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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 1,279 records · Page 71
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Investigation of Cycle-to-Cycle Variations in Internal Combustion Engine Using Proper Orthogonal Decomposition

The understanding, modeling and control of the cycle-to-cycle variation (CCV) in the modern internal combustion engine (ICE) is a key scientific challenge to achieve stable engine operation. High CCV in the engine combustion chamber may contribute to partial burn, misfire and knock, which adversely affects the engine performance and may potentially damage the engine. The objective of the current study is to leverage high-fidelity numerical simulations to improve the understanding of the causes of CCV. Using the massively parallel code, Nek5000, multi-cycle, wall-resolved large-eddy simulations (LES) were performed for the General Motors (GM), Transparent Combustion Chamber (TCC-III) optical engine under motored operating conditions. Further, the large-scale structures of the in-cylinder flow were investigated using a triple proper orthogonal decomposition (POD) technique to explore the characteristics of different parts of the flow and their contributions to CCV. The kinetic energy of the subset of flow structures were determined and correlated between the intake and compression strokes. The insights from the analysis of the large-scale flow structures will be used to assist the development of improved engine designs with reduced CCV and enhance the engine performance.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Representative Phenomena of Cyclic Turbulent Combustion in High-Pressure Fuel Sprays

Abstract Cyclic variations in conventional diesel combustion engines can lead to large differences in engine out emissions even at steady operation. This study uses an optically accessible constant-pressure flow chamber to acquire fuel injections in quick succession to analyze mixing, auto-ignition, and combustion of diesel-surrogate n-heptane using multiple high-speed optical diagnostics. Prior studies have utilized fewer injections and/or they rely on analysis of ensemble average behavior. These approaches do not yield information on injection-to-injection variation or provide confidence in utilizing individual injection measurements for high-fidelity computational fluid dynamics(CFD) model validation. In this study, a large set of 500 injections is used to obtain global parameters including liquid length, vapor penetration length, ignition delay time, and lift-off length. Results for multiple injections are presented to illustrate large injection to injection variations. Potential sources for these variations are analyzed to conclude localized, small scale turbulence and rate of injection variations as the likely sources. Then, a statistical method based on z-scores is proposed and implemented to identify instantaneous injections that best represent the bulk data-set of jet boundaries measured independently by three different diagnostics. This synthesis of statistics-guided screening of data set and ensemble-average analysis offers higher confidence for CFD model validation relying upon both a representative single and average injection results.

42 ENGINEERING↗
DOE OSTI2022

Application of machine learning to characterize gas hydrate reservoirs in Mackenzie Delta (Canada) and on the Alaska north slope (USA)

Here, artificial neural network-trained models were used to predict gas hydrate saturation distributions in permafrost-associated deposits in the Eileen Gas Hydrate Trend on the Alaska North Slope (ANS), USA and at the Mallik research site in the Beaufort-Mackenzie Basin, Northwest Territories, Canada. The database of Logging-While-Drilling (LWD) and wireline logs collected at five wells (Mount Elbert, Ignik Sikumi, and Kuparuk 7–11–12 wells at ANS, plus 2L-38 and 5L-38 wells at the Mallik research site) includes more than 10,000 depth points, which were used for training, validation, and testing the machine learning (ML) models. Data used in training the ML models include the well logs of density, porosity, electrical resistivity, gamma radiation, and acoustic wave velocity measurements. Combinations of two or three out of these five well logs were found to reliably predict the gas hydrate saturation with accuracy varying between 80 and 90% when compared to the gas hydrate saturations derived from Nuclear Magnetic Resonance (NMR)-based technique. The ML models trained on data from three ANS wells achieved high fidelity predictions of gas hydrate saturation at the Mallik site. The results obtained in this study indicate that ML models trained on data from one geological basin can successfully predict key reservoir parameters for permafrost-associated gas hydrate accumulations within another basin. A generalized approach for selecting a well log combination that can improve model accuracy is discussed. Overall, the study outcome supports earlier work demonstrating that ML models trained on non-NMR well logs are a viable alternative to physics-driven methods for predicting gas hydrate saturations.

58 GEOSCIENCES↗
DOE OSTI2022

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗
DOE OSTI2024

Neural lumped parameter differential equations with application in friction-stir processing

Lumped parameter methods aim to simplify the evolution of spatially-extended or continuous physical systems to that of a “lumped” element representative of the physical scales of the modeled system. For systems where the definition of a lumped element or its associated physics may be unknown, modeling tasks may be restricted to full-fidelity physics simulations. Here, in this work, we consider data-driven modeling tasks with limited point-wise measurements of otherwise continuous systems. We build upon the notion of the Universal Differential Equation (UDE) to construct data-driven models for reducing dynamics to that of a lumped parameter and inferring its properties. The flexibility of UDEs allow for composing various known physical priors suitable for application-specific modeling tasks, including lumped parameter methods. The motivating example for this work is the plunge and dwell stages for friction-stir welding; specifically, (i) mapping power input into the tool to a point-measurement of temperature and (ii) using this learned mapping for process control.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

In-situ sensor monitoring of multi-class gas porosity formation in laser powder bed fusion using convolutional neural network

In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.

