thus easing stress on transmission and distribution. This energy storage option has geographic benefits in that energy can be stored locally or regionally depending on the various needs/loads. RTES can also be located across an enormous geographic area, without the need for a traditional hydrothermal resource but where thermal gradients and hydrogeology allow economic exploitation of subsurface heat. The work conducted for this project includes (1) a review of lessons learned from past high-temperature RTES international projects; (2) geochemical experimental investigation and numerical simulations of potential domestic sedimentary reservoirs and (3) development of a thermo-hydrological-mechanical (THM) numerical simulation tool for optimizing formation properties and design parameters to maximize thermal energy storage performance.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Field Laboratory for Emerging Stacked Unconventional Plays in Central Appalachia

The goal of the Field Laboratory for Emerging Stacked Unconventional Plays (ESUP) in Central Appalachia project was to investigate and characterize the resource potential for multi-play production of emerging unconventional reservoirs in Central Appalachia. Project activities included drilling, logging and coring of a vertical characterization well drilled to basement to approximately 15,000 feet in depth. The data from drilling and well logs as well recovered core samples were used by the research team to support characterization of the geology and potential pay zones within the Nora Gas Field of southwestern Virginia and the greater Central Appalachian Basin. This project was led by Dr. Nino Ripepi of the Virginia Center for Coal and Energy Research (VCCER) in close collaboration with EnerVest Operating LLC (EnerVest). VCCER is housed in the Department of Mining and Minerals Engineering at Virginia Tech and was created by an Act of the Virginia General Assembly on March 30, 1977, as an interdisciplinary study, research, information, and resource facility for the Commonwealth of Virginia. EnerVest is a top tier, low-cost oil and natural gas company with a long history of traditional operating relationships with institutional investors as well as public and private companies. This report summarizes two major research activities: 1) Log and Core Analysis and 2) Numerical Modeling. Core analysis comprises the characterization efforts of the ESUP Field Laboratory and includes a discussion of the well logs run in the deep characterization wells, an initial analysis of those, the number, size and location of cores recovered, core testing and analysis done to date as well as plans for future analysis. Numerical modeling is comprised of seven major modeling efforts, including (1) Multiphysics shale transport modeling work, (2) the developed in-house compositional simulator studies, (3) reservoir modeling studies using GEM software, (4) fracture modeling work using EFRAC3D software and (5) numerical modeling efforts with ABAQUS software, (6) Numerical modeling efforts using FLAC3D and PFC3D, and (7) Automatic Machine Learning (AutoML) Studies.

02 PETROLEUM↗
DOE OSTI2020

Time-series machine-learning error models for approximate solutions to parameterized dynamical systems

This work proposes a machine-learning framework for modeling the error incurred by approximate solutions to parameterized dynamical systems. In particular, we extend the machine-learning error models (MLEM) framework proposed in Ref. Freno and Carlberg (2019) to dynamical systems. The proposed Time-Series Machine-Learning Error Modeling (T-MLEM) method constructs a regression model that maps features – which comprise error indicators that are derived from standard a posteriori error-quantification techniques – to a random variable for the approximate-solution error at each time instance. The proposed framework considers a wide range of candidate features, regression methods, and additive noise models. We consider primarily recursive regression techniques developed for time-series modeling, including both classical time-series models (e.g., autoregressive models) and recurrent neural networks (RNNs), but also analyze standard non-recursive regression techniques (e.g., feed-forward neural networks) for comparative purposes. Finally, numerical experiments conducted on multiple benchmark problems illustrate that the long short-term memory (LSTM) neural network, which is a type of RNN, outperforms other methods and yields substantial improvements in error predictions over traditional approaches.

