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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Electrorefining Bismuth Using AC Superimposed DC Waveforms

Bismuth has been successfully electrorefined using both direct current (DC) and alternating current (AC) superimposed DC waveforms on a kilogram scale at Brigham Young University (BYU) in Provo, Utah. Finding a suitable surrogate for Pu Electrorefining has always been a technical challenge. This work allows the possibility to improve Pu electrorefining with nonradioactive material at universities, which greatly reduces the cost at Lawrence Livermore National Laboratory (LLNL) for improving Pu Electrorefining. Several possible surrogates (Ce, In, Sn, Zn, and Bi) were selected based on their ability to mimic the Pu electrorefining process. Ce and In electrorefining experiments were conducted at the same temperature as Pu electrorefining in CaCl 2 while Sn, Zn, and Bi, electrorefining experiments were conducted at a lower temperature in a eutectic molten salt composed of LiCl, KCl, and CaCl 2 . The electrorefining experiments using Ce with a Ga impurity did not produce a cathode ring. While the remaining Ce anode after electrorefining was significantly less than what was initially added, Scanning Electron Microscopy with Energy Dispersive X-Ray (SEM-EDX) analysis showed that the Ce had been oxidized and formed a colloid with the surrounding molten salt. This is supported in the literature by analysis of Ce-rich CaCl 2 mixtures. All the electrorefining experiments except for the Ce electrorefining experiments did not introduce an impurity to the system. Electrorefining experiments with In showed that the InCl 3 volatilized out of the molten salt to an extent that only a low current (<<1 A) could be supported without decomposing the molten salt. Zn electrorefining experiments had marginal success, however an easily separable product was not formed. The Zn had to be rinsed from the salt after the experiment. Of the identified potential surrogates. Investigated, only Bi and Sn yielded an easily separable product ring, which enables quantitative analysis of yields and coulombic efficiencies. Bismuth was first identified as a surrogate at BYU, while Sn was identified as a surrogate at LLNL later. Thus, the electrorefining experiments conducted at BYU using AC superimposed DC waveforms used Bi as the metal to be electrorefined.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Integrated Process Testing of MSR Salt Spill Accidents

Part of the licensing process for new nuclear reactors requires vendors to assess the potential consequences of identified accident scenarios using accident progression modeling. The accident scenario that will likely be evaluated by all molten salt reactor (MSR) developers is a spill of radionuclide-bearing fuel salt onto the reactor containment floor (i.e., a salt spill accident). The development of accident progression models requires experimental data to inform which processes to incorporate, to enable the calculation of parameters to model these processes, and to validate the model predictions. The data should quantify the sensitivities of key processes (e.g., molten salt spreading, heat transfer, containment structure corrosion, radionuclide vaporization, and aerosol generation) towards the initial conditions of the spill, the ambient environment, and the features of the containment. In addition, results from integrated process tests that quantify coupled processes are required to validate systems-level models. This report documents results from integrated process tests conducted on simulated molten salt spill accidents. The generated experimental data simultaneously quantify the heat transfer behavior of the spilled salt, compositional changes to the bulk salt, and the release of surrogate fission products from the spilled salt as aerosol particles. All tests that were conducted used FLiNaK doped with surrogate fission products, and the variables that were evaluated included the initial salt temperature and the concentration of surrogate fission products present in the salt. The major accomplishments of this work include identifying surrogate fuel salt compositions that provide insight into the dispersal behavior of radionuclides of potential significance to the source term, employing previously developed methods and measurement techniques to simultaneously measure key processes, generating data on the coupled processes of molten salt heat transfer and surrogate fission product release as aerosol particles, demonstrating new test methods for real-time monitoring of the flow rate of the spill and aerosol size quantification in an argon atmosphere, and developing a mass transfer model for cesium and iodine release from molten FLiNaK to provide insight into aerosol formation by vapor condensation. The same methodology applied herein can be employed to study different salt compositions of interest to MSR developers, different environmental conditions, and other variables that are relevant to postulated accident scenarios. The insights gained from these integrated process tests conducted at a laboratory scale will be incorporated into future integral effects tests conducted at an engineering scale.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

