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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 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

42 ENGINEERING↗
DOE OSTI2016

Physics-Informed Machine Learning for Predictive Turbulence Modeling: Towards a Complete Framework

Although increased availability of computational resources has enabled high-fidelity simulations (e.g., large eddy simulations) of turbulent flows, the Reynolds-Averaged Navier–Stokes (RANS) models are still the dominant tools in industrial applications. However, the predictive capabilities of RANS models are limited by large model-form discrepancies due to the Reynolds stress closure. Recently, a Physics-Informed Machine Learning (PIML) approach has been proposed to learn the functional form of Reynolds stress discrepancy in RANS simulations based on available data. It has been demonstrated that the learned discrepancy function can be used to improve Reynolds stresses in new flows where data are not available. However, due to a number of challenges, the improvements are only demonstrated in the Reynolds stress prediction but not in corresponding propagated quantities of interest (e.g., velocity field). In this work, we investigate the prediction performance on the velocity field by propagating the corrected Reynolds stresses in PIML approach. To enrich the input features, an integrity basis of invariants is implemented. The fully developed turbulent flow in a square duct is used as the test case. The discrepancy model is trained on flow fields from several Reynolds numbers and evaluated on a duct flow at a higher Reynolds number than any of the training cases. The predicted Reynolds stresses are propagated to velocity field via RANS equations. Numerical results show excellent predictive performances in both Reynolds stresses and their propagated velocities, demonstrating the merits of the PIML approach in predictive turbulence modeling.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

A mesoscale crystal plasticity model to predict room-temperature deformation and martensitic transformation of high-strength Quenching and Partitioning (Q&P) Steels and validation with synchrotron X-ray diffraction

Renowned for the superior mechanical properties and adeptness at cold-forming, Quenching and Partitioning (QP) steels have gained prominence as a promising candidate material in fabricating safety-critical components in various industries. The pertinent research on QP steels focus on the martensitic transformation of the Retained Austenite (RA) phase during cold-forming, a crucial mechanism that substantially influences the overall strength and ductility of QP steels. The austenite stability and transformation rate heavily rely on the local strain path and the initial microstructure, which is challenging for analytical prediction. In this paper, a mesoscale model is developed to capture the deformation and transformation kinetics of QP steels inside the microstructure. The model integrates the detailed explicit microstructure, acquired from characterization experiments, into a high-resolution finite element (FE) mesh. It distinctly model the deformation and interaction between the various phases and the effect on the transformation of RA. The model is validated with high energy X-ray diffraction (HEXRD) data, and shows excellent capability in predicting the asymmetric stress-strain behavior under uniaxial tension and compression, as well as the martensitic transformation rate. The model is used to investigate the strain and load partitioning effect of surrounding matrix to the transformation of RA, offering insights into the complex behavior of QP980 and facilitates further material development.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Dynamic Data-Driven Multiscale Modeling for Predicting Microstructure and Mechanical Properties of 316L Stainless Steel

We have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Kinetic Modeling of Secondary Organic Aerosol in a Weather-Chemistry Model: Parameterizations, Processes, and Predictions for GOAmazon

Secondary organic aerosol (SOA) forms and evolves in the atmosphere through many pathways and processes, over diverse spatial and time scales. Hence, there is a need to represent these widely-varying kinetic processes in large-scale atmospheric models to allow for accurate predictions of the abundance, properties, and impacts of SOA. In this work, we integrated a kinetic, process-level model (simpleSOM-MOSAIC) into a weather-chemistry model (WRF-Chem) to simulate the oxidation chemistry and microphysics of atmospheric SOA. simpleSOM-MOSAIC simulates multigenerational gas-phase chemistry, autoxidation reactions, heterogeneous oxidation, oligomerization, and phase-state-influenced gas/particle partitioning of SOA. As a case study, the integrated WRF-Chem-simpleSOM-MOSAIC (WC-SSM) model was used to simulate the photochemical evolution downwind of a large city (Manaus, Brazil) in the Amazon and, in turn, study the anthropogenic and biogenic interactions in an otherwise pristine environment. Consistent with previous work, we found that OA was enhanced by up to a factor of four in the urban plume due to elevated hydroxyl radical (OH) concentrations, relative to the background, and that this OA was dominated by SOA from biogenic precursors (80%). Further, in addition to accurately simulating the OA enhancement in the urban plume, the model reproduced the magnitude of the OA oxygen-to-carbon (O:C) ratio and broadly tracked the evolution of the aerosol size distribution. Our work highlights the importance of including an integrated, kinetic representation of SOA processes in an atmospheric model

