Results for “Reduced Order Modeling” — Page 71

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

NASA NTRS1972

An analytic guidance technique for planetary and lunar approach trajectories.

An explicit, analytic guidance technique is developed for the hyperbolic approach phases of interplanetary and lunar spacecraft trajectories. The guidance technique is based upon a first-order analytic solution for the perturbed planet-centered (or moon-centered) trajectory. This trajectory is represented as the sum of two components: (1) the unperturbed osculating hyperbola at pericenter, and (2) first-order position and velocity perturbations due to gravitational effects of the sun and other planets. A closed-form analytic approximation for these perturbations valid for the entire approach trajectory is derived, thereby eliminating the need for numerical integration of the equations of motion. By means of this analytic trajectory model, the approach guidance problem is reduced to an equivalent two-body problem. The guidance objectives are specified in terms of actual, attainable conditions at pericenter, and the required corrective velocity is determined explicitly for both fixed and variable times of arrival.

Carlson, N. A.↗

NASA NTRS1985

Effects of muscle atrophy on motor control

As a biological tissue, muscle adapts to the demands of usage. One traditional way of assessing the extent of this adaptation has been to examine the effects of an altered-activity protocol on the physiological properties of muscles. However, in order to accurately interpret the changes associated with an activity pattern, it is necessary to employ an appropriate control model. A substantial literature exists which reports altered-use effects by comparing experimental observations with those from animals raised in small laboratory cages. Some evidence suggests that small-cage-reared animals actually represent a model of reduced use. For example, laboratory animals subjected to limited physical activity have shown resistance to insulin-induced glucose uptake which can be altered by exercise training. This project concerned itself with the basic mechanisms underlying muscle atrophy. Specifically, the project addressed the issue of the appropriateness of rats raised in conventional-sized cages as experimental models to examine this phenomenon. The project hypothesis was that rats raised in small cages are inappropriate models for the study of muscle atrophy. The experimental protocol involved: 1) raising two populations of rats, one group in conventional (small)-sized cages and the other group in a much larger (133x) cage, from weanling age (21 days) through to young adulthood (125 days); 2) comparison of size- and force-related characteristics of selected test muscles in an acute terminal paradigm.

Stuart, D. G.↗

NASA NTRS1988

MHOST: An efficient finite element program for inelastic analysis of solids and structures

An efficient finite element program for 3-D inelastic analysis of gas turbine hot section components was constructed and validated. A novel mixed iterative solution strategy is derived from the augmented Hu-Washizu variational principle in order to nodally interpolate coordinates, displacements, deformation, strains, stresses and material properties. A series of increasingly sophisticated material models incorporated in MHOST include elasticity, secant plasticity, infinitesimal and finite deformation plasticity, creep and unified viscoplastic constitutive model proposed by Walker. A library of high performance elements is built into this computer program utilizing the concepts of selective reduced integrations and independent strain interpolations. A family of efficient solution algorithms is implemented in MHOST for linear and nonlinear equation solution including the classical Newton-Raphson, modified, quasi and secant Newton methods with optional line search and the conjugate gradient method.

Nakazawa, S.↗

NASA NTRS1987

A revised estimate of Pacific-North America motion and implications for Western North America plate boundary zone tectonics

Marine magnetic profiles from the Gulf of Californa are studied in order to revise the estimate of Pacific-North America motion. It is found that since 3 Ma spreading has averaged 48 mm/yr, consistent with a new global plate motion model derived without any data. The present data suggest that strike-slip motion on faults west of the San Andreas is less than previously thought, reducing the San Andreas discrepancy with geodetic, seismological, and other geologic observations.

Demets, Charles↗

NASA NTRS1990

Seal-rotordynamic-coefficient test results for a model SSME ATD-HPFTP turbine interstage seal with and without a swirl brake

Results are presented from a test program that compares predictions and measurements for a model version of the Space Shuttle Main Engine (SSME) Alternate Turbopump Development (ATD) High-Pressure Fuel Turbopump (HPFTP), with and without a swirl brake. The tests were conducted in order to establish a degree of confidence in seal calculations for the ATD turbopumps. Test results demonstrate that the proposed swirl brake design is effective in reducing the seal destabilizing forces. Without the swirl brake, the cross-coupled stiffness k increases monotonically with increasing inlet tangential velocity. With the swirl break, k tends to either be constant or decrease with increasing inlet tangential velocity. Comparisons between Scharrer's (1988) theory and measurements for the seal without a swirl brake indicate that the predictions can be used to provide design guidelines only.