A traits-based approach for prioritizing species for monitoring and surrogacy selection

The bar for justifying the use of vertebrate animals for study is being increasingly raised, thus requiring increased rigor for species selection and study design. Although we have power analyses to provide quantitative backing for the numbers of organisms used, quantitative backing for selection of study species is not frequently employed. This can be especially important when measuring the impacts of ecosystem alteration, when study species must be chosen that are both sensitive to the alteration and of sufficient abundance for study. Just as important is providing justification for designation of surrogate species for study, especially when the species of interest is rare or of conservation concern and selection of an appropriate surrogate can have legal implications. In this study, we use a combination of GIS, a fish traits database and multivariate statistical analyses to quantitatively prioritize species for study and to determine potential study surrogate species. We provide two case studies to illustrate our quantitative, traits-based approach for designating study species and surrogate species. In the first case study, we select broadly representative fish species to understand the effects of turbine passage on adult fishes based on traits that suggest sensitivity to turbine passage. In our second case study, we present a framework for selecting a surrogate species for an endangered species. Lastly, we suggest that our traits-based framework can provide quantitative backing and added justification to selection of study species while expanding the inference space of study results.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2012

Creation of a Rapid High-Fidelity Aerodynamics Module for a Multidisciplinary Design Environment

In the traditional aerospace vehicle design process, each successive design phase is accompanied by an increment in the modeling fidelity of the disciplinary analyses being performed. This trend follows a corresponding shrinking of the design space as more and more design decisions are locked in. The correlated increase in knowledge about the design and decrease in design freedom occurs partly because increases in modeling fidelity are usually accompanied by significant increases in the computational expense of performing the analyses. When running high fidelity analyses, it is not usually feasible to explore a large number of variations, and so design space exploration is reserved for conceptual design, and higher fidelity analyses are run only once a specific point design has been selected to carry forward. The designs produced by this traditional process have been recognized as being limited by the uncertainty that is present early on due to the use of lower fidelity analyses. For example, uncertainty in aerodynamics predictions produces uncertainty in trajectory optimization, which can impact overall vehicle sizing. This effect can become more significant when trajectories are being shaped by active constraints. For example, if an optimal trajectory is running up against a normal load factor constraint, inaccuracies in the aerodynamic coefficient predictions can cause a feasible trajectory to be considered infeasible, or vice versa. For this reason, a trade must always be performed between the desired fidelity and the resources available. Apart from this trade between fidelity and computational expense, it is very desirable to use higher fidelity analyses earlier in the design process. A large body of work has been performed to this end, led by efforts in the area of surrogate modeling. In surrogate modeling, an up-front investment is made by running a high fidelity code over a Design of Experiments (DOE); once completed, the DOE data is used to create a surrogate model, which captures the relationships between input variables and responses into regression equations. Depending on the dimensionality of the problem and the fidelity of the code for which a surrogate model is being created, the initial DOE can itself be computationally prohibitive to run. Cokriging, a modeling approach from the field of geostatistics, provides a desirable compromise between computational expense and fidelity. To do this, cokriging leverages a large body of data generated by a low fidelity analysis, combines it with a smaller set of data from a higher fidelity analysis, and creates a kriging surrogate model with prediction fidelity approaching that of the higher fidelity analysis. When integrated into a multidisciplinary environment, a disciplinary analysis module employing cokriging can raise the analysis fidelity without drastically impacting the expense of design iterations. This is demonstrated through the creation of an aerodynamics analysis module in NASA’s OpenMDAO framework. Aerodynamic analyses including Missile DATCOM, APAS, and USM3D are leveraged to create high fidelity aerodynamics decks for parametric vehicle geometries, which are created in NASA’s Vehicle Sketch Pad (VSP). Several trade studies are performed to examine the achieved level of model fidelity, and the overall impact to vehicle design is quantified.

