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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 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Characterizing the acceleration time of laser-driven ion acceleration with data-informed neural networks

Peak ion energy is an important figure-of-merit in short-pulse, laser-driven ion acceleration and is dependent on an associated acceleration time. Standard metrics for these quantities depend on analytical results such as the self-similar fluid model or empirical models based on relatively small experimental and simulation datasets. In this work we attempt to use a data-informed neural network (NN) as a surrogate model for a large ensemble of PIC simulations to investigate an effective acceleration time. We explore the application of a stacked convolutional and recurrent NN architecture for improved regression by incorporating the time dependencies of the data into the training process. Of particular note is how pretraining a network on lower fidelity data, e.g. 1D analytical results, greatly improves the network's ability to learn more complex, higher fidelity data. Finally, the dependency of the acceleration time on various laser and plasma parameters is explored.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Module-OT: A Hardware Security Module for Operational Technology

Increased penetration levels of renewable energy and other types of distributed energy resources (DERs) on the modern electric grid-combined with technological advancements for electric system monitoring and control-introduce new cyberattack vectors and increase the cyberattack surface of energy systems. According to the IEEE Std. 1547-2018, DERs must use Modbus, Distributed Network Protocol 3 (DNP3), or Smart Energy Profile 2.0 (SEP2) as their communication protocol. Previous research identified several vulnerabilities and security breaches in each one of these communication protocols; despite this, existing standards for DERs do not recommend cybersecurity measures. In order to reduce vulnerabilities in power distribution systems, this paper presents a novel open-source hardware security module that improves both information and operational security to better protect data and communications on the distribution grid. The security hardware is called “module for operational technology,” or simply Module-OT, and it has been validated and tested in an emulated distribution system application. Module-OT is integrated within a communication system in the transport layer of the Open Systems Interconnection (OSI) model. It improves system security through encryption, authentication, authorization, certificate management, and user access control. The main advancement of Module-OT is the addition of hardware cryptographic acceleration that improves the overall communication performance in terms of end-to-end latency.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

The Wonders of Physics -- Public Outreach (Final Technical Report)

The mission of The Wonders of Physics (TWoP) outreach program is to generate interest in physics among people of all ages and backgrounds. The objective is to generate interest in physics, increase appreciation for the significance of physics in our lives, and encourage children to consider careers in science and plasma physics. The primary means for achieving that objective is to make entertaining presentations to audiences that would not normally be motivated to attend a lecture on physics or plasmas, while at the same time introducing some of the fundamental concepts and applications. During this reporting period, the students Michael Hall, Megan Tabbutt and Connor Sullivan, Director of Communications Sarah Perdue, Director of Undergraduate Program Jim Reardon, and Senior Information Processing Consultant Paul Wilhite worked to make outreach programs a success and prepare for the future of The Wonders of Physics, which will continue. Because of the curtailment of public events due to Covid-19, there will not be an in person Annual Show or Physics Fair in 2021, but a video competition has already been announced and planning continues for The Wonders of Physics in 2022 and beyond. The annual shows and Physics Fair are scheduled for February 12-13 and February 19-20, 2022. These continue to be our premier outreach events, engaging diverse audiences in real hands-on science. Further shows and exploration stations are planned.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

RESIN: Responsible Innovation for Highly Recyclable Plastics - TASK 4: Risk Assessment Framework

