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DOE OSTI2025

Large‐Scale 2D Perovskite Nanocrystals Photodetector Array via Ultrasonic Spray Synthesis

Abstract 2D perovskite (PVSK) single crystals have received significant attention due to their unique optical and optoelectronic properties. However, current synthesis methods face limitations, particularly in large‐area fabrication, which remain critical barriers to practical applications. In this study, the synthesis of red/green/purple‐blue‐colored 2D PVSK nanocrystals over a large area (4‐inch wafer) and the fabrication of high‐performance photodetector arrays are presented via a facile yet efficient spray‐coating approach with a liquid‐bridge transport effect. The photodetector array achieves 100% working yield, high photo‐responsivity (1.5 × 10 6 A W −1 ) and specific‐detectivity (1.1 × 10 16 Jones) with competitive photomapping characteristics. An intelligent vision system for automatic shape recognition is further demonstrated with a recognition rate exceeding 90%. This study provides significant advances in the scalable synthesis of nanoscale 2D PVSK crystals, their integration into large‐area optoelectronic devices, and their potential use in artificial‐intelligence systems.

Lee, Yoon Ho [Davidson School of Chemical Engineer↗

DOE OSTI2023

FAIR for AI: An interdisciplinary and international community building perspective

A foundational set of findable, accessible, interoperable, and reusable (FAIR) principles were proposed in 2016 as prerequisites for proper data management and stewardship, with the goal of enabling the reusability of scholarly data. The principles were also meant to apply to other digital assets, at a high level, and over time, the FAIR guiding principles have been re-interpreted or extended to include the software, tools, algorithms, and workflows that produce data. FAIR principles are now being adapted in the context of AI models and datasets. Here, we present the perspectives, vision, and experiences of researchers from different countries, disciplines, and backgrounds who are leading the definition and adoption of FAIR principles in their communities of practice, and discuss outcomes that may result from pursuing and incentivizing FAIR AI research. The material for this report builds on the FAIR for AI Workshop held at Argonne National Laboratory on June 7, 2022.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

MEPHESTO: Modeling Energy-Performance in Heterogeneous SoCs and Their Trade-Offs

Integrated shared memory heterogeneous architectures are pervasive because they satisfy the diverse needs of mobile, autonomous, and edge computing platforms. Although specialized processing units (PUs) that share a unified system memory improve performance and energy efficiency by reducing data movement, they also increase contention for this memory since the PUs interact with each other. Prior work has investigated performance degradation due to memory contention, but few have studied the relationship of power and energy to memory contention. Moreover, a comprehensive solution that models memory contention for kernel placement on contemporary heterogeneous systems on chip (SoCs) in response to energy and performance has been largely unaddressed.This paper presents MEPHESTO, a novel and holistic approach for managing this balance. The authors characterize applications and PUs in terms of two memory contention factors - time factors and power factors - to achieve the desired trade-off between energy and performance for collocated kernel execution on heterogeneous systems. The authors believe that this investigation is the first to combine all of these factors and present a simple knob-based approach that expresses the target trade-off. The approach is evaluated on a diverse integrated shared memory heterogeneous system with a CPU, GPU, and programmable vision accelerator. By using an empirical model for memory contention that provides up to 92% accuracy, the kernel collocation approach can provide a near-optimal ordering and placement based on the user-defined, energy-performance trade-off parameter. Moreover, the dynamic programming-based heuristics provide up to 30% better energy or 20% performance benefits when compared with the greedy approaches commonly employed by previous studies.

