SEARCH · Engineering Papers

Results for “Data-driven model selection”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Opportunities for wave energy in bulk power system operations

Wave energy resources have high, yet largely untapped potential as candidate generation technology. In this paper, we perform a data-driven analysis to characterize the impact of wave energy integration on bulk-scale power systems and market operations. Through data-driven sensitivity studies centered on an optimization-based production cost modeling formulation, our work characterizes the inflection point beyond which wave integration starts impacting power system operations, considering present day transmission infrastructure. Furthermore, our analysis also considers the joint effects of wave energy integration and system-wide transmission expansion. Finally, potential resilience scenarios such as wildfire-driven transmission contingencies and heat wave events are investigated, whereby the contributions of grid-integrated wave energy in alleviating the effects of the resilience events are analyzed. As our demonstration test bed, we consider a reduced-order network topology for the U.S. Western Interconnection with wave energy generation integrated at carefully selected sites across the coastal areas of Washington, Oregon, and northern California. Our results indicate that over a representative year of operations, wave energy integration systematically reduces locational marginal prices (LMPs) of energy and price volatility, especially during periods of high wave resource availability (winter months for the U.S. west coast). Average, maximum, and minimum of hourly LMPs over a typical year of operation was reduced by 2.95, 51.28, and 1.13 $\$$/MWh respectively (over a baseline scenario with no wave energy integration), when the selected network model had a total of 5000 MW wave power installed capacity during the representative year of study. The effects of wave energy integration can remain localized with existing transmission infrastructure (identified to be most pronounced in the Pacific Northwest region in the example we studied). However, with concurrent transmission expansion, the impacts of wave energy integration are likely to have a higher geographical spread. Our results also indicate that wave energy may be able to assist power system operations during resilience events such as major transmission contingencies and heat wave events, although such benefits might be dependent on factors such as proximity of affected area to wave resources, availability of adequate resource potential and adequate transmission capacity.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

Performance analysis and comparison of data-driven models for predicting indoor temperature in multi-zone commercial buildings

Building thermal models, which characterize the properties of a building’s envelope and thermal mass, are essential for accurate indoor temperature and cooling/heating demand prediction. Because of their flexibility and ease of use, data-driven models are increasingly used. Here, this study compared and analyzed the performance of gray-box (resistance-capacitance) and black-box (recurrent neural network) models for predicting indoor air temperature in a real multi-zone commercial building. The developed resistance-capacitance model served as a benchmark model for which full sets of temporal data and building information were used as inputs. The recurrent neural network models were trained and tested assuming various available types and amounts of temporal data and known building physical information to investigate the effects of data and information availability. Feature importance analysis was conducted to select the key variables for different prediction targets under different scenarios. This research provides guidance in selecting an appropriate building thermal response modeling method based on the measured data availability, building physical information, and application.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Physics vs structure: A systematic benchmark of learning strategies for multi-zone building thermal dynamics

Recent advances in physics-informed and data-driven machine learning promise improved thermal models for advanced building control, yet there is limited quantitative evidence on when added physics structure and architectural complexity are beneficial. Here, this work presents a systematic benchmark of five representative system identification methods for modeling multi-zone building thermal dynamics: linear state-space models, multi-layer perceptrons, neural state-space models, neural ordinary differential equations, and physically-consistent neural networks. The methods are evaluated across multiple data regimes and zone coupling strategies. Using a high-fidelity multi-zone commercial building emulator, we examine short-term and long-term prediction accuracy, computational efficiency, and ease of development. Our results reveal critical trade-offs between prediction performance, model complexity, and physical consistency. We demonstrate that decoupled, nonlinear black-box models consistently outperform coupled physics-constrained architectures in both predictive accuracy and out-of-distribution robustness in majority of the test cases for the building type considered in the study. Our findings quantify the cost of complexity in building thermal modeling and provide concrete, actionable, scenario-based guidelines for selecting model classes for control-oriented applications.

