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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Efficient development and processing of thermal math models of very large space truss structures

As the spacecraft moves along the orbit, the truss members are subjected to direct and reflected solar, albedo and planetary infra-red (IR) heating rates, as well as IR heating and shadowing from other spacecraft components. This is a transient process with continuously changing heating loads and the shadowing effects. The resulting nonuniform temperature distribution may cause nonuniform thermal expansion, deflection and stress in the truss elements, truss warping and thermal distortions. There are three challenges in the thermal-structural analysis of the large truss structures. The first is the development of the thermal and structural math models, the second - model processing, and the third - the data transfer between the models. All three tasks require considerable time and computer resources to be done because of a very large number of components involved. To address these challenges a series of techniques of automated thermal math modeling and efficient processing of very large space truss structures were developed. In the process the finite element and finite difference methods are interfaced. A very substantial reduction of the quantity of computations was achieved while assuring a desired accuracy of the results. The techniques are illustrated on the thermal analysis of a segment of the Space Station main truss.

Warren, Andrew H.↗
DOE OSTI2026

Active learning using hybrid surrogate tool life modeling for machining process optimization

Here, this paper describes an active learning approach for part-to-part iterative machining process optimization using a hybrid surrogate tool life model. A probabilistic interpolating tool life model is developed by combining the empirical Taylor-type tool life equation and the model fit error. The probabilistic tool life model is then used to calculate the machining cost per part distribution. The optimal machining parameters are selected using an expected improvement in machining cost per part criterion. The method is validated numerically using experimental results; the results show a median convergence error of 2.2% after three tests over 400 simulations. The method is validated experimentally on two industrial applications for Ti-6Al-4V roughing resulting in a cost per part reduction greater than 23% after two tests. The described method is a robust solution for rapid convergence to optimal machining parameters in an industrial production environment.

Active learning↗
DOE OSTI2023

Subsetted model output for process-tendency-related variables from a LASSO-CACTI WRF simulation

Process-tendency-related model output, mostly for the Thompson microphysics scheme (when used), from a Weather Research and Forecasting (WRF) simulation from the Large-Eddy Simulation (LES) Atmospheric Radiation Measurement (ARM) Symbiotic Simulation and Observation (LASSO) deep-convection scenario for the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign. The LASSO-CACTI simulations span grid spacings from 7.5 km to 100 m for convection near the Sierras de Córdoba mountain range, roughly centered on the ARM Mobile Facility. More information can be found at https://www.arm.gov/capabilities/modeling/lasso. This version of the output is a collection of variables subsetted from the raw WRF output to reduce the file overhead for users not needing the full raw dataset. The subset files are in netCDF format with the height-based variables on the raw, model eta levels.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2000

Modeling of HiPco Process for Carbon Nanotube Production

High-pressure carbon monoxide (HiPco) reactor, developed at Rice University, is used to produce single-walled carbon nanotubes (SWNT) from gas-phase reactions of iron carbonyl and nickel carbonyl in carbon monoxide at high pressures (10 - 100 atm). Computational modeling is used to better understand the HiPco process. In the present model, decomposition of the precursor, metal cluster formation and growth, and carbon nanotube growth are addressed. Decomposition of precursor molecules is necessary to initiate metal cluster formation. The metal clusters serve as catalysts for carbon nanotube growth. Diameter of metal clusters and number of atoms in these clusters are some of the essential information for predicting carbon nanotube formation and growth, which is then modeled by Boudouard reaction (2CO ---> C(s) + CO2) with metal catalysts. The growth kinetic model is integrated with a two-dimensional axisymmetric reactor flow model to predict reactor performance.

Gokcen, T.↗
NASA NTRS1992

Development and application of an acceptance testing model

The process of acceptance testing large software systems for NASA has been analyzed, and an empirical planning model of the process constructed. This model gives managers accurate predictions of the staffing needed, the productivity of a test team, and the rate at which the system will pass. Applying the model to a new system shows a high level of agreement between the model and actual performance. The model also gives managers an objective measure of process improvement.

