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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↗

Preliminary Error Characterization and Parametric Error Model for the Automatic Dependent Surveillance - Contract Extended Projected Profile Message

A critical component of Trajectory-Based Operations (TBO) is the ability for a consistent and accurate 4-dimensional trajectory (4DT) to be shared and synchronized between airborne and ground systems as well as amongst various ground automation systems. The Aeronautical Telecommunication Network—Baseline 2 (ATN-B2) standard defines the Extended Projected Profile (EPP) trajectory that can be sent via Automatic Dependent Surveillance-Contract (ADS-C) from an aircraft to ground automation. The EPP trajectory message contains a representation of the reference trajectory from an aircraft’s Flight Management System (FMS). In this work, a set of scenarios were run in a high-fidelity aircraft and FMS simulation to perform an initial characterization of EPP trajectory errors under a given set of conditions. The parameters investigated were the route length, route type, wind magnitude error, wind direction error, and with and without a required time-of-arrival (RTA) constraint. In addition, linear regression was used to identify a set of EPP error models for the cross-track, vertical, and time errors.

Guerreiro, Nelson M.↗

Power Measurement Errors on a Utility Aircraft

Extensive flight test data obtained from two recent performance tests of a UH 60A aircraft are reviewed. A power difference is calculated from the power balance equation and is used to examine power measurement errors. It is shown that the baseline measurement errors are highly non-Gaussian in their frequency distribution and are therefore influenced by additional, unquantified variables. Linear regression is used to examine the influence of other variables and it is shown that a substantial portion of the variance depends upon measurements of atmospheric parameters. Correcting for temperature dependence, although reducing the variance in the measurement errors, still leaves unquantified effects. Examination of the power difference over individual test runs indicates significant errors from drift, although it is unclear how these may be corrected. In an idealized case, where the drift is correctable, it is shown that the power measurement errors are significantly reduced and the error distribution is Gaussian. A new flight test program is recommended that will quantify the thermal environment for all torque measurements on the UH 60. Subsequently, the torque measurement systems will be recalibrated based on the measured thermal environment and a new power measurement assessment performed.

Bousman, William G.↗

Space shuttle entry and landing navigation analysis

A navigation system for the entry phase of a Space Shuttle mission which is an aided-inertial system which uses a Kalman filter to mix IMU data with data derived from external navigation aids is evaluated. A drag pseudo-measurement used during radio blackout is treated as an additional external aid. A comprehensive truth model with 101 states is formulated and used to generate detailed error budgets at several significant time points -- end-of-blackout, start of final approach, over runway threshold, and touchdown. Sensitivity curves illustrating the effect of variations in the size of individual error sources on navigation accuracy are presented. The sensitivity of the navigation system performance to filter modifications is analyzed. The projected overall performance is shown in the form of time histories of position and velocity error components. The detailed results are summarized and interpreted, and suggestions are made concerning possible software improvements.