Childs, D. W.↗

NASA NTRS1996

High-Lift Systems on Commercial Subsonic Airliners

The early breed of slow commercial airliners did not require high-lift systems because their wing loadings were low and their speed ratios between cruise and low speed (takeoff and landing) were about 2:1. However, even in those days the benefit of high-lift devices was recognized. Simple trailing-edge flaps were in use, not so much to reduce landing speeds, but to provide better glide-slope control without sideslipping the airplane and to improve pilot vision over the nose by reducing attitude during low-speed flight. As commercial-airplane cruise speeds increased with the development of more powerful engines, wing loadings increased and a real need for high-lift devices emerged to keep takeoff and landing speeds within reasonable limits. The high-lift devices of that era were generally trailing-edge flaps. When jet engines matured sufficiently in military service and were introduced commercially, airplane speed capability had to be increased to best take advantage of jet engine characteristics. This speed increase was accomplished by introducing the wing sweep and by further increasing wing loading. Whereas increased wing loading called for higher lift coefficients at low speeds, wing sweep actually decreased wing lift at low speeds. Takeoff and landing speeds increased on early jet airplanes, and, as a consequence, runways worldwide had to be lengthened. There are economical limits to the length of runways; there are safety limits to takeoff and landing speeds; and there are speed limits for tires. So, in order to hold takeoff and landing speeds within reasonable limits, more powerful high-lift devices were required. Wing trailing-edge devices evolved from plain flaps to Fowler flaps with single, double, and even triple slots. Wing leading edges evolved from fixed leading edges to a simple Krueger flap, and from fixed, slotted leading edges to two- and three-position slats and variable-camber (VC) Krueger flaps. The complexity of high-lift systems probably peaked on the Boeing 747, which has a VC Krueger flap and triple-slotted, inboard and outboard trailing-edge flaps. Since then, the tendency in high-lift system development has been to achieve high levels of lift with simpler devices in order to reduce fleet acquisition and maintenance costs. The intent of this paper is to: (1) review available high-lift devices, their functions, and design criteria; (2) appraise high-lift systems presently in service on commercial air liners; (3) present personal study results on high-lift systems; (4) develop a weight and cost model for high-lift systems; and (5) discuss the development tendencies of future high-lift systems.

Rudolph, Peter K. C.↗

NASA NTRS2016

Dynamic Stall Suppression Using Combustion-Powered Actuation (COMPACT)

Retreating blade stall is a well-known phenomenon that limits rotorcraft speed, maneuverability, and efficiency. Airfoil dynamic stall is a simpler problem, which demonstrates many of the same flow phenomena. Combustion Powered Actuation (COMPACT) is an active flow control technology, which at the outset of this work, had been shown to mitigate static and dynamic stall at low Mach numbers. The attributes of this technology suggested strong potential for success at higher Mach numbers, but such experiments had never been conducted. The work detailed in this report documents a 3-year effort focused on assessing the effectiveness of COMPACT for dynamic stall suppression at freestream conditions up to Mach 0.5. The work done has focused on implementing COMPACT on a high-lift rotorcraft airfoil: the VR-12. This selection was made in order to ensure that any measured benefits are over and above the capabilities of state-of-the-art high-lift rotorcraft airfoils. The detailed Computational Fluid Dynamics (CFD) simulations, wind-tunnel experiments, and system-level modeling conducted have shown the following: (1) COMPACT, in its current state of development, is capable of reducing the adverse effects of deep dynamic stall at Mach numbers up to 0.4; (2) The two-dimensional (2D) CFD results trend well compared to the experiments; and (3) Implementation of the CFD results into a system-level model suggest that significant rotor-level benefits are possible.

Matalanis, Claude G.↗

NASA NTRSDate not supplied

Towards Autonomous Lunar Resource Excavation via Deep Reinforcement Learning

To support sustainable infrastructure on the Moon, NASA needs to leverage lunar resources for in-situ processing and construction. NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) is principally designed to mine and deliver regolith for these tasks. To reliably perform these operations on the lunar surface, RASSOR's sensors and control systems need to be robust and maximize information extracted from a reduced sensor payload. Herein, we present our findings from the Intelligent Capabilities Enhanced RASSOR project. We created reduced-order simulation environments in which we applied reinforcement learning algorithms to learn autonomous trenching controllers and produced state estimation architectures. We developed two simulations: a 2D excavation simulation used to facilitate parameter selection, and a 3D simulation developed using a game physics engine to simulate simplified soil interactions and incorporate robotic agents parameterized by dynamic models. Within these simulations, we learned autonomous excavation routines that exceed excavation efficiency measures as compared against RASSOR's existing control and teleoperation-based methods.