Aerodynamic Properties↗
NASA NTRS2016

The First Government Sanctioned Delivery of Medical Supplies by Remotely Controlled Unmanned Aerial System (UAS)

The first government sanctioned delivery of medical supplies by UAS occurred at Wise, Virginia, on July 17, 2015. The "Let's Fly Wisely" event was a demonstration of the humanitarian use of UAS to facilitate delivery of medical supplies to remote or otherwise difficult-to-reach areas. The event was the result of coordinated efforts by a partnership which included the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC), Virginia Polytechnic Institute, the Mid-Atlantic Aviation Partnership (MAAP), Flirtey Corporation, Lonesome Pine Airport, Remote Area Medical (RAM), Health Wagon, SEESPAN Aerial Interactive, Rx Partnership, and Wise County, Virginia. The historic event occurred during the annual Remote Area Medical clinic at the Wise County Fairgrounds. The medical supplies in small packages were delivered to the Wise County Fairgrounds from the Lonesome Pine Airport by UAS operated by Firtey. A larger supply of medical supplies were delivered to the Lonesome Pine Airport from the Tazewell County Airport by NASA Langley's SR22 UAS Surrogate Research aircraft. The UAS Surrogate aircraft was remotely controlled for most of the flight by a UAS Ground Control Station located at the Lonesome Pine Airport. The medical supplies were delivered from the UAS Surrogate to Flirtey for final delivery by Hex Multi-Rotor UAS in smaller packages and multiple trips to the fairgrounds. A Certificate of Authorization (COA) issued by the Federal Aviation Administration (FAA) designated the site as an authorized UAS test site. The paper will present additional details of the historic delivery of pharmaceuticals by UAS during the "Let's Fly Wisely" event. The paper will also provide details of NASA's SR22 UAS Surrogate Research aircraft. The UAS Surrogate was designed to investigate the procedures, aircraft sensors and other systems that may be required to allow Unmanned Aerial Systems (UAS) to safely operate with manned aircraft in the National Airspace System (NAS).

Howell, Charles T., III↗
NASA NTRS2016

The Virtual Tablet: Virtual Reality as a Control System

In the field of human-computer interaction, Augmented Reality (AR) and Virtual Reality (VR) have been rapidly growing areas of interest and concerted development effort thanks to both private and public research. At NASA, a number of groups have explored the possibilities afforded by AR and VR technology, among which is the IT Advanced Concepts Lab (ITACL). Within ITACL, the AVR (Augmented/Virtual Reality) Lab focuses on VR technology specifically for its use in command and control. Previous work in the AVR lab includes the Natural User Interface (NUI) project and the Virtual Control Panel (VCP) project, which created virtual three-dimensional interfaces that users could interact with while wearing a VR headset thanks to body- and hand-tracking technology. The Virtual Tablet (VT) project attempts to improve on these previous efforts by incorporating a physical surrogate which is mirrored in the virtual environment, mitigating issues with difficulty of visually determining the interface location and lack of tactile feedback discovered in the development of previous efforts. The physical surrogate takes the form of a handheld sheet of acrylic glass with several infrared-range reflective markers and a sensor package attached. Using the sensor package to track orientation and a motion-capture system to track the marker positions, a model of the surrogate is placed in the virtual environment at a position which corresponds with the real-world location relative to the user's VR Head Mounted Display (HMD). A set of control mechanisms is then projected onto the surface of the surrogate such that to the user, immersed in VR, the control interface appears to be attached to the object they are holding. The VT project was taken from an early stage where the sensor package, motion-capture system, and physical surrogate had been constructed or tested individually but not yet combined or incorporated into the virtual environment. My contribution was to combine the pieces of hardware, write software to incorporate each piece of position or orientation data into a coherent description of the object's location in space, place the virtual analogue accordingly, and project the control interface onto it, resulting in a functioning object which has both a physical and a virtual presence. Additionally, the virtual environment was enhanced with two live video feeds from cameras mounted on the robotic device being used as an example target of the virtual interface. The working VT allows users to naturally interact with a control interface with little to no training and without the issues found in previous efforts.

virtual control interface↗
NASA NTRS2026

Benchmarking Bayesian Optimization Frameworks and Acquisition Strategies for Materials Discovery and Autonomous Laboratories