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

COMPASS: A Framework for Automated Performance Modeling and Prediction

Flexible, accurate performance predictions offer numerous benefits such as gaining insight into and optimizing applications and architectures. However, the development and evaluation of such performance predictions has been a major research challenge, due to the architectural complexities. To address this challenge, we have designed and implemented a prototype system, named COMPASS, for automated performance model generation and prediction. COMPASS generates a structured performance model from the target application's source code using automated static analysis, and then, it evaluates this model using various performance prediction techniques. As we demonstrate on several applications, the results of these predictions can be used for a variety of purposes, such as design space exploration, identifying performance tradeoffs for applications, and understanding sensitivities of important parameters. COMPASS can generate these predictions across several types of applications from traditional, sequential CPU applications to GPU-based, heterogeneous, parallel applications. Our empirical evaluation demonstrates a maximum overhead of 4%, flexibility to generate models for 9 applications, speed, ease of creation, and very low relative errors across a diverse set of architectures.

Lee, Seyong↗
DOE OSTI2020

The Impact of Nuclear Physics Uncertainties on Galactic Chemical Evolution Predictions

Modeling the evolution of the elements in the Milky Way is a multidisciplinary and challenging task. In addition to simulating the ~13 billion years evolution of our Galaxy, chemical evolution simulations must keep track of the elements synthesized and ejected from every astrophysical site of interest (e.g., supernova, compact binary merger). The elemental abundances of such ejecta, which are a fundamental input for chemical evolution codes, are usually taken from theoretical nucleosynthesis calculations performed by the nuclear astrophysics community. Therefore, almost all chemical evolution predictions rely on the nuclear physics behind those calculations. In this proceedings article, we highlight the impact of nuclear physics uncertainties on galactic chemical evolution predictions. We demonstrate that nuclear physics and galactic evolution uncertainties both have a significant impact on interpreting the origin of neutron-capture elements in our Solar System. Those results serve as a motivation to create and maintain collaborations between the fields of nuclear astrophysics and galaxy evolution.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Combining mechanistic and machine learning models for predictive engineering and optimization of tryptophan metabolism

Abstract Through advanced mechanistic modeling and the generation of large high-quality datasets, machine learning is becoming an integral part of understanding and engineering living systems. Here we show that mechanistic and machine learning models can be combined to enable accurate genotype-to-phenotype predictions. We use a genome-scale model to pinpoint engineering targets, efficient library construction of metabolic pathway designs, and high-throughput biosensor-enabled screening for training diverse machine learning algorithms. From a single data-generation cycle, this enables successful forward engineering of complex aromatic amino acid metabolism in yeast, with the best machine learning-guided design recommendations improving tryptophan titer and productivity by up to 74 and 43%, respectively, compared to the best designs used for algorithm training. Thus, this study highlights the power of combining mechanistic and machine learning models to effectively direct metabolic engineering efforts.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Data-driven prediction of geometry- and toolpath sequence-dependent intra-layer process conditions variations in laser powder bed fusion

Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.

42 ENGINEERING↗
DOE OSTI2017

Data-Driven Nonlinear Subspace Modeling for Prediction and Control of Molten Iron Quality Indices in Blast Furnace Ironmaking

Blast furnace (BF) in ironmaking is a nonlinear dynamic process with complicated physical-chemical reactions, where multi-phase and multi-field coupling and large time delay occur during its operation. In BF operation, the molten iron temperature (MIT) as well as Si, P and S contents of molten iron are the most essential molten iron quality (MIQ) indices, whose measurement, modeling and control have always been important issues in metallurgic engineering and automation field. This paper develops a novel data-driven nonlinear state space modeling for the prediction and control of multivariate MIQ indices by integrating hybrid modeling and control techniques. First, to improve modeling efficiency, a data-driven hybrid method combining canonical correlation analysis and correlation analysis is proposed to identify the most influential controllable variables as the modeling inputs from multitudinous factors would affect the MIQ indices. Then, a Hammerstein model for the prediction of MIQ indices is established using the LS-SVM based nonlinear subspace identification method. Such a model is further simplified by using piecewise cubic Hermite interpolating polynomial method to fit the complex nonlinear kernel function. Compared to the original Hammerstein model, this simplified model can not only significantly reduce the computational complexity, but also has almost the same reliability and accuracy for a stable prediction of MIQ indices. Last, in order to verify the practicability of the developed model, it is applied in designing a genetic algorithm based nonlinear predictive controller for multivariate MIQ indices by directly taking the established model as a predictor. Industrial experiments show the advantages and effectiveness of the proposed approach.