Alaul haque monil, Mohammad↗

DOE OSTI2021

Implementation of Additional Models into the MACCS Code for Nearfield Consequence Analysis

The NRC’s Non-Light Water Reactor Vision and Strategy report discusses the MACCS code readiness for nearfield analyses. To increase the nearfield capabilities of MACCS, the plume meander model from Ramsdell and Fosmire was integrated into MACCS and the MACCS plume meander model based on U.S. NRC Regulatory Guide 1.145 was updated. Test cases were determined to verify the plume meander model implementation into MACCS 4.1. The results using the implemented MACCS plume meander models match the comparisons with other codes and analytical calculations. This verifies that the additional MACCS plume meander models have been successfully implemented into MACCS 4.1. This report documents the verification of these model implementations into MACCS and a comparison of the results using

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Current and future directions in network biology

Network biology is an interdisciplinary field bridging computational and biological sciences that has proved pivotal in advancing the understanding of cellular functions and diseases across biological systems and scales. Although the field has been around for two decades, it remains nascent. It has witnessed rapid evolution, accompanied by emerging challenges. These stem from various factors, notably the growing complexity and volume of data together with the increased diversity of data types describing different tiers of biological organization. We discuss prevailing research directions in network biology, focusing on molecular/cellular networks but also on other biological network types such as biomedical knowledge graphs, patient similarity networks, brain networks, and social/contact networks relevant to disease spread. In more detail, we highlight areas of inference and comparison of biological networks, multimodal data integration and heterogeneous networks, higher-order network analysis, machine learning on networks, and network-based personalized medicine. Following the overview of recent breakthroughs across these five areas, we offer a perspective on future directions of network biology. Additionally, we discuss scientific communities, educational initiatives, and the importance of fostering diversity within the field. This article establishes a roadmap for an immediate and long-term vision for network biology.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2004

Two-Armed, Mobile, Sensate Research Robot

The Anthropomorphic Robotic Testbed (ART) is an experimental prototype of a partly anthropomorphic, humanoid-size, mobile robot. The basic ART design concept provides for a combination of two-armed coordination, tactility, stereoscopic vision, mobility with navigation and avoidance of obstacles, and natural-language communication, so that the ART could emulate humans in many activities. The ART could be developed into a variety of highly capable robotic assistants for general or specific applications. There is especially great potential for the development of ART-based robots as substitutes for live-in health-care aides for home-bound persons who are aged, infirm, or physically handicapped; these robots could greatly reduce the cost of home health care and extend the term of independent living. The ART is a fully autonomous and untethered system. It includes a mobile base on which is mounted an extensible torso topped by a head, shoulders, and two arms. All subsystems of the ART are powered by a rechargeable, removable battery pack. The mobile base is a differentially- driven, nonholonomic vehicle capable of a speed >1 m/s and can handle a payload >100 kg. The base can be controlled manually, in forward/backward and/or simultaneous rotational motion, by use of a joystick. Alternatively, the motion of the base can be controlled autonomously by an onboard navigational computer. By retraction or extension of the torso, the head height of the ART can be adjusted from 5 ft (1.5 m) to 6 1/2 ft (2 m), so that the arms can reach either the floor or high shelves, or some ceilings. The arms are symmetrical. Each arm (including the wrist) has a total of six rotary axes like those of the human shoulder, elbow, and wrist joints. The arms are actuated by electric motors in combination with brakes and gas-spring assists on the shoulder and elbow joints. The arms are operated under closed-loop digital control. A receptacle for an end effector is mounted on the tip of the wrist and contains a force-and-torque sensor that provides feedback for force (compliance) control of the arm. The end effector could be a tool or a robot hand, depending on the application.