This report covers the entirety of Task 4, but its main purpose is to deliver milestones ML4.4 and ML4.5, the last two SOPO milestones under Task 4. ML4.4 reports on the compatibility of polymer properties that affect both environmental performance and functional performance and the tradeoffs involved in turning these properties to the benefit of each. ML4.5 presents a complete set of information on the critical properties of benign target products, where benign products are defined as those with the shortest environmental lifetime which meet performance requirements. To support and provide context to the discussions of ML4.4 and ML4.5 and to provide a complete picture of Task 4, milestones 4.1-4.3 are briefly summarized at the beginning of the report. The discussion of ML4.4 introduces the notion of polymer persistence as a proxy for environmental risk. It then discusses the development and comparison of two machine leaning models explored for estimating polymer degradation rates, a random forest (RF) classifier and an RF regressor. Given the advantage of continuous outputs rather than simple classes, the RF regressor was incorporated in the Excel risk calculator, which to this point could implement the objectives of subtasks 4.1-4.3, estimating polymer release and redistribution. The ML4.4 discussion then addresses the effect of each of the three polymer features used by the RF regressor on polymer functional performance. These features are number molecular weight (Mn), glass transition temperature (T g ) and heat of fusion (H fus ). The discussion of ML4.5 reviews the conceptual framework of the risk model, which served as the foundation for developing the Excel risk calculator and describes the use of, and assumptions within, the calculator. Appendix A is further provided as a user’s guide for the calculator. To demonstrate how the calculator is intended to be used by developers in the design of low-risk polymers, an analysis of 27 hypothetical polymers defined by varying values for the three polymer features used by the RF regressor is presented. The range of parameter values selected produces estimates of polymer degradation rates and lifetimes that may be typical of various consumer products made from polyurethane polymers and shows how changes in polymer features affect lifetimes. The demonstration also predicts the final distribution of released polymer materials in environmental compartments as a function of consumer product mix and assumed leakage rates of end-of-life processes. Lastly, this report summarizes the achievement of Task 4 goals from original conception to final delivery and discusses how and to what degree to which each subtask goal was achieved.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A physics-informed deep learning model of the hot tail runaway electron seed

A challenging aspect of the description of a tokamak disruption is evaluating the hot tail runaway electron seed that emerges during the thermal quench. This problem is made challenging due to the requirement of describing a strongly non-thermal electron distribution, together with the need to incorporate a diverse range of multiphysics processes, including magnetohydrodynamic instabilities, impurity transport, and radiative losses. Here this work develops a physics-informed neural network (PINN) tailored to the solution of the hot tail seed during an axisymmetric thermal quench. Here, a PINN is developed to identify solutions to the adjoint relativistic Fokker–Planck equation in the presence of a rapid quench of the plasma's thermal energy. It is shown that the PINN is able to accurately predict the hot tail seed across a range of parameters, including the thermal quench timescale, initial plasma temperature, and local current density, in the absence of experimental or simulation data. The hot tail PINN is verified by comparison with direct Monte Carlo simulations, with excellent agreement found across a broad range of thermal quench conditions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRSDate not supplied

Some Aeronautical Communications Experiments

Classically there has existed an asymmetry between the computing and communicating sides of aerospace systems. Over the past few decades, this asymmetry has shifted to favoring communication link technologies, meaning that advancements in available central processing units (CPUs), storage devices, and internal data buses have stagnated. Indeed, the increased emphasis placed on refining subsystem performance such as with antenna bandwidth in phased arrays, amplifier power efficiency, software defined radio (SDR) flexibility and encoding for data compression and error correction has given rise to successful debuts of multi-gigabit-per-second data return from long space-link distances. These accomplishments are easily quantifiable through link budgets and illustrate what is possible, but also reveal the deficiencies in overall communications capabilities. In particular, the ever-accelerating presence of aerospace vehicles gives rise to newer and larger classes of challenges to address the needs of 21st century systems. Furthermore remote sensing and imaging capabilities have far outpaced our ability to transmit their products to the ground, so we are increasingly dependent on pre-processing and downselection to contend with the communications bottleneck. No longer may we depend upon the constrained logistics in delivering end-to-end data delivery through manual reconfigurations, static event scheduling and execution on a per-vehicle basis, for these methods do not scale and therefore must give way to dynamic, networked approaches with an overall systems view in mind. Emerging mission requirements exhibit a trend toward multiple smaller-scale vehicles working together to perform dissimilar observations. Such operations necessitate sensor fusion across a constellation, and where data processing may be distributed throughout a fairly disconnected network whose topology changes over time in non-deterministic manners. Individual communications link performance is still very relevant to deploying an effective communications system, but now must be embedded within a greater architecture of capability to optimally utilize the bandwidth available from each link to generate an ultimate end-to-end quality of service. The deleterious effects of timing uncertainty across the arrangement presents a challenge to measurement synchronization and delivery, so a successful deployed system needs to be tolerant to the delays inherent in time-of-light between elements and digital processing latencies existing at each node. In this presentation we share the flight test results from a high performance Gbps laser communications terminal evaluated with a suite of store and forward capabilities called High-rate Delay Tolerant Networking (HDTN). The communications payload is operated over Lake Erie across a range of configurations including several convergence layers, and is evaluated to determine recovery time after link disruptions, information loss, efficiency and speed. The effectiveness of utilizing a flying laboratory to increase the Technology Readiness Level (TRL) of an integrated system in relevant environments is discussed, as well as the value of conducting aeronautics experiments to retire risk for technology infusion into space missions. Upcoming flight campaigns will be presented, including opportunities to demonstrate secure command and control, data intensive hyperspectral imaging, quantum link characterization, 4k High Definition (HD) video streaming and internetworked space-ground-aero relay operations. These experiments will pave the way for future missions which will depend upon interoperability across disparate government and privately owned networks, involve contention with uncertain and dynamic timing, and require agility to autonomously configure optimal parameters across networks of ever-increasing size and complexity to ensure data delivery. https://www1.grc.nasa.gov/space/scan/acs/tech-studies/dtn/

