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DOE OSTI2026

Attention-based 3D – convolutional neural network model for mechanical property predictions using visible light images in metal additive manufacturing

Additive manufacturing (AM), while commonly used for rapid prototyping and creating components with complex geometries, has not been widely adopted for critical applications across the aerospace, automotive, defense, energy, and medical industries. This is, in part, due to the challenges of controlling flaws and uncertainty in the mechanical behavior of additively manufactured components. In recent years, there has been an increase in research aimed at predicting the final mechanical properties of additively manufactured components during the printing process. To address these issues, a 3D-CNN model was trained using low-cost in situ visible-light camera data, anomaly classifications, and the chosen process parameters to predict the ultimate tensile strength (UTS), yield strength (YS), total elongation (TE), and uniform elongation (UE). The 3D-CNN layers of the model employed attention mechanisms to prioritize features in the data, thereby improving prediction accuracy. Furthermore, the effect of each process parameter and anomaly class is investigated using attention-based dynamic sigmoid weighted gates to interpret the influence each class has on the final prediction. Different combinations of the in situ data were fed into the 3D-CNN, with varying amounts of image layers, to determine the ideal combination for predicting mechanical properties in situ. Here, the 3D-CNN model achieved mean absolute percentage errors (MAPE) below 5% for both UTS and YS while using only a single camera input and under half of the available image layers.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Booster aerodynamic heating: Test support

Several technical areas were encompassed in providing support for booster thermal environment test work. These areas included: (1) cavity flow heating, (2) rarefied flow heating, and (3) impulse operated model research and testing. Cavity flow heating problems were studied with respect to the proposed altitude control motors for the space shuttle. Available literature on this subject was reviewed and analytical predictive methods were summarized for use in planning testing work. Rarefied flow heating data was reviewed and correlated. The study showed the importance of considering rarefied flow conditions in launch thermal environment prediction. Impulse operated model research and testing was conducted to provide a basis for understanding and designing such models for booster thermal environment testing.

Engel, C. D.↗

NASA NTRS2000

A Catchment-Based Approach to Modeling Land Surface Processes in a GCM: Parameter Estimation and Model Demonstration - Part 2

The viability of a new catchment-based land surface model (LSM) developed for use with general circulation models is demonstrated. First, simple empirical functions -- tractable enough for operational use in the LSM -- are established that faithfully capture the control of topography on the subgrid variability of soil moisture and the surface water budget, as predicted by theory. Next, the full LSM is evaluated offline. Using forcing and validation datasets developed for PILPS Phase 2c, the minimally calibrated model is shown to reproduce observed evaporation and runoff fluxes successfully in the Red-Arkansas River Basin. A complementary idealized study that employs the range of topographic variability seen over North America demonstrates that the simulated surface water budget does vary strongly with topography, which can, by itself, induce variations in annual evaporation as high as 20%.

Ducharne, Agnes↗

DOE OSTI2024

Multiscale Dynamics of Reactive Fronts in the Subsurface

Understanding and predicting flow and reactive transport in rocks (i.e. geologic porous media) is critical to many technologies at the heart of the energy transition, including CO 2 sequestration and H2 storage. However, accurate modeling and prediction of these systems is very complex because physico-chemical processes that occur at very small spatial scales, i.e. in the pores of the rocks, can dramatically control the system performance at the field scale (km). For example, precipitation reactions at the pore-scale can lead to large permeability changes at the field scale and dramatically alter the migration of stored gases. Properly accounting for multi-scale coupling effects is critical to achieve predictivity and confidence in model outputs, which then can guide design and optimization at the system-scale. This can be achieved through the development of rigorous mathematical models that can appropriately account for fine-scale effects at the large scale. The final report of the Early Career award DE-SC0019075 “Multiscale dynamics of reactive fronts in the subsurface” summarizes the mathematical, numerical and experimental advancements to study and predict reactive transport in geologic porous media across scales.