Pendley, Rex D.↗
NASA NTRS1989

A study of the effect of synoptic scale processes in GCM modelling

Research was conducted to help modeling groups at NASA to develop better weather forecasting and general circulation models (GCM) for activities relating to the meteorological uses of satellite data. The focus was on the physical processes that were being simulated by models: radiative effects and latent heat release associated with clouds; orographic influences; and heat transfer at the ocean and ice surfaces. An attempt was made to deduce the role of diabatic heating in North Atlantic cyclogenesis and in the global heat budget. Inferences were made in four studies: heat budget statistics from GCM assimilations; dynamics of north Atlantic cyclones; Cage-type energy budget calculations; and grid scale cloud formation. Mechanisms that were responsible for the variability and structure of the atmospheric on a hemispheric scale were studied by a hybrid of statistical analysis and theoretical modeling. Variability and structure are both related to synoptic scale processes through baroclinic and barotropic energy transformations.

Herman, Gerald F.↗
NASA NTRS2012

Finite Element Models for Electron Beam Freeform Fabrication Process

Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.

Chandra, Umesh↗
DOE OSTI2020

Dynamical Mass Estimates of the β Pictoris Planetary System through Gaussian Process Stellar Activity Modeling

Nearly 15 yr of radial velocity (RV) monitoring and direct imaging enabled the detection of two giant planets orbiting the young, nearby star β Pictoris. The δ Scuti pulsations of the star, which overwhelm planetary signals, need to be carefully suppressed. In this work, we independently revisit the analysis of the RV data following a different approach than available in the literature to model the activity of the star. We show that a Gaussian process (GP) with a stochastically driven damped harmonic oscillator kernel can model the δ Scuti pulsations. It provides similar results to parametric models but with a simpler framework, using only three hyperparameters. It also enables us to model poorly sampled RV data that were excluded from previous analyses, hence extending the RV baseline by nearly five years. Altogether, the orbit and mass of both planets can be constrained from RV only, which was not possible with the parametric modeling. To characterize the system more accurately, we also perform a joint fit of all available relative astrometry and RV data. Our orbital solutions for β Pic b favor a low eccentricity of 0.029$_{−0.024}^{+0.061}$ and a relatively short period of 21.1$_{−0.8}^{+2.0}$ yr. The orbit of β Pic c is eccentric with 0.206$_{−0.063}^{+0.074}$ with a period of 3.36 ± 0.03 yr. We find model-independent masses of 11.7 ± 1.4 and 8.5 ± 0.5 M Jup for β Pic b and c, respectively, assuming coplanarity. The mass of β Pic b is consistent with the hottest start evolutionary models, at an age of 25 ± 3 Myr. A direct detection of β Pic c would provide a second calibration measurement in a coeval system.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS2012

The Role of Aerosols on Precipitation Processes: Cloud Resolving Model Simulations

Cloud microphysics is inevitably affected by the smoke particle (CCN, cloud condensation nuclei) size distributions below the clouds. Therefore, size distributions parameterized as spectral bin microphysics are needed to explicitly study the effects of atmospheric aerosol concentration on cloud development, rainfall production, and rainfall rates for convective clouds. Recently, a detailed spectral-bin microphysical scheme was implemented into the Goddard Cumulus Ensemble (GCE) model. The formulation for the explicit spectral bin microphysical processes is based on solving stochastic kinetic equations for the size distribution functions of water droplets (i.e., cloud droplets and raindrops), and several types of ice particles [i.e. pristine ice crystals (columnar and plate-like), snow (dendrites and aggregates), graupel and frozen drops/hail]. Each type is described by a special size distribution function containing many categories (i.e., 33 bins). Atmospheric aerosols are also described using number density size-distribution functions. The model is tested by studying the evolution of deep cloud systems in the west Pacific warm pool region, the sub-tropics (Florida) and midlatitudes using identical thermodynamic conditions but with different concentrations of CCN: a low "clean" concentration and a high "dirty" concentration. Results indicate that the low CCN concentration case produces rainfall at the surface sooner than the high CeN case but has less cloud water mass aloft. Because the spectral-bin model explicitly calculates and allows for the examination of both the mass and number concentration of species in each size category, a detailed analysis of the instantaneous size spectrum can be obtained for these cases. It is shown that since the low (CN case produces fewer droplets, larger sizes develop due to greater condensational and collection growth, leading to a broader size spectrum in comparison to the high CCN case. Sensitivity tests were performed to identify the impact of ice processes, radiation and large-scale influence on cloud-aerosol interactive processes, especially regarding surface rainfall amounts and characteristics (i.e., heavy or convective versus light or stratiform types). In addition, an inert tracer was included to follow the vertical redistribution of aerosols by cloud processes. We will also give a brief review from observational evidence on the role of aerosol on precipitation processes.

