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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A Data-Driven Framework for Direct Local Tensile Property Prediction of Laser Powder Bed Fusion Parts

This article proposes a generalizable, data-driven framework for qualifying laser powder bed fusion additively manufactured parts using part-specific in situ data, including powder bed imaging, machine health sensors, and laser scan paths. To achieve part qualification without relying solely on statistical processes or feedstock control, a sequence of machine learning models was trained on 6299 tensile specimens to locally predict the tensile properties of stainless-steel parts based on fused multi-modal in situ sensor data and a priori information. A cyberphysical infrastructure enabled the robust spatial tracking of individual specimens, and computer vision techniques registered the ground truth tensile measurements to the in situ data. The co-registered 230 GB dataset used in this work has been publicly released and is available as a set of HDF5 files. The extensive training data requirements and wide range of size scales were addressed by combining deep learning, machine learning, and feature engineering algorithms in a relay. The trained models demonstrated a 61% error reduction in ultimate tensile strength predictions relative to estimates made without any in situ information. Lessons learned and potential improvements to the sensors and mechanical testing procedure are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Recent Progress on Surface Water Quality Models Utilizing Machine Learning Techniques

Surface waterbodies are heavily exposed to pollutants caused by natural disasters and human activities. Empowering sensor technologies in water quality monitoring, sufficient measurements have become available to develop machine learning (ML) models. Numerous ML models have quickly been adopted to predict water quality indicators in various surface waterbodies. This paper reviews 78 recent articles from 2022 to October 2024, categorizing water quality models utilizing ML into three groups: Point-to-Point (P2P), which estimates the current target value based on other measurements at the same time point; Sequence-to-Point (S2P), which utilizes previous time series data to predict the target value at one time point ahead; and Sequence-to-Sequence (S2S), which uses previous time series data to forecast sequential target values in the future. The ML models used in each group are classified and compared according to water quality indicators, data availability, and model performance. Widely used strategies for improving performance, including feature engineering, hyperparameter tuning, and transfer learning, are recognized and described to enhance model effectiveness. The interpretability limitations of ML applications are discussed. This review provides a perspective on emerging ML for surface water quality models.

machine learning (ML)↗
DOE OSTI2023

What’s the Difference? The Potential for Convolutional Neural Networks for Transient Detection without Template Subtraction

Abstract We present a study of the potential for convolutional neural networks (CNNs) to enable separation of astrophysical transients from image artifacts, a task known as “real–bogus” classification, without requiring a template-subtracted (or difference) image, which requires a computationally expensive process to generate, involving image matching on small spatial scales in large volumes of data. Using data from the Dark Energy Survey, we explore the use of CNNs to (1) automate the real–bogus classification and (2) reduce the computational costs of transient discovery. We compare the efficiency of two CNNs with similar architectures, one that uses “image triplets” (templates, search, and difference image) and one that takes as input the template and search only. We measure the decrease in efficiency associated with the loss of information in input, finding that the testing accuracy is reduced from ∼96% to ∼91.1%. We further investigate how the latter model learns the required information from the template and search by exploring the saliency maps. Our work (1) confirms that CNNs are excellent models for real–bogus classification that rely exclusively on the imaging data and require no feature engineering task and (2) demonstrates that high-accuracy (>90%) models can be built without the need to construct difference images, but some accuracy is lost. Because, once trained, neural networks can generate predictions at minimal computational costs, we argue that future implementations of this methodology could dramatically reduce the computational costs in the detection of transients in synoptic surveys like Rubin Observatory's Legacy Survey of Space and Time by bypassing the difference image analysis entirely.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Matrix Multiply Performance of GPUs on Exascale-class HPE/Cray Systems

The computation of dense matrix-matrix products (GEMMs) is central to many modeling and simulation workloads as well as AI/ML deep learning campaigns. In fact, millions of dollars are spent annually on computing GEMMs, and large model training demands are increasing exponentially. Specialized processors such as GPUs are designed to perform well for these operations. However, the performance of GEMMs on GPUs can exhibit complex behaviors depending on many factors, making it challenging to optimize the performance of GEMMs on these processors. In this study we undertake an examination of GEMM performance on several leading GPU models taken from product lines of GPUs to be deployed in forthcoming exascale computing systems. We show results to illustrate the many factors that can affect performance of GEMMs on GPUs. We then present data collected from a large number of test runs for an example GEMM operation to show the dependence behaviors of GEMM rate on matrix dimensions. Finally, we show results from machine learning-based performance models using novel feature engineering methods to fit the measured performance, providing a potential basis for GEMM performance tuning and autotuning methods for GPUs. Recommendations are also given for how to achieve high GEMM performance on modern GPUs.