Engelberger, J. F.↗

NASA NTRS2005

Video-Camera-Based Position-Measuring System

A prototype optoelectronic system measures the three-dimensional relative coordinates of objects of interest or of targets affixed to objects of interest in a workspace. The system includes a charge-coupled-device video camera mounted in a known position and orientation in the workspace, a frame grabber, and a personal computer running image-data-processing software. Relative to conventional optical surveying equipment, this system can be built and operated at much lower cost; however, it is less accurate. It is also much easier to operate than are conventional instrumentation systems. In addition, there is no need to establish a coordinate system through cooperative action by a team of surveyors. The system operates in real time at around 30 frames per second (limited mostly by the frame rate of the camera). It continuously tracks targets as long as they remain in the field of the camera. In this respect, it emulates more expensive, elaborate laser tracking equipment that costs of the order of 100 times as much. Unlike laser tracking equipment, this system does not pose a hazard of laser exposure. Images acquired by the camera are digitized and processed to extract all valid targets in the field of view. The three-dimensional coordinates (x, y, and z) of each target are computed from the pixel coordinates of the targets in the images to accuracy of the order of millimeters over distances of the orders of meters. The system was originally intended specifically for real-time position measurement of payload transfers from payload canisters into the payload bay of the Space Shuttle Orbiters (see Figure 1). The system may be easily adapted to other applications that involve similar coordinate-measuring requirements. Examples of such applications include manufacturing, construction, preliminary approximate land surveying, and aerial surveying. For some applications with rectangular symmetry, it is feasible and desirable to attach a target composed of black and white squares to an object of interest (see Figure 2). For other situations, where circular symmetry is more desirable, circular targets also can be created. Such a target can readily be generated and modified by use of commercially available software and printed by use of a standard office printer. All three relative coordinates (x, y, and z) of each target can be determined by processing the video image of the target. Because of the unique design of corresponding image-processing filters and targets, the vision-based position- measurement system is extremely robust and tolerant of widely varying fields of view, lighting conditions, and varying background imagery.

Lane, John↗

DOE OSTI2025

Designing Future Energy Systems with Generative AI

Energy systems are experiencing various changes that impact the distribution, use, and reliability of energy. Local utilities and municipalities must respond and adapt to these changes, moving towards a future energy system with modernized infrastructure and other targeted investments and policy decisions. However, planning for and enacting these advancements requires significant effort from experts and engineers to develop strategies that ensure a reliable and secure energy future. This includes characterizing the current energy infrastructure, identifying areas for development, and engaging with local community members. Emerging generative artificial intelligence techniques can alleviate pain points and help support the development of the next generation of energy systems. Here, in this article, we highlight on-going generative AI work in the areas of atmospheric modeling, building energy management, and distribution network design, and we propose a vision for the role of generative AI that considers opportunities and identifies challenges inherent to this technology.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2007

SPARTAN: A High-Fidelity Simulation for Automated Rendezvous and Docking Applications

bd Systems (a subsidiary of SAIC) has developed the Simulation Package for Autonomous Rendezvous Test and ANalysis (SPARTAN), a high-fidelity on-orbit simulation featuring multiple six-degree-of-freedom (6DOF) vehicles. SPARTAN has been developed in a modular fashion in Matlab/Simulink to test next-generation automated rendezvous and docking guidance, navigation,and control algorithms for NASA's new Vision for Space Exploration. SPARTAN includes autonomous state-based mission manager algorithms responsible for sequencing the vehicle through various flight phases based on on-board sensor inputs and closed-loop guidance algorithms, including Lambert transfers, Clohessy-Wiltshire maneuvers, and glideslope approaches The guidance commands are implemented using an integrated translation and attitude control system to provide 6DOF control of each vehicle in the simulation. SPARTAN also includes high-fidelity representations of a variety of absolute and relative navigation sensors that maybe used for NASA missions, including radio frequency, lidar, and video-based rendezvous sensors. Proprietary navigation sensor fusion algorithms have been developed that allow the integration of these sensor measurements through an extended Kalman filter framework to create a single optimal estimate of the relative state of the vehicles. SPARTAN provides capability for Monte Carlo dispersion analysis, allowing for rigorous evaluation of the performance of the complete proposed AR&D system, including software, sensors, and mechanisms. SPARTAN also supports hardware-in-the-loop testing through conversion of the algorithms to C code using Real-Time Workshop in order to be hosted in a mission computer engineering development unit running an embedded real-time operating system. SPARTAN also contains both runtime TCP/IP socket interface and post-processing compatibility with bdStudio, a visualization tool developed by bd Systems, allowing for intuitive evaluation of simulation results. A description of the SPARTAN architecture and capabilities is provided, along with details on the models and algorithms utilized and results from representative missions.