Jones, H. L.↗

Use of Quality Controlled AIRS Temperature Soundings to Improve Forecast Skill

AIRS was launched on EOS Aqua on May 4, 2002, together with AMSU-A and HSB, to form a next generation polar orbiting infrared and microwave atmospheric sounding system. The primary products of AIRS/AMSU-A are twice daily global fields of atmospheric temperature-humidity profiles, ozone profiles, sea/land surface skin temperature, and cloud related parameters including OLR. Also included are the clear column radiances used to derive these products which are representative of the radiances AIRS would have seen if there were no clouds in the field of view. All products also have error estimates. The sounding goals of AIRS are to produce 1 km tropospheric layer mean temperatures with an rms error of 1K, and layer precipitable water with an rms error of 20 percent, in cases with up to 90 percent effective cloud cover. The products are designed for data assimilation purposes for the improvement of numerical weather prediction, as well as for the study of climate and meteorological processes. With regard to data assimilation, one can use either the products themselves or the clear column radiances from which the products were derived. The AIRS Version 5 retrieval algorithm is now being used operationally at the Goddard DISC in the routine generation of geophysical parameters derived from AIRS/AMSU data. A major innovation in Version 5 is the ability to generate case-by-case level-by-level error estimates for retrieved quantities and clear column radiances, and the use of these error estimates for Quality Control. The temperature profile error estimates are used to determine a case-by-case characteristic pressure pbest, down to which the profile is considered acceptable for data assimilation purposes. The characteristic pressure p(sub best) is determined by comparing the case dependent error estimate (delta)T(p) to the threshold values (Delta)T(p). The AIRS Version 5 data set provides error estimates of T(p) at all levels, and also profile dependent values of pbest based on use of a Standard profile dependent threshold (Delta)T(p). These Standard thresholds were designed as a compromise between optimal use for data assimilation purposes, which requires highest accuracy (tighter Quality Control), and climate purposes, which requires more spatial coverage (looser Quality Control). Subsequent research using Version 5 sounding and error estimates showed that tighter Quality Control performs better for data assimilation proposes, while looser Quality Control better spatial coverage) performs better for climate purposes. We conducted a number of data assimilation experiments using the NASA GEOS-5 Data Assimilation System as a step toward finding an optimum balance of spatial coverage and sounding accuracy with regard to improving forecast skill. The model was run at a horizontal resolution of 0.5 degree latitude x 0.67 degree longitude with 72 vertical levels. These experiments were run during four different seasons, each using a different year. The AIRS temperature profiles were presented to the GEOS-5 analysis as rawinsonde profiles, and the profile error estimates (delta)T(p) were used as the uncertainty for each measurement in the data assimilation process.

Susskind, Joel↗

ACIX-Aqua: A Global Assessment of Atmospheric Correction Methods for Landsat-8 and Sentinel-2 Over Lakes, Rivers, and Coastal Waters

Atmospheric correction over inland and coastal waters is one of the major remaining challenges in aquatic remote sensing, often hindering the quantitative retrieval of biogeochemical variables and analysis of their spatial and temporal variability within aquatic environments. The Atmospheric Correction Intercomparison Exercise (ACIX-Aqua), a joint NASA – ESA activity, was initiated to enable a thorough evaluation of eight state-of-the-art atmospheric correction (AC) processors available for Landsat-8 and Sentinel-2 data processing. Over 1000 radiometric matchups from both freshwaters (rivers, lakes, reservoirs) and coastal waters were utilized to examine the quality of derived aquatic reflectances (ρ̂w). This dataset originated from two sources: Data gathered from the international scientific community (henceforth called Community Validation Database, CVD), which captured predominantly inland water observations, and the Ocean Color component of AERONET measurements (AERONET-OC), representing primarily coastal ocean environments. This volume of data permitted the evaluation of the AC processors individually (using all the matchups) and comparatively (across seven different Optical Water Types, OWTs) using common matchups. We found that the performance of the AC processors differed for CVD and AERONET-OC matchups, likely reflecting inherent variability in aquatic and atmospheric properties between the two datasets. For the former, the median errors in ρ̂w560 and ρ̂w664 were found to range from 20 to 30% for best-performing processors. Using the AERONET-OC matchups, our performance assessments showed that median errors within the 15–30% range in these spectral bands may be achieved. The largest uncertainties were associated with the blue bands (25 to 60%) for best-performing processors considering both CVD and AERONET-OC assessments. We further assessed uncertainty propagation to the downstream products such as near-surface concentration of chlorophyll-a (Chla) and Total Suspended Solids (TSS). Using satellite matchups from the CVD along with in situ Chla and TSS, we found that 20–30% uncertainties in ρ̂w490≤λ≤743nm yielded 25–70% uncertainties in derived Chla and TSS products for top-performing AC processors. We summarize our results using performance matrices guiding the satellite user community through the OWT-specific relative performance of AC processors. Our analysis stresses the need for better representation of aerosols, particularly absorbing ones, and improvements in corrections for sky- (or sun-) glint and adjacency effects, in order to achieve higher quality downstream products in freshwater and coastal ecosystems.