Melesse Vergara, Veronica↗
DOE OSTI2025

Tandem Predictions for HPC Jobs: Preprint

At the core of the predictive analytics applied to High Performance Computing (HPC), the most prominent tasks are the prediction of job runtimes and the prediction of job queue times, both of which have the potential for informing HPC users during their every-day decision making. Accurate runtime predictions can help users better choose so-called wallclock times at job submission, decreasing the odds of their jobs waiting in queues longer than necessary. The accurate and timely queue time predictions offered for the available partitions can inform the favorable selection of partitions for running jobs. This potential is well understood as we see in the abundance of research studies that propose solutions for these tasks, including the work published in the last several years. These tasks are seemingly receptive to the Machine Learning (ML) solutions, considering that there is no shortage of training data where HPC centers over time run millions and millions of jobs. However, we study the existing research literature, as well as look for examples in the toolchains supported on the exemplar HPC facilities, and, surprisingly, do not find any practical solutions that are ready to be adopted. We interpret this as a manifestation of the shortage of UX/UI efforts that support HPC analytics and also as a sign that the research has not come to the consensus on solving these tasks. In this study, we aim to shed new light on the long-running task of job queue time prediction by exploring the utility of runtime predictions in improving prediction accuracy and, actually, predicting these two metrics together, in tandem. In other words, we show how runtime predictions become valuable input in the queue time modeling. We challenge the existing approaches to feature engineering for the queue time prediction and describe promising results we obtained for a large dataset of HPC jobs from a supercomputer at the National Renewable Energy Laboratory.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Achieving Unprecedented CO 2 Utilization InCO 2 Concrete™: System Design, Product Development and Process Demonstration

Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. This is due to the clinkering process whereby limestone (mainly consisting of CaCO 3 ) is decomposed into CaO and CO 2 , and combined with silica rich clays at high temperatures to form clinkers (i.e. the four key minerals that comprise cement). The high temperature range of 1400 – 1550°C required for this process accounts for up to 60% of the generated CO 2 from cement production. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. Therefore, a CO 2 mineralization technology (CO 2 mineralization concrete) to reduce the OPC content in concrete, while utilizing flue gas emissions from fossil fuel combustion has been developed to address both areas simultaneously. This Reversa™ technology utilizes low-carbon cementation agents produced by in situ CO 2 mineralization (“mineral carbonation reactions”) to offer a promising alternative to OPC. CO 2 mineralization relies upon the reaction of dissolved CO 2 with inorganic alkaline reactants to precipitate mineral carbonates (e.g., CaCO 3 ), which bind proximate particles and achieve cementation. Herein, a concrete green body, which is composed of a mixture of binder, water, and mineral aggregates, is exposed to CO 2 borne in industrial flue gas streams. This manner of CO 2 mineralization allows the production of construction components that feature equivalent engineering attributes as their OPC-based counterparts while featuring a much smaller embodied carbon intensity (eCI). The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of three standard industrial concrete products selected during the course of the project. The results detailed herein will demonstrate the evolution of this technology to the industrial scale. The culmination of this work resulted in 9 production runs completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. Collection of this data will be used to determine the success of the demonstration goals: (1) achieving in excess of 0.2gCO 2 /g reactant , (2) achieving greater than 50% reduction in global warming potential compared to standard produced units, and (3) ensuring compliance of carbonated concrete with industry standard specifications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗
DOE OSTI2024

Deep learning approaches for instantaneous laser absorptance prediction in additive manufacturing

Abstract The quantification of absorbed light is essential for understanding laser-material interactions and melt pool dynamics in order to minimize defects in additively manufactured metal components. The geometry of a vapor depression formed during laser melting is closely related to laser energy absorption. This relationship has been observed by the state-of-the-art in situ high-speed synchrotron X-ray visualization and integrating sphere radiometry. These two techniques create a temporally resolved dataset consisting of vapor depression images and corresponding laser absorptance. In this work, we propose two different approaches to predict instantaneous laser absorptance. The end-to-end approach uses deep convolutional neural networks to learn implicit features of X-ray images automatically and predict the laser energy absorptance. The two-stage approach uses a semantic segmentation model to engineer geometric features and predict absorptance using classical regression models. While having distinct advantages, both approaches achieved a consistently low mean absolute error of less than 3.3%.

