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At least 163 records · Page 9

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Combining In-situ Diagnostics and Data Analytics for Discovery of Process-Structure-Property Relationships in AM parts – A Step Toward Digital Twins

In-situ additive manufacturing (AM) diagnostic tools (e.g., optical/infrared imaging, acoustic, etc.) already exist to correlate process anomalies to printed part defects. This current work aimed to augment existing capabilities by: 1) Incorporating in-situ imaging w/ machine learning (ML) image processing software (ORNL- developed "Peregrine") for AM process anomaly detection 2) Synchronizing multiple in-situ sensors for simultaneous analysis of AM build events 3) Correlating in-situ AM process data, generated part defects and part mechanical properties The key R&D question investigated was to determine if these new combined hardware/software tools could be used to successfully quantify defect distributions for parts build via SNL laser powder bed fusion (LPBF) machines, aiming to better understand data-driven process-structure-property- performance relationships. High resolution optical cameras and acoustic microphones were successfully integrated in two LPBF machines and linked to the Peregrine ML software. The software was successfully calibrated on both machines and used to image hundreds of layers of multiple builds to train the ML software in identifying printed part vs powder. The software's validation accuracy to identify this aspect increased from 56% to 98.8% over three builds. Lighting conditions inside the chamber were found to significantly impact ML algorithm predictions from in-situ sensors, so these were tailored to each machine's internal framework. Finally, 3D part reconstructions were successfully generated for a build from the compressed stack of layer-wise images. Resolution differences nearest and furthest from the optical camera were discussed. Future work aims to improve optical resolution, increase process anomalies identified, and integrate more sensor modalities.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Distributed fiber sensor and machine learning data analytics for pipeline protection against extrinsic intrusions and intrinsic corrosions

This paper presents an integrated technical framework to protect pipelines against both malicious intrusions and piping degradation using a distributed fiber sensing technology and artificial intelligence. A distributed acoustic sensing (DAS) system based on phase-sensitive optical time-domain reflectometry (φ-OTDR) was used to detect acoustic wave propagation and scattering along pipeline structures consisting of straight piping and sharp bend elbow. Signal to noise ratio of the DAS system was enhanced by femtosecond induced artificial Rayleigh scattering centers. Data harnessed by the DAS system were analyzed by neural network-based machine learning algorithms. The system identified with over 85% accuracy in various external impact events, and over 94% accuracy for defect identification through supervised learning and 71% accuracy through unsupervised learning.

Peng, Zhaoqiang↗

DOE OSTI2020

What can we learn from N 2 O isotope data? – Analytics, processes and modelling

The isotopic composition of nitrous oxide (N 2 O) provides useful information for evaluating N 2 O sources and budgets. Due to the co–occurrence of multiple N 2 O transformation pathways, it is, however, challenging to use isotopic information to quantify the contribution of distinct processes across variable spatiotemporal scales. Here, we present an overview of recent progress in N 2 O isotopic studies and provide suggestions for future research, mainly focusing on: analytical techniques; production and consumption processes; and interpretation and modelling approaches. Comparing isotope–ratio mass spectrometry (IRMS) with laser absorption spectroscopy (LAS), we conclude that IRMS is a precise technique for laboratory analysis of N 2 O isotopes, while LAS is more suitable for in situ/inline studies and offers advantages for site–specific analyses. When reviewing the link between the N 2 O isotopic composition and underlying mechanisms/processes, we find that, at the molecular scale, the specific enzymes and mechanisms involved determine isotopic fractionation effects. In contrast, at plot–to–global scales, mixing of N 2 O derived from different processes and their isotopic variability must be considered. We also find that dual isotope plots are effective for semi–quantitative attribution of co–occurring N 2 O production and reduction processes. More recently, process–based N 2 O isotopic models have been developed for natural abundance and 15 N–tracing studies, and have been shown to be effective, particularly for data with adequate temporal resolution. Here, despite the significant progress made over the last decade, there is still great need and potential for future work, including development of analytical techniques, reference materials and inter–laboratory comparisons, further exploration of N 2 O formation and destruction mechanisms, more observations across scales, and design and validation of interpretation and modelling approaches. Synthesizing all these efforts, we are confident that the N 2 O isotope community will continue to advance our understanding of N 2 O transformation processes in all spheres of the Earth, and in turn to gain improved constraints on regional and global budgets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