Laser powder bed fusion, Multi-class pores, In-sit↗
DOE OSTI2020

Realization of the Werner-Holevo and Landau-Streater Quantum Channels for Qutrits on Quantum Computers.

We realize the Landau-Streater (LS) and Werner-Holevo (WH) quantum channels for qutrits on IBM quantum computers. These channels correspond to the interaction between a qutrit and its environment that results in the globally unitarily covariant qutrit transformation violating the multiplicativity of the maximal p-norm. Our realization of the LS and WH channels is based on embedding the qutrit states into states of two qubits and using the single-qubit and two-qubit CNOT gates to implement the specific interaction. We employ the standard quantum gates, hence the developed algorithm suits any quantum computer. We run our algorithm on a 5-qubit computer and a 20-qubit computer, as well as on a simulator. We quantify the quality of the implemented channels comparing their action on different input states with theoretical predictions. The overall efficiency is quantified by the fidelity between the theoretical and experimental Choi states implemented on the 20-qubit computer.

completely-positive trace-preserving map↗
DOE OSTI2023

Sensitivity-Driven Experimental Design to Facilitate Control of Dynamical Systems

Control of nonlinear dynamical systems is a complex and multifaceted process. Essential elements of many engineering systems include high-fidelity physics-based modeling, offline trajectory planning, feedback control design, and data acquisition strategies to reduce uncertainties. Here this article proposes an optimization-centric perspective which couples these elements in a cohesive framework. We introduce a novel use of hyper-differential sensitivity analysis to understand the sensitivity of feedback controllers to parametric uncertainty in physics-based models used for trajectory planning. These sensitivities provide a foundation to define an optimal experimental design which seeks to acquire data most relevant in reducing demand on the feedback controller. Our proposed framework is illustrated on the Zermelo navigation problem and a hypersonic trajectory control problem using data from NASA’s X-43 hypersonic flight tests.

42 ENGINEERING↗
DOE OSTI2021

Multilevel Graph Partitioning for Three-Dimensional Discrete Fracture Network Flow Simulations

We present a topology-based method for mesh-partitioning in three-dimensional discrete fracture network (DFN) simulations that takes advantage of the intrinsic multi-level nature of a DFN. DFN models are used to simulate flow and transport through low-permeability fractured media in the subsurface by explicitly representing fractures as discrete entities. The governing equations for flow and transport are numerically integrated on computational meshes generated on the interconnected fracture networks. Modern high-fidelity DFN simulations require high-performance computing on multiple processors where performance and scalability depends partially on obtaining a high-quality partition of the mesh to balance work-loads and minimize communication across all processors. The discrete structure of a DFN naturally lends itself to various graph representations, which can be thought of as coarse-scale representations of the computational mesh. Using this concept, we develop two applications of the multilevel graph partitioning algorithm to partition the mesh of a DFN. In the first, we project a partition of the graph based on the DFN topology onto the mesh of the DFN and in the second, this DFN-based projection is used as the initial condition for further partitioning refinement of the mesh. We compare the performance of these methods with standard multi-level graph partitioning using graph-based metrics (cut, imbalance, partitioning time), computational-based metrics (FLOPS, iterations, solver time), and total run time. The DFN-based and the mesh-based partitioning methods are comparable in terms of the graph-based metrics, but the time required to obtain the partition is several orders of magnitude faster using the DFN-based partitions. The computation-based metrics show comparable performance between both methods so, in combination, the DFN-based partitions are several orders of magnitude faster than the mesh-based partition. Furthermore, the method which uses the DFN-partition solution as the initial condition of the mesh partition provided cut and imbalance values that were close to the mesh-based partition but in a fraction of the time. In turn, this hybrid method outperformed both of the other methods in terms of the total run time.

