Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Data Availability”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,189 records · Page 66
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

SECARB-USA: Needs Assessment Framework for Storage Complexes (Task 2.1.b)

A team of SECARB storage experts examined 63 formations at 39 sites that were selected to represent the range of diversity of newly assessed, as well as well-advanced, storage prospects in the SECARB region. We inventoried the data needs triggered by the requirements to obtain a Class VI UIC storage permit, the data needs that results from the requirement to create geocellular fluid flow models to support that permit, and by pragmatic and best practice inputs such as public acceptance, regulatory readiness, and pore space leasing. We anchored both the needs inventory and the processes for and cost of meeting the needs with data from 9 sites in in the SECARB area that have advanced far in characterization. Results show that the total cost of characterization prior to obtaining a permit is convergent, because the permit and modeling requirements drive projects to obtain the same types of data for all cases. The high cost data that control cost are 1) drilling, coring, core-testing, logging, sampling and testing a characterization well and 2) collection of a 3-D seismic survey to map reservoir and confining system properties over the area of the plume or the area of elevated pressure. In 5 of our case study sites we determined that one or both of these costs could be avoided because the needs are met by available data.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Maximized Information Gain of Next Generation Pulsed Power Using Optimized Design of Z-Machine Experiments

This project develops a Bayesian optimization approach to extracting insights from Z Machine experimental data to determine if and how these insights can be used to extrapolate to a larger facility. The primary goal is to address the scientific challenge of informing how confidently experimental conditions can be predicted on a next generation facility, the design of which requires the reliable extrapolation of current high energy density technologies to regimes yet unobserved, except by costly high-fidelity computational models. Maximizing the use of presently available data and understanding how it informs future endeavors is critically important to enable transformative pulsed power and the science of extreme conditions. We explore a Bayesian optimization approach to experimental design which combines information theory, experimental data, and computational modeling to explore how information gain can be maximized.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Innovations Driven by Advanced Characterization to Strategize Critical Mineral Production and Beneficial Reuse from Fossil Energy Waste

Critical minerals (CM), such as rare earth elements (REE), cobalt, nickel, and lithium, have important uses in modern electronics and advanced manufacturing, yet are vulnerable to potential supply chain disruptions. Relatively abundant and readily available fossil energy (FE) wastes, such as coal combustion ash, acid mine drainage (AMD) and treatment solids (AMD solids), and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters) are under consideration as CM feedstocks. The National Energy Technology Laboratory (NETL) has studied CM resources for various FE wastes as part of the U.S. Department of Energy’s mission of bolstering the domestic CM supply, and makes the data available to the public on EDX at sites such as the NEWTS group. Advanced characterization utilizing synchrotron x-ray techniques coupled with laboratory extractions has been performed to identify CM hosting phases in these FE wastes to inform CM recoverability mechanisms. Novel methods to selectively recover CMs while co-producing other valuable byproducts have been developed. Successful examples discussed here include: (1) The identification of REE/Co/Ni/Sc binding and hosting phases in select FE waste (coal combustion ash and AMD solids), resulting in the development of a patented CM step-extraction process, (2) coupled production of functional sorbents from these extraction wastes and for CM recovery. A pilot-scale testing to evaluate the patent’s technical feasibility for extracting REE from coal ash on a barrel scale has been successfully performed. Additionally, (3) evaluation and measurements of brine geochemistry from U.S. O&G produced waters has informed a high Li recovery potential from Marcellus Shale produced water. NETL researchers have been developing tailored pre-treatment processes, an innovative and highly durable lithium sorbent, and geochemical model guided precipitation to accelerate Li production from the Marcellus Shale produced waters. These innovations driven by characterization are integral for maximizing and advancing the potential for CM recovery while offsetting the cost and environmental footprint for FE waste management.

critical mineral processing↗
DOE OSTI2020

Probing Transit Timing Variation and Its Possible Origin with 12 New Transits of TrES-3b