Turbe, Michael A.↗

DOE OSTI2024

Traffic Signal Control for Large-Scale Urban Traffic Networks: Real-World Experiments using Vision-Based Sensors

Effective control of traffic signals plays a critical role in ensuring smooth vehicle flow in urban areas. Expertly engineered traffic signal controllers can considerably minimize travel delays and enhance sustainability. In this paper, the team proposes the Model Predictive Control (MPC) traffic signal control strategy using real-time traffic flow data from a vision-based camera as feedback information. Also, a realistic signal timing plan that considers National Electrical Manufacturers Association (NEMA) constraints has been developed to be applied to real-world scenarios. The primary aim is to reduce the number of vehicles across all links in the controlled area, thereby optimizing traffic flow and reducing energy consumption. To validate the proposed method, several real-life experiments were conducted at 24 intersections in Chattanooga, Tennessee, by collaborating with traffic field engineers. These experiments demonstrated significant performance improvements in comparison to the existing method.

data processing↗

DOE OSTI2023

Machine Learning for Advanced Building Construction

High-efficiency retrofits can play a key role in reducing carbon emissions associated with buildings if processes can be scaled-up to reduce cost, time, and disruption. Here we demonstrate an artificial intelligence/computer vision (AI/CV)-enabled framework for converting exterior build scans and dimensional data directly into manufacturing and installation specifications for overclad panels. In our workflow point clouds associated with LiDAR-scanned buildings are segmented into a facade feature space, vectorized features are extracted using an iterative random-sampling consensus algorithm, and from this representation an optimal panel design plan satisfying manufacturing constraints is generated. This system and the corresponding construction process is demonstrated on a test facade structure constructed at the National Renewable Energy Laboratory (NREL). We also include a brief summary of a techno-economic study designed to estimate the potential energy and cost impact of this new system.

build scans↗

NASA NTRS2015

Spinoff 2015

Topics covered include: 3D Endoscope to Boost Safety, Cut Cost of Surgery; Audio App Brings a Better Night's Sleep Liquid Cooling Technology Increases Exercise Efficiency; Algae-Derived Dietary Ingredients Nourish Animals; Space Grant Research Launches Rehabilitation Chair; Vision Trainer Teaches Focusing Techniques at Home; Aircraft Geared Architecture Reduces Fuel Cost and Noise; Ubiquitous Supercritical Wing Design Cuts Billions in Fuel Costs; Flight Controller Software Protects Lightweight Flexible Aircraft; Cabin Pressure Monitors Notify Pilots to Save Lives; Ionospheric Mapping Software Ensures Accuracy of Pilots' GPS; Water Mapping Technology Rebuilds Lives in Arid Regions; Shock Absorbers Save Structures and Lives during Earthquakes; Software Facilitates Sharing of Water Quality Data Worldwide; Underwater Adhesives Retrofit Pipelines with Advanced Sensors; Laser Imaging Video Camera Sees through Fire, Fog, Smoke; 3D Lasers Increase Efficiency, Safety of Moving Machines; Air Revitalization System Enables Excursions to the Stratosphere; Magnetic Fluids Deliver Better Speaker Sound Quality; Bioreactor Yields Extracts for Skin Cream; Private Astronaut Training Prepares Commercial Crews of Tomorrow; Activity Monitors Help Users Get Optimum Sun Exposure; LEDs Illuminate Bulbs for Better Sleep, Wake Cycles; Charged Particles Kill Pathogens and Round Up Dust; Balance Devices Train Golfers for a Consistent Swing; Landsat Imagery Enables Global Studies of Surface Trends; Ruggedized Spectrometers Are Built for Tough Jobs; Gas Conversion Systems Reclaim Fuel for Industry; Remote Sensing Technologies Mitigate Drought; Satellite Data Inform Forecasts of Crop Growth; Probes Measure Gases for Environmental Research; Cloud Computing Technologies Facilitate Earth Research; Software Cuts Homebuilding Costs, Increases Energy Efficiency; Portable Planetariums Teach Science; Schedule Analysis Software Saves Time for Project Planners; Sound Modeling Simplifies Vehicle Noise Management; Custom 3D Printers Revolutionize Space Supply Chain; Improved Calibration Shows Images' True Colors; Micromachined Parts Advance Medicine, Astrophysics, and More; Metalworking Techniques Unlock a Unique Alloy; Low-Cost Sensors Deliver Nanometer-Accurate Measurements; Electrical Monitoring Devices Save on Time and Cost; Dry Lubricant Smooths the Way for Space Travel, Industry; and Compact Vapor Chamber Cools Critical Components.