58 GEOSCIENCES↗
DOE OSTI2021

Variational approach to relative entropies with an application to QFT

Abstract We define a new divergence of von Neumann algebras using a variational expression similar in nature to Kosaki’s formula for Umegaki’s relative entropy. Our divergence satisfies several of the usual desirable properties, upper bounds the sandwiched Renyi entropy and reduces to the fidelity in a limit. As an illustration, we use the formula in quantum field theory to compute our divergence between the vacuum in a bipartite system and an “orbifolded”—in the sense of a conditional expectation—system in terms of the Jones index. We take the opportunity to point out an entropic certainty relation associated with an inclusion of von Neumann factors related to the relative entropy. This certainty relation has an equivalent formulation in terms of error correcting codes.

Hollands, Stefan↗
DOE OSTI2022

Approximate recoverability and relative entropy II: 2-positive channels of general von Neumann algebras

Abstract We generalize our results in paper I in this series to quantum channels between general von Neumann algebras, proving the approximate recoverability of states which undergo a small change in relative entropy through the channel. To this end, we derive a strengthened form of the quantum data processing inequality for the change in relative entropy of two states under a channel between two von Neumann algebras. Compared to the usual inequality, there is an explicit lower bound involving the fidelity between the original state and a recovery channel.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Parametric reduced-order modeling for component-oriented treatment and localized nonlinear feature inclusion

Abstract We propose coupling a physics-based reduction framework with a suited response decomposition technique to derive a component-oriented reduction (COR) approach, which is suitable for assembly systems featuring localized nonlinearities. Dependencies on influencing parameters are injected into the reduced-order model (ROM), thus ensuring robustness and validity over a domain of parametric inputs, while capturing nonlinear effects. The implemented approach employs individual component modes to capture localized features while additionally relying on reduced modes of a global nature to approximate the system’s dynamics accurately. The global modes are derived from a linear monolithic system, defined as a result of a coordinate separation scheme, which permits the proposed COR-ROM to naturally couple the response between linear and nonlinear subdomains. The derived low-order representation utilizes a proper orthogonal decomposition projection and is additionally reinforced with the inclusion of a hyper-reduction technique to capture the underlying high-fidelity model response while providing accelerated computations. The resulting approach is exemplified in the synthetic case studies of a four-story shear frame with multiple nonlinear regions driven by hysteresis and a large-scale kingpin connection featuring plasticity.

Vlachas, Konstantinos (ORCID:000000029124219X)↗
DOE OSTI2022

Real-time dispatch optimization for concentrating solar power with thermal energy storage

Concentrating solar power (CSP) plants present a promising path towards utility-scale renewable energy. The power tower, or central receiver, configuration can achieve higher operating temperatures than other forms of CSP, and, like all forms of CSP, naturally pairs with comparatively inexpensive thermal energy storage, which allows CSP plants to dispatch electricity according to market price incentives and outside the hours of solar resource availability. Currently, CSP plants commonly include a steam Rankine power cycle and several heat exchange components to generate high-pressure steam using stored thermal energy. The efficiency of the steam Rankine cycle depends on the temperature of the plant's operating fluid, and so is a main concern of plant operators. However, the variable nature of the solar resource and the conservatism with which the receiver is operated prevent perfect control over the receiver outlet temperature. Therefore, during periods of solar variability, collection occurs at lower-than-design temperature. To support operator decisions in a real-time setting, we develop a revenue-maximizing non-convex mixed-integer, quadradically-constrained program which determines a dispatch schedule with sub-hourly time fidelity and considers temperature-dependent power cycle efficiency. The exact nonlinear formulation proves intractable for real-time decision support. Here we present exact and inexact techniques to improve problem tractability that include a hybrid nonlinear and linear formulation. Our approach admits solutions within approximately 3% of optimality, on average, within a five-minute time limit, demonstrating its usability for decision support in a real-time setting.

14 SOLAR ENERGY↗
DOE OSTI2023

Optimal Sizing and Dispatch of Solar Power with Storage

Designers of utility-scale solar plants with storage, seeking to maximize some aspect of plant performance, face multiple challenges. In many geographic locations, there is significant penetration of photovoltaic generation, which depresses energy prices during the hours of solar availability. An energy storage system affords the opportunity to dispatch during higher-priced time periods, but complicates plant design and dispatch decisions. Solar resource variability compounds these challenges, because determining optimal system sizes requires simultaneously considering how the plant will be operated under the imposed market and weather conditions. We develop an approach to analyze the economic performance of hybrid and single-technology solar power plants, which incorporates optimal dispatch, and considers the expected electricity market and weather conditions. We utilize the System Advisor Model software package to simulate the operation of multiple renewable generation and energy storage technologies, in conjunction with hourly-fidelity generation decisions determined by a revenue-maximizing, mixed-integer linear program. We show that, under our assumed market and weather conditions, the lifetime benefit-to-cost ratio can be improved by 6 to 19 percent, relative to a baseline design without optimizing, and that a concentrating solar power with thermal energy storage design produces significantly more energy per year, but is less profitable under our cost assumptions.