58 GEOSCIENCES↗

DOE OSTI2021

Integrating Systems and Synthetic Biology to Understand and Engineer Microbiomes

Microbiomes are complex and ubiquitous networks of microorganisms whose seemingly limitless chemical transformations could be harnessed to benefit agriculture, medicine, and biotechnology. Here, the spatial and temporal changes in microbiome composition and function are influenced by a multitude of molecular and ecological factors. This complexity yields both versatility and challenges in designing synthetic microbiomes and perturbing natural microbiomes in controlled, predictable ways. In this review, we describe factors that give rise to emergent spatial and temporal microbiome properties and the meta-omics and computational modeling tools that can be used to understand microbiomes at the cellular and system levels. We also describe strategies for designing and engineering microbiomes to enhance or build novel functions. Throughout the review,we discuss key knowledge and technology gaps for elucidating the networks and deciphering key control points for microbiome engineering, and highlight examples where multiple omics and modeling approaches can be integrated to address these gaps.

42 ENGINEERING↗

NASA NTRS1997

A Cognitive System Model for Human/Automation Dynamics in Airspace Management

NASA has initiated a significant thrust of research and development focused on providing the flight crew and air traffic managers automation aids to increase capacity in en route and terminal area operations through the use of flexible, more fuel-efficient routing, while improving the level of safety in commercial carrier operations. In that system development, definition of cognitive requirements for integrated multi-operator dynamic aiding systems is fundamental. In order to support that cognitive function definition, we have extended the Man Machine Integrated Design and Analysis System (MIDAS) to include representation of multiple cognitive agents (both human operators and intelligent aiding systems) operating aircraft, airline operations centers and air traffic control centers in the evolving airspace. The demands of this application require representation of many intelligent agents sharing world-models, and coordinating action/intention with cooperative scheduling of goals and actions in a potentially unpredictable world of operations. The MIDAS operator models have undergone significant development in order to understand the requirements for operator aiding and the impact of that aiding in the complex nondeterminate system of national airspace operations. The operator model's structure has been modified to include attention functions, action priority, and situation assessment. The cognitive function model has been expanded to include working memory operations including retrieval from long-term store, interference, visual-motor and verbal articulatory loop functions, and time-based losses. The operator's activity structures have been developed to include prioritization and interruption of multiple parallel activities among multiple operators, to provide for anticipation (knowledge of the intention and action of remote operators), and to respond to failures of the system and other operators in the system in situation-specific paradigms. The model's internal representation has been be modified so that multiple, autonomous sets of equipment will function in a scenario as the single equipment sets do now. In order to support the analysis requirements with multiple items of equipment, it is necessary for equipment to access the state of other equipment objects at initialization time (a radar object may need to access the position and speed of aircraft in its area, for example), and as a function of perception and sensor system interaction. The model has been improved to include multiple world-states as a function of equipment am operator interaction. The model has been used -1o predict the impact of warning and alert zones in aircraft operation, and, more critic-ally, the interaction of flight-deck based warning mechanisms and air traffic controller action in response to ground-based conflict prediction and alerting systems. In this operation, two operating systems provide alerting to two autonomous, but linked sets of operators, whose view of the system and whose dynamics in response are radically different. System stability and operator action was predicted using the MIDAS model.

Corker, Kevin M.↗

DOE OSTI2021

Toward a First-Principles Framework for Predicting Collective Properties of Electrolytes