Nima Pahlevan↗

Effect of Detector Dead Time on the Performance of Optical Direct-Detection Communication Links

Avalanche photodiodes (APDs) operating in the Geiger mode can provide a significantly improved single-photon detect ion sensitivity over conventional photodiodes. However, the quenching circuit required to remove the excess charge carriers after each photon event can introduce an undesirable dead time into the detection process. The effect of this detector dead time on the performance of a binary pulse-position-modulted (PPM) channel is studied by analyzing the error probability. It is shown that, when back- ground noise is negligible, the performance of the detector with dead time is similar to that o f a quantum-limited receiver. For systems with increasing background intensities, the error rate of the receiver starts to degrade rapidly with increasing dead time. The power penalty due to detector dead time is also evaluated and shown to depend critically on background intensity as well as dead time. Given the expected background strength in an optical channel, therefore, a constraint must be placed on the bandwidth of the receiver to limit the amount of power penalty due to detector dead time.

Chen, C.-C.↗

Error-controlled Progressive Retrieval of Scientific Data under Derivable Quantities of Interest

The unprecedented amount of scientific data has introduced heavy pressure on the current data storage and transmission systems. Progressive compression has been proposed to mitigate this problem, which offers data access with on-demand precision. However, existing approaches only consider precision control on primary data, leaving uncertainties on the quantities of interest (QoIs) derived from it. In this work, we present a progressive data retrieval framework with guaranteed error control on derivable QoIs. Our contributions are three-fold. (1) We carefully derive the theories to strictly control QoI errors during progressive retrieval. Our theory is generic and can be applied to any QoIs that can be composited by the basis of derivable QoIs proved in the paper. (2) We design and develop a generic progressive retrieval framework based on the proposed theories, and optimize it by exploring feasible progressive representations. (3) We evaluate our framework using five real-world datasets with a diverse set of QoIs. Experiments demonstrate that our framework can faithfully respect any user-specified QoI error bounds in the evaluated applications. This leads to over 2.02× performance gain in data transfer tasks compared to transferring the primary data while guaranteeing a QoI error that is less than 1E-5.

Wu, Xuan↗

Performance Sensitivity Studies on the PIAA Implementation of the High-Contrast Imaging Testbed

This slide presentation reviews the sensitivity studies on the Phase-Induced Amplitude Apodization (PIAA), or pupil mapping using the High-Contrast Imaging Testbed (HCIT). PIAA is a promising technique in high-dynamic range stellar coronagraph. This presentation reports on the investigation of the effects of the phase and rigid-body errors of various optics on the narrowband contrast performance of the PIAA/HCIT hybrid system. The results have shown that the 2-step wavefront control method utilizing 2-DMs is quite effective in compensating the effects of realistic phase and rigid-body errors of various optics

Phase-Induced Amplitude Apodization (PIAA)↗

Ground-testing of One-way Ranging from a Lunar Beacon Demonstrator Payload (Lunar Node -1)

Similar to lighthouses providing navigation aids and awareness to ships sailing along the coast, in-situ navigation beacons can be used to provide redundancy, awareness, and improved onboard position knowledge for vehicles operating in and around the lunar sphere of influence. Lunar Node - 1 is a radio frequency navigation beacon that is manifested on Intuitive Machines' NOVA-C lunar lander flight in 2022 for operation during cruise and from a mid-latitude landing location. This payload utilizes commercial components developed for Low Earth Orbit applications and packages them into an integrated package to provide a navigation reference signal as part of a large lunar-centric navigation network. As part of its operations, Deep Space Network ground stations will operate as the notional "user" of this service, allowing for performance characterization, calibration, and operation of the beacon payload. This paper provides an overview of the payload, how its fits into a large concept of operations, and ground testing results. A specific focus is on ground testing of the payload with DSN ground receivers as part of RF Compatibility Testing. A primary goal of this testing was to characterize a pseudo-noise ranging code sequence generated by the payload. The results in this paper define the testing sequence, unique operational constraints with two-way ranging ground equipment, and applications of the ground-derived error model to predicted in-flight performance of the ranging code.

