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DOE OSTI2025

Co-training of multiple neural networks for simultaneous optimization and training of physics-informed neural networks for composite curing

This paper introduces a Physics-Informed Neural Network (PINN) technique that co-trains neural networks (NNs) that represent each function in a system of equations to simultaneously solve equations representing an out-of-autoclave (OOA) cure process while conducting optimization in adherence to process requirements. Specifically, this co-training approach benefits from using NNs to represent OOA inputs (air temperature profile) and outputs (part and tool temperature profiles and degree of cure). Production requirements can then be levied on the inputs, such as maximum air temperature and minimum cure cycle, and simultaneously on the outputs, such as degree of cure, maximum part temperature, and part temperature rate limits. The technique is validated with finite element (FE) simulations and physical experiments for curing a Toray T830H-6 K/3900-2D composite panel. Furthermore, this novel approach efficiently models and optimizes the OOA cure process.

Composite curing↗

DOE OSTI2022

A simplified, efficient approach to hybrid wind and solar plant site optimization

Abstract. Wind plant layout optimization is a difficult, complex problem with a large number of variables and many local minima. Layout optimization only becomes more difficult with the addition of solar generation. In this paper, we propose a parameterized approach to wind and solar hybrid power plant layout optimization that greatly reduces problem dimensionality while guaranteeing that the generated layouts have a desirable regular structure. Thus far, hybrid power plant optimization research has focused on system sizing. We go beyond sizing and present a practical approach to optimizing the physical layout of a wind–solar hybrid power plant. We argue that the evolution strategy class of derivative-free optimization methods is well-suited to the parameterized hybrid layout problem, and we demonstrate how hard layout constraints (e.g., placement restrictions) can be transformed into soft constraints that are amenable to optimization using evolution strategies. Next, we present experimental results on four test sites, demonstrating the viability, reliability, and effectiveness of the parameterized evolution strategy approach for generating optimized hybrid plant layouts. Completing the tool kit for parameterized layout generation, we include a brief tutorial describing how the parameterized evolutionary approach can be inspected, understood, and debugged when applied to hybrid plant layouts.

14 SOLAR ENERGY↗

DOE OSTI2023

A Computational Framework for Control Co-Design of Resilient Cyber–Physical Systems With Applications to Microgrids

Critical infrastructure networks, such as power and transportation networks, can be modelled as cyber-physical systems. As the complexity of such systems grow, there is need for developing metrics and design tools that will co-optimize the physical components of the system and the control policies to guarantee resilience against cyber and natural threats. To that end, we develop a simulation-based control co-design computational framework that will concurrently determine the system and control parameters of a cyber-physical system to meet pre-specified resilience, operational and economic objectives. Here, the capabilities of the developed co-design engine is demonstrated by designing the physical components and control parameters of a microgrid system that will meet its resiliency objectives when subjected to various cyber and physical threats.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Anomaly detection in collider physics via factorized observables

To maximize the discovery potential of high-energy colliders, experimental searches should be sensitive to unforeseen new physics scenarios. This goal has motivated the use of machine learning for unsupervised anomaly detection. In this paper, we introduce a new anomaly detection strategy called : factorized observables for regressing conditional expectations. Our approach is based on the inductive bias of factorization, which is the idea that the physics governing different energy scales can be treated as approximately independent. Assuming factorization holds separately for signal and background processes, the appearance of nontrivial correlations between low- and high-energy observables is a robust indicator of new physics. Under the most restrictive form of factorization, a machine-learned model trained to identify such correlations will in fact converge to the optimal new physics classifier. We test on a benchmark anomaly detection task for the Large Hadron Collider involving collimated sprays of particles called jets. By teasing out correlations between the kinematics and substructure of jets, our method can reliably extract percent-level signal fractions. This strategy for uncovering new physics adds to the growing toolbox of anomaly detection methods for collider physics with a complementary set of assumptions. Published by the American Physical Society 2024

Astronomy & Astrophysics↗

DOE OSTI2020

Design of an Axial Flux Machine With an Integrated Hydraulic Pump for Off-Highway Vehicle Electrification

Axial flux machines offer an inherent torque density advantage over conventional radial flux machines and are increasingly being considered for transportation electrification applications. Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper investigates the use of axial flux machines for off-highway vehicle electrification. To maximize the power density, a hydraulic pump is integrated with the axial flux machine, resulting in a single modular, electric/hydraulic machine. This paper first compares three popular axial flux machine variants using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to search the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and magnet wire)

Off-highway vehicles, Axial flux machines, Multi-p↗

DOE OSTI2022

Development of an Integrated Electro-Hydraulic Machine to Electrify Off-highway Vehicles

Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper proposes and develops an axial flux machine integrated with a hydraulic pump to realize a single modular, electro-hydraulic machine to electrify off-highway vehicle implements. This integrated machine eliminates redundant bearings, couplings, and shaft seals, re-uses surfaces, and enables direct cooling of the electric machine with the hydraulic fluid, to significantly increase power density. Three popular axial flux machine variants are first compared using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to characterize the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and enamelled copper wire). Furthermore, a prototype axial flux machine has been experimentally characterized and integrated with a hydraulic pump to demonstrate the integrated electro-hydraulic machine concept.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Criticality analysis of nuclear binding energy neural networks

Machine learning methods, in particular deep learning methods such as artificial neural networks (ANNs) with many layers, have become widespread and useful tools in nuclear physics. However, these ANNs are typically treated as ‘black boxes’, with their architecture (width, depth, and weight/bias initialization) and the training algorithm and parameters chosen empirically by optimizing learning based on limited exploration. We test a non-empirical approach to understanding and optimizing nuclear physics ANNs by adapting a criticality analysis based on renormalization group flows in terms of the hyperparameters for weight/bias initialization, training rates, and the ratio of depth to width. This treatment utilizes the statistical properties of neural network initialization to find a generating functional for network outputs at any layer, allowing for a path integral formulation of the ANN outputs as a Euclidean statistical field theory. We use a prototypical example to test the applicability of this approach: a simple ANN for nuclear binding energies. We find that with training using a stochastic gradient descent optimizer, the predicted criticality behavior is realized, and optimal performance is found with critical tuning. However, the use of an adaptive learning algorithm leads to somewhat superior results without concern for tuning and thus obscures the analysis. Nevertheless, the criticality analysis offers a way to look within the black box of ANNs, which is a first step towards potential improvements in network performance beyond using adaptive optimizers.

artificial neural network↗

DOE OSTI2024

Scalable Control Co-design for Resilient-by-Design Cyber Physical Systems

Critical infrastructure networks, such as power and transportation networks, are often modelled as cyber-physical systems. With ever increasing complexity of these systems, there is a need for newer and more relevant metrics and design tools that will co-optimize the physical system components and control policies to guarantee resilience against cyber and natural threats. To this end, a simulation-based control co-design computational framework that will concurrently determine the system and control parameters of a cyber-physical system to meet pre-specified resilience, operational and economic objectives has been developed. The capabilities of the developed co-design engine are demonstrated by designing the physical components and control parameters of a microgrid system that will meet its resiliency objectives when subjected to various cyber and physical threats.

42 ENGINEERING↗

DOE OSTI2020

Resilient Operations of Networked Microgrids (RONM)

Objective: Improve the resiliency of power systems with optimization-based methods that leverage advanced microgrid technologies to reduce system recovery times after extreme event induced outages. Outcome: First-of-kind, high-fidelity physics-based optimization method for modeling networked microgrids which includes key engineering constraints associated with system recovery after extreme events.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Development and assessment of prognosis digital twin in a NAMAC system

The nearly autonomous management and control (NAMAC) system is a comprehensive control system to assist plant operations by furnishing control recommendations to operators. Prognosis digital twin (DT-P) is a critical component in NAMAC for predicting action effects and supporting NAMAC decision-making during normal and accident scenarios. To quantifying and reducing uncertainty of machine-learning-based DT-Ps in multi-step predictions, this work investigates and derives insights from the application of three techniques for optimizing the performance of DT-P by long short-term memory recurrent neural networks, including manual search, sequential model-based optimization, and physics-guided machine learning. Finally, sequential model-based optimization and physics-guide machine learning result in smallest errors when the predicting transients are similar to the training data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Conceptual monopile and tower sizing for the IEA Wind Task 37 Borssele reference wind farm

This paper explores the preliminary design of the support structures for the IEA Wind Task 37 reference wind farm at the Borssele site III and IV. The study looks at two different design methods that might be used within larger wind farm system design optimization (i.e. lay-out, electrical systems, etc.). The first consists of a scaling tool that scales a detailed design according to the rated power, water depth, hub height and rotor diameter. The second is a physics-based optimization approach that relies on the WISDEM® design tool. This research compares the results of these two methods for the design of both the tower and monopile of the IEA 10-MW and 15-MW reference wind turbines at a range of sea depths (25 m, 30 m, 35 m, 40 m). The two tools yield very similar results in terms of monopile base diameter, support structure natural frequency and mass. WISDEM is then used to also investigate the sensitivity of the design to the tower top forces, wave conditions and the soil conditions. It is shown that tower top forces dominate the design. In general, large diameter structures can carry additional costs associated with manufacturing and transportation requirements. Thus, the paper is concluded with a trade-off study between mass and diameter that quantifies the effect of the reduction in monopile diameter with the increase in structural mass.

