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At least 19 records

VADER: A Tool for Criticality Safety Validation

The purpose of criticality safety is to prevent any inadvertent criticality from occurring during the handling or storage of fissile material. Calculations are frequently used to demonstrate that a sufficient subcritical margin exists. Validation is a key aspect of the evaluation process, establishing the suitability, accuracy, and associated uncertainty of the computational method and data to be used for the intended application. The validation process is performed by comparing the results of critical experiments with the calculated results from models of the experiments using the computational method to be validated. Laboratory critical experiments are controlled systems that achieve a k eff of approximately 1 in order to investigate the parameters at which such a critical condition is achieved. The validation parameters that are traditionally applied to safety analysis calculations are the bias and the bias uncertainty . The bias is the deviation of the average k eff of the validation suite from unity. The bias uncertainty accounts for the statistical uncertainty in the bias based on the standard deviation, sample size, and distribution of k eff values of the validation suite. The values of bias and bias uncertainty ensure that the systems predicted to be subcritical by the computational method will indeed be subcritical. The bias and bias uncertainty are often combined to determine an upper subcritical limit (USL) or computational margin that can then be applied to safety analysis calculations. Many methods have been developed by different organizations to calculate the bias and bias uncertainty for various types of criticality analyses. Each of these methods typically requires that the validity of various underpinning statistical assumptions be confirmed to demonstrate that the method is appropriate for the analysis of a given validation suite. An example of the validation decision making flow is shown in Fig.1. As shown in Fig. 1, the analyst performing the validation fits a trend line to the data and performs a test to determine if the trend was a statistically better representation of the data than if it were treated as an uncorrelated sample. If the trend line is a better representation of the data, then the analyst uses any one of a number of trending techniques to determine the bias and bias uncertainty. If a trend is not an appropriate representation of the data, then the analyst proceeds to perform a normality assessment for the data. If the normal assumption can be shown to be acceptable, then the analyst calculates the bias and bias uncertainty with the parametric technique. If the assumption of normality cannot be justified, then the nonparametric technique is used. Once the decision flow has been followed and the appropriate technique has been selected, the bias and bias uncertainty is typically combined with an administrative margin to determine a USL below which calculated values of k eff for safety analysis models can be considered subcritical. The calculations used in each decision are often performed with spreadsheets or with small programs available at various sites performing criticality analyses. Expertise in understanding and interpreting the results must be maintained to perform these calculations. This can often be an error-prone process. Oak Ridge National Laboratory (ORNL) is currently developing the Validation and Data Evaluation Resource (VADER) to simplify and automate the criticality safety validation process and to provide a software quality assurance pedigree to the calculational methods used. This paper discusses the use of the Fulcrum user interface with VADER, the anticipated initial capabilities of VADER to perform validation analyses, and the output from the code.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Time-temperature-superposition analysis of diverse datasets by the minimum-arclength method: long-term prediction with uncertainty margins

In a recent publication, we carried out an extensive analysis of an unsupervised method of determining optimum shift factors in time-temperature-superposition of accelerated-aging data that involves minimizing the vertical arclength to obtain the master curve. For synthetic Arrhenius data with a variety of noise distributions, the work showed that, in conjunction with bootstrap-resampling, the method can produce reliable estimates of the mean activation energy along with uncertainty quantification. Here, we apply the above method to six different datasets taken from the published literature and demonstrate accurate prediction of mean activation energy from the data as-is without the need for any pre-processing or fitting. We also compare uncertainty margins computed by second-order bootstrap with that by linear regression theory and show that the former appears to provide consistent margins in the presence of common noise types in real data, including intra-isotherm measurement-errors, sample-to-sample variations, and intrinsic deviation from perfect Arrhenius behavior.

36 MATERIALS SCIENCE↗

Chaotic neural dynamics facilitate probabilistic computations through sampling

Cortical neurons exhibit highly variable responses over trials and time. Theoretical works posit that this variability arises potentially from chaotic network dynamics of recurrently connected neurons. Here, we demonstrate that chaotic neural dynamics, formed through synaptic learning, allow networks to perform sensory cue integration in a sampling-based implementation. We show that the emergent chaotic dynamics provide neural substrates for generating samples not only of a static variable but also of a dynamical trajectory, where generic recurrent networks acquire these abilities with a biologically plausible learning rule through trial and error. Furthermore, the networks generalize their experience in the stimulus-evoked samples to the inference without partial or all sensory information, which suggests a computational role of spontaneous activity as a representation of the priors as well as a tractable biological computation for marginal distributions. These findings suggest that chaotic neural dynamics may serve for the brain function as a Bayesian generative model.