Daniel Raible↗
DOE OSTI2021

How much information on precipitation is contained in satellite infrared imagery?

Satellite infrared (IR) brightness temperature providing information on the characteristics of cloud tops is one of the primary input data used for estimating precipitation from satellites. Thus, the natural questions to ask are: Does IR imagery contain more information about precipitation in some regions more than others? What are the factors that lead to such differences? Should we expect the amount of information provided by IR imagery to change with respect to temporal or spatial aggregation? Comprehensive analysis of the accuracy of satellite-based precipitation estimates obtained from any given algorithm may provide qualitative answers to the above questions. However, such an approach only offers conclusions within the limited context of the algorithm used to obtain precipitation estimates; that is, patterns caused by the inherent information content of IR imagery are inextricable from those induced by assumptions embedded in the precipitation estimation algorithm. Here, we address the abovementioned questions from a different perspective using an information-theoretic measure, free of structural assumptions and general to a wide range of relationships, to characterize the average and seasonal dependence between IR imagery provided by satellite sensors in the spectral range (10.7–11.5 μm) and precipitation rates in the contiguous United States (CONUS) across distinct temporal and spatial scales. We analyze a total of more than 1.3 billion pairs of IR and precipitation observations over CONUS, and we observe interesting patterns. First, we show that there is a strong inverse relationship (ρ = - 0.73) between the information content of IR data and the number of no-rain observations; however, its robustness varies regionally and seasonally with less significant correlation during the warm season. Second, we demonstrate that the intuitive relationship of increasing dependence between IR and precipitation as a result of temporal or spatial aggregation exhibits a diminishing returns behavior. For instance, temporal aggregation from 1 to 3 h increases the dependence approximately 7 times as much as temporal aggregation from 12 to 24 h. Furthermore, we quantitatively examine and re-confirm several statements previously reported in the literature such as the strong association between IR and precipitation in convective storms and the low association in orographic rainfall. Finally, we conclude by illustrating the potential of the analysis in diagnosis of operational algorithms for estimating precipitation from IR brightness temperature. The findings of this study pinpoint spatial domains and time scales at which IR is not an adequate proxy for estimating precipitation. Thus, they can potentially guide the development of operational algorithms that utilize satellite Infrared imagery for estimating, downscaling and data fusion of precipitation. Finally, the analysis presented here opens up the possibility of developing new methodologies for diagnosis of satellite-based precipitation estimation algorithms.