Conspectus Given the universal importance of electrolyte solutions, it is natural to expect that we have a nearly complete understanding of the fundamental properties of these solutions (e.g., the chemical potential) and that we can therefore explain, predict, and control the phenomena occurring in them. In fact, reality falls short of these expectations. But, recent advances in the simulation and modeling of electrolyte solutions indicate that it should soon be possible to make progress toward these goals. In this Account, we will discuss the use of first-principles interaction potentials based in quantum mechanics (QM) to enhance our understanding of electrolyte solutions. Specifically, we will focus on the use of quantum density functional theory (DFT) combined with molecular dynamics simulation (DFT-MD) as the foundation for our approach. The overarching concept is to understand and accurately reproduce the balance between local or short-ranged (SR) structural details and long-range (LR) correlations, allowing the prediction of the thermodynamics of both single ions in solution as well as the collective interactions characterized by activity/osmotic coefficients. In doing so, relevant collective motions and driving forces characterized by chemical potentials can be determined. Here, in this Account, we will make the case that understanding electrolyte solutions requires a faithful QM representation of the SR nature of the ion–ion, ion–water, and water–water interactions. However, the number of molecules that is required for collective behavior makes the direct application of high-level QM methods that contain the best SR physics untenable, making methods that balance accuracy and efficiency a practical goal. Alternatives such as continuum solvent models (CSMs) and empirically based classical molecular dynamics have been extensively employed to resolve this problem but without yet overcoming the fundamental issue of SR accuracy. We will demonstrate that accurately describing the SR interaction is imperative for predicting both intrinsic properties, namely, at infinite dilution, and collective properties of electrolyte solutions. DFT has played an important role in our understanding of condensed phase systems, e.g., bulk liquid water, the air–water interface, ions in bulk, and at the air–water interface. This approach holds huge promise to provide benchmark calculations of electrolyte solution properties that will allow for the development and improvement of more efficient methods, as well as an enhanced understanding of fundamental phenomena. However, the standard protocol using the generalized gradient approximation with van der Waals (vdW) correction requires improvement in order to achieve a high level of quantitative accuracy. Simply simulating with higher level DFT functionals may not be the best route considering the significant computational cost. Alternative methods of incorporating information from higher levels of QM should be explored; e.g., using force matching techniques on small clusters, where high level benchmark calculations are possible, to develop ideal correction terms to the DFT functional is a promising possibility. We argue that DFT with statistical mechanics is becoming an increasingly useful framework enabling the prediction of collective electrolyte properties.

Duignan, Timothy T.↗

DOE OSTI2023

Multiphysics Pebble-Bed Reactor Control Rod Withdrawal Study

This work studied the responses of both a generic gas- and a fluoride-cooled PBR concept---the gPBR-200 and gFHR, respectively---during reactivity insertion accidents. Both models rely on 2-D axisymmetric simulations to solve the neutron flux distribution, nuclide concentrations, and temperature across the core---in addition to numerous representative pebble and TRISO particle simulations for determining fuel and moderator temperatures. This not only allows for computing maximum temperatures in the core---thus enabling estimation of how near the fuel is to peak operational and safety limits---as prescribed by specified acceptable fuel design limits, which are determined in such a way that fuel is not damaged during operational or anticipated abnormal occurrences---but also predicting how much of the core exceeds a given temperature limit, as well as determining the local energy deposition rate. These models consider both control rod withdrawal and ejection events. The former introduces a great deal more reactivity, as all the control rods are withdrawn (as opposed to a single one in the latter case), though at a much slower pace. In addition, for the gPBR-200, two limiting cases were considered: one with the core starting under hot full-power conditions and one with it starting under cold zero-power conditions. While the amount of reactivity added in the latter case is much higher (due to the far lower temperatures and the lack of neutron poisons such as Xe-135), the margin to temperature limits is also much more significant. Overall, for the design considered, none of the accidents resulted in the maximum fuel temperature reaching values close to the TRISO limit. However, the methodology presented herein could be very relevant if some designs consider reduced margins (e.g., higher temperatures) to achieve enhanced economics. Further model improvement is needed to better capture control rod worth, both in terms of cusping effects (as the rods are slowly withdrawn) and differential worth, especially as the tips of the rods near the upper cavity.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2021

Non-Causal Controller Approximation Methodology Augmented with Model Reference Control – Robust Design