Bayesian optimization (BO) can accelerate materials discovery by guiding expensive experiments toward the most promising processing conditions. We systematically compare five BO surrogate and framework combinations (Gaussian processes in Ax, Gaussian processes and Monte-Carlo neural networks in BayBE, random forests in Lolopy, and tree-structured Parzen (TPE) estimators in Hyperopt) on three benchmarks that mimic common materials design tasks (a discrete solid-electrolyte composition space, a hybrid discrete/continuous laminate-composite design problem solved with micromechanics modeling, and the continuous Ishigami analytic function which is a standard optimization benchmark). Each BO surrogate is paired with posterior mean, probability of improvement, and expected improvement acquisition functions and run for 100 trials from randomized initial samples with uniform random search providing a control. Across five random seeds per setting, BayBE’s Gaussian-process surrogate with expected improvement consistently reached ≥95 % of the known optimum in the fewest evaluations, while Lolopy’s random forest matched or exceeded GP performance on purely categorical or mixed spaces at a higher computational cost. Posterior mean alone often stagnated at local optima, underscoring the need for exploration, whereas probability and expected improvement balanced exploration and exploitation leading to better optimization in fewer trials. Execution times ranged from milliseconds for TPE to minutes for neural-network and random-forest surrogates. These results establish baseline expectations for BO in automated materials laboratories and highlight expected improvement with Gaussian processes as a reliable first choice, with random forests offering a strong alternative when categorical variables dominate. The benchmark suite and code are released to facilitate future surrogate, acquisition, and constraint-handling research in data-driven materials optimization.

Bayesian optimization↗
DOE OSTI2014

Potential Impact of Interfacial Bonding Efficiency on High-Burnup Spent Nuclear Fuel Vibration Integrity during Normal Transportation

Finite element analysis (FEA) was used to investigate the impacts of interfacial bonding efficiency at pellet pellet and pellet clad interfaces on spent nuclear fuel (SNF) vibration integrity. The FEA simulation results were also validated and benchmarked with reverse bending fatigue test results on surrogate rods consisting of stainless steel (SS) tubes with alumina-pellet inserts. Bending moments (M) are applied to the FEA models to evaluate the system responses of the surrogate rods. From the induced curvature, , the flexural rigidity EI can be estimated as EI=M/ . The impacts of interfacial bonding efficiency on SNF vibration integrity include the moment carrying capacity distribution between pellets and clad and the impact of cohesion on the flexural rigidity of the surrogate rod system. The result also indicates that the immediate consequences of interfacial de-bonding are a load carrying capacity shift from the fuel pellets to the clad and a reduction of the composite rod flexural rigidity. Therefore, the flexural rigidity of the surrogate rod and the bending moment bearing capacity between the clad and fuel pellets are strongly dependent on the efficiency of interfacial bonding at the pellet pellet and pellet clad interfaces. The above-noted phenomenon was calibrated and validated by reverse bending fatigue testing using a surrogate rod system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

POTENTIAL IMPACT OF INTERFACIAL BONDING EFFICIENCY ON USED NUCLEAR FUEL VIBRATION INTEGRITY DURING NORMAL TRANSPORTATION

Finite element analysis (FEA) was used to investigate the impacts of interfacial bonding efficiency at pellet pellet and pellet clad interfaces on surrogate of used nuclear fuel (UNF) vibration integrity. The FEA simulation results were also validated and benchmarked with reversible bending fatigue test results on surrogate rods consisting of stainless steel (SS) tubes with alumina-pellet inserts. Bending moments (M) are applied to the FEA models to evaluate the system responses of the surrogate rods. From the induced curvature, , the flexural rigidity EI can be estimated as EI=M/ . The impacts of interfacial bonding efficiency include the moment carrying capacity distribution between pellets and clad and cohesion influence on the flexural rigidity of the surrogate rod system. The result also indicates that the immediate consequences of interfacial de-bonding are a load carrying capacity shift from the fuel pellets to the clad and a reduction of the composite rod flexural rigidity. Therefore, the flexural rigidity of the surrogate rod and the bending moment bearing capacity between the clad and fuel pellets are strongly dependent on the efficiency of interfacial bonding at the pellet pellet and pellet clad interfaces. FEA models will be further used to study UNF vibration integrity.