When physics-informed data analytics outperforms black-box machine learning: A case study in thickness control for additive manufacturing

Aerosol jet printing (AJP) has emerged as a promising noncontact additive manufacturing method for high-resolution printing for a wide range of material systems. A key challenge limiting the broader adoption of AJP in the material science community is the lack of methods to precisely control thickness. Herein, we develop a model-based design of experiment (MBDoE) framework that integrates physics-informed models, nonlinear regression, and information criteria to postulate, select and calibrate the best model to describe and optimize the AJP manufacturing process. Starting with already available data from system commissioning (e.g., prior single variable sensitivity analysis), four candidate physics-informed models are postulated and trained. MBDoE identifies a single additional optimal experiment to validate these predictive models with quantified uncertainties, which are then used to determine the best experimental conditions to control printed film thickness. As a comparative benchmark, the analysis is repeated using the same dataset with nonparametric Gaussian process regression (GPR) model that does not incorporate physical information. Using MBDoE principles, we find that only five experiments are necessary to calibrate the nonlinear physics-informed parametric model, and with said limited data, this model outperforms the black-box machine learning GPR model. This key result underscores an emerging trend in the data science community: incorporating physical information into predictive models often drastically reduces the data requirements. Leveraging MBDoE further increased the data efficiency. By design, the proposed data science framework is general in nature and can be easily extended to other experimental and additive manufacturing systems beyond AJP.

Aerosol jet printing↗

DOE OSTI2017

Data Driven Smart Proxy for CFD: Application of Big Data Analytics & Machine Learning in Computational Fluid Dynamics (Part 1)

Simulation technologies can reduce the time and cost of the development and deployment of advanced technologies and allow rapid scale-up of these technologies for fossil fuel based energy systems. However, to ensure their usefulness in practice, the credibility of the simulations needs to be established with Uncertainty Quantification (UQ) methods. National Energy Technology Laboratory (NETL) has been applying non-intrusive UQ methodologies to categorize and quantify uncertainties in CFD simulations of gas-solid multiphase flows. To reduce the computational cost associated with gas-solid flow simulations required for UQ analysis, techniques commonly used in the area of Artificial Intelligence (AI) and Data Mining (DM) are used to construct smart proxy models, which can reduce the computational cost of conducting large number of multiphase CFD simulations.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Data Analytics for Alloy Qualification

9-12% Cr-steels are used as structural material in boiler and turbine (rotor/casing) applications, with a power plant designed to operate for at least 30 years at either sub- or supercritical conditions (high pressure and temperature). In high-efficiency power plants, some components must withstand high stress and temperature for 100,000 h of operation without failure (Abe, 2011; Abe, et al., 2008; Coleman & Newell Jr., 2007; Viswanathan, 1989; Viswanathan & Bakker, 2001; Viswanathan & Bakker, 2001; Masuyama, 2001). Motivation for this project came from the need for rigorous and time-consuming alloy qualification (standardization) process, for crucial applications. Material scientists have traditionally manipulated alloying element composition and thermomechanical processing to achieve specific mechanical properties in alloys. The goals of this work were to develop a systematic and data-centric framework for analysis and characterization of materials information, to explore new alloy compositions and/or processing, and to better predict stress-rupture lifetime and other mechanical properties. A small subset of carbon steels with similar ferritic or martensitic lath microstructure (and average prior austenite grain size) was chosen for this analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Data Analytics for Concrete Structural Health Monitoring in Nuclear Power Plants