Chemistry↗
DOE OSTI2023

High-speed X-ray study of process dynamics caused by surface features during continuous-wave laser polishing

During high-speed X-ray imaging of laser surface polishing experiments of specimens of 316L stainless steel at Argonne National Lab's Advanced Photon Source, it was discovered that the induced keyhole changes shape and dimensions while crossing an engineered surface feature without altering process parameters. It was observed that the post-surface feature keyhole was deeper than that of the pre surface feature keyhole. Here, this work reports on the first in-situ observation of the effect of localized surface geometry on underlying melt pool behavior. This has implications for defect formation mechanisms during laser melting processes that rely on melt pool geometry.

42 ENGINEERING↗
DOE OSTI2023

Advanced Visualization for Scientific Data Analysis and Insight [Slides]

This talk will explore how we have used advanced visualization technologies to support analytical reasoning and knowledge discovery. Specifically, we will present several examples detailing some recent scientific successes using state-of-the-art immersive and high-resolution visualization at the National Renewable Energy Laboratory's Computational Science Center. On multiple occasions, we have observed scientists and engineers discover features in their data using advanced visualization technologies that they had not seen in prior investigations of their data on traditional desktop displays. We have embedded more information into our analytics tools, allowing engineers to explore complex multivariate spaces. We have observed how interactions seem to catalyze understanding.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Correlating Time-Resolved Pressure Measurements With Rim Sealing Effectiveness for Real-Time Turbine Health Monitoring

Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, this study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modeling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Here, the results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within 3% of measured values.

42 ENGINEERING↗
DOE OSTI2022

One fold, many functions—M23 family of peptidoglycan hydrolases

Bacterial cell walls are the guards of cell integrity. They are composed of peptidoglycan that provides rigidity to sustain internal turgor and ensures isolation from the external environment. In addition, they harbor the enzymatic machinery to secure cell wall modulations needed throughout the bacterial lifespan. The main players in this process are peptidoglycan hydrolases, a large group of enzymes with diverse specificities and different mechanisms of action. They are commonly, but not exclusively, found in prokaryotes. Although in most cases, these enzymes share the same molecular function, namely peptidoglycan hydrolysis, they are leveraged to perform a variety of physiological roles. A well-investigated family of peptidoglycan hydrolases is M23 peptidases, which display a very conserved fold, but their spectrum of lytic action is broad and includes both Gram- positive and Gram- negative bacteria. In this review, we summarize the structural, biochemical, and functional studies concerning the M23 family of peptidases based on literature and complement this knowledge by performing large-scale analyses of available protein sequences. This review has led us to gain new insight into the role of surface charge in the activity of this group of enzymes. We present relevant conclusions drawn from the analysis of available structures and indicate the main structural features that play a crucial role in specificity determination and mechanisms of latency. Our work systematizes the knowledge of the M23 family enzymes in the context of their unique antimicrobial potential against drug-resistant pathogens and presents possibilities to modulate and engineer their features to develop perfect antibacterial weapons.

Razew, Alicja↗
DOE OSTI2025

CFD modeling of non-catalytic, partial-oxidation engine reformer for flare mitigation

Flaring associated natural gas is commonly employed in the oil and gas industry to reduce methane (CH 4 ) emissions but generates carbon dioxide (CO 2 ) and harmful pollutants, significantly contributing to air pollution and posing risks to public health. To mitigate this impact, M2X Energy Inc. has developed a small-scale, modular gas-to-methanol system. This system features an engine reformer that performs fuel-rich partial oxidation of wellhead gas to produce syngas—a mixture of carbon monoxide (CO) and hydrogen (H 2 )—followed by a downstream reactor for methanol synthesis. This study focused on computational fluid dynamics (CFD) modeling of the engine reformer to simulate partial oxidation chemistry, predict the rich-burn operating limit, and assess syngas quality, ultimately aiding in design and operational optimization. The CFD model, developed within a Reynolds-Averaged Navier-Stokes (RANS) turbulence framework, incorporated sub-models for turbulent combustion, a chemical mechanism with polycyclic aromatic hydrocarbon (PAH) pathways, and soot emissions to accurately capture the fuel-rich, turbulent jet ignition and combustion processes. Model validation against experimental data showed good agreement across pre- and main-chamber pressures, apparent heat release rates, and exhaust gas concentrations of key species (H 2 , CO, CO 2 , CH 4 ) for varying intake equivalence ratios. Here, the model identified a rich-burn operating limit near a fuel-air equivalence ratio of 2.35, consistent with experimental observations. Furthermore, syngas quality analysis revealed that extending the rich-burn limit through engine reformer optimization could enhance syngas production, contributing to higher methanol synthesis efficiency.