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

Common Column Identification for Table Similarity Detection in Electrified Transportation Data Lakes

Electrified transportation often requires researchers and operators to interact with datasets from a wide range of sources and disciplines, such as transportation, power systems, public health, policies, and regulations. These datasets vary in quality and format, making it difficult to understand, preprocess, and identify key columns representing real-world entities or values for indexing and joining, which can negatively impact downstream analysis and operation. Existing solutions are limited, requiring extensive manual customization or data expertise to utilize. In this article, we propose a multi-layered approach to automatically identify key columns to expedite preprocessing and aid in analysis of electrified transportation data. Our method leverages a dynamic ontology to identify common fields and an information theory-based strategy for edge cases that are difficult to generalize. Evaluations on a number of datasets from data.gov and kaggle.com show improved performance of our methods over several baseline techniques, and our ablation analyses illustrate the efficacy of individual components of our method. Our case studies also demonstrate that our methods have the potential to improve analysis of electrified transportation data and aid in automatic integration of such datasets.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗
NASA NTRS2020

An Evolutionary System of Mineralogy. Part I: Stellar Mineralogy (>13 to 4.6 Ga)

Minerals preserve records of the physical, chemical, and biological histories of their origins and subsequent alteration, and thus provide a vivid narrative of the evolution of Earth and other worlds through billions of years of cosmic history. Mineral properties, including trace and minor elements, ratios of isotopes, solid and fluid inclusions, external morphologies, and other idiosyncratic attributes, represent information that points to specific modes of formation and subsequent environmental histories—information essential to understanding the co-evolving geosphere and biosphere. This perspective suggests an opportunity to amplify the existing system of mineral classification, by which minerals are defined solely on idealized end-member chemical compositions and crystal structures. Here we present the first in a series of contributions to explore a complementary evolutionary system of mineralogy—a classification scheme that links mineral species to their paragenetic modes. The earliest stage of mineral evolution commenced with the appearance of the first crystals in the universe at >13 Ga and continues today in the expanding, cooling atmospheres of countless evolved stars, which host the high-temperature (T > 1000 K), low-pressure (P < 10-2 atm) condensation of refractory minerals and amorphous phases. Most stardust is thought to originate in three distinct processes in carbon- and/or oxygen-rich mineral-forming stars: (1) condensation in the cooling, expanding atmospheres of asymptotic giant branch stars; (2) during the catastrophic explosions of supernovae, most commonly core collapse (Type II) supernovae; and (3) classical novae explosions, the consequence of runaway fusion reactions at the surface of a binary white dwarf star. Each stellar environment imparts distinctive isotopic and trace element signatures to the micro- and nanoscale stardust grains that are recovered from meteorites and micrometeorites collected on Earth’s surface, by atmospheric sampling, and from asteroids and comets. Although our understanding of the diverse mineral-forming environments of stars is as yet incomplete, we present a preliminary catalog of 41 distinct natural kinds of stellar minerals, representing 22 official International Mineralogical Association (IMA) mineral species, as well as 2 as yet unapproved crystalline phases and 3 kinds of non-crystalline condensed phases not codified by the IMA.

Robert M. Hazen↗
DOE OSTI2022

Platform for probing radiation transport properties of hydrogen at conditions found in the deep interiors of red dwarfs

We describe an experimental concept at the National Ignition Facility for specifically tailored spherical implosions to compress hydrogen to extreme densities (up to ∼800× solid density, electron number density ne∼4×1025 cm−3) at moderate temperatures (T∼200 eV), i.e., to conditions, which are relevant to the interiors of red dwarf stars. The dense plasma will be probed by laser-generated x-ray radiation of different photon energy to determine the plasma opacity due to collisional (free–free) absorption and Thomson scattering. The obtained results will benchmark radiation transport models, which in the case for free–free absorption show strong deviations at conditions relevant to red dwarfs. This very first experimental test of free–free opacity models at these extreme states will help to constrain where inside those celestial objects energy transport is dominated by radiation or convection. Moreover, our study will inform models for other important processes in dense plasmas, which are based on electron–ion collisions, e.g., stopping of swift ions or electron–ion temperature relaxation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Exploring the High-Pressure Phases of Carbon through X-ray Diffraction of Dynamic Compression Experiments on Sandia’s Z Pulsed Power Facility