Building thermal modeling↗

DOE OSTI2024

Machine learning-guided discovery of polymer membranes for CO 2 separation with genetic algorithm

Designing polymer membranes with high gas permeability and selectivity is a difficult multi-task constrained problem due to the trade-off between these two properties. In this work, we present a machine learning (ML) driven genetic algorithm to tackle the design problem of polymer membranes for CO 2 separation from N 2 and O 2 . Using literature data of permeability for three gases, we constructed multiple ML models with different fingerprinting featurization schemes to predict gas permeabilities. Then, we employed a genetic algorithm to design new polymers and evaluated their performance using our ML models. We were able to identify new polymer membranes that are promising for both CO 2 /N 2 and CO 2 /O 2 separations. Further, the top discovered polymers are predicted to have high glass transition temperatures. Similarly, the pyridine functionality was found in ≈20% of the predicted polymers. This framework can be used to design polymers for any application involving constrained optimization. Finally, we outlined the challenges and opportunities with using ML guided data-driven inverse design of polymers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Bayesian Optimized Deep Ensemble for Uncertainty Quantification of Deep Neural Networks: a System Safety Case Study on Sodium Fast Reactor Thermal Stratification Modeling

Deep neural networks (DNNs) are increasingly important to scientific computing and engineering system simulations. Accurate uncertainty quantification (UQ) for DNNs is critical in safety-sensitive engineering domains. Traditional Deep Ensemble (DE) methods, while easy to implement, frequently suffer from poorly calibrated uncertainty estimates and limited predictive accuracy due to reliance on fixed architectures with varied weight initializations. To address these issues, we introduce a workflow that combines Bayesian Optimization (BO) and DE. The workflow is modular, scalable, and integrates parallel BO initialized with Sobol sequences to individually optimize the hyperparameters of each ensemble member. This method enhances ensemble diversity, improves predictive accuracy, and provides reliable uncertainty estimates. We evaluate the proposed BODE approach in a sodium fast reactor thermal stratification modeling case study, where we used a densely connected convolutional neural network to predict turbulent viscosity during the reactor transient with consideration of data noise. We benchmark its performance against several optimization approaches, including baseline deep ensemble, evolutionary algorithm-optimized ensemble, ensemble formed via random search combined with greedy selection, and a BO ensemble using random initialization. Here, our results demonstrate superior performance of the developed BODE approach. In noise-free scenarios, BODE notably reduces incorrect aleatoric uncertainty and significantly enhances predictive accuracy. Under conditions of 5% and 10% Gaussian noise, BODE adaptively quantifies uncertainty proportional to data noise, achieving up to an 80% reduction in root mean square error compared to baseline methods and producing well-calibrated prediction intervals.

Bayesian optimization↗

DOE OSTI2023

Data-driven analysis and prediction of stable phases for high-entropy alloy design

High-entropy alloys (HEAs) represent a promising class of materials with exceptional structural and functional properties. However, their design and optimization pose challenges due to the large composition-phase space coupled with the complex and diverse nature of the phase formation dynamics. In this study, a data-driven approach that utilizes machine learning (ML) techniques to predict HEA phases and their composition-dependent phases is proposed. By employing a comprehensive dataset comprising 5692 experimental records encompassing 50 elements and 11 phase categories, we compare the performance of various ML models. Our analysis identifies the most influential features for accurate phase prediction. Furthermore, the class imbalance is addressed by employing data augmentation methods, raising the number of records to 1500 in each category, and ensuring a balanced representation of phase categories. The results show that XGBoost and Random Forest consistently outperform the other models, achieving 86% accuracy in predicting all phases. Additionally, this work provides an extensive analysis of HEA phase formers, showing the contributions of elements and features to the presence of specific phases. We also examine the impact of including different phases on ML model accuracy and feature significance. Notably, the findings underscore the need for ML model selection based on specific applications and desired predictions, as feature importance varies across models and phases. This study significantly advances the understanding of HEA phase formation, enabling targeted alloy design and fostering progress in the field of materials science.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Modeling of the metal–insulator transition temperature in alio-valently doped VO 2 through symbolic regression