Source record↗

NASA NTRS2007

Integrating Human Factors into Crew Exploration Vehicle Design

With NASA's new Vision for Exploration to send humans beyond Earth orbit, it is critical to consider the human as a system that demands early and continuous user involvement, and an iterative prototype/test/redesign process. Addressing human-system interface issues early on can be very cost effective even cost reducing when performed early in the design and development cycle. To achieve this goal within Crew Exploration Vehicle (CEV) Project Office, human engineering (HE) team is formed. Key tasks are to apply HE requirements and guidelines to hardware/software, and provide HE design, analysis and evaluation of crew interfaces. Initial activities included many practice-orientated evaluations using low-fidelity CEV mock-ups. What follows is a description of such evaluations that focused on a HE requirement regarding Net Habitable Volume (NHV). NHV is defined as the total remaining pressurized volume available to on-orbit crew after accounting for the loss of volume due to deployed hardware and structural inefficiencies which decrease functional volume. The goal of the NHV evaluations was to develop requirements providing sufficient CEV NHV for crewmembers to live and perform tasks in support of mission goals. Efforts included development of a standard NHV calculation method using computer models and physical mockups, and crew/ stakeholder evaluations. Nine stakeholders and ten crewmembers participated in the unsuited evaluations. Six crewmembers also participated in a suited evaluation. The mock-up was outfitted with volumetric representation of sub-systems such as seats, and stowage bags. Thirteen scenarios were developed to represent mission/crew tasks and considered to be primary volume drivers (e.g., suit donning) for the CEV. Unsuited evaluations included a structured walkthrough of these tasks. Suited evaluations included timed donning of the existing launch and entry suit to simulate a contingency scenario followed by doffing/ stowing of the suits. All mockup evaluations were videotaped. Structured questionnaires were used to document user interface issues and volume impacts of layout configuration. Computer model and physical measures of the NHV agreed within 1 percent. This included measurement of the gross habitable volume, subtraction of intrusive volumes, and other non-habitable spaces. Calculation method developed was validated as a standard means of measuring NHV, and was recommended as a verification method for the NHV requirements. Evaluations confirmed that there was adequate volume for unsuited scenarios and suit donning/ doffing activity. Seats, suit design stowage and waste hygiene system noted to be critical volume drivers. The low-fidelity mock-up evaluations along with human modeling analysis generated discussions that will lead to high-level systems requirements and human-centered design decisions. This approach allowed HE requirements and operational concepts to evolve in parallel with engineering system concepts and design requirements. As the CEV design matures, these evaluations will continue and help with design decisions, and assessment, verification and validation of HE requirements.