We present 12 new transit light curves of the hot-Jupiter TrES-3b observed during 2012−2018 to probe the transit timing variation (TTV). By combining the midtransit times determined from these 12 transit data with those reestimated through uniform procedure from 71 transit data available in the literature, we derive new linear ephemeris and obtain the timing residuals that suggest the possibility of TTV in the TrES-3 system. However, the frequency analysis shows that the possible TTV is unlikely to be periodic, indicating the absence of an additional body in this system. To explore the other possible origins of TTV, the orbital decay and apsidal precession ephemeris models are fitted to the transit time data. We find the decay rate of TrES-3b to be P-dot {sub q}=−4.1±3.1 ms yr{sup −1}, and the corresponding estimated modified stellar tidal quality factor of Q{sub ∗}{sup ′}∼1.11×10{sup 5} is consistent with the theoretically predicted values for the stars hosting the hot-Jupiters. The shift in the transit arrival time of TrES-3b after 11 years is expected to be T {sub shift} ∼ 69.55 s, which is consistent with the rms of the timing residuals. Besides, we find that the apsidal precession ephemeris model is statistically less probable than the other considered ephemeris models. It is also discussed that despite the fact that the linear ephemeris model appears to be the most plausible model to represent the transit time data, the possibility of the orbital decay cannot be completely ruled out in the TrES-3 system. To confirm this, further high-precision and high-cadence follow-up observation of transits of TrES-3b would be important.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1972

The thermodynamic properties of oxygen and nitrogen. Part 2: Thermodynamic properties of oxygen from 100 R to 600 R with pressure to 5000 psia

An equation of state is presented for liquid and gaseous oxygen for temperatures from 100 R to 600 R and pressures to 5000 psia. The pressure-density-temperature data available from the published literature have been reviewed, and appropriate corrections have been applied to bring experimental temperatures into accord with the International Practical Temperature Scale of 1968. Representative comparisons of property values calculated from the equation of state to measured values are included to illustrate the accuracy of the equation of state. The coefficients of the equation of state were determined by a weighted least squares fit to selected published data, and simultaneously to isochoric heat capacity data, and to data which define the phase equilibrium for the saturated liquid and saturated vapor. The equation of state is estimated to be accurate for the liquid to within 0.1 percent in density, to within 0.2 percent for the vapor below the critical temperature and for states above the critical temperatures to 250 K, and within 0.1 percent for supercritical states at temperatures from 250 K to 300 K. The vapor pressure equation is accurate to within + or - 0.01 K between the triple point and the critical point.

Stewart, R. B.↗
NASA NTRS1988

Peculiar velocities of cD galaxies - MX spectroscopy of Abell 1795

Spectroscopic observations of galaxies in the Abell 1795 field have been obtained using the MX multiple-object spectrograph on the Steward Observatory 2.3 m telescope. Redshifts are presented for 46 galaxies, including 41 cluster members. It is found that the A1795 cD galaxy is not at rest in the cluster gravitational potential well; it has a peculiar radial velocity, cz, of 365 km/s, and the hypothesis that the mean cluster velocity is as large as the cD's velocity can be rejected at the 99.5 percent confidence level. This conclusion is supported by spectroscopic data for the 'cooling flow' gas found in the central region of the cluster; this gas, except for the portion coincident with the cD nucleus, lies at the velocity derived for the cluster mean. It is suggested that current models of the formation of cD galaxies are unlikely to account for the large peculiar velocities of the cD galaxies in A1795 and A2670 unless substantial subclustering is still present. However, the available data show no evidence for velocity subclustering in either A1795 or A2670.

Hill, John M.↗
NASA NTRSDate not supplied

The INSTEP Monitoring Network: Merging High-and-Low Cost Measurements to Characterize California Wildfires