finite element method↗
DOE OSTI2015

BAYESIAN CALIBRATION OF SAFETY CODES USING DATA FROM SEPARATE-AND INTEGRAL EFFECTS TESTS

Large-scale system codes for simulation of safety performance of nuclear plants may contain parameters whose values are not known very accurately. In order to be able to use the results of these simulation codes with confidence, it is important to learn how the uncertainty on the values of these parameters affects the output of the codes. New information from tests or operating experience is incorporated into safety codes by a process known as calibration, which reduces uncertainty in the output of the safety code, and thereby improves its support for decision-making. Modern analysis capabilities afford very significant improvements on classical ways of doing calibration, and the work reported here implements some of those improvements. The key innovation has come from development of safety code surrogate model (code emulator) construction and prediction algorithms. A surrogate is needed for calibration of plant-scale simulation codes because the multivariate nature of the problem (i.e., the need to adjust multiple uncertain parameters at once to fit multiple pieces of new information) calls for multiple evaluations of performance, which, for a computation-intensive model, makes calibration very computation-intensive. Use of a fast surrogate makes the calibration processes used here with Markov Chain Monte Carlo (MCMC) sampling feasible. Moreover, most traditional surrogates do not provide uncertainty information along with their predictions, but the Gaussian Process (GP) based code surrogates used here do. This improves the soundness of the code calibration process. Results are demonstrated on a simplified scenario with data from Separate and Integral Effect Tests.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Evaluation of Computed Tomography Techniques for Material Identification in Low Level and Intermediate Level Waste - 16648

Measures required to assure long term safe storage of Low-level and intermediate-level short-lived (LIL/SL) waste generated by the nuclear-power industry in France include the characterization of the waste and identification of materials within the waste. Digital Radiography (DR) techniques using x-ray at energies in the 6 MeV range have been shown to be effective for validation of the integrity of the concrete containers, and it was considered that the use of this technique together with the addition of Computed Tomography (CT) techniques could effectively identify materials within the waste. This paper describes the initial evaluation of two DR imaging techniques and two CT techniques using x-ray energy spectra up to 9 MeV to inspect a surrogate waste package, which comprised an outer concrete cylindrical container of 1400 mm diameter with 148 mm wall thickness, and an overall volume of 2 meters cubed, within which a 200 liter drum containing representative heterogeneous inactive waste, was placed in the center and the annulus between the 200 liter drum and the outer cylindrical package was filled with cement grout. The surrogate waste within the 200 liter drum comprised three separate layers of high density, medium density and low density mixed materials. The equipment used was a linear accelerator producing high energy spectra at either 6 MeV or 9 MeV and a high-precision CT manipulator with X, Y, Z and rotation motions, which were common to all techniques investigated. Two different digital detectors were used in the DR and CT performance evaluations, a Digital Detector Array (DDA) comprising a columnar Thallium-doped Cesium-Iodide scintillator screen in intimate contact with a 2 k by 2 k array of amorphous silicon detectors, 200 μm x 200 μm in area, and a Linear Diode Array (LDA) comprising a line of Cadmium-Tungstate columns, 1 cm thick and 400 μm x 400 μm in area. The work comprised evaluations of linear accelerator spectra and the attenuation effects of the waste container and contents, image acquisition performance of each detector, and CT techniques using area detector and linear detector. The results presented in this paper include mathematical evaluation of the two CT techniques, and analysis of measurement data, digital images, CT reconstruction images, and estimated material densities. The data was compared with recorded details and photographs of the actual configuration of materials within the surrogate waste. The Digital Detector Array can generate CT inspection volumes with considerable resolution and detail for the low-density and medium-density sections of the surrogate waste, however, the high-density sections were not imaged with sufficient detail and the images contained a large number of artifacts mainly due to the detectors lack of high energy photon stopping power. Materials identification with the Digital Detector Array, while possible for certain materials, for materials in the steel to plastic density range the attenuation values of the voxels in the reconstruction are too similar and difficult to resolve from the artifacts present. The Linear Diode Array can generate CT inspection volumes of regions of interest of the low-density and medium-density sections with considerable resolution and contrast, and potentially acceptable levels of resolution and contrast of the high-density section of the waste. While a few artifacts were present in the reconstructions, the majority are not due to the fundamental properties of the detector and are considered to be correctable. Materials identification with the LDA inspection data appear to be viable, with steel, copper, and higher-density metals being readily be distinguished from other materials on the basis of voxel value. Future work is needed to obtain a better definition of optimum spatial resolution and inspection speed, and to develop a system of 'calibration rods' which would consist of a series of 50 mm diameter cylinders of 7 materials; Plastic, Teflon, Concrete, Aluminum, Copper, Tungsten and Lead. The cylinders will be distributed at a certain radius in the surrogate waste and will be used as reference points in the evaluation and demonstration of the contrastive performance for the low, medium and high-density cases. The ability to identify the materials within a sealed waste container, by nondestructive examination, enables the verification of waste acceptance criteria without the need to open the waste containers. This eliminates the need for complex and expensive equipment to open and remotely handle the intermediate level waste, avoids potential hazards and risk of personnel dose uptake, and does not increase the volume of waste caused by repackaging of materials after examination and the decontamination or disposal of equipment used.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