Whitmore, Mihriban↗

NASA NTRS2021

LiDAR-Based Map Relative Localization Performance Analysis for Landing on Europa

This paper presents preliminary simulations andanalyses done to assess the feasibility of performing Map RelativeLocalization (MRL) with the Europa Lander LiDAR beingdeveloped for the Europa Lander Pre-Phase A concept. MapRelative Localization is the process of determining the horizontalposition of a lander with respect to an onboard, a-priori map,by comparing the map to sensor observations of the terrain duringdeorbit, descent, and landing (DDL). Although kilometerscaleposition knowledge is commonly available during DDL,landing in hazard-rich environments requires position errors of100 m or less. Prior knowledge in the case of Europa Landerwill be visual and topographic maps collected by the upcomingEuropa Clipper mission. The Mars 2020 Lander Vision System(LVS) uses images from a camera to localize with respect tovisual maps. This technology, as well as a 3D imaging LiDAR indevelopment for hazard detection, is currently baselined for theEuropa Lander Pre-Phase A concept. This paper investigatesthe potential use of the hazard detection LiDAR to performMRL with respect to a 3D digital elevation model (DEM)provided by the Europa Clipper mission, as an alternative orbackup solution to passive optical MRL. Compared to passiveoptical MRL, one advantage of LiDAR-based localization isthat it is insensitive to lighting conditions, potentially relaxingrequirements on synchronizing map acquisition and landingtime of day. To analyze LiDAR based MRL performance,six representative terrains are synthetically up-sampled fromGalileo-derived maps of Europa to a resolution of 0.5 m/pxand covering an area of 4 km by 4 km. These maps are usedas ground-truth to generate simulated noisy a-priori onboardtopographic maps expected from Europa Clipper as well assimulated LiDAR DEMs generated at an altitude of 5 km duringEuropa Lander DDL. The simulated LiDAR DEM is matchedagainst the simulated map via 2D normalized cross-correlation,exploiting the accurately known spacecraft attitude to avoidthe need for more computationally intensive algorithms such asIterative Closest Point (ICP). Two sources of measurement errorare identified for analysis: 1) additive Gaussian noise in therange measurements from the Europa Lander LiDAR and theEuropa Clipper derived maps and 2) errors in the LiDAR DEMinduced by errors in the Europa Lander state estimate which isused to de-warp the LiDAR scan data into a DEM format. Weassess the effect of each of these types of errors independently onmatching performance as well as the overall performance whenall types of error are introduced. Additionally, we present theresult of a sensitivity study to terrain frequency content.

Trawny, Nikolas↗

DOE OSTI2020

TORONE: Total Characterisation by Remote Observation of Nuclear Environments - 20591

This paper describes the autonomous robotic systems developed in the TORONE project (Total Characterisation by Remote Observation of Nuclear Environments) for combined characterisation by remote techniques in nuclear environments. There are four main components to the system. Firstly, robot operation which uses a Robot Operating System (ROS) allowing ease of communication between hardware and software alongside robot vision systems such as Lidar and/or photogrammetry. Secondly, radiation detection instrumentation for gamma and neutron sources which is also collimated for spatial resolution. Thirdly, photonic characterisation instrumentation for remote material identification by means of Raman spectroscopy and Laser induced breakdown spectroscopy (LIBS). Finally, a data management system is described which contains the TORONE characterisation data with the ability to overlay material characterisation information onto 3D maps of the nuclear environment. Preliminary results are described alongside discussion of some of the synergies of the combined approach. There are many applications of such an autonomous system in nuclear decommissioning, waste management and asset management. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2013