Evan Anzalone↗

Ground-Testing of One-Way Ranging from a Lunar Beacon Demonstrator Payload (Lunar Node -1)

Similar to lighthouses providing navigation aids and awareness to ships sailing along the coast, in-situ navigation beacons can be used to provide redundancy, awareness, and improved onboard position knowledge for vehicles operating in and around the lunar sphere of influence. Lunar Node - 1 is a radio frequency navigation beacon that is manifested on Intuitive Machines' NOVA-C lunar lander flight in 2022 for operation during cruise and from a mid-latitude landing location. This payload utilizes commercial components developed for Low Earth Orbit applications and packages them into an integrated package to provide a navigation reference signal as part of a large lunar-centric navigation network. As part of its operations, Deep Space Network ground stations will operate as the notional "user" of this service, allowing for performance characterization, calibration, and operation of the beacon payload. This paper provides an overview of the payload, how its fits into a large concept of operations, and ground testing results. A specific focus is on ground testing of the payload with DSN ground receivers as part of Radio Frequency (RF) Compatibility Testing. A primary goal of this testing was to characterize a pseudo-noise ranging code sequence generated by the payload. The results in this paper define the testing sequence, unique operational constraints with two-way ranging ground equipment, and applications of the ground-derived error model to predicted in-flight performance of the ranging code.

Evan J Anzalone↗

A numerical algorithm to propagate navigation error covariance matrices associated with generalized strapdown inertial measurement units

The design and operation of a Strapdown Navigation Analysis Program (SNAP) developed to perform covariance analysis on spacecraft inertial-measurement-unit (IMU) navigation errors are described and demonstrated. Consideration is given to the IMU modeling subroutine (with user-specified sensor characteristics), the data input procedures, state updates and the simulation of instrument failures, the determination of the nominal trajectory, the mapping-matrix and Monte Carlo covariance-matrix propagation methods, and aided-navigation simulation. Numerical results are presented in tables for sample applications involving (1) the Galileo/IUS spacecraft from its deployment from the Space Shuttle to a point 10 to the 8th ft from the center of the earth and (2) the TDRS-C/IUS spacecraft from Space Shuttle liftoff to a point about 2 h before IUS deployment. SNAP is shown to give reliable results for both cases, with good general agreement between the mapping-matrix and Monte Carlo predictions.

Weir, Kent A.↗

Performance of direct and iterative algorithms on an optical systolic processor

The frequency-multiplexed optical linear algebra processor (OLAP) is treated in detail with attention to its performance in the solution of systems of linear algebraic equations (LAEs). General guidelines suitable for most OLAPs, including digital-optical processors, are advanced concerning system and component error source models, guidelines for appropriate use of direct and iterative algorithms, the dominant error sources, and the effect of multiple simultaneous error sources. Specific results are advanced on the quantitative performance of both direct and iterative algorithms in the solution of systems of LAEs and in the solution of nonlinear matrix equations. Acoustic attenuation is found to dominate iterative algorithms and detector noise to dominate direct algorithms. The effect of multiple spatial errors is found to be additive. A theoretical expression for the amount of acoustic attenuation allowed is advanced and verified. Simulations and experimental data are included.

Ghosh, A. K.↗

The snapshot survey - A search for gravitationally lensed quasars with the Hubble Space Telescope

The first results from the HST Non-Proprietary Snapshot Survey are presented in order to investigate new examples of multiply imaged quasars that are the result of gravitational lensing. None of the approximately 30 quasars observed at high spatial resolution show evidence of multiple imaging by gravitational lensing. These results are compared with lower resolution ground-based surveys and current theoretical predictions. Several engineering problems in the observatory's performance are addressed. It particular, the large telescope pointing errors and drift rates are found to be primarily the result of the lack of correction for stellar aberration when pointing and tracking are performed solely with gyroscopes. The implications for the possibly low intrinsic gyro drift rate on future observations are discussed.

