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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 OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗
DOE OSTI2025

GRinding Automated Classification Engine

This work is an ML-driven framework for automated surface analysis of microscopy images. We create a training dataset by imaging stainless steel samples to benchmark four developed deep neural network architectures. These models, based on a YOLOv8n-cls backend, integrate image features and process metadata using various fusion methods to distinguish between acceptable and unacceptable surface finishes. This code is associated with publication "Classifying Alloy Surface Preparation Quality with Metadata-Infused Machine Learning for Rapid Alloy Discovery" for project APEX LDRD-ER (25-ERD-039)

Gongora, AldairE [Lawrence Livermore National Labo↗
NASA NTRS2013

Mid-infrared Study of Stones from the Sutters Mill Meteorite

The Sutter's Mill meteorite fell in northern California on April 22, 2012, and numerous pieces have been recovered and studied with several analytical techniques [1]. We present a Fourier-transform infrared (FTIR) spectroscopy analysis of fragments from several stones of the meteorite. Methods and analysis: Infrared spectra of samples SM2 and SM12 were recorded with a Nicolet iN10 MX FTIR microscope in the mid-IR range (4000-650/cm; spectral resolution 4/cm), while samples SM20 and SM30 were analyzed with a synchrotron-based Nicolet Continuum IR microscope in the same range. Samples were deposited on a clean glass slide, crushed with either a stainless steel roller tool or between 2 slides, and placed directly on the focal plane of the microscopes. Results: IR spectra of non-fusion crust samples show several absorption features associated with minerals such as olivines, phyllosilicates, carbonates (calcite and dolomite), and pyroxenes, as well as organics [2]. The carbonates display a main, broad band centered at 1433/cm, with additional bands at 2515/cm, 1797/cm, 882/cm, and 715/cm. Features associated with phyllosilicates include a symmetric Si-O stretching mode band centered at 1011/cm and several O-H stretching mode bands―a broad band centered at 3415/cm that is probably due to adsorbed H2O, and occasionally a much weaker, narrower feature centered near 3680/cm due to structural O-H. Features observed in the 2985-2855/cm range suggest the presence of aliphatic -CH3 and -CH2- groups. However, some of these bands show unusual relative intensities, mainly because of carbonate overtone bands that fall in the same spectral range, which can make the identification of C-H stretching bands problematic. The positions and relative strengths of the aliphatic -CH2- and -CH3 features, where they can be distinguished from overlapping carbonate bands, are consistent with those in interplanetary dust particles (IDPs) and Murchison. Finally, the absence of a strong C=O absorption feature near 1700/cm distinguishes the organics in the Sutter's Mill meteorite from that in most IDPs and in Murchison, but is consistent with the organic matter in Tagish Lake.

mid-infrared study↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
DOE OSTI2022

Extension of the energetic particle transport kick model in TRANSP to multiple fast ion species

Abstract Alfvénic instabilities (AEs) are well known to cause enhanced transport of energetic particles (EPs) in fusion devices. Most studies until now have focused on characterizing and understanding AE stability in single-species plasmas heated by neutral beams (NB), where deuterium is typically used as both main plasma species and NB fuel. As the fusion community moves toward fusion reactors that target burning plasma conditions, such as ITER, the single-species picture breaks down. Burning plasmas, which will use a mix of deuterium and tritium (DT) as main fuel, also feature the presence of several supra-thermal fusion products such as alpha particles, protons, helium isotopes and high-energy tritium ions. This work presents the extension of the EP transport kick model implemented in the TRANSP time-dependent tokamak transport code to study the combined effect of multiple EP species on AE stability and, in turn, the response of different EP species to plasma instabilities in terms of their redistribution and losses. Further validation of the enhanced model is planned based on experimental results expected from the JET DT campaign scheduled for 2021, in preparation for ITER plasmas and beyond.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of consideration for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 10 5 – 10 7 K/s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Interpreting experimental measurements of helium bubbles using stochastic cluster dynamics models of heterogeneous nucleation and growth in irradiated ferritic alloys