42 ENGINEERING↗
NASA NTRS2021

From Low-Cost Sensors to High-Quality Data: A Review of Challenges and Summary of Best Practices for Effectively Using Low-Cost Particulate Matter Mass Sensors

Low-cost sensors for particulate matter mass (PM) enable spatially dense, high temporal resolution measurements of air quality that traditional reference monitoring cannot. Low-cost PM sensors are especially beneficial in low and middle-income countries where few, if any, reference grade measurements exist and in areas where the concentration fields of air pollutants have significant spatial gradients. Unfortunately, low-cost PM sensors also come with a number of challenges that must be addressed if their data products are to be used for anything more than a qualitative characterization of air quality. The various PM sensors used in low-cost monitors are all subject to biases and calibration dependencies, corrections for which range from relatively straightforward(e.g. meteorology, age of sensor) to complex (e.g. aerosol source, composition, refractive index). The methods for correcting and calibrating these biases and dependencies that have been used in the literature likewise range from simple linear and quadratic models to complex machine learning algorithms. Here we review the needs and challenges when trying to get high-quality data from low-cost sensors. We also present a set of best practices to follow to obtain high-quality data from these low-cost sensors.

low-cost sensors↗
DOE OSTI2025

Scalable edge clustering of dynamic graphs via weighted line graphs

Timestamped relational datasets consisting of records (or connections) between pairs of entities are ubiquitous in network science. For applications like peer-to-peer communication, email, various social network interactions, and computer network security, it is useful to organize these records into groups based on how and when they are occurring. Weighted line graphs offer a natural way to model how records are related in such datasets but for large real-world graph topologies, building and utilizing the line graph is prohibitively expensive. Here, we present the framework to cluster the edges of a dynamic graph via the associated line graph that contains two major contributions. The first is a method to work with the line graph implicitly and the second is a distributed scale implementation of an agglomerative hierarchical graph clustering algorithm. We outline a novel hierarchical dynamic graph edge clustering approach that efficiently breaks massive relational datasets into small sets of edges containing events at various timescales. This is in stark contrast to traditional graph clustering algorithms that prioritize highly connected (clique-like) community structures. Our approach relies on constructing a sufficient subgraph of a weighted line graph and applying a hierarchical agglomerative clustering. This approach is related to scalable techniques from spatial clustering, nonlinear-dimension reduction, topological data analysis, and draws particular inspiration from HDBSCAN. As an edge clustering, this method yields an overlapping node clustering. Our algorithm is parallelizable and we demonstrate efficient clustering of a billion-scale, real-world dynamic graph into small edge sets that correlate in topology and time. The entire clustering process for a graph with tens of billions of edges takes just a few minutes of run time on 256 nodes of a distributed compute environment. We argue how the output of the edge clustering is useful for a multitude of data visualization and powerful machine learning tasks, both involving the original massive dynamic graph data and metadata associated with the nodes and edges. Finally, we describe how this approach can be extended to dynamic hypergraphs and dynamic graphs/hypergraphs with unstructured data living on vertices and edges.

Data Analysis↗
DOE OSTI2025

Enhancing Multi-Step Reservoir Inflow Forecasting: A Time-Variant Encoder–Decoder Approach

Accurate reservoir inflow forecasting is vital for effective water resource management. Reliable forecasts enable operators to optimize storage and release strategies to meet competing sectoral demands—such as water supply, irrigation, and hydropower scheduling—while also mitigating flood and drought risks. To address this need, in this study, we propose a novel time-variant encoder–decoder (ED) model designed specifically to improve multi-step reservoir inflow forecasting, enabling accurate predictions of reservoir inflows up to seven days ahead. Unlike conventional ED-LSTM and recursive ED-LSTM models, which use fixed encoder parameters or recursively propagate predictions, our model incorporates an adaptive encoder structure that dynamically adjusts to evolving conditions at each forecast horizon. Additionally, we introduce the Expected Baseline Integrated Gradients (EB-IGs) method for variable importance analysis, enhancing interpretability of inflow by incorporating multiple baselines to capture a broader range of hydrometeorological conditions. The proposed methods are demonstrated at several diverse reservoirs across the United States. Our results show that they outperform traditional methods, particularly at longer lead times, while also offering insights into the key drivers of inflow forecasting. These advancements contribute to enhanced reservoir management through improved forecasting accuracy and practical decision-making insights under complex hydroclimatic conditions.