The correlated semiconductor vanadium dioxide (VO 2 ) exhibits an insulator–metal transition (IMT) near room temperature, which is of interest in various device applications. Precise IMT temperature control is crucial to determine the use cases across technologies such as thermochromic windows, actuators for robots or neuronal oscillators. Doping the cation or anion sites can modulate the IMT by several tens of degrees and control hysteresis. However, modeling the effects of control parameters (e.g., doping concentration, type of dopants) is challenging due to complex experimental procedures and limited data, hindering the use of traditional data-driven machine learning approaches. Symbolic regression (SR) can bridge this gap by identifying nonlinear expressions connecting key input parameters to target properties, even with small data sets. In this work, we develop SR models to capture the IMT trends in VO 2 influenced by different dopant parameters. Using experimental data from the literature, our study reveals a dual nature of the IMT temperature with varying tungsten (W) doping concentrations. The symbolic model captures data trends and accounts for experimental variability, providing a complementary approach to first-principles calculations. Our feature-driven analysis across a broader class of dopants informs selectivity and provides qualitative insights into tuning phase transition properties valuable for neuromorphic computing and thermochromic windows.

36 MATERIALS SCIENCE↗

DOE OSTI2023

What drives the variance of galaxy spectra?

We present a study aimed at understanding the physical phenomena underlying the formation and evolution of galaxies following a data-driven analysis of spectroscopic data based on the variance in a carefully selected sample. We apply principal component analysis (PCA) independently to three subsets of continuum-subtracted optical spectra, segregated into their nebular emission activity as quiescent, star-forming, and active galactic nuclei (AGNs). We emphasize that the variance of the input data in this work only relates to the absorption lines in the photospheres of the stellar populations. The sample is taken from the Sloan Digital Sky Survey (SDSS) in the stellar velocity dispersion range 100–150 km s −1 , to minimize the ‘blurring’ effect of the stellar motion. We restrict the analysis to the first three principal components (PCs) and find that PCA segregates the three types with the highest variance mapping SSP-equivalent age, along with an inextricable degeneracy with metallicity, even when all three PCs are included. Spectral fitting shows that stellar age dominates PC1, whereas PC2 and PC3 have a mixed dependence of age and metallicity. The trends support – independently of any model fitting – the hypothesis of an evolutionary sequence from star formation to AGN to quiescence. As a further test of the consistency of the analysis, we apply the same methodology in different spectral windows, finding similar trends, but the variance is maximal in the blue wavelength range, roughly around the 4000 Å break.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

First Double-Differential Cross Section Measurement of Neutral-Current 𝜋 0 Production in Neutrino-Argon Scattering in the MicroBooNE Detector

We report the first double-differential cross section measurement of neutral-current neutral pion (NC⁢𝜋 0 ) production in neutrino-argon scattering, as well as single-differential measurements of the same channel in terms of final states with and without protons. The kinematic variables of interest for these measurements are the 𝜋 0 momentum and the 𝜋 0 scattering angle with respect to the neutrino beam. A total of 4971 candidate NC⁢𝜋 0 events fully contained within the MicroBooNE detector are selected using data collected at a mean neutrino energy of ∼0.8 GeV from 6.4 ×10 20 protons on target from the Booster Neutrino Beam at the Fermi National Accelerator Laboratory. After extensive data-driven model validation to ensure unbiased unfolding, the Wiener-singular-value-decomposition method is used to extract nominal flux-averaged cross sections. The results are compared to predictions from commonly used neutrino event generators, which tend to overpredict the measured NC⁢𝜋 0 cross section, especially in the 0.2–0.5 GeV/c 𝜋 0 momentum range and at forward scattering angles. Events with at least one proton present in the final state are also underestimated. This data will help improve the modeling of NC⁢𝜋 0 production, which represents a major background in measurements of charge-parity violation in the neutrino sector and in searches for new physics beyond the standard model.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

