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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process

Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.

Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗
DOE OSTI2022

Machine-learning from Pseudomonas putida KT2440 transcriptomes reveals its transcriptional regulatory network

Bacterial gene expression is orchestrated by numerous transcription factors (TFs). Elucidating how gene expression is regulated is fundamental to understanding bacterial physiology and engineering it for practical use. In this study, a machine-learning approach was applied to uncover the genome-scale transcriptional regulatory network (TRN) in Pseudomonas putida KT2440, an important organism for bioproduction. We performed independent component analysis of a compendium of 321 high-quality gene expression profiles, which were previously published or newly generated in this study. We identified 84 groups of independently modulated genes (iModulons) that explain 75.7% of the total variance in the compendium. With these iModulons, we (i) expand our understanding of the regulatory functions of 39 iModulon associated TFs (e.g., HexR, Zur) by systematic comparison with 1993 previously reported TF-gene interactions; (ii) outline transcriptional changes after the transition from the exponential growth to stationary phases; (iii) capture group of genes required for utilizing diverse carbon sources and increased stationary response with slower growth rates; (iv) unveil multiple evolutionary strategies of transcriptome reallocation to achieve fast growth rates; and (v) define an osmotic stimulon, which includes the Type VI secretion system, as coordination of multiple iModulon activity changes. Taken together, this study provides the first quantitative genome-scale TRN for P. putida KT2440 and a basis for a comprehensive understanding of its complex transcriptome changes in a variety of physiological states.

09 BIOMASS FUELS↗
DOE OSTI2025

Morphotype-resolved characterization of microalgal communities in a nutrient recovery process with ARTiMiS flow imaging microscopy

Microalgae-driven nutrient recovery represents a promising technology for phosphorus removal from wastewater while simultaneously generating biomass that can be valorized to offset treatment costs. As full-scale processes come online, system parameters including biomass composition must be carefully monitored to optimize performance and prevent culture crashes. In this study, flow imaging microscopy (FIM) was leveraged to characterize microalgal community composition in near real-time at a full-scale municipal wastewater treatment plant (WWTP) in Wisconsin, USA, and population and morphotype dynamics were examined to identify relationships between water chemistry, biomass composition, and system performance. Two FIM technologies, FlowCam and ARTiMiS, were evaluated as monitoring tools. ARTiMiS provided a more accurate estimate of total system biomass, and estimates derived from particle area as a proxy for biovolume yielded better approximations than particle counts. Deep learning classification models trained on annotated image libraries demonstrated equivalent performance between FlowCam and ARTiMiS, and convolutional neural network (CNN) classifiers proved significantly more accurate when compared to feature table-based dense neural network (DNN) models. Across a two-year study period, Scenedesmus spp. appeared most important for phosphorus removal, and were negatively impacted by elevated temperatures and increase in nitrite/nitrate concentrations. Chlorella and Monoraphidium also played an important role in phosphorus removal. For both Scenedesmus and Chlorella, smaller morphological types were more often associated with better system performance, whereas larger morphotypes likely associated with stress response(s) correlated with poor phosphorus recovery rates. Furthermore, these results demonstrate the potential of FIM as a critical technology for high-resolution characterization of industrial microalgal processes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Probing Slow Earthquakes With Deep Learning

Abstract Slow earthquakes may trigger failure on neighboring locked faults that are stressed sufficiently to break, and slow slip patterns may evolve before a nearby great earthquake. However, even in the clearest cases such as Cascadia, slow earthquakes and associated tremor have only been observed in intermittent and discrete bursts. By training a convolutional neural network to detect known tremor on a single seismic station in Cascadia, we isolate and identify tremor and slip preceding and following known larger slow events. The deep neural network can be used for the detection of quasi‐continuous tremor, providing a proxy that quantifies the slow slip rate. Furthermore, the model trained in Cascadia recognizes tremor in other subduction zones and also along the San Andreas Fault at Parkfield, suggesting a universality of waveform characteristics and source processes, as posited from experiments and theory.