60 APPLIED LIFE SCIENCES↗

Reliability Estimation for One-Shot Devices (Rev. 1)

We present an engineering-oriented summary of statistical methods for estimation of the reliability (or equivalently, failure probability) of one-shot devices such as explosive detonators and other weapon components. Estimates may be given as single points or intervals, based on pass/fail tests, margin analysis, computational models, expert judgment, or a combination of these. We focus on highly reliable devices for which few or no failures are expected to occur in testing.

42 ENGINEERING↗

Comparison Study of Upper Subcritical Limits Derived Using Sensitivity/Uncertainty Tools: Case Studies of U233-SOL-THERM-001-001, MIX-COMP-THERM-001-001, IEU-MET-FAST-002-001, LEU-COMP-THERM-001-001, LEU-SOL-THERM-004-001

Neutron transport methods used to establish subcriticality require validation by comparison to critical experiments considered to be benchmarks. Whisper is a sensitivity/uncertainty analysis tool developed to assist with the task of validation in nuclear criticality safety. Details on the Whisper methodology can be found in References 1-3 on the MCNP® reference collection website at https://mcnp.lanl.gov. Whisper-1.0 was originally developed in 2014 and used to assist with nuclear criticality safety validation at Los Alamos National Laboratory. Whisper was upgraded in 2016 to Whisper-1.1 and prepared for release with MCNP6.2 [References 3-5]. Whisper contains a library of over 1100 critical experiment benchmarks and quantifies neutronic similarity of an application to benchmarks in the library. Using highest similarity benchmarks, Whisper computes a calculational margin (CM) encompassing of the worst-case bias and bias uncertainty at a 99% confidence level for each application. In addition, portions of the margin of subcriticality (MOS) for nuclear data uncertainty and potential code errors are computed. The baseline upper subcritical limit (USL) computed by Whisper is comprised of the CM, MOS nuclear data , and MOS code errors . The Whisper baseline USL is absent a portion of the MOS due to the area of application, which is applied based upon judgment by the criticality safety analyst. An objective of this paper is to present the baseline USL, CM and portions of the MOS as computed by Whisper for comparison with similar sensitivity/uncertainty tools, such as those used by IRSN and ORNL. An initial comparison involved four critical experiment benchmarks: HEU-MET-FAST-013-001, HEU-SOLTHERM-001-008, PU-MET-FAST-022-001, AND PU-SOL-THERM-001-001, which have been documented in References 10-13. This study extends the comparison to include cases U233-SOL-THERM-001-001, MIX-COMP-THERM-001-001, IEU-MET-FAST-002-001, LEU-COMP-THERM-001-001, LEU-SOL-THERM- 004-001.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Comparison Study of Upper Subcritical Limits Derived Using Sensitivity/Uncertainty Tools Case Studies of Benchmarks and Applications