A Weakly Supervised Machine Learning Procedure for Magnet Quench Diagnostics

Voltage taps remain the standard and reliable diagnostic tool for detecting quenches in superconducting magnets. However, they identify a quench only at the time of voltage rise and do not provide information on earlier physical precursors. In this work, we investigate whether acoustic emission data can reveal precursor activity that occurs before conventional voltage detection using machine learning techniques. We introduce an event selection method and a weakly supervised machine learning procedure to learn data-driven criteria for identifying potential acoustic precursors to quenches. Two Convolutional Neural Network (CNN) architectures are trained: one on acoustic sensor events from our selection procedure and one on the Fast Fourier Transforms (FFTs) of these events. Both networks are trained iteratively using confidence-weighted loss functions to associate certain subsets of training data with a precursor label. We evaluate the performance of these models by examining the time distribution of events classified as potential precursors relative to the quench onset. Results indicate that the proposed approach can possibly distinguish acoustic emission events occurring closer to the quench from earlier acoustic activity during ramping, suggesting the potential for flagging quench precursors in acoustic data.

Khan, Maira [Fermilab] (ORCID:0009000891602387)↗

DOE OSTI2024

A Data-Driven Framework for Power System Event Type Identification via Safe Semi-Supervised Techniques

Herein this paper investigates the use of phasor measurement unit (PMU) data with deep learning techniques to construct real-time event identification models for transmission networks. Increasing penetration of distributed energy resources represents a great opportunity to achieve decarbonization, as well as challenges in systematic situational awareness. When high-resolution PMU data and sufficient manually recorded event labels are available, the power event identification problem is defined as a statistical classification problem that can be solved by numerous cutting-edge classifiers. However, in real grids, collecting tremendous high-quality event labels is quite expensive. Utilities frequently have a large number of event records without in-depth details (i.e., unlabeled events). To bridge this gap, we propose a novel semi-supervised learning-based method to improve the performance of event classifiers trained with a limited number of labeled events by exploiting the information from massive unlabeled events. In other words, compared to existing data-driven methods, our method requires only a small portion of labeled data to achieve a similar level of accuracy. Meanwhile, this work discusses and addresses the performance degradation caused by class distribution mismatch between the training set and the real applications. Based on the proposed safe learning mechanism, our model does not directly use all unlabeled events during model training, but selectively uses them through a comprehensive evaluation procedure. Numerical studies on a sizable PMU dataset have been used to validate the performance of the proposed method.

42 ENGINEERING↗

DOE OSTI2024

Securing Grid-interactive Efficient Buildings (GEB) through Cyber Defense and Resilient System (CYDRES)