This paper describes the development of a new control design methodology based on a non-causal controller structure and its approximation. The non-causal controller design is based on a loop shaping approach. Partial fraction decomposition is used, along with derivative approximations, to derive a proper transfer function design for a causal control structure. The premise for this non-causal control methodology is that the phase delay as a function of frequency ideally remains within approximately -90o, which tends to make the system robustly stable to uncertainties in the plant dynamics. To have a predictable control system response in lieu of the tolerance of this methodology to relatively large uncertainty in the plant dynamics, the approach is augmented with model reference control. The addition of model reference control can potentially further enhance the robustness of the design. A control system design example is presented in this paper, along with simulation results, to demonstrate the high degree of robustness of this non-causal methodology and its augmentation.

Control Systems↗

DOE OSTI2025

Predictive turbulence-driven flux model of scrape-off layer widths across confinement regimes in tokamaks

Reliable scrape-off layer (SOL) profile decay lengths predictions are needed to design and operate future tokamaks. The present manuscript describes a new model based on turbulent transport that is able to predict SOL widths for both L-mode and H-mode plasmas. The model is based upon the sheared-spectral filament paradigm (Peret et al (WEST Team) 2022 Phys. Plasmas 29 072306), however, incorporating the effects of thermal transport in order to calculate the parallel heat fluxes. The effects of magnetic shear and ExB shear on the cross-field transport are crucial to explain the shorter SOL decay lengths found in H-mode. The model is validated against a database of thousands of DIII-D L-mode and H-mode SOL profiles. We also calculate SOL decay length predictions in terms of plasma and engineer control parameters, which are in agreement with the multi-machine empirical H-mode scaling (Eich et al (ASDEX Upgrade Team and JET EFDA Contributors) 2013 Nucl. Fusion 53 093031), however, with an additional device geometry dependence. ITER SOL width predictions by the model are 3 times higher than the empirical scaling.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

MARS-F/K modeling of plasma response and fast ion losses due to RMP in KSTAR

Abstract The toroidal single-fluid magnetohydrodynamic (MHD) code MARS-F (Liu et al 2000 Phys. Plasmas 7 3681) and the MHD-kinetic hybrid code MARS-K (Liu et al 2008 Phys. Plasmas 15 112503) are utilized to study the plasma response to the n = 1 ( n is the toroidal mode number) resonant magnetic perturbation (RMP), applied to suppress the type-I edge localized mode (ELM) in a KSTAR discharge. Both the resistive-rotating and ideal-static plasma models identify strong screening of the resonant radial field harmonics of the applied RMP due to the plasma response, and predict a strong edge-peeling response of the plasma which is consistent with the optimal ELM control coil current configuration adopted in experiment. The RMP-induced radial displacement of the plasma, computed by the resistive-rotating plasma model, agrees reasonably well with that reconstructed from the measured data in the plasma core. Taking into account the drift kinetic response of fast ions, MARS-K hybrid modeling also finds quantitative agreement of the plasma core fluid pressure perturbation with experiment. Based on the MARS-F computed plasma response, a guiding-center orbit-tracing simulation finds about 0.3% of fast ion losses due the n = 1 RMP in the KSTAR ELM control experiment considered. Most losses are associated with counter-current fast ions located near the plasma edge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2004

On Efficient Multigrid Methods for Materials Processing Flows with Small Particles

Multiscale modeling of materials requires simulations of multiple levels of structural hierarchy. The computational efficiency of numerical methods becomes a critical factor for simulating large physical systems with highly desperate length scales. Multigrid methods are known for their superior efficiency in representing/resolving different levels of physical details. The efficiency is achieved by employing interactively different discretizations on different scales (grids). To assist optimization of manufacturing conditions for materials processing with numerous particles (e.g., dispersion of particles, controlling flow viscosity and clusters), a new multigrid algorithm has been developed for a case of multiscale modeling of flows with small particles that have various length scales. The optimal efficiency of the algorithm is crucial for accurate predictions of the effect of processing conditions (e.g., pressure and velocity gradients) on the local flow fields that control the formation of various microstructures or clusters.