WIND ENERGY↗

DOE OSTI2022

Optimal Control of Families of Quantum Gates

Quantum optimal control (QOC) enables the realization of accurate operations, such as quantum gates, and supports the development of quantum technologies. To date, many QOC frameworks have been developed, but those remain only naturally suited to optimize a single targeted operation at a time. Here, we extend this concept to optimal control with a continuous family of targets, and demonstrate that an optimization based on neural networks can find families of time-dependent Hamiltonians realizing desired classes of quantum gates in minimal time.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Organic carbon enables the biotic engineering of beneficial soil structure in Profundihumic and Haplic Ferralsols

We investigated how organic matter may, directly and indirectly, modify the porosity of Ferralsols, that is, deeply weathered soils of the tropics and subtropics. Although empirical and anecdotal evidence suggests that organic matter accumulation may increase porosity, a mechanistic understanding of the processes underlying this beneficial effect is lacking, especially so for Ferralsols. To achieve our end, we leveraged the fact that the Profundihumic qualifier of Ferralsols (PF) is distinguished from Haplic Ferralsols (HF) by both a much larger average carbon content in the first 1 m of soil depth (19 kg C m -3 in PF vs. 10 kg C m -3 in HF) and a significantly lower bulk density (1.05 ± 0.08 kg L -1 in PF vs. 1.21 ± 0.05 kg L -1 in HF). Through exhaustive modelling of carbon – bulk density relationships, we demonstrate that the lower bulk density of PF cannot be satisfactorily explained by a simple dilution effect. Rather, we found that bulk density correlated with carbon content when combined with carbon: nitrogen ratio (r 2 = 0.51), black carbon content (r 2 = 0.75), and Δ 14 C (r 2 =0.81). Total pore space was greater in PF (61± 3%) than in HF (55 ± 2%), but x-ray computed tomography revealed that pore space inside soil aggregates of 4–5 mm diameter does not vary between the studied Ferralsols. We further observed nearly twice as many roots and burrows in PF compared with HF. We thus infer that the mechanism responsible for the increase in porosity is most likely an enhancement of resource availability (e.g., energy, carbon, and nutrients) for the organisms (earthworms, ants, termites, etc.) that physically displace soil particles and promote soil aggregation. As a result of increased resource availability, soil organisms can create especially the mesoscale structural soil features necessary for unrestricted water flow and rapid gas exchange. In conclusion, this insight paves the way for the development of land management technologies to optimize the physical shape and capacity of the soil bioreactor.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Application of Neutron Multiplicity Counting Experiments to Optimal Cross-Section Adjustments

This paper presents the first application of model calibration to neutron multiplicity counting (NMC) experiments for cross-section optimization that is informed by adjoint-based sensitivity analysis (SA) and first-order uncertainty quantification (UQ). We summarize previous work on SA applied to NMC and describe notable modifications and additions. We give the procedure for first-order UQ and Bayesian-inference-based parameter estimation (PE). We then discuss model calibration applied to NMC of a 4.5-kg sphere of weapons-grade, alpha-phase plutonium metal (the BeRP ball) with the nPod neutron multiplicity counter. For the BeRP ball in bare and polyethylene-reflected configurations, we discuss the sensitivity of the first- and second-moment detector responses (i.e., first and second moments of the NMC distribution, respectively) to the cross sections. We describe the sources of uncertainty in the measured and simulated responses. Specifically, uncertainty in the measured responses is due to both random and systematic sources. Uncertainty in the simulated responses is due to the cross-section covariances. We describe in detail the adjustment to the cross sections and cross-section covariances due to the optimization. Due to the contribution of systematic uncertainties to the measured response uncertainties, the adjustment to the cross sections is similar in trend but larger in magnitude compared to that recommended by previous work. We compare the measured responses to responses simulated with nominal and optimized cross sections, demonstrating that the best-estimate cross sections produce simulations of NMC experiments that are more accurate with reduced uncertainty.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Toward Accelerating Discovery via Physics-Driven and Interactive Multifidelity Bayesian Optimization