A general predictive methodology for fuel-mixture properties up to supercritical conditions

A predictive thermodynamic model is utilized for the calculation of fuel properties of oxymethylene dimethyl ethers (OME 3–4 ), surrogates for gasoline, diesel and aviation fuel, as well as alcohol blends with gasoline and diesel. The alcohols used for these blends are methanol, ethanol, propanol, butanol and pentanol; their mixing ratio ranges from 10 to 50% by volume. The model is based on the Perturbed-Chain Statistical Association Fluid Theory (PC-SAFT) equation of state (EoS) and Vapor Liquid Equilibrium (VLE) calculations at constant temperature, density and composition. The model includes the association term, with the assumption of two association sites (2B scheme), to enable the modeling of alcohols. The pure-component parameters are estimated based on the Group Contribution (GC) method of various sources, as well as a parametrization model specifically designed for the case of OME 3–4 . The results of the computational model for the density, vapor pressure and distillation curves at various conditions, including high-pressure, high-temperature (HPHT), are compared to experimental and computational data available in the literature. In the cases where no measurements are available for the surrogates, experimental data for the corresponding target fuel are used, taking into consideration the inherent deviation in properties between real and surrogate fuel. Overall, the results are in good agreement with the data from the literature, with the average deviation not exceeding 12% for temperature (Kelvin) on the distillation curves, 10% for density and 46% for vapor pressure and the general trend being captured successfully. The use of different pure component parameter estimation techniques can further improve the prediction quality in the cases of OME3–4 and the aviation fuel surrogate, especially for the vapor pressure, leading to an average deviation lower than 18%. These results demonstrate the predictive capabilities of the model, which extend to a wide range of fuel types and pressure/temperature conditions. Through this investigation, the present work aims to establish the limits of applicability of this thermodynamic property prediction methodology.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Taylor approximation variance reduction for approximation errors in PDE-constrained Bayesian inverse problems

In numerous applications, surrogate models are used as a replacement for accurate parameter-to-observable mappings when solving large-scale inverse problems governed by partial differential equations (PDEs). The surrogate model may be a computationally cheaper alternative to the accurate parameter-to-observable mappings and/or may ignore additional unknowns or sources of uncertainty. The Bayesian approximation error (BAE) approach provides a means to account for the induced uncertainties and approximation errors, i.e. the errors between the accurate parameter-to-observable mapping and the surrogate. The statistics of these errors are, however, in general unknown a priori, and are thus calculated using Monte Carlo sampling. Although the sampling is typically carried out offline, i.e. before considering the data, the process can still represent a computational bottleneck. In this work, we develop a scalable computational approach for reducing the costs associated with the sampling stage of the BAE approach. Specifically, we consider the Taylor expansion of the accurate and surrogate forward models with respect to the uncertain parameter fields either as a control variate for variance reduction or as a means to directly and efficiently approximate the mean and covariance of the approximation errors. We propose efficient methods for evaluating the expressions for the mean and covariance of the Taylor approximations based on linear(-ized) PDE solves. Furthermore, the proposed approach is independent of the dimension of the uncertain parameter, depending instead on the intrinsic dimension of the data, ensuring scalability to high-dimensional problems. The potential benefits of the proposed approach are demonstrated for two high-dimensional inverse problems governed by PDE examples, namely for the estimation of a distributed Robin boundary coefficient in a linear diffusion problem, and for a coefficient estimation problem governed by a nonlinear diffusion problem.