The carbon phase diagram is rich with polymorphs which possess very different physical and optical properties ideal for different scientific and engineering applications. An understanding of the dynamically driven phase transitions in carbon is particularly important for applications in inertial confinement fusion, as well as planetary and meteorite impact histories. Experiments on the Z Pulsed Power Facility at Sandia National Laboratories generate dynamically compressed high-pressure states of matter with exceptional uniformity, duration, and size that are ideal for investigations of fundamental material properties. X-ray diffraction (XRD) is an important material physics measurement because it enables direct observation of the strain and compression of the crystal lattice, and it enables the detection and identification of phase transitions. Several unique challenges of dynamic compression experiments on Z prevent using XRD systems typically utilized at other dynamic compression facilities, so novel XRD diagnostics have been designed and implemented. We performed experiments on Z to shock compress carbon (pyrolytic graphite) samples to pressures of 150–320 GPa. The Z-Beamlet Laser generated Mn-Heα (6.2 keV) X-rays to probe the shock-compressed carbon sample, and the new XRD diagnostics measured changes in the diffraction pattern as the carbon transformed into its high-pressure phases. Quantitative analysis of the dynamic XRD patterns in combination with continuum velocimetry information constrained the stability fields and melting of high-pressure carbon polymorphs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An ML-based terrestrial data fusion and augmentation framework to enable advanced understanding of the terrestrial carbon and water interactions

Soil moisture is essential to the terrestrial carbon and water cycles and land–atmosphere interactions. There are various types of soil moisture data, and each type has the distinct spatiotemporal strengths and limitations, depending on the diverse applications and retrieval methodologies of different data types (Li et al., in review; The PNNL-82151 FY23 Report). However, the limitations of different soil moisture data in terms of accuracy and spatiotemporal coverage hinder our ability to further understand the soil moisture dynamics across scales. To have a gap free soil moisture data product with a fine spatiotemporal coverage and vertical profiles, we train extreme gradient boosting (XGBoost) models by using (1) in-situ soil moisture measurements from the International Soil Moisture Network (ISMN), (2) soil moisture from the ECMWF reanalysis (ERA) at the 9 km and sub-daily spatiotemporal resolution, (3) the Daymet meteorological fields, and (4) data products that characterize surface conditions, including soil texture, organic content, topography, vegetation type, and rooting depth. We use the trained XGBoost models that have consistent performance across seven soil layers, i.e., 0–5 cm, 5–10 cm, 10–20 cm, 20–40 cm, 40–60 cm, 60–100 cm, and 100–200 cm, and the gridded model predictors to generate a soil moisture data at the 1 km and daily spatiotemporal resolution for the Continental United States (CONUS) from 2001–2020. This dataset can be broadly used for Earth system model benchmark, monitoring extreme weathers, making informed decisions regarding agriculture, water resource management, climate change mitigation, and ecosystem preservation.

58 GEOSCIENCES↗
DOE OSTI2024

Full time-dependent SOLPS-ITER simulation of the SPARC tokamak: actuator design for particle and divertor condition control *

Abstract This paper presents the application of full time-dependent SOLPS-ITER simulations for actuator design in the SPARC tokamak. This study employs both the EIRENE module, a neutral solver, and the B2.5 plasma module in a time-dependent mode. This is in contrast to most SOLPS simulations, which focus on steady-state solutions, where the neutral distribution is evolved without any time limit or for a time step of 1 ⋅ 10 − 3 second, which is several orders of magnitude larger than the fluid plasma time step. The time-dependent EIRENE was tested with a fixed B2.5 background and compared with a simple conductance based model in a simplified pump chamber geometry. This comparison aimed to verify the reliability of the neutral relaxation timescale derived from the time-dependent EIRENE. Subsequently, a full time-dependent simulation was performed in a realistic geometry, with the Monte-Carlo neutral time step synchronized with the plasma fluid time step. The numerical setup of the code, including relative time steps and the size of the census data used to store Monte-Carlo particle information is considered. The full-time dependent simulations are then applied to inform the design of the SPARC louver structure, which affects divertor plasma parameters by regulating the neutral conductance from the divertor to the pump. The response of the plasma and neutral parameters was captured on a timescale that enables the design of the actuator to consider time-dependent control capability. It was found that changing the louver opacity has an equivalent effect as varying the gas throughput via puff actuation. Therefore, equivalent divertor plasma conditions can be obtained from both actuators, while the neutral pressure distribution in the pump and divertor differs for each actuator.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