Tao, Wei-Kuo↗
DOE OSTI2020

Markovian transport processes in a heterogeneous, variably saturated watershed: A multi-domain spatial Markov model

Transport processes in watersheds remain challenging to describe accurately with upscaled models because of their intricate complexities at multiple scales that can lead to multi-modal, non-Fickian breakthrough curves. One of the recent advances in solute transport modeling has been the Lagrangian spatial Markov model (SMM), which describes transport using velocity increments and models the correlated transitions between them. The method has been applied previously to saturated porous media and fractured media, but these successful applications suggest it may be useful for describing watershed scale processes as well. An existing, 3-D, heterogeneous variably saturated model of a headwaters catchment and classical random walk particle tracking were used to generate a forward simulation and the resulting transport was analyzed with a spatial Markov framework. Existing SMM methods were used to analyze the transport paths through the complex, unconfined domain and we found that the vadose zone plays an important role in the correlation structure. As such, a new kind of SMM is proposed, termed a multi-domain SMM (MD-SMM), that uses separate correlation models for auto-transitions in the vadose zone and the saturated zone, and for the cross-transitions between them. The MD-SMM improves representation of transport relative to the single domain model and can naturally delineate times when a particle is in the vadose zone or the saturated zone, adding an additional degree of realism to the upscaled model. Lastly, we show that the transition probability matrix for transport in the saturated portion of this unconfined system is approximately Markovian, which is an important validation of the proposed framework.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2007

Using Multi-scale Modeling Systems to Study the Precipitation Processes

Numerical cloud models, which are based the non-hydrostatic equations of motion, have been extensively applied to cloud-scale and mesoscale processes during the past four decades. Because cloud-scale dynamics are treated explicitly, uncertainties stemming from convection that have to be parameterized in (hydrostatic) large-scale models are obviated, or at least mitigated, in cloud models. Global models will use the non-hydrostatic framework when their horizontal resolution becomes about 10 km, the theoretical limit for the hydrostatic approximation. This juncture will be reached one to two decades from now. Recently, a multi-scale modeling system with unified physics was developed at NASA Goddard. It consists of (1) a cloud-resolving model (CRM), (2) a regional scale model, (3) a coupled CRM and global model, and (4) a land modeling system. The same microphysical processes, long and short wave radiative transfer processes and the explicit cloud-radiation, and cloudland surface interactive processes are applied in this multi-scale modeling system. In this talk, a review of developments and applications of the multi-scale modeling system will be presented. In particular, the results from using multi-scale modeling system to study the interactions between clouds, precipitation, and aerosols will be presented.

Tao, Wei-Kuo↗
NASA NTRS2004

Modeling the VARTM Composite Manufacturing Process

A comprehensive simulation model of the Vacuum Assisted Resin Transfer Modeling (VARTM) composite manufacturing process has been developed. For isothermal resin infiltration, the model incorporates submodels which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly effect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly.

Song, Xiao-Lan↗
DOE OSTI2025

A neural master equation framework for multiscale modeling of molecular processes: application to atomic-scale plasma processes

Plasma-surface interactions (PSI) play a crucial role in microelectronics fabrication; however, their multiscale nature and array of complex, often unknown interactions make computational modeling of PSIs extremely difficult. To this end, we propose a general neural master equation (NME) framework that uses master equations to describe the dynamics of a molecular process, wherein neural networks learned from atomistic simulations represent unknown transitions between different system states. By leveraging the physics-based structure of master equations and data-driven state transitions, the NME framework promotes generalizability and physics interpretability, and can bridge disparate length and time scales. The framework is demonstrated for multiscale modeling of Si atomic layer etching and reactive ion etching, where the learned NME-based surface kinetic models exhibit good predictive and extrapolative capabilities for predicting experimentally relevant observables as a function of process parameters. The NME-based surface kinetic models obey physical constraints, which are violated in models based on neural ordinary differential equations. The proposed NME framework for multiscale modeling of molecular processes can pave the way for the discovery of new chemistries and materials in atomic-scale plasma processes.