58 GEOSCIENCES↗
DOE OSTI2025

Additive manufacturing of metal matrix composites

Although Metal matrix composites (MMCs) are superior to most sought-after metallic alloys, their challenging fabricability has limited their widespread use in bulk-form applications. Among the many advanced fabrication techniques, Additive Manufacturing (AM), owing to its unique capabilities to produce near-net shapes, has drawn significant traction in the past two decades, especially for materials that are difficult to process using traditional methods. However, unlike pure metal/alloy systems, MMCs are highly sensitive to the processing conditions prevailing in AM techniques due to factors such as the high melting point of reinforcement particles and the potential for in-situ reactions. Therefore, it may be a while before metal matrix composites are commercially produced via AM. This review will discuss the current state-of-the-art design, fabricability, and performance of various additively manufactured MMCs. A particular focus will be on microstructural evolution and microstructure-property relationships. The most employed AM techniques, such as directed energy deposition, powder bed fusion, binder jetting, sheet lamination, and solid-state friction stir processing, are fundamentally different in terms of thermo-kinetics, forming the perspective for this review. A detailed comparison of microstructural evolution and process parameter optimization, including feedstock preparation methods and the role of machine learning and modeling among the different AM processes, is also presented. Finally, a critical evaluation of emerging AM technologies for MMCs is also provided, highlighting their potential advantages and challenges.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Flat and Level Analysis Tool (FLAT) for real-time automated segmentation and analysis of concrete slab point clouds

In the United States, the flatness and levelness of concrete floors during construction is traditionally specified by a maximum allowable gap under a 3 meter straightedge. However, the straightedge method is inexact and rarely representative of the entire floor since the technician is free to choose any location on the floor to perform the measurement. In cases requiring a higher degree of precision and repeatability, concrete floor flatness and levelness can be measured using the standard test method ASTM E1155. With the recent introduction of advanced surveying instruments such as robotic theodolites and terrestrial laser scanners (TLS), the means now exist to modernize and expedite the measurement of floor flatness and levelness. This paper details the development and demonstration of a digital tool, named the Flat and Level Analysis Tool (FLAT), to automate and expedite the segmentation and analysis of flatness and levelness from dense point cloud data of concrete floor slabs. Segmentation algorithms were developed using unsupervised machine learning to extract the set of points belonging to the concrete floor slab from a full 360 scan of a construction site. After segmentation, automated analysis algorithms report the results according to the standard method. The developed algorithms were demonstrated on a dense point cloud captured from a concrete slab-on-grade at a construction site. Results show that the digital tool can quickly provide estimates for floor flatness and levelness with minimal human involvement with comparable accuracy to manual methods.

Hayes, Nolan↗
NASA NTRSDate not supplied

Novel Observing Strategies (NOS) and Earth System Digital Twins (ESDT) for Disaster Resilience

"Earth systems have now been observed continuously for more than 50 years, not only from space but also from airplanes, balloons and in-situ sensors. With the addition of commercial remote sensing providers, many more Internet-of-Things sensors and new NASA and international observatories being planned, these incredible amounts of data will soon be augmented by even larger amounts of diverse data and therefore will become more and more difficult to access, integrate, understand and utilize. At the same time, because of climate change and its impacts, in order to predict, manage, and mitigate the effects of extreme science events and disasters, the information produced by all of this data needs to be optimized, organized and analyzed in such a way that it can be utilized by traditional as well as many new non-traditional users. This calls for the development of observing systems that are agile, coordinated and responsive to events of interest, and for information systems to be dynamic, interactive and fast. With these objectives in mind, the Advanced Information Systems Technology (AIST) Program has been developing technologies that will allow for the development of Novel Observing Strategies (NOS) in a distributed, coordinated fashion (i.e., similar to an “Internet-of-Earth-Things”), as well as for the development of novel information systems or Earth System Digital Twins (ESDT) that will build a digital replica of the past and current states of the Earth systems, will derive forecasts of future states under nominal assumptions and will also offer the capability to investigate many hypothetical evolution scenarios under varying impact assumptions. Both NOS and ESDT will be facilitated by the unprecedented advances of Artificial Intelligence technologies, especially Machine Learning (ML), for extracting relevant information from these large amounts of data, for fusing and assimilating diverse data together and for running complex models faster. Together NOS and ESDT will help build the capabilities needed to anticipate, predict and mitigate the effects of future disasters."