Both computational and experimental material discovery bring forth the challenge of exploring multidimensional and often nondifferentiable parameter spaces, such as phase diagrams of Hamiltonians with multiple interactions, composition spaces of combinatorial libraries, processing spaces, and molecular embedding spaces. Often these systems are expensive or time consuming to evaluate a single instance, and hence classical approaches based on exhaustive grid or random search are too data intensive. This resulted in strong interest toward active learning methods such as Bayesian optimization (BO) where the adaptive exploration occurs based on human learning (discovery) objective. However, classical BO is based on a predefined optimization target, and policies balancing exploration and exploitation are purely data driven. In practical settings, the domain expert can pose prior knowledge of the system in the form of partially known physics laws and exploration policies often vary during the experiment. Here, we propose an interactive workflow building on multifidelity BO (MFBO), starting with classical (data-driven) MFBO, then expand to a proposed structured (physics-driven) structured MFBO (sMFBO), and finally extend it to allow human-in-the-loop interactive interactive MFBO (iMFBO) workflows for adaptive and domain expert aligned exploration. These approaches are demonstrated over highly nonsmooth multifidelity simulation data generated from an Ising model, considering spin–spin interaction as parameter space, lattice sizes as fidelity spaces, and the objective as maximizing heat capacity. Detailed analysis and comparison show the impact of physics knowledge injection and real-time human decisions for improved exploration with increased alignment to ground truth. Here, the associated notebooks allow to reproduce the reported analyses and apply them to other systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Quantum Information for Fusion Energy Sciences (Final Technical Report)

The simulation of plasma dynamics is a critical area of Fusion Energy Sciences (FES) due to it’s usefulness in predicting, controlling, and confining plasmas in the context of potential fusion reactors. The simulation of plasmas is a computationally difficult problem in both classical and quantum physics, motivating investigation into the potential of quantum computers to simulate these systems. This project took several concrete steps towards this goal by developing tools for improving the control, characterization, and calibration of quantum gates on a superconducting quantum computer, developing error suppression and mitigation tools to reduce errors on the quantum computer, and utilizing these advancements to simulate reduced models of plasma dynamics on the quantum computer. In order to efficiently simulate plasma physics, an optimal control method which synthesizes, directly at the pulse level, any quantum gate on qubit and qutrit systems was developed. Using four superconducting transmon quantum processors at Rigetti and LLNL, it was demonstrated that any arbitrary quantum gate on qubits and qutrits could be implemented with high fidelity, leading to a significantly reduced length of a gate sequence. A problem of interest in FES is the nonlinear optical process of laser pulse compression within a plasma. Since quantum physics is linear, simulating nonlinear operations is not naturally feasible on a quantum computer, however it is possible to simulated a quantized version of the nonlinear process. A quantization approach to convert nonlinear wave-wave interaction problems to Hamiltonian simulation problems was developed and demonstrated using two qubits on a Rigetti device. In this experiment, a number of error suppression and mitigation techniques were investigated to determine how best to utilize the finite quantum resources. This study provides an example of how plasma problems may be solved on near-term, noisy quantum computing platforms and identified a promising set of techniques. Building on the insights of these experiments, the investigation turned to linear electron-plasma wave physics. A connection was identified between a local one-dimensional lattice spin model and linear wave phenomena, allowing a plasma physics problem to be efficiently mapped to the quantum computer. In this framework, reflection and transmission of plasma waves at a sharp boundary was studied, as well as the propagation of waves through an inhomogeneous plasma medium. In addition to the suite of error suppression and mitigation techniques developed, this experiment introduced the use of a digital-analog gate scheme designed to efficiently simulate the plasma Hamiltonian. With hardware available at the conclusion of the project, simulation at the scale of 9 qubits and 15 timesteps (60 entangling layers) was achieved.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

In-Situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, we report an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.

42 ENGINEERING↗

DOE OSTI2025

A Route to Design Novel Functional Peptides by Applying a Denoising Diffusional Model to mRNA Display Libraries

In vitro directed evolution techniques, such as mRNA display, enable peptide ligand discovery and optimization. However, physical libraries that rely on a genetic code can only search a small fraction of sequence space due to inherent biases in the genetic code and experimental limitations. To address this challenge, denoising diffusion implicit models (DDIMs) are applied to generate novel peptide ligands against B‐cell lymphoma extra‐large (Bcl‐x L ), a key cancer target. Starting with high‐throughput sequencing data from previous selections, a DDIM is trained to produce novel sequences with high affinity binding. Experimental validation confirms that most generated sequences are functionally equivalent to the original library members for Bcl‐x L binding and demonstrated comparable binding kinetics and affinity relative to the wildtype and nearest original neighbors. Importantly, this approach generated rare sequences not easily accessible via mutation and directed evolution. These results indicate that DDIMs can complement and expand directed evolution data, efficiently exploring underrepresented regions of sequence space. This approach provides a broadly applicable framework for accelerating ligand discovery and optimizing molecular properties across diverse targets.

Qi, Pearl [Mork Family Department of Chemical Engi↗