58 GEOSCIENCES↗
DOE OSTI2023

Comparison of machine learning systems trained to detect Alfvén eigenmodes using the CO 2 interferometer on DIII-D

Abstract A Machine-Learning (ML) based detection scheme that automatically detects Alfvén Eigenmodes (AE) in a labelled DIII-D database is presented here. Controlling AEs is important for the success of planned burning plasma devices such as ITER, since resonant fast ions can drive AEs unstable and degrade the performance of the plasma or damage the first walls of the machine vessel. Artificial Intelligence could be useful for real-time detection and control of AEs in steady-state plasma scenarios by implementing ML-based models into control algorithms that drive actuators for mitigation of AE impacts. Thus, the objective is to compare differences in performance between using two different recurrent neural network systems (Reservoir Computing Network and Long Short Term Memory Network) and two different representations of the C O 2 phase data (simple and crosspower spectrograms). All C O 2 interferometer chords are used to train both models, but only one is processed during each training step. The results from the model and data comparison show higher performance for the RCN model (True Positive Rate = 90% and False Positive Rate = 14%), and that using simple magnitude spectrograms is sufficient to detect AEs. Also, the vertical C O 2 interferometer chord passing near the center is better for ML-based detection of AEs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

A deterministic gradient-based approach to avoid saddle points

Abstract Loss functions with a large number of saddle points are one of the major obstacles for training modern machine learning (ML) models efficiently. First-order methods such as gradient descent (GD) are usually the methods of choice for training ML models. However, these methods converge to saddle points for certain choices of initial guesses. In this paper, we propose a modification of the recently proposed Laplacian smoothing gradient descent (LSGD) [Osher et al., arXiv:1806.06317 ], called modified LSGD (mLSGD), and demonstrate its potential to avoid saddle points without sacrificing the convergence rate. Our analysis is based on the attraction region, formed by all starting points for which the considered numerical scheme converges to a saddle point. We investigate the attraction region’s dimension both analytically and numerically. For a canonical class of quadratic functions, we show that the dimension of the attraction region for mLSGD is $\lfloor (n-1)/2\rfloor$ , and hence it is significantly smaller than that of GD whose dimension is $n-1$ .

Mathematics↗
DOE OSTI2020

Active Learning Accelerated Discovery of Stable Iridium Oxide Polymorphs for the Oxygen Evolution Reaction

The discovery of high-performing and stable materials for sustainable energy applications is a pressing goal in catalysis and materials science. Understanding the relationship between a material’s structure and functionality is an important step in the process, such that viable polymorphs for a given chemical composition need to be identified. Machine-learning-based surrogate models have the potential to accelerate the search for polymorphs that target specific applications. Herein, we report a readily generalizable active-learning (AL) accelerated algorithm for identification of electrochemically stable iridium oxide polymorphs of IrO 2 and IrO 3 . The search is coupled to a subsequent analysis of the electrochemical stability of the discovered structures for the acidic oxygen evolution reaction (OER). Structural candidates are generated by identifying all 956 structurally unique AB2 and AB3 prototypes in existing materials databases (more than 38000). Next, using an active learning approach, we find 196 IrO 2 polymorphs within the thermodynamic amorphous synthesizability limit and reaffirm the global stability of the rutile structure. We find 75 synthesizable IrO 3 polymorphs and report a previously unknown FeF 3 -type structure as the most stable, termed α-IrO 3 . To test the algorithms performance, we compare to a random search of the candidate space and report at least a 2-fold increase in the rate of discovery. Additionally, the AL approach can acquire the most stable polymorphs of IrO 2 and IrO 3 with fewer than 30 density functional theory optimizations. Analysis of the structural properties of the discovered polymorphs reveals that octahedral local coordination environments are preferred for nearly all low-energy structures. Subsequent Pourbaix Ir–H 2 O analysis shows that α-IrO3 is the globally stable solid phase under acidic OER conditions and supersedes the stability of rutile IrO 2 . Calculation of theoretical OER surface activities reveal ideal weaker binding of the OER intermediates on α-IrO 3 than on any other considered iridium oxide. We emphasize that the proposed AL algorithm can be easily generalized to search for any binary metal oxide structure with a defined stoichiometry.

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

Data-Driven Optimal Control of Traffic Signals for Urban Road Networks

This paper studies the issue of data-driven optimal control design for traffic signals of oversaturated urban road networks. The signal control system based on the store and forward model is generally uncontrollable for which the controllable decomposition is needed. Instead of identifying the unknown parameters like saturation rates and turning ratios, a finite number of measured trajectories can be used to parametrize the system and help directly construct a transformation matrix for Kalman controllable decomposition through the fundamental lemma of J. C. Willems. On top of that, an infinite-horizon linear quadratic regulator (LQR) problem is formulated considering the constraints of green times for traffic signals. The problem can be solved through a two-phase data-driven learning process, where one solves an infinite-horizon unconstrained LQR problem and the other solves a finite-horizon constrained LQR problem. The simulation result shows the theoretical analysis is effective and the proposed data-driven controller can yield desired performance for reducing traffic congestion.