Earth Science Remote Sensing; Information Systems↗
DOE OSTI2023

TEACHING AN OLD ACCELERATOR NEW TRICKS

The Argonne Tandem Linac Accelerator System (ATLAS) has been a National User Facility since 1985. In that time, many of the systems that help operators retrieve, modify, and store beamline parameters have not kept pace with the advancement of technology. Development of a new method of storing and retrieving beamline parameters resulted in the testing and installation of a time-series database as a potential replacement for the traditional relational database. InfluxDB was selected due to its self-hosted Open-Source version availability as well as the simplicity of installation and setup. A program was written to periodically gather all accelerator parameters in the control system and store them in the time-series database. This resulted in over 13,000 distinct data points, captured at 5-minute intervals. A second test captured 35 channels on a 1-minute cadence. Graphing of the captured data is being done on Grafana, an Open-Source version is available that co-exists well with InfluxDB as the back-end. Grafana made visualizing the data simple and flexible. The testing has allowed for the use of modern graphing tools to generate new insights into operating the accelerator, as well as opened the door to building large data sets suitable for Artificial Intelligence and Machine Learning applications.

Novak, D.↗
DOE OSTI2023

Scalable in situ non-destructive evaluation of additively manufactured components using process monitoring, sensor fusion, and machine learning

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. However, the current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques, which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. In this work, an in situ NDE (INDE) system was engineered to detect subsurface flaws detected in X-Ray Computed Tomography (XCT) directly from process monitoring data. A multilayer, multimodal data input allowed the INDE system to detect numerous subsurface flaws in the size range of 200–1000µm using a novel human-in-the-loop annotation procedure. Furthermore, a framework was established for generating probability-of-detection (POD) and probability-of-false-alarm (PFA) curves compliant with NDE standards by systematically comparing instances of detected subsurface flaws to post-build XCT data. Here, we also introduce for the first time in the AM in situ sensing literature the a 90/95 – the flaw size corresponding to a 90% detection rate on the lower 95% confidence interval of the POD curve. The INDE system successfully demonstrated POD capabilities commensurate with traditional NDE methods. Traditional ML performance metrics were also shown to be inadequate for assessing the ability of the INDE system’s flaw detection performance. It is the hope of the authors that future studies will adopt the POD and PFA approach outlined here to provide better insight into the utility of process monitoring for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Grand challenges in the design, manufacture, and operation of future wind turbine systems

Abstract. Wind energy is foundational for achieving 100 % renewable electricity production, and significant innovation is required as the grid expands and accommodates hybrid plant systems, energy-intensive products such as fuels, and a transitioning transportation sector. The sizable investments required for wind power plant development and integration make the financial and operational risks of change very high in all applications but especially offshore. Dependence on a high level of modeling and simulation accuracy to mitigate risk and ensure operational performance is essential. Therefore, the modeling chain from the large-scale inflow down to the material microstructure, and all the steps in between, needs to predict how the wind turbine system will respond and perform to allow innovative solutions to enter commercial application. Critical unknowns in the design, manufacturing, and operability of future turbine and plant systems are articulated, and recommendations for research action are laid out. This article focuses on the many unknowns that affect the ability to push the frontiers in the design of turbine and plant systems. Modern turbine rotors operate through the entire atmospheric boundary layer, outside the bounds of historic design assumptions, which requires reassessing design processes and approaches. Traditional aerodynamics and aeroelastic modeling approaches are pressing against the limits of applicability for the size and flexibility of future architectures and flow physics fundamentals. Offshore wind turbines have additional motion and hydrodynamic load drivers that are formidable modeling challenges. Uncertainty in turbine wakes complicates structural loading and energy production estimates, both around a single plant and for downstream plants, which requires innovation in plant operations and flow control to achieve full energy capture and load alleviation potential. Opportunities in co-design can bring controls upstream into design optimization if captured in design-level models of the physical phenomena. It is a research challenge to integrate improved materials into the manufacture of ever-larger components while maintaining quality and reducing cost. High-performance computing used in high-fidelity, physics-resolving simulations offer opportunities to improve design tools through artificial intelligence and machine learning, but even the high-fidelity tools are yet to be fully validated. Finally, key actions needed to continue the progress of wind energy technology toward even lower cost and greater functionality are recommended.

17 WIND ENERGY↗