Memory-Efficient Onboard Rock Segmentation

Rockster-MER is an autonomous perception capability that was uploaded to the Mars Exploration Rover Opportunity in December 2009. This software provides the vision front end for a larger software system known as AEGIS (Autonomous Exploration for Gathering Increased Science), which was recently named 2011 NASA Software of the Year. As the first step in AEGIS, Rockster-MER analyzes an image captured by the rover, and detects and automatically identifies the boundary contours of rocks and regions of outcrop present in the scene. This initial segmentation step reduces the data volume from millions of pixels into hundreds (or fewer) of rock contours. Subsequent stages of AEGIS then prioritize the best rocks according to scientist- defined preferences and take high-resolution, follow-up observations. Rockster-MER has performed robustly from the outset on the Mars surface under challenging conditions. Rockster-MER is a specially adapted, embedded version of the original Rockster algorithm ("Rock Segmentation Through Edge Regrouping," (NPO- 44417) Software Tech Briefs, September 2008, p. 25). Although the new version performs the same basic task as the original code, the software has been (1) significantly upgraded to overcome the severe onboard re source limitations (CPU, memory, power, time) and (2) "bulletproofed" through code reviews and extensive testing and profiling to avoid the occurrence of faults. Because of the limited computational power of the RAD6000 flight processor on Opportunity (roughly two orders of magnitude slower than a modern workstation), the algorithm was heavily tuned to improve its speed. Several functional elements of the original algorithm were removed as a result of an extensive cost/benefit analysis conducted on a large set of archived rover images. The algorithm was also required to operate below a stringent 4MB high-water memory ceiling; hence, numerous tricks and strategies were introduced to reduce the memory footprint. Local filtering operations were re-coded to operate on horizontal data stripes across the image. Data types were reduced to smaller sizes where possible. Binary- valued intermediate results were squeezed into a more compact, one-bit-per-pixel representation through bit packing and bit manipulation macros. An estimated 16-fold reduction in memory footprint relative to the original Rockster algorithm was achieved. The resulting memory footprint is less than four times the base image size. Also, memory allocation calls were modified to draw from a static pool and consolidated to reduce memory management overhead and fragmentation. Rockster-MER has now been run onboard Opportunity numerous times as part of AEGIS with exceptional performance. Sample results are available on the AEGIS website at http://aegis.jpl.nasa.gov.

Burl, Michael C.↗

DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Spinoff 2010

Topics covered include: Burnishing Techniques Strengthen Hip Implants; Signal Processing Methods Monitor Cranial Pressure; Ultraviolet-Blocking Lenses Protect, Enhance Vision; Hyperspectral Systems Increase Imaging Capabilities; Programs Model the Future of Air Traffic Management; Tail Rotor Airfoils Stabilize Helicopters, Reduce Noise; Personal Aircraft Point to the Future of Transportation; Ducted Fan Designs Lead to Potential New Vehicles; Winglets Save Billions of Dollars in Fuel Costs; Sensor Systems Collect Critical Aerodynamics Data; Coatings Extend Life of Engines and Infrastructure; Radiometers Optimize Local Weather Prediction; Energy-Efficient Systems Eliminate Icing Danger for UAVs; Rocket-Powered Parachutes Rescue Entire Planes; Technologies Advance UAVs for Science, Military; Inflatable Antennas Support Emergency Communication; Smart Sensors Assess Structural Health; Hand-Held Devices Detect Explosives and Chemical Agents; Terahertz Tools Advance Imaging for Security, Industry; LED Systems Target Plant Growth; Aerogels Insulate Against Extreme Temperatures; Image Sensors Enhance Camera Technologies; Lightweight Material Patches Allow for Quick Repairs; Nanomaterials Transform Hairstyling Tools; Do-It-Yourself Additives Recharge Auto Air Conditioning; Systems Analyze Water Quality in Real Time; Compact Radiometers Expand Climate Knowledge; Energy Servers Deliver Clean, Affordable Power; Solutions Remediate Contaminated Groundwater; Bacteria Provide Cleanup of Oil Spills, Wastewater; Reflective Coatings Protect People and Animals; Innovative Techniques Simplify Vibration Analysis; Modeling Tools Predict Flow in Fluid Dynamics; Verification Tools Secure Online Shopping, Banking; Toolsets Maintain Health of Complex Systems; Framework Resources Multiply Computing Power; Tools Automate Spacecraft Testing, Operation; GPS Software Packages Deliver Positioning Solutions; Solid-State Recorders Enhance Scientific Data Collection; Computer Models Simulate Fine Particle Dispersion; Composite Sandwich Technologies Lighten Components; Cameras Reveal Elements in the Short Wave Infrared; Deformable Mirrors Correct Optical Distortions; Stitching Techniques Advance Optics Manufacturing; Compact, Robust Chips Integrate Optical Functions; Fuel Cell Stations Automate Processes, Catalyst Testing; Onboard Systems Record Unique Videos of Space Missions; Space Research Results Purify Semiconductor Materials; and Toolkits Control Motion of Complex Robotics.

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