Chemical engineering↗
NASA NTRS2016

An Integrated Economics Model for ISRU in Support of a Mars Colony - Initial Results Report

This database, the Mars Colony Architecture Model (MCAM), is then linked to a variety of “downsteam” analytic models. In particular, we integrated an Extraction Process (i.e., “Mining”) Model, an Infrastructure and Integrated Logistics Support (ILS) Model, and an Economics Integration Model. The Extraction Process Model focuses on the technologies associated with in situ resource extraction, processing, storage and handling, and delivery. For each mined resource, which may involve multiple cooperating In Situ Resource Utilization (ISRU) systems in a given architecture, the Extraction Process Model computes the production rate as a function of the systems’ technical parameters and the local Mars environment. As with our earlier work, this model focuses on the extraction and processing of Mars water/ice.

Shishko, Robert↗
NASA NTRS2018

A Prognostic Launch Vehicle Probability of Failure Assessment Methodology for Conceptual Systems Predicated on Human Causal Factors

Create an improved method to calculate reliability of a conceptual launch vehicle system prior to fabrication by using historic data of actual root causes of failures. While failures have unique "proximate causes", there are typically a finite amount of common "root causes". Heretofore launch vehicle reliability evaluation typically hardware-centric statistical analyses, while most root causes of failures are been shown to be human-centric. A method based on human-centric root causes can be used to quantify reliability assessments and focus proposed actions to mitigate problems. Existing methods have been optimistic in their projections of launch vehicle reliability compared to actuals. Hypothesis: reliability of a conceptual launch vehicle can be more accurately evaluated based on a rational, probabilistic approach using past failure assessment teams' findings predicated on human-centric causes."Human Reliability Analysis Methods Selection Guidance for NASA"Chandler F.T., et al., NASA HQ/OSMA study group, July 2006. Outside HRA experts from academia, other federal labs, and the private sector. 50 system reliability methods considered, fourteen selected for further study, four finally selected as best suited for human spaceflight. Probabilistic Risk Analysis (PRA) + Human Reliability Analysis (HRA) enabled incorporating effects and probabilities of human errors. While four down-selected methods deemed appropriate for failure assessment, it did not appear that these methods could be concisely applied to perform major system-wide assessment of probability of failure of a conceptual design without becoming unwieldy."Engineering a Safer World", Detailed, comprehensive study external to NASA Leveson N. G., MIT, 2011.Systems-Theoretic Accident Model and Processes (STAMP). All-encompassing accident model based on systems theory analyzed accidents after they occurred and created approaches to prevent occurrence in developing systems not focused on failure prevention per se, but rather reducing hazards by influencing human behavior through use of constraints, hierarchical control structures, and process models to improve system safetySystem Theoretic Process Analysis (STPA) addresses predictive part of problem (a "hazard analysis"). Includes all causal factors identified in STAMP: "...design errors, software flaws, component interaction accidents, cognitively complex human decision-making errors, and social organizational and management factors contributing to accidents" can guide design process rather than require it to exist before-hand did not appear capable of concise application for system-wide assessment of probability of failure of a conceptual design without becoming unwieldy.

Williams, Craig H.↗
NASA NTRS1981

Adiabatic and nonadiabatic processes in thermal models of solar hard X-ray bursts

The temporal evolution of thermal-bremsstrahlung-emitting material at the top of a solar coronal loop under various processes is examined as a model of solar hard X-ray bursts. The behavior of emission measure and temperature with time is analyzed for the hot plasma confined in a segment at the top of a loop, taking into account the effects or the time variation of the confining toroidal magnetic field, the longitudinal expansion of the source through the motion of a pair of collisionless conduction fronts and unspecified heating or cooling processes. Analytic expressions for the behavior of the toroidal magnetic field and the heating rate necessary to reproduce a given behavior of emission measure and temperature with time are obtained in terms of the initial magnetic field strength and density of the heated region and a characteristic longitudinal expansion time. Results are applied to observations of two impulsive solar hard X-ray bursts, and it is shown that the contribution of heating is negligible after the first few seconds of the events, although significant nonadiabatic heating occurs early in the events.

Emslie, A. G.↗