Despite challenges with data quality and scope, low-cost sensor networks have skyrocketed in popularity over the last 15 years, making air quality data available on refined spatial scales. More recently, studies have leveraged both high and low-quality instruments to create stronger “hybrid” models, with most studies focusing on particulate matter. Low-cost measurements typically represent ground-level emissions only, providing context for human health issues from climate change-driven events such as wildfires. Since low-cost sensors’ capabilities are localized, daily events and microclimates tend to dominate the data rather than larger regional or atmospheric trends. Likewise, their low cost explains their high uncertainty. In contrast, some regulatory-grade instruments produce column measurements as well, providing reliable information on a broader scope. To bridge this gap while expanding into gas-phase measurements, we deployed 12 air quality sensor packages in California, USA during the 2022 wildfire season. These INSTEP (Inexpensive Network Sensor Technology Exploring Pollution) monitors measure carbon monoxide (CO), carbon dioxide (CO2), ozone (O3), nitrogen dioxide (NO2), and several hydrocarbons including methane (CH4) and formaldehyde (HCHO). Half of the monitors were co-located with remote sensing spectrometers: NASA Pandora and Total Column Carbon Observing Network (TCCON). The overlap in pollutants includes NO2, O3, and HCHO between the INSTEP monitors and the Pandora column measurements. TCCON covers column CO, CO2, and CH4, rounding out our comparison. Most of the monitors were distributed throughout the San Francisco Bay area, and an additional three were located within 100 km of Los Angeles. The sites ranged in geographic and population characteristics, including desert, mountainous, coastal, and urban locations. Since varying environmental conditions such as temperature and pressure are known to challenge sensor performance, we will apply newer sensor “calibration” techniques meant to combat this. We will normalize our sensor signals by z-scoring them prior to applying a single calibration model in the form of multivariate linear regression or an artificial neural network. While this technique has been validated for the hydrocarbon and ozone sensor types (metal oxide), it has not yet been tested on electrochemical and non-dispersive infrared sensors, which are also used in the INSTEP monitors. This will serve as a test to see if this normalization technique – or another – is most effective in accounting for environmental differences among sensors. Related data analysis efforts have found success with a variety of geospatial analysis techniques, including weighted network models in which high-quality instruments are given higher weights than their low-cost counterparts. Our preliminary analysis will focus on kriging, which uses a Gaussian algorithm to assign weights, providing estimated pollution levels at locations between monitors. Smoke trajectory and evolution will also be considered using both measurement types. We also aim to baseline subtract our emission estimates from each region to determine which portion of emissions are regional and local, further characterizing burn differences in northern and southern California fires. Future directions include using INSTEP jointly with TEMPO satellite data, and mobile deployments on aircraft and uncrewed aerial vehicles (UAV).

Low-cost sensors↗
DOE OSTI2022

Regional Feedstock Partnership Biomass Quality Assessment Final Report

The United States (U.S.) Department of Energy (DOE) developed the Billion-Ton Vision to enable production of one-billion tons of sustainable, reliable biomass for the bioenergy industry by 2030 (Perlack et al., 2005). The Sun Grant Regional Feedstock Partnership (RFP) was organized to fill information gaps and validate biomass yield assumptions related to the Billion-Ton Study (Owens, 2018; Owens, Karlen, and Lacey, 2016). Along with the more than 130 scientific publications generated from these studies, yield and sustainability data from the RFP field trials not only validated the Billion-Ton estimates, but were critical in developing both the U.S. Billion-Ton Update report in 2011 and the 2016 Billion-Ton Report (DOE, 2011; 2016). The intention of this biomass quality assessment report is to build on these initial successes from the RFP field trials by focusing on variability in biomass quality data necessary to evaluate conversion performance. This report contains a summary of chemical quality results from samples collected as part of the RFP field trials. This report focuses on assessment of the impact of experimental agronomic designs on biomass properties followed by analyses of the impact of environmental and production variables on biomass properties. Datasets include species and other genetic variables, fertilizer treatments, harvest information, and yield, as well as other publicly available data such as precipitation, temperature, soil properties, and drought. The key outcomes from this chemical quality focused assessment have included: • Complete evaluation of the impacts of agronomic designs, genetics, and environmental conditions on chemical properties for Miscanthus, switchgrass, sorghum, energycane, mixed perennial grasses, and shrub willow short-rotation feedstocks • Over 30 peer review publications and technical reports focused on variability in quality data • Development of spatial and temporal environmental quality prediction maps for Miscanthus and switchgrass feedstocks allowing for comprehensive evaluation of variability in feedstock chemical quality across U.S. regions and over multiple harvest years

09 BIOMASS FUELS↗
DOE OSTI2026

Measuring labor productivity dynamics in U.S. industrial and electric power sectors: a case study (2014–2023)