black-box optimization↗
DOE OSTI2025

Optimizing qubit control pulses for state preparation

In the burgeoning field of quantum computing, the precise design and optimization of quantum pulses are essential for enhancing qubit operation fidelity. This study focuses on refining the pulse engineering techniques for superconducting qubits, employing a detailed analysis of square and Gaussian pulse envelopes under various approximation schemes. We evaluated the effects of coherent errors induced by naive pulse designs. Furthermore, we identified the sources of these errors in the Hamiltonian model’s approximation level. We mitigated these errors through adjustments to the external driving frequency and pulse durations, thus implementing a pulse scheme with stroboscopic error reduction. Our results demonstrate that these refined pulse strategies improve performance and reduce coherent errors. Moreover, the techniques developed herein are applicable across different quantum architectures, such as ion-trap, atomic, and photonic systems.

Chirp modulation↗
DOE OSTI2022

Quantifying Equiaxed vs Epitaxial Solidification in Laser Melting of CMSX-4 Single Crystal Superalloy

The competition between epitaxial vs. equiaxed solidification has been investigated in CMSX-4 single crystal superalloy during laser melting as practiced in additive manufacturing. Single-track laser scans were performed on a powder-free surface of directionally solidified CMSX-4 alloy with several combinations of laser power and scanning velocity. Electron backscattered diffraction (EBSD) mapping facilitated identification of new orientations, i.e., “stray grains” that nucleated within the fusion zone along with their area fraction and spatial distribution. Using high-fidelity computational fluid dynamics simulations, both the temperature and fluid velocity fields within the melt pool were estimated. This information was combined with a nucleation model to determine locations where nucleation has the highest probability to occur in melt pools. In conformance with general experience in metals additive manufacturing, the as-solidified microstructure of the laser-melted tracks is dominated by epitaxial grain growth; nevertheless, stray grains were evident in elongated melt pools. It was found that, though a higher laser scanning velocity and lower power are generally helpful in the reduction of stray grains, the combination of a stable keyhole and minimal fluid velocity further mitigates stray grains in laser single tracks.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Monte Carlo Simulations of 347H Stainless Steel Aging for the Synthetic Generation of Microstructures Under Creep Conditions

Here, a Monte Carlo simulation method capable of replicating the kinetics of M 23 C 6 precipitation in 347H stainless steels was developed for the purpose of producing synthetic microstructures that approximate its microstructural evolution under aging periods of up to 10,000 hours at temperatures between 600 °C and 750 °C. To accomplish this, experimental data from the literature was used to parameterize simulations and replicate the nucleation and growth kinetics of M 23 C 6 particles within 347H and similar austenitic stainless steel alloys. These simulations were found to have considerable fidelity to previous efforts to study the precipitation of M 23 C 6 in other 300 series stainless steel alloys. Synthetic 347H microstructures were then generated that accounted the effects of aging temperature, duration, dislocation density, and the presence of boron within the microstructure. These simulations predict several key trends, those being that (1) the size of M 23 C 6 precipitates decreased with aging temperature and (2) the growth rate of M 23 C 6 particles decreased with aging temperature. Further, while (3) the addition of dislocation density due to creep conditions resulted in increasing intragranular nucleation of M 23 C 6 precipitates with increasing dislocation density and (4) B additions within the microstructure led to modest increases in precipitate size above 700 °C, which indicates that more complex physics are necessary to account for the presence of B.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fundamental Issues Identified for Thermodynamic Description of Molten Salt Systems

Thermodynamic modeling of the molten salt systems is critical in the design of advanced nuclear power plants, materials recycling, and many other important clean energy applications. As one of the most capable computational thermodynamic approaches, the CALPHAD (Calculation of Phase Diagrams) method has been widely used for multicomponent thermodynamic database development and further support more physics-based modeling. Although considerable CALPHAD modeling efforts for molten salt systems have been made, we found that no evaluation has been performed regarding the unary thermodynamic models for the molten salt systems despite the fact that more than one pure substance database is available for the CALPHAD modeling. Therefore, the thermodynamic descriptions of the pure salts should be critically evaluated to ensure a high-fidelity molten salt thermodynamic database. In this work, we comprehensively analyzed some selected molten salts using different available thermodynamic descriptions from two databases as an example. One is the SSUB database released by the SGTE (Scientific Group Thermodata Europe), and the other is the FactPS database from the FactSage. Finally, the significant discrepancies observed in the thermodynamic description between the existing CALPHAD pure substance databases and experiments call for an urgent effort to improve.

42 ENGINEERING↗