Liu, Tong↗
DOE OSTI2020

The Value of Information From Horizontal Distributed Acoustic Sensing Compared to Multicomponent Geophones Via Machine Learning

Abstract Faults play an important role in recharging many geothermal reservoirs, and seismic information can image the locations of these faults. The value of information (VOI) metric is used to objectively quantify and compare the value of two types of seismic receiver data via a machine learning approach. The demonstrated VOI methodology is novel by including spatial models from seismic data and obtaining the information statistics from machine learning. Our two-dimensional numerical experiments compare images created from sparsely spaced (80 m), two-component geophone sampling to high spatial resolution (1 m), single-component DAS. We used a three-fold cross validation of a U-Net convolutional neural networks to achieve average classification statistics. The results suggest that when horizontal sources are utilized, geophones and DAS identify reflectors and non-reflectors at roughly the same rate. The average F1 score for horizontal DAS is 0.939 and 0.931 for geophones. For images created from a vertical source, DAS performed marginally better (F1 = 0.919) than geophones (F1 = 0.877). Our transferrable methodology can provide guidance on which acquisition scenarios can improve images of important structures in the subsurface and present an efficient method for obtaining reliability statistics from high-dimensional, spatial data.

Energy & Fuels↗
DOE OSTI2023

Technoeconomic Evaluation of Solid Oxide Fuel Cell Hydrogen-Electricity Co-Generation Concepts

This report evaluates the cost and performance of several types of Integrated Energy Systems (IES) based on solid oxide fuel cells (SOFCs) to generate power and solid oxide electrolysis cells (SOECs) to produce hydrogen. All cases feature carbon capture at rates exceeding 97 percent. The report also describes the development of optimized steady state process models for each system. These are used to calculate overall electricity and hydrogen production costs using a consistent methodology that facilitates comparisons of these cases to one another and to prior NETL cost and performance estimates. The SOFC and SOEC costs and performance are based on nth-of-a-kind systems and include research and development and learning associated with mass-scale commercial deployment of the technology over the next decade required for commercial utility-scale systems.

08 HYDROGEN↗
DOE OSTI2021

Exploring PV Circularity by Modeling Socio-Technical Dynamics of Modules' End-of-Life Management: Preprint

The circular economy (CE) tackles environmental and resource scarcity issues by maximizing value retention in the economy. The concept implies design strategies such as reducing the use of materials or improving products’ durability and end-of-life (EOL) strategies such as reusing products and components and recycling materials. With an estimated 80 million tons of global cumulative EOL photovoltaic (PV) modules, applying CE principles to the PV industry could alleviate resource scarcity issues while also providing economic benefits. However, transitioning to a CE may imply changes in organizations and consumer behaviors. In this context, assessment of CE strategies may require accounting for behavioral change, a requirement that methods from complex system science such as agent-based modeling meet. Thus, this paper uses an agent-based modeling (ABM) approach to study circularity in the photovoltaics supply chain. Four types of agents are represented in the ABM: PV owners, installers, recyclers, and manufacturers. Moreover, five possible EOL options – including three CE strategies – are modeled. Departing from traditional techno-economic analysis, the model includes techno-economic factors as well as social factors to model EOL management decisions. Results show that each dollar decrease in the recycling fees improves the recycling rate by roughly 1.1%. However, excluding social factors underestimates the effect that lower recycling prices have on material circularity.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2024