Thomas, James↗

DOE OSTI2020

Taxonomic and nutrient controls on phytoplankton iron quotas in the ocean

Abstract Phytoplankton iron contents (i.e., quotas) directly link biogeochemical cycles of iron and carbon and drive patterns of nutrient limitation, recycling, and export. Ocean biogeochemical models typically assume that iron quotas are either static or controlled by dissolved iron availability. We measured iron quotas in phytoplankton communities across nutrient gradients in the Pacific Ocean and found that quotas diverged significantly in taxon‐specific ways from laboratory‐derived predictions. Iron quotas varied 40‐fold across nutrient gradients, and nitrogen‐limitation allowed diatoms to accumulate fivefold more iron than co‐occurring flagellates even under low iron availability. Modeling indicates such “luxury” uptake is common in large regions of the low‐iron Pacific Ocean. Among diatoms, both pennate and centric genera accumulated luxury iron, but the cosmopolitan pennate genus Pseudo‐nitzschia maintained iron quotas 10‐fold higher than co‐occurring centric diatoms, likely due to enhanced iron storage. Biogeochemical models should account for taxonomic and macronutrient controls on phytoplankton iron quotas.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Predicting Kyasanur forest disease in resource-limited settings using event-based surveillance and transfer learning

In recent years, the reports of Kyasanur forest disease (KFD) breaking endemic barriers by spreading to new regions and crossing state boundaries is alarming. Effective disease surveillance and reporting systems are lacking for this emerging zoonosis, hence hindering control and prevention efforts. We compared time-series models using weather data with and without Event-Based Surveillance (EBS) information, i.e., news media reports and internet search trends, to predict monthly KFD cases in humans. We fitted Extreme Gradient Boosting (XGB) and Long Short-Term Memory models at the national and regional levels. We utilized the rich epidemiological data from endemic regions by applying Transfer Learning (TL) techniques to predict KFD cases in new outbreak regions where disease surveillance information was scarce. Overall, the inclusion of EBS data, in addition to the weather data, substantially increased the prediction performance across all models. The XGB method produced the best predictions at the national and regional levels. The TL techniques outperformed baseline models in predicting KFD in new outbreak regions. Novel sources of data and advanced machine-learning approaches, e.g., EBS and TL, show great potential towards increasing disease prediction capabilities in data-scarce scenarios and/or resource-limited settings, for better-informed decisions in the face of emerging zoonotic threats.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Causality guided machine learning model on wetland CH 4 emissions across global wetlands

Wetland CH 4 emissions are among the most uncertain components of the global CH 4 budget. The complex nature of wetland CH 4 processes makes it challenging to identify causal relationships for improving our understanding and predictability of CH 4 emissions. In this study, we used the flux measurements of CH 4 from eddy covariance towers (30 sites from 4 wetlands types: bog, fen, marsh, and wet tundra) to construct a causality-constrained machine learning (ML) framework to explain the regulative factors and to capture CH 4 emissions at sub-seasonal scale. We found that soil temperature is the dominant factor for CH 4 emissions in all studied wetland types. Ecosystem respiration (CO 2 ) and gross primary productivity exert controls at bog, fen, and marsh sites with lagged responses of days to weeks. Integrating these asynchronous environmental and biological causal relationships in predictive models significantly improved model performance. More importantly, modeled CH 4 emissions differed by up to a factor of 4 under a +1°C warming scenario when causality constraints were considered. These results highlight the significant role of causality in modeling wetland CH 4 emissions especially under future warming conditions, while traditional data-driven ML models may reproduce observations for the wrong reasons. Our proposed causality-guided model could benefit predictive modeling, large-scale upscaling, data gap-filling, and surrogate modeling of wetland CH 4 emissions within earth system land models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1980