Bayesian approximation error↗
DOE OSTI2019

An Adaptive Bayesian Parameter Estimation of a Synchronous Generator Under Gross Errors

Polynomial-chaos-expansion-based surrogate models have recently been advocated in the literature for power system dynamic parameter estimation. Regarding the estimation of the uncertain generator parameters, a Bayesian inference framework has been proposed based on a polynomial-based reduced-order representation of the synchronous machines using assumed parameter values. Then, the non-Gaussian posterior probability distribution functions (pdfs) of these parameters are recovered through the stochastic sampling approach efficiently. However, facing very large parameter errors, the reliability of the surrogate model decreases, yielding biased estimation results. To overcome this problem, here we develop hierarchical Bayesian inference framework that processes the measurements provided by phasor measurement units, while making use of multifidelity surrogates together with the importance sampling method. The latter allows us to estimate in an efficient manner the posterior pdfs of the uncertain parameters through the normalized weights of the prior samples. To improve the accuracy of the posterior pdfs, an adaptive procedure is further adopted in the importance sampling for the gradual evolution of its proposal functions. The new proposals assist in fine-tuning the sample space and thereby help to construct surrogates with higher fidelity. Through an iterative process, this approach is able to estimate accurately and efficiently non-Gaussian posterior pdfs of the uncertain generator parameters subject to gross errors.

42 ENGINEERING↗
DOE OSTI2022

Latent Space Simulation for Carbon Capture Design Optimization

The CO2 capture efficiency in solvent-based carbon capture systems (CCSs) critically depends on the gas-solvent interfacial area (IA), making maximization of IA a foundational challenge in CCS design. While the IA associated with a particular CCS design can be estimated via a computational fluid dynamics (CFD) simulation, using CFD to derive the IAs associated with numerous CCS designs is prohibitively costly. However, previous works such as Deep Fluids (Kim et al., 2019) show that large simulation speed-ups and low error are achievable by replacing CFD simulators with neural-network (NN) surrogates that mimic the CFD simulation process. This raises the possibility for a fast, accurate replacement for a CFD simulator, and thus computationally feasible IA-based CCS-design optimization. As such, here, we explore whether an existing NN-surrogate approach (and variants we develop) can successfully be applied to our complex carbon-capture CFD simulations, with the ultimate goal of obtaining a fast and accurate simulator for our CCS-design application. Our experiments build on the Deep Fluids approach and find that resulting surrogates can produce large speed ups (4000x) while maintaining IA relative errors as low as 4% on unseen CCS configurations (interpolating between configurations seen during training). Thus, despite less faithfulness to the underlying physics of the problem, NN surrogates may be a promising tool for our CCS design optimization problem. Notably, though, the Deep Fluids approach has limitations for our application (such as model non-transferability to CCS-packing changes), which we discuss. We conclude with potential directions for future work that may, like innovations we introduced here (e.g., transformer-based dynamics prediction), improve performance on our complicated dataset of CCS CFD simulations.

AI Surrogate Simulation, Carbon Capture, design op↗
DOE OSTI2024

Accelerating Thermochemical Equilibrium Calculations for Nuclear Reactor Applications