Using Machine Learning to Predict Cloud Turbulent Entrainment–Mixing Processes

Different turbulent entrainment–mixing mechanisms between clouds and environment are essential to cloud–related processes; however, accurate representation of entrainment–mixing in weather/climate models still poses a challenge. This study exploits the use of machine learning (ML) to address this challenge. Four ML (Light Gradient Boosting Machine [LGB], eXtreme Gradient Boosting, Random Forest, and Support Vector Regression) are examined and compared. It is found that LGB performs best, and thus is selected to understand the impact of entrainment–mixing on microphysics using simulation data from Explicit Mixing Parcel Model. Compared with traditional parameterizations, the trained LGB provides more accurate microphysical properties (number concentration and cloud droplet spectral dispersion). The partial dependences of predicted microphysics on features exhibit a strong alignment with physical mechanisms and expectations, as determined by the interpreting method, thus overcoming the limitations of the “black box” scheme. The underlying mechanisms are that the smaller number concentration and larger spectral dispersion correspond to more inhomogeneous entrainment–mixing. Specifically, number concentration after entrainment–mixing is positively correlated with adiabatic number concentration and liquid water content affected by entrainment–mixing, and inversely correlated with adiabatic volume mean radius. Spectral dispersion after entrainment–mixing is negatively correlated with liquid water content affected by entrainment–mixing, turbulent dissipation rate and relative humidity of entrained air. Sensitivity analysis further suggests that number concentration is mainly determined by cloud microphysical properties whereas spectral dispersion is influenced by both cloud microphysical properties and environmental variables. The results indicate that the LGB scheme has the potential to enhance the representation of entrainment–mixing in weather/climate models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Enhancing Gaussian Process Surrogates for Optimization and Posterior Approximation via Random Exploration

This paper proposes novel noise-free Bayesian optimization strategies that rely on a random exploration step to enhance the accuracy of Gaussian process surrogate models. The new algorithms retain the ease of implementation of the classical GP-UCB algorithm, but the additional random exploration step accelerates their convergence, nearly achieving the optimal convergence rate. Furthermore, to facilitate Bayesian inference with intractable likelihoods, we propose to utilize optimization iterates for maximum a posteriori estimation to build a Gaussian process surrogate model for the unnormalized log-posterior density. We provide bounds for the Hellinger distance between the true and the approximate posterior distributions in terms of the number of design points. We demonstrate the effectiveness of our Bayesian optimization algorithms in nonconvex benchmark objective functions, in a machine learning hyperparameter tuning problem, and in a black-box engineering design problem. The effectiveness of our posterior approximation approach is demonstrated in two Bayesian inference problems for parameters of dynamical systems.

Bayesian inference↗
DOE OSTI2020

Smart Proxy Modeling Application of Artificial Intelligence & Machine Learning in Computational Fluid Dynamics

Smart proxy technology leverages the art of artificial intelligence and machine learning in order to build accurate and very fast proxy models for highly complex numerical simulation models. In this project, smart proxy technology is used to replicate the results of a highly complex single phase CFD simulation with reasonable degree of accuracy while reducing the computational cost associated with such CFD simulations. The CFD model under study simulates the combustion of natural gas under various conditions such as varying natural gas composition and flow rate, inlet air flow rate and temperature, and outlet pressure in a High-Pressure Combustion Facility (B6 Combustor) with more than 4 million simulation cells. Only eight CFD simulation runs were used to create a smart proxy model that replicates the detail distribution of Pressure, Temperature, Nitrogen, Oxygen and Carbon-dioxide concentration in the CFD simulation model in seconds with less than 10% error.

03 NATURAL GAS↗
DOE OSTI2023

Envisioning urban environments resilient to vector-borne diseases: a protocol to study dengue in Vietnam

Transmitted primarily by Aedes aegypti (Ae. aegypti) and Aedes albopictus (Ae. albopictus), arboviral diseases pose a major global public health threat. Dengue, chikungunya, and zika are increasingly prevalent in Southeast Asia. Among other arboviruses, dengue and zika are becoming more common in Central and South America. Given human encroachment into previously uninhabited, often deforested areas, to provide new housing in regions of population expansion, conceptualizing built urban environments in a novel way is urgently needed to safeguard against the growing climate change-driven threat of vector-borne diseases. By understanding the spread from a One Health perspective, enhanced control and prevention can be achieved. This is particularly important considering that climate change is likely to significantly impact the persistence of ponded water where mosquitoes breed due to increasing temperature and shifting rainfall patterns with regard to magnitude, duration, frequency, and season. Models can incorporate aquatic mosquito stages and adult spatial dynamics when habitats are heterogeneously available, thereby including dispersal and susceptible-exposed-infected-recovered (SEIR) epidemiology. Coupled with human population distribution (density, locations), atmospheric conditions (air temperature, precipitation), and hydrological conditions (soil moisture distribution, ponding persistence in topographic depressions), modeling has improved predictive ability for infection rates. However, it has not informed interventional approaches from an urban environment perspective which considers the role of ponds/lakes that support green spaces, the density of population that enables rapid spread of disease, and varying micro-habitats for various mosquito stages under climate change. Here, for an example of dengue in Vietnam, a preventive and predictive approach to design resilient urban environments is proposed, which uses data from rapidly expanding metropolitan communities to learn continually. This protocol deploys computational approaches including simulation and machine learning/artificial intelligence, underpinned by surveillance and medical data for validation and adaptive learning. Its application may best inform urban planning in low-middle income countries in tropical zones where arboviral pathogens are prevalent.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Deep learning model for fast, science-based forecasting of fluid migration along faults in geologic carbon storage scenarios