The DOE CYDRES project is driven by the urgent need to address critical research gaps in the domain of cyber-physical security of smart buildings, including Grid-interactive Efficient Buildings (GEBs). CYDRES, a real-time advanced building resilient platform, aims to enhance the cyber-attack-immune capabilities of buildings through multi-layered prevention, detection, and adaptation mechanisms. CYDRES consists of five key modules: a multi-layer network analyzer, an Automatic Fault Detection, Diagnosis, and Prognosis (AFDDP) framework, an intelligent mode selector, a cyber-resilient control framework, and a situation awareness platform. The Network Analyzer employs a data-driven framework that includes a protocol state learning tool and a CRF (Conditional Random Field) command validator. In Hardware-In-the-Loop (HIL) testbeds, it achieved 100% detection accuracy with a false alarm rate of 3%, validating its efficacy in identifying selected cyber-attacks. The AFDDP framework leverages pattern matching, PCA (Principal Component Analysis)-based strategies, and a DBN (Dynamic Bayesian Network)-based fault diagnosis approach to pinpoint the causes of physical system abnormalities using Building Automation System (BAS) data. In HIL experiments, the AFDDP module attained a detection accuracy of over 95% with a false alarm rate below 7%. Additionally, the fault detector utilized machine learning (Random Forest) and deep learning (Multi-Layer Perceptron) methods with acoustic sensor data to achieve a 100% fault detection accuracy in Heating, Ventilation, and Air-Conditioning (HVAC) equipment. The Mode Selector offered real-time impact analysis, allowing immediate actions to protect BASs in the face of emerging threats. The cyber-resilient control framework included an adaptive Model Predictive Control (MPC) and a measurement compensator, reducing temperature violations by up to 94% and improving the total demand flexibility by up to 70% in HIL experiments. Such HIL experiments covered a cyber-attack case and a physical fault case, showcasing CYDRES’ efficiency in maintaining operational continuity during threats. The situation awareness platform in Grafana enhanced real-time threat detection and response visualization, augmenting the operational awareness for building operators. CYDRES demonstrated high technical effectiveness in various test scenarios, particularly in HIL environments. The project's phased development approach ensured efficient use of resources, highlighting its practical feasibility and readiness for commercialization. By enhancing the security and resilience of building operations, CYDRES represents a significant advance in mitigating risks associated with cyber-physical systems, thereby enhancing public confidence in the safety of modern building infrastructure. Future directions for the project include expanding testing protocols, refining AFDDP methodologies, exploring more comprehensive resilient control strategies, and testing in real commercial buildings.

42 ENGINEERING↗

DOE OSTI2024

Spin-Controllable Dynamics in Defect-Engineered Carbon Nanotubes as Single Photon Emitters: Data-Driven Modeling and Computations

Quantum technologies, such as quantum computing and sensing, require efficient single-photon emission (SPE) sources that operate at room temperature in telecom wavelengths. While several materials can serve as SPE sources, no single platform meets all the criteria for efficiency, ambient operation, and scalability. Single-walled carbon nanotubes (SWCNTs) with covalently attached molecules offer a promising solution. Their SPE can be easily tuned via modifications of the SWCNT's diameter, chirality, and bonded molecules, enabling emission across near-IR to telecom wavelengths at ambient conditions. However, to fully realize the potential of SWCNTs and unlock their quantum capabilities, a deeper understanding of how structural defects from molecular adducts affect their emission and competing photoexcited processes is essential. To address this gap in our knowledge, this project combined quantum chemistry calculations with data-driven methods of cheminformatics (QSAR) and machine learning (ML). The developed computational approaches have provided several design strategies for covalent functionalization of SWCNTs to improve their optical response. The collaboration with Los Alamos National Lab (LANL) enabled direct comparison of computational and experimental data, facilitating method validation. This partnership was enhanced through access to LANL's Center for Integrated Nanotechnologies (CINT) utilizing User Facility Program and summer internships, which provided three NDSU graduate students with hands-on experience at LANL. The outcomes of this project included (1) Advancing the current stage of computational methods in accurate modeling of non-adiabatic spin-dependent photoexcited dynamics and its applicability to nanosystems consisting of thousands of atoms, realized as open-access codes linked to existing DFT-based software; (2) Establishing the relationship between the structure of adducts and SWCNTs and intrinsic excitonic and spin properties of defect states for guiding novel synthetic strategies and experimental probes of chemically functionalized SWCNTs as near-IR emitting materials; (3) Generating virtual libraries of hypothetical functionalized SWCNTs for virtual screening of their chemical structures and optical properties, leveraging new functionalities of SWCNTs; (4) Offering a unique experience for NDSU graduate students that prepared them for future scientific careers related to materials modeling and big data processing. These results were summarized in 12 published journal papers and 3 recently submitted papers. One of a key finding is that the position of defect sites on the SWCNT surface primarily drives the emission redshift (up to 100 meV), while the polarity of the defect-inducing molecules has a much smaller effect (~10 meV). However, the electron-donating or withdrawing properties of a molecule influence selecting reactivity of defect sites. These insights important for optimizing synthetic protocols for desired emissions in SWCNTs. We also revealed that the interaction between two defects at various positions on the SWCNT enhances the redshift and optical activity of states, favoring strong near-IR emission. This suggests that manipulations in defect concentrations is a promising strategy for controlling efficient emission. Mostly important, the defect position was found controllable by the spin states of photoexcited intermediates: Excited aromatic molecules form ortho defects with SWCNTs at their singlet states in the presence of oxygen, while oxygen-free conditions favor para defects via the triplet-state mechanism. Additionally, a heat-activated [2+2] cycloaddition reaction facilitates divalent defect formation with fewer bonding positions that narrows emission bands. These groundbreaking findings have been experimentally validated and significantly advance our understanding of defect chemistry in SWCNTs. Using a novel encoding technique and 3D-MoRSE descriptors, we developed highly accurate ML/QSAR models to predict both the 3D structure and optical properties of SWCNTs with chemical defects. This model enabled the creation of a virtual library of 125,556 structures, providing new insights into the relationship between SWCNT-defect structure and emission.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2025