Neutron transport methods used to establish subcriticality require validation by comparison to critical experiments considered to be benchmarks. Whisper is a sensitivity/uncertainty analysis tool developed to assist with the task of validation in nuclear criticality safety. Details on the Whisper methodology can be found in References 1-3 on the MCNP ® reference collection website at https://mcnp.lanl.gov. Whisper-1.0 was originally developed in 2014 and used to assist with nuclear criticality safety validation at Los Alamos National Laboratory. Whisper was upgraded in 2016 to Whisper-1.1 and prepared for release with MCNP6.2. Whisper contains a library of over 1100 critical experiment benchmarks and quantifies neutronic similarity of an application to benchmarks in the library. Using highest similarity benchmarks, Whisper computes a calculational margin (CM) encompassing of the worst-case bias and bias uncertainty at a 99% confidence level for each application. In addition, portions of the margin of subcriticality (MOS) for nuclear data uncertainty and potential code errors are computed. The baseline upper subcritical limit (USL) computed by Whisper is comprised of the CM, MOS nuclear data , and MOS code errors . The Whisper baseline USL is absent a portion of the MOS due to the area of application, which is applied based upon judgment by the criticality safety analyst. An objective of this paper is to present the baseline USL, CM and portions of the MOS as computed by Whisper for comparison with similar sensitivity/uncertainty tools, such as those used by IRSN and ORNL. The initial comparison involves four critical experiment benchmarks: HEU-MET-FAST-013-001, HEU-SOLTHERM-001-008, PU-MET-FAST-022-001, AND PU-SOL-THERM-001-001, which have been: 1. modeled independently by LANL, IRSN, and ORNL based upon information provided in the ICSBEP Handbook, 2. are common in S/U libraries for LANL, IRSN, and ORNL, 3. span a range of energy spectrum and fissile material, and 4. taken as applications for the purposes of this study and therefore excluded from use as a benchmark for calculating the upper subcritical limit. Results presented in this paper have been computed using covariance data for all isotopes in ENDF/BVII.0 using a 44-group energy structure. Benchmarks in the Whisper library were run in MCNP6.2 using 100,000 neutrons per cycle, skipping 100 cycles for 500 active cycles. Reference 10 also compares the results for baseline USL with an order of magnitude greater neutrons, using the same total number of cycles with 1,000,000 neutrons per cycle. Subsequent to the results presented in Reference 10 changes were made to the benchmark library, as discussed in Reference 11. Newer results using the revised benchmark library are presented herein.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Convergence acceleration of Monte Carlo many-body perturbation methods by using many control variates

Herein, the use of many control variates is proposed as a method to accelerate the second- and third-order Monte Carlo (MC) many-body perturbation (MC-MP2 and MC-MP3) calculations. A control variate is an exactly integrable function that is strongly correlated or anti-correlated with the target function to be integrated by the MC method. Evaluating both integrals as well as their covariances in the same MC run, one can effect a mutual cancellation of the statistical uncertainties and biases in the MC integrations, thereby accelerating its convergence considerably. Six and thirty-six control variates, whose integrals are known a priori, are generated for MC-MP2 and MC-MP3, respectively, by systematically replacing one or more two-electron-integral vertexes of certain configurations by zero-valued overlap-integral vertexes in their Goldstone diagrams. The variances and co- variances of these control variates are computed at a marginal cost, enhancing the overall efficiency of the MC-MP2 and MC-MP3 calculations by a factor of up to 14 and 20, respectively.

74 ATOMIC AND MOLECULAR PHYSICS↗

Reactivity initiated accident uncertainty quantification for fuel assembly with subchannel code

UNIST CORE lab has developed a multiphysics coupling framework (MPCORE) consisting of Neutronics, Thermal Hydraulics and Fuel Performance modules. It can accommodate one-dimensional as well as sub-channel code Thermal Hydraulics (TH) module. Generally, running a transient requires more computational power due to the convergence of modules with each other. The difference between one-dimensional and sub-channel TH modules is studied in this research for a Reactivity Initiated Accident (RIA). Both TH modules are compared for a RIA uncertainty propagation in a single VERA fuel assembly with 2.11% enrichment. MPCORE is capable of analyzing the transient at any burnup point but for current work, only fresh fuel has been considered. The results have been obtained using dynamic gap heat conductance in FRAPTRAN. Peak centerline temperature, fuel enthalpy and DNBR are compared for both the approaches. The results indicate that the use of sub-channel code lead to greater safety margin for critical parameters. Computation time comparison is also presented for both the cases. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