Assessment and management of aging concrete structures in nuclear power plants require a more systematic approach than simple reliance on existing code margins of safety. Structural health monitoring of concrete structures aims to understand the current health condition of a structure based on heterogeneous measurements to produce high-confidence actionable information regarding structural integrity that supports operational and maintenance decisions. This ongoing research project is seeking to develop a probabilistic framework for health diagnosis and prognosis of aging concrete structures in a nuclear power plant that is subjected to physical, chemical, environment, and mechanical degradation. In this paper, experimental set up at Vanderbilt University’s Laboratory for Systems Integrity and Reliability is used to research effective combinations of full field techniques, which include infrared thermography, digital image correlation, and ultrasonic measurement. The full-field imaging data collected were processed using contour mapping technique to identify holes in a concrete slab. The techniques discussed and presented in this paper allow diagnosis of damage. The framework will enable plant operators to make risk informed decisions on the struc-tural integrity, remaining useful life, and performance of concrete structures.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Deep data analytics for genetic engineering of diatoms linking genotype to phenotype via machine learning

Abstract Genome engineering for materials synthesis is a promising avenue for manufacturing materials with unique properties under ambient conditions. Biomineralization in diatoms, unicellular algae that use silica to construct micron-scale cell walls with nanoscale features, is an attractive candidate for functional synthesis of materials for applications including photonics, sensing, filtration, and drug delivery. Therefore, controllably modifying diatom structure through targeted genetic modifications for these applications is a very promising field. In this work, we used gene knockdown in Thalassiosira pseudonana diatoms to create modified strains with changes to structural morphology and linked genotype to phenotype using supervised machine learning. An artificial neural network (NN) was developed to distinguish wild and modified diatoms based on the SEM images of frustules exhibiting phenotypic changes caused by a specific protein (Thaps3_21880), resulting in 94% detection accuracy. Class activation maps visualized physical changes that allowed the NNs to separate diatom strains, subsequently establishing a specific gene that controls pores. A further NN was created to batch process image data, automatically recognize pores, and extract pore-related parameters. Class interrelationship of the extracted paraments was visualized using a multivariate data visualization tool, called CrossVis, and allowed to directly link changes in morphological diatom phenotype of pore size and distribution with changes in the genotype.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2016

Visual Data-Analytics of Large-Scale Parallel Discrete-Event Simulations

Parallel discrete-event simulation (PDES) is an important tool in the codesign of extreme-scale systems because PDES provides a cost-effective way to evaluate designs of highperformance computing systems. Optimistic synchronization algorithms for PDES, such as Time Warp, allow events to be processed without global synchronization among the processing elements. A rollback mechanism is provided when events are processed out of timestamp order. Although optimistic synchronization protocols enable the scalability of large-scale PDES, the performance of the simulations must be tuned to reduce the number of rollbacks and provide an improved simulation runtime. To enable efficient large-scale optimistic simulations, one has to gain insight into the factors that affect the rollback behavior and simulation performance. We developed a tool for ROSS model developers that gives them detailed metrics on the performance of their large-scale optimistic simulations at varying levels of simulation granularity. Model developers can use this information for parameter tuning of optimistic simulations in order to achieve better runtime and fewer rollbacks. In this work, we instrument the ROSS optimistic PDES framework to gather detailed statistics about the simulation engine. We have also developed an interactive visualization interface that uses the data collected by the ROSS instrumentation to understand the underlying behavior of the simulation engine. The interface connects real time to virtual time in the simulation and provides the ability to view simulation data at different granularities. We demonstrate the usefulness of our framework by performing a visual analysis of the dragonfly network topology model provided by the CODES simulation framework built on top of ROSS. The instrumentation needs to minimize overhead in order to accurately collect data about the simulation performance. To ensure that the instrumentation does not introduce unnecessary overhead, we perform a scaling study that compares instrumented ROSS simulations with their noninstrumented counterparts in order to determine the amount of perturbation when running at different simulation scales.

Ross, Caitlin↗

DOE OSTI2018