Thermochemical properties play a key role in modeling and simulation of several key phenomena in nuclear reactors. There has been an increasing interest in incorporating CALPHAD-based formulations in multiphysics simulations including for Molten Salt Reactors where knowledge of phase evolution of the salt and the chemical potentials of various elements are of utmost importance in source term analyses and redox control. However, the size of such simulations is often limited by the high computational cost of full thermodynamic equilibrium calculations. This work discusses the current efforts aimed at accelerating thermochemical equilibrium calculations for multiphysics simulations performed using the open-source finite element / finite volume code Multiphysics Object Oriented Simulation Environment (MOOSE) [1]. While several methods have been proposed for accelerating phase equilibrium calculations [2], most focus on relatively small systems and often rely on a- priori knowledge of the state-space of the system. Nuclear materials, however, are often multi-component systems owing to the evolution of composition under irradiation and an approach based on a-priori mapping of phase diagram is often not enough. This work is aimed at demonstrating an on-the-fly surrogate modeling framework that uses active learning to reduce the number of full equilibrium calculations that must be performed. By combining with efficient coupling approaches, the surrogate framework helps in reducing the computational cost of thermodynamic equilibrium informed multiphysics simulations of nuclear materials. The performance is benchmarked against full coupling with the thermochemistry library Thermochimica [3]. This work uses a machine learning based approach for constructing surrogate models to predict the stable phases in a multicomponent system. The surrogates were constructed using neural networks and Gaussian process classification. In this work, we compare the relative performance of the two methods. We also demonstrate the use of caching previous calculations by interpolating the values from nearest neighbors. References [1] Lindsay, A.D., et al. "2.0 – MOOSE: Enabling massively parallel multiphysics simulation", SoftwareX, 20 (2022): 101202. [2] Roos, W.A. and Zietsman J.H. "Accelerating complex chemical equilibrium calculations – A Review", Calphad, 77 (2022): 102380. [3] Piro, M.H.A., et al. "The thermochemistry library Thermochimica", Computational Materials Science, 67 (2013): 266-272.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machine Learning for First Principles Calculations of Material Properties for Ferromagnetic Materials

The investigation of finite temperature properties using Monte-Carlo (MC) methods requires a large number of evaluations of the system’s Hamiltonian to sample the phase space needed to obtain physical observables as function of temperature. DFT calculations can provide accurate evaluations of the energies, but they are too computationally expensive for routine simulations. To circumvent this problem, machine-learning (ML) based surrogate models have been developed and implemented on high-performance computing (HPC) architectures. In this paper, we describe two ML methods (linear mixing model and HydraGNN) as surrogates for first principles density functional theory (DFT) calculations with classical MC simulations. These two surrogate models are used to learn the dependence of target physical properties from complex compositions and interactions of their constituents. We present the predictive performance of these two surrogate models with respect to their complexity while avoiding the danger of overfitting the model. An important aspect of our approach is the periodic retraining with newly generated first principles data based on the progressive exploration of the system’s phase space by the MC simulation. The numerical results show that HydraGNN model attains superior predictive performance compared to the linear mixing model for magnetic alloy materials.

Eisenbach, Markus↗
DOE OSTI2024

A Gaussian process autoregressive model capturing microstructure evolution paths in a Ni–Mo–Nb alloy

Additive manufacturing is increasingly being employed to produce components of complex geometries in structural alloys because of the expected energy savings associated with the near-net-shape capability and the ability to build in novel internal features that are not possible with many conventional manufacturing approaches. However, because of the extreme thermal conditions encountered, the non-equilibrium microstructures produced during powder bed-based additive manufacturing processes must be subjected to custom post-heat treatment processes to recover the target mechanical properties. Phase-field models and simulation techniques have matured to a state where the microstructure evolution paths, and the morphologies of the resulting precipitate phases can be predicted reasonably accurately, considering alloy-specific thermodynamic and kinetic aspects of the nucleation and growth processes. However, phase-field simulations are computationally intensive, which precludes the ability to apply the simulations directly to the length scale of the entire component. Therefore, it is highly desirable to develop low-computational-cost surrogate models that effectively capture the physics at the microstructural length scale, while facilitating the design of optimized processing conditions resulting in location-specific targeted microstructures at the component scale. The work presented here demonstrates the application of the materials knowledge system framework to develop a surrogate model that effectively captures the microstructural path during annealing of a Ni–Mo–Nb alloy containing different Mo and Nb compositions known to segregate during solidification under additive manufacturing conditions. Specifically, the surrogate model built in this work is based on a Gaussian process autoregressive model informed by statistical representation of simulated microstructures using two-point correlations and dimensionality reduction through principal component analysis. In conclusion, this surrogate model is shown to capture the bifurcation of the microstructural path during precipitation, which yields a microstructure dominated by the $\gamma^{\prime\prime}$ phase at high Nb concentrations and the $\delta$ phase at low Nb concentrations.

36 MATERIALS SCIENCE↗