THERMAL MODELING OF HANFORD LEAD CANISTER’S HEATER BENCH TESTS

A computational fluid dynamics (CFD) model was built to simulate planned testing of heater assemblies for the Hanford Lead Canister (HLC) project. The HLC is a canister storage system that will contain heaters to simulate the decay heat of nuclear material and provide the canister storage system with environmental conditions equivalent to the operating conditions on a dry storage pad. The HLC will be equipped with long-term data collection and monitoring systems to provide an early warning of corrosion, pitting, cracking, or other signs of canister degradation that might threaten the integrity of the containment boundary over the potentially long term of dry storage. An important part of the HLC development is to confirm the function and ability of the electric heater assemblies that were specially designed to provide heating similar to the decay heat of nuclear material contained within the canister storage system. Heater bench testing is planned for early 2022 in a test configuration that does not include the canister. The goal of the bench testing is to verify that the heaters can replicate the decay heat of a canister with nuclear material and to validate the thermal models, which are critical to understanding the HLC’s thermal environment, including the local air flow within the canister storage system. Testing of the heater assemblies inside the canister system are planned in the future to validate canister level thermal models, and rigorous pre-deployment testing of the complete HLC cask and canister system is intended to be completed before the HLC is deployed in the 2025-2026 timeframe. This study presents the pre-test temperature predictions of the bench testing. A description of the heater assemblies and planned bench testing is presented. The model was developed with the commercial CFD code STAR-CCM+. An uncertainty analysis was run with the CFD model to determine the uncertainty in the temperature predictions and provide a range over which the predicted temperatures are expected to vary. The uncertainty analysis was performed by coupling STAR-CCM+ with the software Dakota, which provides advanced parametric analyses, including quantification of margins and uncertainty with computational models. This work is expected to provide insight into SNF canister behavior.

Suffield, Sarah R.↗

THERMAL MODELING OF HANFORD CESIUM AND STRONTIUM CANISTERS DURING SIMULATED LOADING

A computational fluid dynamics (CFD) model was built to simulate planned testing of heater assemblies within a canister and overpack for the Hanford Lead Canister (HLC) project. The HLC is a canister storage system that will contain heaters to simulate the decay heat of nuclear material and provide the canister storage system with environmental conditions equivalent to the operating conditions on a dry storage pad. The HLC will be equipped with long-term data collection and monitoring systems to provide an early warning of corrosion, pitting, cracking, or other signs of canister degradation that might threaten the integrity of the containment boundary over the potentially long term of dry storage. An important part of the HLC development is to make pretest numerical predictions for the behavior of the heated canister during the simulated radiolytic decay heat testing, which simulates the dry storage system during loading operations. The simulated radiolytic decay heat test is planned for mid-2024 in a configuration that includes the heater assembly, overpack, and canister, but with the lids removed to allow loading cesium and strontium capsules into the canister. One of the goals of the test is to evaluate the thermal behavior of the canister and overpack assembly in the ambient air of the test facility, which will provide data critical to validating the thermal models and understanding how the HLC will perform as a system once deployed. To best approximate real-world conditions, the CFD model includes the full air volume of the mock-up truck bay the heated canister test will be performed in, enabling detailed investigation of how the heated canister affects airflow around it. Rigorous pre-deployment testing of the complete HLC cask and canister system is intended to be completed before the HLC is deployed in the 2028 timeframe. This study presents the pre-test temperature predictions of the simulated radiolytic decay heat test. A description of the heater assembly, canister, and overpack system is presented. The model was developed with the commercial CFD software STAR-CCM+. An uncertainty analysis was run with the CFD model to determine the uncertainty in the temperature predictions and provide a range over which the predicted temperatures are expected to vary. The uncertainty analysis was preformed by coupling STAR-CCM+ with the software Dakota, which provides advanced parametric analyses, including quantification of margins and uncertainty with computational models. This work is expected to provide insight into SNF canister behavior.

Carpenter-Graffy, Dina E.↗

S/U Comparison Study with a Focus on USLs

Under a DOE Nuclear Criticality Safety Program (NCSP) task involving Analytical Methods, three Laboratories collaborated in a comparison of results obtained from Sensitivity/Uncertainty (S/U) packages relevant to validation of transport codes. The task involves Institut de Radioprotection et de Sûreté Nucléaire (IRSN), Los Alamos National Laboratory (LANL), and Oak Ridge National Laboratory (ORNL) comparing results of MORET 5/MACSENS V3.0, MCNP6.2/Whisper-1.1, and SCALE 6.2.3/TSUNAMI/USLSTATS respectively. All Monte Carlo transport code results utilize ENDF/B-VII.1. Four cases from the International Handbook of Evaluated Criticality Safety Benchmark Experiments (ICSBEP Handbook) were selected as application models: HEU-MET-FAST-013-001, HEU-SOL-THERM 001-008, PU-MET-FAST-022-001, and PU-SOL-THERM 001-001. Ultimately, comparison is made between Upper Subcritical Limits (USLs) obtained using each code package for each application case. Since differences exist in whether packages take into account margin of subcriticality (MOS), the USL may be computed using bias and bias uncertainty, also known as the calculational margin (CM) in ANSI/ANS 8.24. Application of portions of MOS to the USL for nuclear data uncertainty of and potential code margin is referred to as USL herein. In either case, additional MOS is considered for actual application cases.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Benchmark Specification for FFTF LOFWOS Test #13