RASSOR↗

NASA NTRSDate not supplied

Towards Autonomous Lunar Resource Excavation via Deep Reinforcement Learning

To support sustainable infrastructure on the Moon, NASA needs to leverage lunar resources for in-situ processing and construction. NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) is principally designed to mine and deliver regolith for these tasks. To reliably perform these operations on the lunar surface, RASSOR's sensors and control systems need to be robust and maximize information extracted from a reduced sensor payload. Herein, we present our findings from the Intelligent Capabilities Enhanced RASSOR project. We created reduced-order simulation environments in which we applied reinforcement learning algorithms to learn autonomous trenching controllers and produced state estimation architectures. We developed two simulations: a 2D excavation simulation used to facilitate parameter selection, and a 3D simulation developed using a game physics engine to simulate simplified soil interactions and incorporate robotic agents parameterized by dynamic models. Within these simulations, we learned autonomous excavation routines that exceed excavation efficiency measures as compared against RASSOR's existing control and teleoperation-based methods.

RASSOR↗

NASA NTRS1994

Three-dimensional structure of Schistosoma japonicum glutathione S-transferase fused with a six-amino acid conserved neutralizing epitope of gp41 from HIV

The 3-dimensional crystal structure of glutathione S-transferase (GST) of Schistosoma japonicum (Sj) fused with a conserved neutralizing epitope on gp41 (glycoprotein, 41 kDa) of human immunodeficiency virus type 1 (HIV-1) (Muster T et al., 1993, J Virol 67:6642-6647) was determined at 2.5 A resolution. The structure of the 3-3 isozyme rat GST of the mu gene class (Ji X, Zhang P, Armstrong RN, Gilliland GL, 1992, Biochemistry 31:10169-10184) was used as a molecular replacement model. The structure consists of a 4-stranded beta-sheet and 3 alpha-helices in domain 1 and 5 alpha-helices in domain 2. The space group of the Sj GST crystal is P4(3)2(1)2, with unit cell dimensions of a = b = 94.7 A, and c = 58.1 A. The crystal has 1 GST monomer per asymmetric unit, and 2 monomers that form an active dimer are related by crystallographic 2-fold symmetry. In the binding site, the ordered structure of reduced glutathione is observed. The gp41 peptide (Glu-Leu-Asp-Lys-Trp-Ala) fused to the C-terminus of Sj GST forms a loop stabilized by symmetry-related GSTs. The Sj GST structure is compared with previously determined GST structures of mammalian gene classes mu, alpha, and pi. Conserved amino acid residues among the 4 GSTs that are important for hydrophobic and hydrophilic interactions for dimer association and glutathione binding are discussed.

Schistosoma japonicum/enzymology/genetics/immunolo↗

DOE OSTI2024

Hydrological controls of a riparian wetland based on stable isotope data and model simulations

Isotopic evidence of groundwater and stream water is frequently used to investigate water exchanges with groundwater. Monthly sampling of rain, stream water, and groundwater was conducted at Tims Branch watershed in South Carolina for the oxygen and hydrogen stable isotope (δ 2 H and δ 18 O) measurement, as well as pH and oxidation–reduction potential (ORP). Together with a mass balance perspective, it was determined that it takes a few weeks to one month for groundwater in the hyporheic zone to fully exchange with stream water. From hydrodynamic modelling, we show that substantial (up to 70 %) groundwater exchange occurs at gaining and losing sites. Groundwater exfiltration, i.e. inflow into stream water, contributes up to 4 % to stream water, with the remainder from upstream exfiltration. A 2–4 % per day renewal rate of adjacent groundwater would indirectly indicate a groundwater residence time in the order of half a month to a full month (assuming either a well-mixed case or large dispersion rate in pulse flow case), in agreement with a greatly reduced variability of δ 2 H and δ 18 O of groundwater compared to stream water and rain. This reduced variability of stable isotope signal from groundwater confirms our hypothesis that riparian groundwater mixing at Tims Branch is more of a mixed type rather than a pulse flow type. As a result, a monthly time scale is sufficient for groundwater to become anoxic at exit points into stream water resulting in the episodic production of natural organic matter- and iron-rich flocs upon oxidation.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1977

An improved lunar moment of inertia determination - A proposed strategy

A strategy for determining an improved lunar moment of inertia is proposed. An improved uncertainty in the lunar inhomogeneity parameter could reduce the core density error from 4.20 gr/cu cm to 0.1 gm/cu cm for the case of a lunar density model having a 300 km core radius. The current error of 0.0025 for the lunar inhomogeneity parameter is mostly due to the uncertainties in the C20 and C22 gravity harmonics. An optimum reduction strategy for obtaining an order of magnitude improvement in the gravity estimates is based on covariance analyses of Doppler data. The long-arc reduction method is shown to provide better results than the short-arc technique, and the use of an orbit with a 7000 km semimajor axis along with certain terms of up to degree and order eight is recommended.