Wind-tunnel investigation of longitudinal and lateral-directional stability and control characteristics of a 0.237-scale model of a remotely piloted research vehicle with a thick, high-aspect-ratio supercritical wing

A 0.237-scale model of a remotely piloted research vehicle equipped with a thick, high-aspect-ratio supercritical wing was tested in the Langley 8-foot transonic tunnel to provide experimental data for a prediction of the static stability and control characteristics of the research vehicle as well as to provide an estimate of vehicle flight characteristics for a computer simulation program used in the planning and execution of specific flight-research mission. Data were obtained at a Reynolds number of 16.5 x 10 to the 6th power per meter for Mach numbers up to 0.92. The results indicate regions of longitudinal instability; however, an adequate margin of longitudinal stability exists at a selected cruise condition. Satisfactory effectiveness of pitch, roll, and yaw control was also demonstrated.

Byrdsong, T. A.↗

DOE OSTI2023

Experimental demonstration of a data-driven control system for subcritical nuclear facility

Here this paper presents an experimental demonstration of a data-driven control system (DCS) designed for the MIT Graphite Exponential Pile (MGEP). The DCS aims to regulate the neutron flux profile such that symmetry is preserved. Neutron flux perturbations are introduced into the MGEP to test the DCS's capabilities by the movement of an initiating control rod (ICR). To realize this functionality, a control system that relies on an artificial neural network (ANN) was developed, and then demonstrated on the MGEP. A Helium-3 ( 3 He) neutron detector and dual control rods, including their moving mechanisms, were fabricated. The perturbed flux profile was monitored by the moving neutron detector. The prediction accuracy of the neural network (NN) was examined and the DCS response was presented. Our results show that neural network regression model trained by experimental data can achieve a prediction error of less than 2.5 cm with a 95% confidence interval. The demonstration experiment also shows that a perturbation of the ICR can be captured by the control system and flux symmetry can be maintained within 1% after the response of the responding control rod (RCR).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1995

Statistical studies of impulsive events at high latitudes

A statistical study has been made of the high-latitude impulsive events that were observed during the 1985-1986 South Pole Balloon Campaign. The events were selected by searching for unipolar pulses greater than or equal to 10 nT above background in the vertical component of the magnetic field on the ground and/or pedestal or 'W' shaped horizontal electric field perturbations greater than or equal to 10 mV/m in amplitude and accompanied by perturbations in the vertical electric field at balloon altitude. A main event list comprising 112 events was compiled from the 468 hours of data available. Three aspects of the events were examined: the solar wind conditions prior to the event, local time of observation, and intrinsic properties of the events. The local time distribution was obtained from the 112 entry main event list and was found to be nearly uniform across the dayside, with no midday gap. The event rate found using our low-amplitude selection criteria was 0.7 event/hr, comparable to expectations based on in situ studies of the magnetopause. A total of 42 events were found for which data were available from Interplanetary Monitoring Platform (IMP) 8. Of these events, 12 occurred when the Z(sub GSM) component (B(sub Z)) of the interplanetary magnetic field (IMF) was northward and 30 occurred when B(sub Z) was southward or fluctuating. Only three of the B(sub Z) northward cases and only five of the B(sub Z) southward cases were preceded by pressure pulses greater than 0.4 nPa in amplitude. Ten of the events were studied in detail by means of a model-fitting method discussed elsewhere. This method infers values of several parameters, including the total current flowing in a coaxial or monopole system and a two-dimensional dipole system. The intrinsic properties of the events showed that only approximately 10% of the total current contributed to momentum transfer to the high-latitude ionosphere, that the direction of the motion depended more on local time of observation than IMF B(sub y), and that events were usually several hundred kilometers in size. The observed B(sub z) control found in the 42 event list and the prevalence of coaxial current dominated events are inconsistent with the predictions of the pressure pulse model.

Lin, Z. M.↗