Blast furnace (BF)↗
DOE OSTI2015

Final Report Systems Level Analysis of the Function and Adaptive Responses of Methanogenic Consortia

The purpose of this research was to determine whether the syntrophic microbial associations that are central to the functioning of methane-producing terrestrial wetlands can be predictively modeled with coupled multi-species genome-scale metabolic models. Such models are important because methane is an important greenhouse gas and there is a need to predictively model how the methane-producing microbial communities will respond to environmental perturbations, such as global climate change. The research discovered that the most prodigious methane-producing microorganisms on earth participate in a previously unrecognized form of energy exchange. The methane-producers Methanosaeta and Methanosarcina forge biological electrical connections with other microbes in order to obtain electrons to reduce carbon dioxide to methane. This direct interspecies electron transfer (DIET) was demonstrated in complex microbial communities as well as in defined co-cultures. For example, metatranscriptomic analysis of gene expression in both natural communities and defined co-cultures demonstrated that Methanosaeta species highly expressed genes for the enzymes for the reduction of carbon dioxide to methane. Furthermore, Methanosaeta’s electron-donating partners highly expressed genes for the biological electrical connections known as microbial nanowires. A series of studies involving transcriptomics, genome resequencing, and analysis of the metabolism of a series of strains with targeted gene deletions, further elucidated the mechanisms and energetics of DIET in methane-producing co-cultures, as well as in a co-culture of Geobacter metallireducens and Geobacter sulfurreducens, which provided a system for studying DIET with two genetically tractable partners. Genome-scale modeling of DIET in the G. metallireducens/G. sulfurreducens co-culture suggested that DIET provides more energy to the electron-donating partner that electron exchange via interspecies hydrogen transfer, but that the performance of DIET may be strongly influenced by environmental factors. These studies have significantly modified conceptual models for carbon and electron flow in methane-producing environments and have developed a computational framework for predictive modeling the influence of environmental perturbations on methane-producing microbial communities. The results have important implications for modeling the response of methane-producing microbial communities to climate change as well as for the bioenergy strategy of converting wastes and biomass to methane.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2017

Regression-based reduced-order models to predict transient thermal output for enhanced geothermal systems

Reduced-order modeling is a promising approach, as many phenomena can be described by a few parameters/mechanisms. An advantage and attractive aspect of a reduced-order model is that it is computational inexpensive to evaluate when compared to running a high-fidelity numerical simulation. A reduced-order model takes couple of seconds to run on a laptop while a high-fidelity simulation may take couple of hours to run on a high-performance computing cluster. The goal of this paper is to assess the utility of regression-based reduced-order models (ROMs) developed from high-fidelity numerical simulations for predicting transient thermal power output for an enhanced geothermal reservoir while explicitly accounting for uncertainties in the subsurface system and site-specific details. Numerical simulations are performed based on equally spaced values in the specified range of model parameters. Key sensitive parameters are then identified from these simulations, which are fracture zone permeability, well/skin factor, bottom hole pressure, and injection flow rate. We found the fracture zone permeability to be the most sensitive parameter. The fracture zone permeability along with time, are used to build regression-based ROMs for the thermal power output. The ROMs are trained and validated using detailed physics-based numerical simulations. Finally, predictions from the ROMs are then compared with field data. We propose three different ROMs with different levels of model parsimony, each describing key and essential features of the power production curves. The coefficients in the proposed regression-based ROMs are developed by minimizing a non-linear least-squares misfit function using the Levenberg–Marquardt algorithm. The misfit function is based on the difference between numerical simulation data and reduced-order model. ROM-1 is constructed based on polynomials up to fourth order. ROM-1 is able to accurately reproduce the power output of numerical simulations for low values of permeabilities and certain features of the field-scale data. ROM-2 is a model with more analytical functions consisting of polynomials up to order eight, exponential functions and smooth approximations of Heaviside functions, and accurately describes the field-data. At higher permeabilities, ROM-2 reproduces numerical results better than ROM-1, however, there is a considerable deviation from numerical results at low fracture zone permeabilities. ROM-3 consists of polynomials up to order ten, and is developed by taking the best aspects of ROM-1 and ROM-2. ROM-1 is relatively parsimonious than ROM-2 and ROM-3, while ROM-2 overfits the data. ROM-3 on the other hand, provides a middle ground for model parsimony. Based on R 2 -values for training, validation, and prediction data sets we found that ROM-3 is better model than ROM-2 and ROM-1. For predicting thermal drawdown in EGS applications, where high fracture zone permeabilities (typically greater than 10 –15 m 2 ) are desired, ROM-2 and ROM-3 outperform ROM-1. As per computational time, all the ROMs are 10 4 times faster when compared to running a high-fidelity numerical simulation. In conclusion, this makes the proposed regression-based ROMs attractive for real-time EGS applications because they are fast and provide reasonably good predictions for thermal power output.