Ananda, M. P.↗

NASA NTRS1979

Filtering of non-linear instabilities

For Courant numbers larger than one and cell Reynolds numbers larger than two, oscillations and in some cases instabilities are typically found with implicit numerical solutions of the fluid dynamics equations. This behavior has sometimes been associated with the loss of diagonal dominance of the coefficient matrix. It is shown here that these problems can in fact be related to the choice of the spatial differences, with the resulting instability related to aliasing or nonlinear interaction. Appropriate 'filtering' can reduce the intensity of these oscillations and in some cases possibly eliminate the instability. These filtering procedures are equivalent to a weighted average of conservation and non-conservation differencing. The entire spectrum of filtered equations retains a three-point character as well as second-order spatial accuracy. Burgers equation has been considered as a model. Several filters are examined in detail, and smooth solutions have been obtained for extremely large cell Reynolds numbers.

Khosla, P. K.↗

NASA NTRS1989

Theoretical and numerical study of a three-dimensional turbulent boundary layer

A boundary layer created on an infinite flat plate by a time-dependent freestream velocity vector whose magnitude is independent of time but whose direction changes at a constant angular velocity is theoretically studied using Reynolds-number scaling laws and numerical simulations performed over a range of Reynolds numbers. Results obtained with a higher-order version of existing theories of the Ekman layer are shown to agree well with the numerical results at three Reynolds numbers. The present results can be extrapolated to the case of high Reynolds numbers. The Reynolds-averaged equations reduce to a one-dimensional steady problem, making possible the easy and accurate testing of turbulence models.

Spalart, Philippe R.↗

NASA NTRS1991

Model order reduction applied to a hot-bench simulation of an aeroelastic wind-tunnel model

Simulations of an aeroelastically scaled wind-tunnel model were developed for hot-bench testing of a digital controller. The digital controller provided active flutter-suppression, rolling-maneuver-load alleviation, and plant estimation. To achieve an acceptable time scale for the hot-bench application, the mathematical model of the wind-tunnel model was reduced from 220 states to approximately 130 states while assuring that the required accuracy was preserved for all combinations of 10 inputs and 56 outputs. The reduction was achieved by focussing on a linear, aeroelastic submodel of the full mathematical model and by applying a method based on the internally balanced realization of a dynamic system. The error-bound properties of the internally balanced realization significantly contribute to its utility in the model reduction process. The reduction method and the results achieved are described.

Buttrill, Carey S.↗

NASA NTRS2006

Development of an Experimental Rig for Investigation of Higher Order Modes in Ducts

Continued progress to reduce fan noise emission from high bypass ratio engine ducts in aircraft increasingly relies on accurate description of the sound propagation in the duct. A project has been undertaken at NASA Langley Research Center to investigate the propagation of higher order modes in ducts with flow. This is a two-pronged approach, including development of analytic models (the subject of a separate paper) and installation of a laboratory-quality test rig. The purposes of the rig are to validate the analytical models and to evaluate novel duct acoustic liner concepts, both passive and active. The dimensions of the experimental rig test section scale to between 25% and 50% of the aft bypass ducts of most modern engines. The duct is of rectangular cross section so as to provide flexibility to design and fabricate test duct liner samples. The test section can accommodate flow paths that are straight through or offset from inlet to discharge, the latter design allowing investigation of the effect of curvature on sound propagation and duct liner performance. The maximum air flow rate through the duct is Mach 0.3. Sound in the duct is generated by an array of 16 high-intensity acoustic drivers. The signals to the loudspeaker array are generated by a multi-input/multi-output feedforward control system that has been developed for this project. The sound is sampled by arrays of flush-mounted microphones and a modal decomposition is performed at the frequency of sound generation. The data acquisition system consists of two arrays of flush-mounted microphones, one upstream of the test section and one downstream. The data are used to determine parameters such as the overall insertion loss of the test section treatment as well as the effect of the treatment on a modal basis such as mode scattering. The methodology used for modal decomposition is described, as is a description of the mode generation control system. Data are presented which demonstrate the performance of the controller to generate the desired mode while suppressing all other cut on modes in the duct.

Gerhold, Carl H.↗