General-Purpose Unsupervised Cyber Anomaly Detection via Non-Negative Tensor Factorization

Distinguishing malicious anomalous activities from unusual but benign activities is a fundamental challenge for cyber defenders. Prior studies have shown that statistical user behavior analysis yields accurate detections by learning behavior profiles from observed user activity. These unsupervised models are able to generalize to unseen types of attacks by detecting deviations from normal behavior, without knowledge of specific attack signatures. However, approaches proposed to date based on probabilistic matrix factorization are limited by the information conveyed in a two-dimensional space. Non-negative tensor factorization, on the other hand, is a powerful unsupervised machine learning method that naturally models multi-dimensional data, capturing complex and multi-faceted details of behavior profiles. Herein, our new unsupervised statistical anomaly detection methodology matches or surpasses state-of-the-art supervised learning baselines across several challenging and diverse cyber application areas, including detection of compromised user credentials, botnets, spam e-mails, and fraudulent credit card transactions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Integrating the Value of Resilience into Energy Decisions

The value of resilience can be quantified and integrated into decision making to help inform economic, resilient, and sustainable energy deployment decisions using tools and analysis. Traditionally, distributed energy deployment decisions have often been based on how much energy, or how much money, a system can save. More and more, building owners and communities are recognizing that these systems can also provide a resilience value by sustaining critical loads during an outage. In order to consider the value of resilience in investment decisions, we must quantify how much resilience a system provides, assign a value to that resilience, and monetize that value through grid services, incentives, or other methods. This presentation discusses methods, tools, advantages, and challenges inherent to the process.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Improving ideal MHD equilibrium accuracy with physics-informed neural networks

We present a novel approach to compute three-dimensional magnetohydrodynamic equilibria with isotropic pressure profiles and nested surfaces by parametrizing Fourier modes with artificial neural networks (NNs). The full nonlinear global force residual of single equilibria across the volume in real space is then minimized with first order optimizers and compared to equilibria computed by conventional solvers. Already, we observe competitive computational cost to arrive at the same minimum residuals computable with existing codes. With increased computational cost, lower minima of the residual are computable with the NNs than with any other tested solver, establishing a new lower bound for the force residual. We use minimally complex NNs, and we expect significant improvements for solving not only single equilibria with NNs, but also for creating NN models valid over continuous distributions of equilibria.

ideal magnetohydrodynamics↗
DOE OSTI2021

Melt Pool and Heat Treatment Optimization for the Fabrication of High-Strength and High-Toughness Additively Manufactured 4340 Steel

Additively manufactured (AM) components offer superior design flexibility compared to their conventionally manufactured counterparts, and optimizing processing parameters is key to achieving high-quality depositions with desirable and predictable mechanical properties. This study was focused on 4340 steel fabricated using laser powder bed fusion (LPBF), and 42 laser power and scan speed combinations have been systematically investigated to determine an optimized melt pool geometry that would ensure fully-dense parts. The AM material was compared with a wrought 4340 equivalent and studied in two customized heat treated conditions, optimized for strength and toughness, respectively. The microstructures of the as-fabricated and heat treated AM and wrought materials were characterized to assess differences introduced by the layer-by-layer fabrication process and subsequent heat treatment. Tensile properties of both materials were also evaluated and demonstrate that the AM materials offer equal or superior properties compared to the wrought equivalents. Differences in fracture surface morphologies indicate the distinct failure mechanisms associated with the materials’ characteristic microstructures, and the role of inclusions in the failures was studied to elucidate these differences. Complementary to the experimental investigations, the dataset was leveraged to make recommendations for future design of experiments to optimize AM build parameters in other material systems. A statistical Monte Carlo analysis was used to predict the interpolation error produced using reduced datasets and to enable informed processing parameters selection. These findings are discussed to make recommendations for the use of AM materials for high-integrity structural applications.

36 MATERIALS SCIENCE↗