58 GEOSCIENCES↗
DOE OSTI2024

Dynamic data-driven multiscale modeling for predicting the degradation of a 316L stainless steel nuclear cladding material

Here, we have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
DOE OSTI2015

Baseline and Target Values for PV Forecasts: Toward Improved Solar Power Forecasting

Accurate solar power forecasting allows utilities to get the most out of the solar resources on their systems. To truly measure the improvements that any new solar forecasting methods can provide, it is important to first develop (or determine) baseline and target solar forecasting at different spatial and temporal scales. This paper aims to develop baseline and target values for solar forecasting metrics. These were informed by close collaboration with utility and independent system operator partners. The baseline values are established based on state-of-the-art numerical weather prediction models and persistence models. The target values are determined based on the reduction in the amount of reserves that must be held to accommodate the uncertainty of solar power output.

14 SOLAR ENERGY↗
DOE OSTI2015

The Effect of Global Warming on Severe Thunderstorms in the United States

How will warming temperatures influence thunderstorm severity? This question can be explored by using climate models to diagnose changes in large-scale convective instability (CAPE) and wind shear, conditions that are known to be conducive to the formation of severe thunderstorms. First, an ensemble of climate models from phase 5 of the Coupled Model Intercomparison Project (CMIP5) is evaluated on its ability to reproduce a radiosonde climatology of such storm-favorable conditions in the current climate's spring and summer seasons, focusing on the contiguous United States (CONUS). Of the 11 climate models evaluated, a high-performing subset of four (GFDL CM3, GFDL-ESM2M, MRI-CGCM3, and NorESM1-M) is identified. Second, the twenty-first-century changes in the frequency of environments favorable to severe thunderstorms are calculated in these high-performing models as they are forced by the RCP4.5 and RCP8.5 emissions pathways. For the RCP8.5 scenario, the models predict consistent CONUS-mean fractional springtime increases in the range of 50%-180% by the end of the twenty-first century; for the summer, three of the four models predict increases in the range of 40%-120% and one model predicts a small decrease. This disagreement between the models is traced to divergent projections for future CAPE and boundary layer humidity in the Great Plains. This paper also explores the sensitivity of the results to the relative weight given to wind shear in determining how "favorable" a large-scale environment is for the development of severe thunderstorms, and it is found that this weighting is not the dominant source of uncertainty in projections of future thunderstorm severity.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Uncertainty Quantification and Comparison of Weld Residual Stress Measurements and Predictions.

In pressurized water reactors, the prevention, detection, and repair of cracks within dissimilar metal welds is essential to ensure proper plant functionality and safety. Weld residual stresses, which are difficult to model and cannot be directly measured, contribute to the formation and growth of cracks due to primary water stress corrosion cracking. Additionally, the uncertainty in weld residual stress measurements and modeling predictions is not well understood, further complicating the prediction of crack evolution. The purpose of this document is to develop methodology to quantify the uncertainty associated with weld residual stress that can be applied to modeling predictions and experimental measurements. Ultimately, the results can be used to assess the current state of uncertainty and to build confidence in both modeling and experimental procedures. The methodology consists of statistically modeling the variation in the weld residual stress profiles using functional data analysis techniques. Uncertainty is quantified using statistical bounds (e.g. confidence and tolerance bounds) constructed with a semi-parametric bootstrap procedure. Such bounds describe the range in which quantities of interest, such as means, are expected to lie as evidenced by the data. The methodology is extended to provide direct comparisons between experimental measurements and modeling predictions by constructing statistical confidence bounds for the average difference between the two quantities. The statistical bounds on the average difference can be used to assess the level of agreement between measurements and predictions. The methodology is applied to experimental measurements of residual stress obtained using two strain relief measurement methods and predictions from seven finite element models developed by different organizations during a round robin study.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