Among a number of other advantageous features, ferritic/martensitic steels are being considered as fusion reactor structural materials due to their low intrinsic swelling under irradiation. However, under high-energy neutron irradiation, He produced through (n, α) reactions stabilizes vacancy clusters, which then act as seeds for bubble formation and growth, negating the intrinsic swelling resistance of these alloys. Standard models of irradiation damage accumulation and microstructural evolution consider homogeneous nucleation as the basis for bubble formation and growth. However, this generally does not explain the large bubble densities and sizes observed experimentally under a number of different conditions. Here, we propose a more realistic physical model of bubble nucleation, formation, and growth designed to capture recent experimental measurements of He-bubble formation and evolution during co-implantation of He and Fe ions in model ferritic alloys. We find that experimental results are explained only when the following three features are considered simultaneously: (i) heterogeneous nucleation of He-vacancy bubbles at defect sinks (e.g., dislocations, grain boundaries, and second-phase precipitates), (ii) nucleation and growth of bubbles via the ‘trap mutation’ mechanism (i.e., spontaneous production of Frenkel pairs due to absorption of He atoms), and (iii) transition from a growth-limited, He-stabilized bubble regime to a ‘runaway’ void-type growth scenario. The model is implemented into a stochastic cluster dynamics framework that takes advantage of cluster size grouping methods to accelerate the simulations, allowing us to reach 10 dpa of simulated irradiated dose, and to capture cluster sizes in excess of 20 nm. Further, a careful extrapolation exercise conducted assuming classical nucleation theory leads to excellent agreement with the experimental measurements at 50 dpa of irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Velocity-space compression from Fermi acceleration with Lorentz scattering

The Fermi acceleration model describes how cosmic ray particles accelerate to great speeds by interacting with moving magnetic fields. In this work, we identify a variation of the model where light ions interact with a moving wall while undergoing pitch angle scattering through Coulomb collisions due to the presence of a heavier ionic species. The collisions introduce a stochastic component which adds complexity to the particle acceleration profile and sets it apart from collisionless Fermi acceleration models. The unusual effect captured by this simplified variation of Fermi acceleration is the nonconservation of phase space, with the possibility for a distribution of particles initially monotonically decreasing in energy to exhibit an energy peak upon compression. A peaked energy distribution might have interesting applications, such as to optimize fusion reactivity or to characterize astrophysical phenomena that exhibit nonthermal features.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2001

Enhancement of Tropical Land Cover Mapping with Wavelet-Based Fusion and Unsupervised Clustering of SAR and Landsat Image Data

The characterization and the mapping of land cover/land use of forest areas, such as the Central African rainforest, is a very complex task. This complexity is mainly due to the extent of such areas and, as a consequence, to the lack of full and continuous cloud-free coverage of those large regions by one single remote sensing instrument, In order to provide improved vegetation maps of Central Africa and to develop forest monitoring techniques for applications at the local and regional scales, we propose to utilize multi-sensor remote sensing observations coupled with in-situ data. Fusion and clustering of multi-sensor data are the first steps towards the development of such a forest monitoring system. In this paper, we will describe some preliminary experiments involving the fusion of SAR and Landsat image data of the Lope Reserve in Gabon. Similarly to previous fusion studies, our fusion method is wavelet-based. The fusion provides a new image data set which contains more detailed texture features and preserves the large homogeneous regions that are observed by the Thematic Mapper sensor. The fusion step is followed by unsupervised clustering and provides a vegetation map of the area.

LeMoigne, Jacqueline↗
DOE OSTI2022

On Feature, Classifier and Detector Fusers for 235U Signatures Using Gamma Spectral Counts

Three types of information fusion strategies are studied to assess the performance of classifiers for detecting low-level 235 U radiation sources, using features obtained from gamma spectra of NaI detectors. These three strategies are based on using two spectral region features, fusing eight classifiers of diverse designs, and fusing multiple detectors located at different positions around the source. The inner, middle and outer groups of detectors, within a formation of two concentric circles and a spiral of 21 detectors, are identified based on their distance to the source, which is located at the center. This study provides two main qualitative insights into this classification task. First, the fusion of detectors leads to an overall improved classification performance, least in the inner group, most in the outer group, and in between for the middle group. Second, several classifiers and fusers achieve lower training error which does not translate to lower generalization error, indicating their over-fitting to training data.