Bahcall, J. N.↗

Rotational wind indicator enhances control of rotated displays

Rotation by 108 deg of the spatial mapping between a visual display and a manual input device produces large spatial errors in a discrete aiming task. These errors are not easily corrected by voluntary mental effort, but the central nervous system does adapt gradually to the new mapping. Bernotat (1970) showed that adding true hand position to a 90 deg rotated display improved performance of a compensatory tracking task, but tracking error rose again upon removal of the explicit cue. This suggests that the explicit error signal did not induce changes in the neural mapping, but rather allowed the operator to reduce tracking error using a higher mental strategy. In this report, we describe an explicit visual display enhancement applied to a 108 deg rotated discrete aiming task. A 'wind indicator' corresponding to the effect of the mapping rotation is displayed on the operator-controlled cursor. The human operator is instructed to oppose the virtual force represented by the indicator, as one would do if flying an airplane in a crosswind. This enhancement reduces spatial aiming error in the first 10 minutes of practice by an average of 70 percent when compared to a no enhancement control condition. Moreover, it produces adaptation aftereffect, which is evidence of learning by neural adaptation rather than by mental strategy. Finally, aiming error does not rise upon removal of the explicit cue.

Cunningham, H. A.↗

The role of communications, socio-psychological, and personality factors in the maintenance of crew coordination

The influence of group dynamics on the capability of aircraft crew members to make full use of the resources available on the flight deck in order to maintain flight safety is discussed. Instances of crewmembers withholding altimeter or heading information from the captain are cited as examples of domineering attitudes from command pilots and overconscientiousness on the parts of copilots, who may refuse to relay information forcefully enough or to take control of the aircraft in the case of pilot incapacitation. NASA studies of crew performance in controlled, simulator settings, concentrating on communication, decision making, crew interaction, and integration showed that efficient communication reduced errors. Acknowledgements served to encourage correct communication. The best crew performance is suggested to occur with personnel who are capable of both goal and group orientation. Finally, one bad effect of computer controlled flight is cited to be the tendency of the flight crew to think that someone else is taking care of difficulties in threatening situations.

Foushee, H. C.↗

An auditory display in a dual-axis tracking task.

Results of a study in which subjects were presented concurrently with the primary task of controlling a second-order plant and the secondary task of controlling a first-order plant. The plant errors for the two tasks were shown on separate visual displays. An auditory display, whose output varied in frequency and volume with the error, was used to supplement the secondary task in half of the runs. To study the effects of the auditory display, two performance measures were obtained: (1) the integral of the squared error (ISE) and (2) the describing functions of the human operator. Statistical analysis of the ISE measures indicated that when the secondary task was supplemented with an auditory display, there was a significant improvement in performance on the secondary task. The performance on the primary task improved on the average, but not significantly. The variances of the ISE values decreased for both the tasks, indicating a more consistent behavior with the auditory display. The describing function analysis showed that supplementing the secondary task with the auditory display increased the low frequency gain of the human operator for this task. The describing functions for the primary task did not show any apparent changes.

Mirchandani, P. B.↗

Exponentially Reduced Circuit Depths Using Trotter Error Mitigation

Product formulas are a popular class of digital quantum simulation algorithms due to their conceptual simplicity, low overhead, and performance, which often exceeds theoretical expectations. Recently, Richardson extrapolation and polynomial interpolation have been proposed to mitigate the Trotter error incurred by the use of these formulas. This work provides a rigorous, general analysis of these techniques for computing time-evolved observables, simplifying the interpolation algorithm in the process, and shows that extrapolation generically improves the performance of product formulas for this task. We demonstrate that, to achieve error 𝜖 in a simulation of time 𝑇 using a 𝑝 ⁢th-order product formula with extrapolation, circuit depths of 𝑂⁡(𝑇 1+1/𝑝 ⁢polylog (1/𝜖)) are sufficient—an exponential improvement in the precision over product formulas alone. Furthermore, we prove that these algorithms achieve commutator scaling, and improve the 𝑇 complexity for the interpolation algorithm. By relaxing the requirement of performing exact Chebyshev interpolation, our simplified algorithm eliminates the need for fractional implementations of Trotter steps, reducing computational overhead. Finally, we show these techniques can be combined with the classical shadows method to estimate many time-evolved local observables. Taken together, our findings provide the strongest evidence yet for the utility of Trotter error-mitigation techniques in algorithmic applications.

quantum algorithms & computation↗