This study proposes a subsystem methodology for measuring labor productivity in the U.S. industrial and electric power sectors by leveraging public data available between 2014 and 2023. Building on Pasinetti’s framework and subsequent developments, the approach employs Vertically Integrated Sectors (VIS) to account for both direct and indirect productivity effects. The novelty of this work is twofold. First, it enables the estimation of productivity trends over time, providing a robust foundation for empirical analysis. Second, it applies the methodology to a case study of the electric generation sector, highlighting its practical relevance. Using data from the Bureau of Economic Analysis, the Bureau of Labor Statistics, and the Impact Analysis for Planning (IMPLAN) tool, the study reveals significant discrepancies between conventional productivity measures and those derived from the VIS approach. Furthermore, the proposed method aligns with the principles of Integrated Energy Systems by capturing the interrelations among generation, distribution, storage, and consumption. This alignment underscores its utility and applications for energy-related policy and planning. Overall, the findings contribute to more precise labor productivity assessments, supporting informed decision-making and future research. Additionally, the method highlights the importance of considering the whole supply chain, providing interrelated metrics for labor productivity which includes both, direct and indirect effects on the final labor productivity metric. By incorporating intersectoral dependencies, this method offers a more comprehensive and accurate measure of labor productivity compared to traditional metrics.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2005

A least-squares parameter estimation algorithm for switched hammerstein systems with applications to the VOR

A "Multimode" or "switched" system is one that switches between various modes of operation. When a switch occurs from one mode to another, a discontinuity may result followed by a smooth evolution under the new regime. Characterizing the switching behavior of these systems is not well understood and, therefore, identification of multimode systems typically requires a preprocessing step to classify the observed data according to a mode of operation. A further consequence of the switched nature of these systems is that data available for parameter estimation of any subsystem may be inadequate. As such, identification and parameter estimation of multimode systems remains an unresolved problem. In this paper, we 1) show that the NARMAX model structure can be used to describe the impulsive-smooth behavior of switched systems, 2) propose a modified extended least squares (MELS) algorithm to estimate the coefficients of such models, and 3) demonstrate its applicability to simulated and real data from the Vestibulo-Ocular Reflex (VOR). The approach will also allow the identification of other nonlinear bio-systems, suspected of containing "hard" nonlinearities.

Evaluation Studies↗
NASA NTRSDate not supplied

Impact Real World System Validation

Introduction NASA has developed a new evidence-based data-driven probabilistic risk assessment and tradespace analysis tool as a successor to the Integrated Medical Model. This updated decision support tool is known as IMPACT (Informing Mission Planning via Analysis of Complex Tradespaces). IMPACT estimates the frequency and consequences of medical conditions that might arise during exploration missions. A validation analysis of IMPACT was performed with respect to a set of International Space Station (ISS) and Shuttle Transportation System (STS) real world system (RWS) referent data due to the limited referent data available from exploration missions. Methods Observed mission and crew characteristics from STS and ISS missions were used as model inputs within MEDPRAT (Medical Extensible Dynamic Probabilistic Risk Assessment Tool). For each mission, two hundred thousand simulations were generated. For each mission, model outputs included occurrence counts for each condition, total medical events (TME), and the probability of loss of crew life (LOCL). These simulated model outputs were compared to the RWS referent data. Results The predicted number of total medical events exceeded the total RWS medical events for ISS missions and combined ISS and STS missions and fell within the 90% confidence interval for STS missions. For the 32 ISS missions simulated by IMPACT, the number of total medical events was overpredicted for 19 missions and fell within the 90% confidence interval for 13 missions. For the 21 STS missions, the total number of medical events was overpredicted for 3 missions, fell within the 90% confidence interval for 16 missions, and was underpredicted for 2 missions. Combined, 29 missions were in range, 22 were overpredicted, and 2 were underpredicted. The predicted LOCL probability for the 32 ISS missions, the 21 STS missions, and the combined ISS and STS missions was consistent with the zero LOCL events observed in the RWS referent data. The validation analysis included a comparison of the number of medical events predicted by IMPACT and the number of medical events observed in the RWS data on a condition-by-condition basis. For ISS missions, 50 conditions were in range, 52 conditions were statistically underpowered (not enough observed sample to draw any conclusions on precision), 8 conditions were overpredicted, and 9 conditions were underpredicted. Overall, only 14% (17/119) of conditions were out of range for STS missions, 40 conditions were in range, 59 conditions were statistically underpowered, 10 conditions were overpredicted, and 10 conditions were underpredicted. Overall, only 17% (20/119) of conditions were out of range. For combined ISS and STS missions, 11 conditions were overpredicted, and 11 conditions were underpredicted. Overall, only 18% (22/119) of conditions were out of range. For combined ISS and STS missions, 49 conditions were in range, 46 conditions were statistically underpowered, 18 conditions were overpredicted, and 8 conditions were underpredicted. Overall, 21% (26/121) of conditions were out of range. Conclusion The results of this validation analysis should not be interpreted as a pass/fail test of the validity of IMPACT. Instead, this validation analysis should be used to assess some of the IMPACT outcomes in terms of consistencies and inconsistencies with the ISS and STS RWS referent data.