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development and deployment of advanced materials and components fabricated via additive manufacturing with a specific focus on laser powder bed fusion (LPBF). As an initial case study, the program has selected 316H stainless steel (SS) as an initial material around which to develop a code case development strategy. This strategy involves two parallel approaches: (1) an equivalency approach whereby round-robin testing across multiple collaborating laboratories demonstrates repeatability in processing and direct comparisons with conventional wrought 316H material and (2) a revolutionary approach to code qualification combining in situ data collection and high-fidelity modeling to capture, predict, and bound the performance of LPBF 316HSS components. As part of this campaign, this work package has initiated an extensive process optimization campaign across three laboratories, each printing variations of LPBF 316HSS using three different LPBF units (Concept Laser, EOS, and Renishaw). In FY23, ORNL has focused on unique experimental designs spanning wide ranges in energy inputs and turning knobs such as scan speed, laser power, hatch spacing, layer thickness, spot size, scan rotation, and more. On the Concept Laser M2, 72 different combinations of processing variables were investigated with duplicate samples and different powder compositions. In total, 252 samples were printed with combined in situ sensing data. A parallel design of experiments was conducted on the Renishaw AM400 with an additional 390 printed specimens for analysis. All 642 miniature specimens, each with unique features included in each print to capture geometry-related heterogeneity, were subjected to high-throughput x-ray computed tomography (XCT) analysis to enable the downselection of specific processing parameters of interest. Then, using electrical discharge machining (EDM), miniature tensile specimens were extracted for mechanical testing and microscopy investigations. From the analysis performed in FY23, it was found that powder composition drastically affects the resulting microstructure and mechanical performance of 316SS. Specifically, changing from 316L to 316HSS powder results in a wide range of grain sizes with varying degrees of preferred grain orientation, which increases as a function of energy density. It was also found that due to stored heat in thin fin–type features, large microstructural differences can be seen within one part printed with one set of processing parameters. These variations in microstructure features, including grain size, the nanoscale dislocation structure, and grain texture, will all affect the irradiation performance and high-temperature mechanical performance of LPBF 316HSS parts. Two sets of concept laser processing parameters, spanning both refined and columnar grain structures, were scaled to print larger 316H builds for campaign testing (high-temperature creep and irradiation). In addition, at least two optimized processing parameter sets were identified for the Renishaw AM400 for round-robin testing in FY24 with Argonne National Laboratory. Future work includes printing samples using identical parameters identified by partner institutions, providing material for corrosion and high-temperature mechanical testing, and continuing evaluations of heterogeneity in larger printed parts.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Web-Based Tools for Data-Informed Remedy Optimization: Software Theory and User Guide