Rao, Nageswara↗
DOE OSTI2023

On the role of mode resonances in regulating zonal-flow-moderated plasma microturbulence

Abstract The onset of turbulent heat transport at a higher temperature gradient than the critical gradient of linear instability, known as the Dimits shift, is a recurring feature of nonlinear simulations for magnetically confined fusion plasmas. Resonance in the nonlinear coupling between the modes that dominate energy transfer can lead to suppression of turbulence and transport above the linear critical gradient. As an expression of this resonance, gyrokinetic simulations show a quasi-coherent interaction between streamers and sidebands coupled through the zonal flow within the Dimits regime. This mechanism is further confirmed by use of artificial complex frequencies which break the resonance. By incorporating corresponding saturation physics, the standard quasilinear model for rapid head flux prediction is improved, which can now predict reduced heat flux in the Dimits regime. In particular, the triplet correlation time, the lifetime of the nonlinear interaction, is shown to be well-approximated by combinations of linear eigenvalues, and yields good representations of the heat flux variation both in and above the Dimits regime. Thus, a reduced but predictive model for transport near the critical gradient of zonal-flow saturated turbulence now exists.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

On Feature, Classifier and Detector Fusers for U-235 Signatures Using Gamma Spectral Counts

Three types of information fusion strategies are studied to assess the performance of classifiers for detecting low-level U-235 radiation sources, using features obtained from gamma spectra of NaI detectors. These three strategies are based on using two spectral region features, fusing eight classifiers of diverse designs, and fusing multiple detectors located at different positions around the source. The inner, middle and outer groups of detectors, within a formation of two concentric circles and a spiral of 21 detectors, are identified based on their distance to the source, which is located at the center. This study provides two main qualitative insights into this classification task. First,the fusion of detectors leads to an overall improved classification performance, least in the inner group, most in the outer group, and in between for the middle group. Second, several classifiers and fusers achieve lower training error which does not translate to lower generalization error, indicating their over-fitting to training data.

Rao, Nageswara↗
DOE OSTI2023

Machine learning for detection of 3D features using sparse x-ray tomographic reconstruction

In many inertial confinement fusion (ICF) experiments, the neutron yield and other parameters cannot be completely accounted for with one and two dimensional models. This discrepancy suggests that there are three dimensional effects that may be significant. Sources of these effects include defects in the shells and defects in shell interfaces, the fill tube of the capsule, and the joint feature in double shell targets. Due to their ability to penetrate materials, x rays are used to capture the internal structure of objects. Methods such as computational tomography use x-ray radiographs from hundreds of projections, in order to reconstruct a three dimensional model of the object. In experimental environments, such as the National Ignition Facility and Omega-60, the availability of these views is scarce, and in many cases only consists of a single line of sight. Mathematical reconstruction of a 3D object from sparse views is an ill-posed inverse problem. These types of problems are typically solved by utilizing prior information. Neural networks have been used for the task of 3D reconstruction as they are capable of encoding and leveraging this prior information. We utilize half a dozen, different convolutional neural networks to produce different 3D representations of ICF implosions from the experimental data. Deep supervision is utilized to train a neural network to produce high-resolution reconstructions. These representations are used to track 3D features of the capsules, such as the ablator, inner shell, and the joint between shell hemispheres. Machine learning, supplemented by different priors, is a promising method for 3D reconstructions in ICF and x-ray radiography, in general.

Wolfe, Bradley T. (ORCID:0000000268301614)↗
NASA NTRS1992

A neuro-fuzzy architecture for real-time applications

Neural networks and fuzzy expert systems perform the same task of functional mapping using entirely different approaches. Each approach has certain unique features. The ability to learn specific input-output mappings from large input/output data possibly corrupted by noise and the ability to adapt or continue learning are some important features of neural networks. Fuzzy expert systems are known for their ability to deal with fuzzy information and incomplete/imprecise data in a structured, logical way. Since both of these techniques implement the same task (that of functional mapping--we regard 'inferencing' as one specific category under this class), a fusion of the two concepts that retains their unique features while overcoming their individual drawbacks will have excellent applications in the real world. In this paper, we arrive at a new architecture by fusing the two concepts. The architecture has the trainability/adaptibility (based on input/output observations) property of the neural networks and the architectural features that are unique to fuzzy expert systems. It also does not require specific information such as fuzzy rules, defuzzification procedure used, etc., though any such information can be integrated into the architecture. We show that this architecture can provide better performance than is possible from a single two or three layer feedforward neural network. Further, we show that this new architecture can be used as an efficient vehicle for hardware implementation of complex fuzzy expert systems for real-time applications. A numerical example is provided to show the potential of this approach.