Effective long-term geologic storage depends on robust site selection and credible, science-based forecasting of subsurface behavior to ensure storage integrity. For this work, we develop a deep learning–based reduced-order model (ROM) to quantify potential carbon dioxide (CO₂) and brine migration through geological faults. The ROM combines a Transformer model for binary classification and a Stacked Ensemble for regression, trained on a comprehensive dataset generated from 1400 physics-based reservoir simulations. Key geologic and operational parameters—including fault geometry, reservoir structure, and injection conditions—were systematically varied to capture a wide range of fluid migration scenarios. The ROM accurately predicts the onset of migration, cumulative migration volumes of both CO₂ and brine, and associated migration rates, as compared to an independent set of validation simulations, while significantly reducing computational cost compared to traditional simulation methods. Model performance was evaluated across diverse fault configurations, revealing that shallow reservoir geometry and fault angle are among the most influential factors governing migration behavior. Sensitivity analysis using SHapley Additive exPlanations (SHAP) provided interpretability, revealing distinct patterns in how geological and operational features drive transient versus cumulative migration outcomes. The ROM’s ability to rapidly simulate fault migration scenarios enables efficient sensitivity analyses, scenario evaluations, and decision support for site selection and monitoring design. This approach enhances the safety, scalability, and long-term operational performance of geologic carbon storage (GCS) systems by providing a robust, interpretable tool for predicting subsurface fluid migration and assessing fault-related migration potential.

42 ENGINEERING↗
DOE OSTI2023

Accelerating discrete dislocation dynamics simulations with graph neural networks

Discrete dislocation dynamics (DDD) is a widely employed computational method to study plasticity at the mesoscale that connects the motion of dislocation lines to the macroscopic response of crystalline materials. However, the computational cost of DDD simulations remains a bottleneck that limits its range of applicability. Here, we introduce a new DDD-GNN framework in which the expensive time-integration of dislocation motion is entirely substituted by a graph neural network (GNN) model trained on DDD trajectories. As a first application, we demonstrate the feasibility and potential of our method on a simple yet relevant model of a dislocation line gliding through an array of obstacles. We show that the DDD-GNN model is stable and reproduces very well unseen ground-truth DDD simulation responses for a range of straining rates and obstacle densities, without the need to explicitly compute nodal forces or dislocation mobilities during time-integration. Our approach opens new promising avenues to accelerate DDD simulations and to incorporate more complex dislocation motion behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Wavelet Analysis of Properties of Marine Boundary Layer Mesoscale Cells Observed From AMSR–E

Marine boundary layer clouds tend to organize into closed or open mesoscale cellular convection (MCC). Here, two-dimensional wavelet analysis is applied for the first time to passive microwave retrievals of cloud water path (CWP), water vapor path (WVP), and rain rate (RR) from Advanced Microwave Scanning Radiometer for Earth Observing System in 2008 over the Northeast and Southeast Pacific, and the Southeast Atlantic subtropical stratocumulus to cumulus transition regions. The (co-)variability between CWP, WVP, and RR in 160 × 160 km 2 analysis boxes is partitioned between four mesoscale wavelength octaves (20, 40, 80, and 160 km). The cell scale is identified as the wavelength of the peak CWP variance. Together with a machine-learning classification of cell type, this allows the statistical characteristics of open and closed MCC of various scales, and its relation to WVP, RR, and potential environmental controlling factors to be analyzed across a very large set of cases. Here, the results show that the cell wavelength is most commonly 40–80 km. Cell-scale CWP perturbations are good predictors of the WVP and RR perturbations. For cells larger than 20 km, there is no obvious dependence of cell scale on the environmental controlling factors tested, suggesting that the cell scale may depend more on its historical evolution than the current environmental conditions.

54 ENVIRONMENTAL SCIENCES↗