The Fast Flux Test Facility (FFTF) at the Hanford site in Washington was designed by the Westinghouse Electric Corporation for the U.S. Department of Energy. FFTF was a 400 MW thermal, oxide-fueled, liquid sodium cooled test reactor, built to assist development and testing of advanced fuels and materials for fast breeder reactors. After reaching criticality in 1980, FFTF operated until 1992, providing the U.S. Department of Energy (DOE) with the means to test fuels, materials, and other components in a fast neutron flux environment. In July 1986, a series of unprotected transients (with the plant protection system intentionally disabled) were performed in FFTF as part of the passive safety demonstration program. Among these were thirteen loss of flow without scram (LOFWOS) tests. The goals of this program included confirming the liquid metal reactor safety margins, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of specific design features. The test defined in this benchmark is LOFWOS Test #13, which was initiated at 50% power and 100% flow with the pump pony motors turned off. This benchmark specification is intended to support collaborative efforts within international partnerships on the validation of simulation tools and models in the area of Sodium-cooled Fast Reactor (SFR) safety. Validated tools and models are needed to evaluate SFR inherent safety characteristics and assess the impact of passive design features in response to accident initiators. Comparisons with experimental data and the results of safety analyses from other groups create unique opportunities to improve predictive capabilities of computational codes and methods for SFR modeling and simulation. The conditions of the LOFWOS test along with the feedback from FFTF’s limited free bow core restraint system and the novel passive reactivity control Gas-Expansion Modules (GEMs) pose a very challenging and uniquely valuable benchmark exercise.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

UPDATES FROM THE INVOLUTE WORKING GROUP

The HFIR, RHF, and FRM II reactors represent a particular class of Research and Test Reactors that provide some of the most intense and continuous neutron fluxes for science, industry, and medical applications. These high-performance reactors have achieved compact cores by operating with Highly Enriched Uranium fuel (HEU, 235U/U ≥ 20 wt. %) and utilizing fuel plates curved as an involute. Due to the proliferation risks, the international community aims to reduce or eliminate, when possible, the use of HEU fuel in civilian facilities by converting them to a Low-Enriched Uranium fuel (LEU, 235U/U < 20 wt. %). Conversion of these reactors without significantly compromising their performance or safety is a challenging endeavor that can tremendously benefit from advanced computational tools and thus, eliminate unnecessary conservatism to ensure sufficient thermal margins. Therefore, models are being developed using modern Computational Fluid Dynamics (CFD) and Computational Structural Mechanics (CSM) software to evaluate the steady-state safety margins of various LEU designs instead of being reliant on the more traditional, conservative methods. To gain the confidence and acceptance of high-fidelity modeling by the nuclear regulators, Argonne National Laboratory (ANL) and the involute reactors have formed an informal scientific group, the Involute Working Group (IWG). The IWG facilitates inter-organizational collaboration on experimental benchmarking, code-to-code comparisons, and Verification and Validation (V&V). This paper describes some of the recent IWG efforts in validating software against the existing experimental data, as well as code-to-code comparisons of different software used by the IWG members.

Bergeron, Aurelien↗

Sensitivity/Uncertainty Comparison Study Involving IRSN, LANL, and ORNL Tools to Support Validation