Ramamoorthy, P. A.↗
DOE OSTI2026

Negative fluxes and cell-miss errors in the random ray method

The random ray method is a recently developed stochastic method for solving neutral particle transport problems based on the method of characteristics. Perhaps surprisingly for a characteristics-based method using flat sources, we note that the random ray method can produce negative fluxes which may be numerically troublesome in several situations. These occur most severely in fixed source problems where the source is in a region with a small cross section. Additionally, we briefly discuss another source of bias which can occur in similar situations, namely a ray missing a mesh with a strong source and small cross section, resulting in the entirety of the source being unphysically deposited locally. This paper describes the mechanism by which negative fluxes may occur and several different methods to mitigate their effects. These fixes are tested on an eigenvalue problem, a ‘fusion-like’ shielding problem, and a shielding problem featuring an adjoint calculation. Even when extremely coarse random ray quadratures are used such that 20%–30% of cells are missed during a given iteration, use of the preferred fix technique ensures local flux tally errors remain trivial (below 1%). The preferred fix is now the default option in SCONE and OpenMC.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Materials data science using CRADLE: A distributed, data-centric approach

Abstract There is a paradigm shift towards data-centric AI, where model efficacy relies on quality, unified data. The common research analytics and data lifecycle environment (CRADLE™) is an infrastructure and framework that supports a data-centric paradigm and materials data science at scale through heterogeneous data management, elastic scaling, and accessible interfaces. We demonstrate CRADLE’s capabilities through five materials science studies: phase identification in X-ray diffraction, defect segmentation in X-ray computed tomography, polymer crystallization analysis in atomic force microscopy, feature extraction from additive manufacturing, and geospatial data fusion. CRADLE catalyzes scalable, reproducible insights to transform how data is captured, stored, and analyzed. Graphical abstract

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Computational Design to Advance AM Fabrication of High Gamma Prime Alloys for Hot Gas Path Components in Gas Turbine Engines: A Pathway to Enhanced Gas Turbine Efficiency and Energy Saving (Final CRADA Report)

Raising turbine inlet temperature is a key lever for improving industrial gas-turbine efficiency and power output, but it increases thermo-mechanical demands on hot-gas-path components. Additive manufacturing (AM), particularly laser powder bed fusion (L-PBF), enables complex internal cooling features in critical components such as turbine tip shoes that are difficult to produce by conventional casting. However, qualification of new high-temperature AM alloys and aggressive geometries is often limited by trial-and-error iteration of build parameters and post-build heat treatments, with cracking during stress relieving or hot isostatic pressing (HIP) being a recurring failure mode.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Electron tail suppression and effective collisionality due to synchrotron emission and absorption in mildly relativistic plasmas

Synchrotron radiation losses are a significant cause of concern for high-temperature aneutronic fusion reactions such as proton–Boron 11. The fact that radiation losses occur primarily in the high-energy tail, where the radiation itself has a substantial impact on the electron distribution, necessitates a self-consistent approach to modeling the diffusion and drag induced by synchrotron absorption and emission. Furthermore, an accurate model must account for the fact that the radiation emission spectrum is momentum-dependent, and the plasma opacity is frequency-dependent. Here, we present a simple Fokker–Planck operator, built on a newly solved-for blackbody synchrotron diffusion operator, which captures all relevant features of the synchrotron radiation. Focusing on magnetic mirror fusion plasmas, we show that significant suppression of the electron distribution occurs for relativistic values of the perpendicular electron momentum, which therefore emit much less radiation than predicted under the assumption of a Maxwell–Jüttner distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