L. Boley↗
DOE OSTI2024

Recent Progress on Surface Water Quality Models Utilizing Machine Learning Techniques

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

machine learning (ML)↗
NASA NTRS1979

Release adiabat measurements on minerals: The effect of viscosity

The current inversion of pressure-particle velocity data for release from a high pressure shock state to a pressure-density path is analyzed. It is assumed that the release process is isentropic. It was shown that for geological materials below stresses of 150 GPa, the effective viscosity must be 1000 kg/m/s in order that the viscous (irreversible) work carried out on the material in the shock state remains small compared to the mechanical work recovered upon adiabatic rarefaction. The available data pertaining to the offset of the Rayleigh line from the Hugoniot for minerals, the magnitude of the shear stress in the high pressure shock state for minerals, and the direct measurements of the viscosities of several engineering materials shocked to pressures below 150 GPa yield effective viscosities of 1000 kg/m/s or less. An inferance that this indicates that the conditions for isentropic release of minerals from shock states are achieved, and a conclusion that the application of the Riemann integral to obtain pressure-density states along the release adiabats of minerals in shock experiments is valid are made.

Jeanloz, R.↗
NASA NTRS1989

Trends in total column ozone measurements

It is important to ensure the best available data are used in any determination of possible trends in total ozone in order to have the most accurate estimates of any trends and the associated uncertainties. Accordingly, the existing total ozone records were examined in considerable detail. Once the best data set has been produced, the statistical analysis must examine the data for any effects that might indicate changes in the behavior of global total ozone. The changes at any individual measuring station could be local in nature, and herein, particular attention was paid to the seasonal and latitudinal variations of total ozone, because two dimensional photochemical models indicate that any changes in total ozone would be most pronounced at high latitudes during the winter months. The conclusions derived from this detailed examination of available total ozone can be split into two categories, one concerning the quality and the other the statistical analysis of the total ozone record.

Rowland, F. S.↗
NASA NTRS2013

Experimental Data from the Benchmark SuperCritical Wing Wind Tunnel Test on an Oscillating Turntable

The Benchmark SuperCritical Wing (BSCW) wind tunnel model served as a semi-blind testcase for the 2012 AIAA Aeroelastic Prediction Workshop (AePW). The BSCW was chosen as a testcase due to its geometric simplicity and flow physics complexity. The data sets examined include unforced system information and forced pitching oscillations. The aerodynamic challenges presented by this AePW testcase include a strong shock that was observed to be unsteady for even the unforced system cases, shock-induced separation and trailing edge separation. The current paper quantifies these characteristics at the AePW test condition and at a suggested benchmarking test condition. General characteristics of the model's behavior are examined for the entire available data set.

Heeg, Jennifer↗
NASA NTRS2014

NASA SPoRT Modeling and Data Assimilation Research and Transition Activities Using WRF, LIS and GSI