Computational Fluid Dynamics↗
DOE OSTI2026

Feature issue introduction: laser driven inertial confinement fusion and bridging the gaps to inertial fusion energy systems

Major fusion research milestones have been achieved using laser driven inertial confinement fusion (ICF) in recent years, and these successes have ignited tremendous enthusiasm for inertial fusion energy (IFE). However, the complexity and difficulty of obtaining fusion ignition with a laser driver in a research setting are often underappreciated, as are the gaps to high driver efficiency, high repetition rates, and laser and target durability requirements needs for IFE. On the academic side, several new research laser systems have been constructed over the past few years, enabling researchers to probe the limits of ICF physics and engineering. This feature issue highlights the challenges and capabilities of laser research and development targeted towards advancing IFE.

Physics - Plasma physics↗
DOE OSTI2021

Effects of multiple simultaneous faults on characteristic fault detection features of a heat pump in cooling mode

Faults in air-cooled vapor compression air-conditioning systems are known to reduce performance, including efficiency, capacity, and lifespan. Their effects have been studied, and fault detection and diagnostic (FDD) methods have been developed as tools for field technicians to install or repair systems, or for monitoring to alert operators to the fault’s presence. Most of this work has focused on faults that occur singly. It is likely that in some systems, multiple faults occur simultaneously, but it is uncertain what effects this may have on diagnostics. Here, this paper describes a laboratory study of a split system air source heat pump in which combinations of two, three, and four simultaneous faults occur. The study includes all combinations of: improper evaporator airflow; overcharge or undercharge of refrigerant; liquid line restrictions; and non-condensable gas in the refrigerant, each at multiple fault intensities. Fault features – those characteristics that can be determined from measurements, for use in diagnostics – are analyzed, and the key fault features are presented. A robust existing method for determining refrigerant charge, the virtual refrigerant charge sensor (VRC) is tested using the multiple fault data, in order to understand how its performance is impacted by the combined faults. The VRC performs well, typically able to correctly determine whether a system is undercharged or overcharged, but the magnitude estimates are impacted. The results suggest that simple subcooling-based methods of charging a system are likely to provide unsatisfactory results when other faults are present.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

A systematic review of machine learning in groundwater monitoring

With increasing concerns about water scarcity, groundwater has become crucial since this resource provides most of the freshwater needs. However, various human and natural activities often contaminate the groundwater, making it unsuitable for use. Over the years, scientists and engineers have used many methods to predict and track groundwater contamination as part of environmental monitoring. Consequently, there is an urgent need for improved methods, particularly in the face of increasing contamination. Machine learning has sometimes been used to monitor groundwater, air quality, and climate. Traditional methods must be improved due to the complexity and large amount of environmental data. This includes using hybrid models that combine traditional and new techniques. Despite the use of machine learning in many scientific areas, there is a lack of comprehensive reviews focusing on its use in environmental monitoring, especially groundwater monitoring. We aim to fill this gap by exploring machine-learning applications in groundwater monitoring. We discuss relevant methods, their limitations, and future potential. We summarize research on automating data processing and model training using groundwater sensor data. Our research underscores the transformative potential of machine learning to revolutionize long-term groundwater monitoring and contamination detection, providing valuable insights for future research and practical applications.

AI/ML↗
DOE OSTI2025

Systematic feature design for cycle life prediction of lithium-ion batteries during formation

Optimization of the formation step in lithium-ion battery manufacturing is challenging due to limited physical understanding of solid-electrolyte interphase formation and the long testing time (∼100 days) for cells to reach the end of life. We propose a systematic feature-design framework that requires minimal domain knowledge for accurate cycle life prediction during formation. By only using two simple Q (V) features designed from our framework, extracted from formation data without any additional diagnostic cycles, we achieved an average of 9.87% error for cycle life prediction. Here, the physics-based investigation guided by the two designed features shows that the voltage ranges identified by our framework capture the effects of formation temperature and microscopic-particle resistance heterogeneity. By designing highly predictive, robust, and interpretable features, our approach can accelerate industrial battery formation research, leveraging the interplay between data-driven feature design and mechanistic understanding.

25 ENERGY STORAGE↗