Under a DOE Nuclear Criticality Safety Program (NCSP) task involving Analytical Methods, three Laboratories collaborated in a comparison of results obtained from Sensitivity/Uncertainty (S/U) packages relevant to validation of transport codes. The task involves Institut de Radioprotection et de Sûreté Nucléaire (IRSN), Los Alamos National Laboratory (LANL), and Oak Ridge National Laboratory (ORNL) comparing results of MORET 5/MACSENS V3.0, MCNP6.2/Whisper-1.1, and SCALE 6.2.3/TSUNAMI/USLSTATS respectively. All Monte Carlo transport code results utilize nuclear data from ENDF/B-VII.1 evaluation. This study examines five cases from the International Handbook of Evaluated Criticality Safety Benchmark Experiments (ICSBEP Handbook) selected as application models: IEU-MET- FAST-002-001, LEU-COMP-THERM-001-001, LEU-SOL-THERM-004-001, MIX-COMP- THERM-001-001, and U233-SOL-THERM-001-001. This is a continuation of a previous study to examine Pu and HEU cases: HEU-MET-FAST-013-001, HEU-SOL-THERM-001-008, PU-MET- FAST-022-001, and PU-SOL-THERM-001-001. Ultimately, comparison is made between Upper Subcritical Limits (USLs) obtained using each code package for each application case. Since differences exist in whether packages take into account margin of subcriticality (MOS), the USL is computed using only bias and bias uncertainty, also known as the calculational margin (CM) in ANSI/ANS-8.24. Results comparison appears to show that benchmark selection has a greater influence on the USL than the method used for calculation of bias and bias uncertainty.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Light in the dark forest. Part I. An efficient optimal estimator for 3D Lyman-alpha forest power spectrum

The highly anisotropic nature of the Lyman-alpha (Lyα) forest data introduces a complex survey window function that complicates the measurement of the three-dimensional power spectrum ( P 3D ). In this paper, we present the first fully optimal estimator for P 3D , which exactly deconvolves the survey window function and marginalizes contaminated modes that distort the power spectrum. Our approach adapts optimal estimator techniques developed for the 2D cosmic microwave background data to the 3D case. To achieve computational feasibility, we employ the conjugate gradient method and implement the P 3 M formalism to handle large-scale and small-scale operations separately and efficiently. We validate our estimator using Monte Carlo mocks and Gaussian simulations, demonstrating its accuracy and computational efficiency. We confirm that mode marginalization eliminates distortions arising from quasar continuum errors and delivers robust power spectrum estimation, though it also inflates errors at large scales. This first implementation works in the flat-sky case; we discuss the remaining steps needed to generalize it to the curved-sky case. This formalism offers a foundation for the Lyα forest P 3D measurements and a new path toward cosmological constraints from the Lyα forest data.

Lyman alpha forest↗

Green AI: Insights Into Deep Learning's Looming Energy Efficiency Crisis

As demands grow to integrate artificial intelligence into every aspect of industry, commerce, and life, deep learning's exploding energy cost has become a looming crisis, making AI systems a salient energy-efficiency challenge. One might expect that doubling a neural network's size would halve its error rate, or at least allow it to achieve greater performance given the same amount of time and energy. I will present clear and substantial scientific evidence which indicates that not only is this intuition wildly wrong, but that neural networks scale so poorly that to increase deep learning performance by only a small fraction can easily require an order of magnitude or more increase in computational resources and energy. Further, the marginal trade-off price of to increase model performance rapidly explodes as performance targets are increased. To address this challenge, I will provide a toolkit of techniques that can be applied today to mitigate the inefficiency of modern deep learning. And, I will conclude by illuminating a practical path forward towards efficient, Green AI.

artificial intelligence↗

Accurate and efficient predictions of keyhole dynamics in laser materials processing using machine learning-aided simulations

The keyhole phenomenon has been widely observed in laser materials processing, including laser welding, remelting, cladding, drilling, and additive manufacturing. Keyhole-induced defects, primarily pores, dramatically affect the performance of final products, impeding the broad use of these laser-based technologies. The formation of these pores is typically associated with the dynamic behavior of the keyhole. So far, the accurate characterization and prediction of keyhole features, particularly keyhole depth, as a function of time, has been a challenging task. In situ characterization of keyhole dynamic behavior using the synchrotron X-ray technique is informative but complicated and expensive. Current simulations are generally hindered by their poor accuracy and generalization abilities in predicting keyhole depths due to the lack of accurate laser absorptance data. In this study, we develop a machine learning-aided simulation method that accurately predicts keyhole dynamics, especially in keyhole depth fluctuations, over a wide range of processing parameters. In two case studies involving titanium and aluminum alloys, we achieve keyhole depth prediction with a mean absolute percentage error of 10 %, surpassing those simulated using the ray-tracing method with an error margin of 30 %, while also reducing computational time. This exceptional fidelity and efficiency empower our model to serve as a cost-effective alternative to synchrotron experiments. Our machine learning-aided simulation method is affordable and readily deployable for a large variety of materials, opening new doors to eliminate or reduce defects for a wide range of laser materials processing techniques.

Computational fluid dynamics↗