weather research and forecasting ===== The NASA Short‐term Prediction Research and Transition (SPoRT) program has numerous modeling and data assimilation (DA) activities in which the WRF model is a key component. SPoRT generates realtime, research satellite products from the MODIS and VIIRS instruments, making the data available to NOAA/NWS partners running the WRF/EMS, including: (1) 2‐km northwestern‐hemispheric SST composite, (2) daily, MODIS green vegetation fraction (GVF) over CONUS, and (3) NASA Land Information System (LIS) runs of the Noah LSM over the southeastern CONUS. Each of these datasets have been utilized by specific SPoRT partners in local EMS model runs, with select offices evaluating the impacts using a set of automated scripts developed by SPoRT that manage data acquisition and run the NCAR Model Evaluation Tools verification package. SPoRT is engaged in DA research with the Gridpoint Statistical Interpolation (GSI) and Ensemble Kalman Filter in LIS for soil moisture DA. Ongoing DA projects using GSI include comparing the impacts of assimilating Atmospheric Infrared Sounder (AIRS) radiances versus retrieved profiles, and an analysis of extra‐tropical cyclones with intense non‐convective winds. As part of its Early Adopter activities for the NASA Soil Moisture Active Passive (SMAP) mission, SPoRT is conducting bias correction and soil moisture DA within LIS to improve simulations using the NASA Unified‐WRF (NU‐WRF) for both the European Space Agency's Soil Moisture Ocean Salinity and upcoming SMAP mission data. SPoRT has also incorporated real‐time global GVF data into LIS and WRF from the VIIRS product being developed by NOAA/NESDIS. This poster will highlight the research and transition activities SPoRT conducts using WRF, NU‐WRF, EMS, LIS, and GSI.

Case, Jonathan L.↗
DOE OSTI2025

Evaluating the limitations of Bayesian metabolic control analysis

AbstractBayesian Metabolic Control Analysis (BMCA) has emerged as a promising framework for inferring metabolic control coefficients in data-limited scenarios by integrating Bayesian inference with linlog rate laws. However, its predictive accuracy and limitations remain underexplored. This study systematically evaluates BMCA’s ability to infer elasticity values, flux control coefficients (FCCs), and concentration control coefficients (CCCs) under varying data availability conditions using three synthetic metabolic network models. Our findings highlight the strengths and weaknesses of BMCA, guiding its application in metabolic engineering and emphasizing the need for methodological refinements.Author summaryUnderstanding how enzymes control metabolic pathways is crucial for optimizing biomanufacturing and synthetic biology applications. Bayesian Metabolic Control Analysis (BMCA) is a promising computational method that integrates Bayesian inference with metabolic control analysis to estimate key control parameters, even in cases with limited experimental data. However, the accuracy and limitations of BMCA remain unclear. In this study, we systematically evaluate BMCA using three synthetic metabolic networks to determine how different types of physiological data impact its predictive performance. We find that BMCA requires flux and enzyme concentration data for accurate predictions, while external metabolite concentrations contribute little. Additionally, BMCA fails to predict elasticity values beyond a magnitude of 1.5 and reliably infer allosteric regulation, even when strong regulatory interactions exist. In addition, BMCA does not accurately rank metabolic control points, which may limit its utility in identifying key enzymes in engineered pathways. Our work provides practical insights into when and how BMCA can be applied, guiding future research in metabolic modeling and control analysis.

Shin, Janis (ORCID:0000000216572455)↗
DOE OSTI2022

When physics-informed data analytics outperforms black-box machine learning: A case study in thickness control for additive manufacturing

Aerosol jet printing (AJP) has emerged as a promising noncontact additive manufacturing method for high-resolution printing for a wide range of material systems. A key challenge limiting the broader adoption of AJP in the material science community is the lack of methods to precisely control thickness. Herein, we develop a model-based design of experiment (MBDoE) framework that integrates physics-informed models, nonlinear regression, and information criteria to postulate, select and calibrate the best model to describe and optimize the AJP manufacturing process. Starting with already available data from system commissioning (e.g., prior single variable sensitivity analysis), four candidate physics-informed models are postulated and trained. MBDoE identifies a single additional optimal experiment to validate these predictive models with quantified uncertainties, which are then used to determine the best experimental conditions to control printed film thickness. As a comparative benchmark, the analysis is repeated using the same dataset with nonparametric Gaussian process regression (GPR) model that does not incorporate physical information. Using MBDoE principles, we find that only five experiments are necessary to calibrate the nonlinear physics-informed parametric model, and with said limited data, this model outperforms the black-box machine learning GPR model. This key result underscores an emerging trend in the data science community: incorporating physical information into predictive models often drastically reduces the data requirements. Leveraging MBDoE further increased the data efficiency. By design, the proposed data science framework is general in nature and can be easily extended to other experimental and additive manufacturing systems beyond AJP.

Aerosol jet printing↗