This report documents the development and application of two web-based decision-support tools for pump-and-treat (P&T) groundwater remediation systems: PTOLEMY (Pump-and-Treat Optimized Location Evaluation to Maximize Yields) and OPTIMA (Optimization for Pump-and-Treat Implementation, Management, & Assessment). These tools enhance remedy design and management by leveraging advanced computational methods – specifically deep learning and multi-objective optimization – within a user-friendly platform. By integrating data-driven models with established hydrogeological knowledge, PTOLEMY and OPTIMA enable more efficient evaluation of well placement and operational strategies, helping site managers balance multiple remediation objectives under complex conditions. Both tools are implemented as modules within the SOCRATES (Suite Of Comprehensive Rapid Analysis Tools for Environmental Sites) web platform, which provides data access, visualization, and analytics to support remedy optimization across sites in the U.S. Department of Energy Office of Environmental Management complex. PTOLEMY is a rapid screening module designed to identify promising locations for new extraction wells. It employs a multi-channel three-dimensional convolutional neural network (MC3D-CNN) trained on high-fidelity simulation data to predict the relative performance (in terms of contaminant mass recovery) of potential well sites. Through an interactive web interface, PTOLEMY visualizes the probability of high performance across a site, highlighting areas where an extraction well is likely to yield above-threshold contaminant removal over a multi-year period. PTOLEMY’s map-based displays and exportable results support transparent communication of screening analyses. By focusing attention on the most favorable candidate locations, the tool augments traditional engineering judgment and physics-based modeling, providing a data informed basis for subsequent detailed evaluations. OPTIMA is a multi objective optimization module designed to find wellfield layouts and operating schedules that meet various cleanup goals. It quickly evaluates thousands of candidate setups – combinations of well locations, timing, and rates – and returns a small set of best trade-off options for comparison. At its core, OPTIMA uses a U-Net-based surrogate model – a deep-learning emulator of a groundwater flow and transport simulator – to dramatically accelerate scenario evaluations. Coupling this fast surrogate with the NSGA-II (Non-dominated Sorting Genetic Algorithm II) evolutionary algorithm, OPTIMA explores a wide decision space of well locations and schedules to identify Pareto-optimal solutions that trade off key objectives (e.g., minimizing cleanup time, maximizing contaminant mass removal, and minimizing plume extent). The tool outputs a family of optimal configurations and visualizes their trade-offs (Pareto frontiers of cleanup metrics and maps of optimized well placements). Site managers can use these results to understand the range of viable strategies and to select candidate designs for more detailed verification. OPTIMA is currently under active development and not yet fully released; this guide provides early documentation to support planning and gather user feedback.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Data-Driven Optimization of the Processing Window for 316H Components Fabricated Using Laser Powder Bed Fusion

36 MATERIALS SCIENCE↗

DOE OSTI2025

Data-Driven State of Health Estimation for Second-Life Batteries Using Interpolated Synthetic Data and Feature Selection

Accurate estimation of the State of Health (SOH) for second-life batteries (SLBs) is crucial given their increasing use in energy storage applications. Precise SOH prediction is essential for safe operation and robust battery management systems. A major challenge is the limited availability of datasets for building reliable degradation models. To address this, synthetic data generation through linear interpolation is performed to extend the available data, making it more representative of real-world battery operating conditions. By analyzing feature correlation with SOH, the most relevant features are selected for the model. The proposed approach employs a convolutional neural network (CNN) model trained on this interpolated, feature-selected dataset, using time series data of voltage, temperature, and current over a cycle. By focusing on highly correlated features, the model achieves over 95% accuracy, with mean absolute error and root mean squared error up to 2.27% and 2.64%, respectively, in SOH estimation for two battery datasets tested. These results highlight the potential of combining synthetic data generation and feature selection to enhance SOH predictions, showcasing the superior performance of the proposed CNN model for both new batteries and SLBs.

feature selection↗