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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Real-Time Sea State Estimation for Wave Energy Converter Control via Machine Learning

Wave energy converters (WECs) harness the untapped power of ocean waves to generate renewable energy, offering a promising solution to sustainable energy. An optimal WEC control strategy is essential to maximize power capture that dynamically adjusts system parameters in response to rapidly changing sea states. This study presents a novel control approach that leverages neural networks to estimate sea states from onboard WEC measurements such as position, velocity, and force. Using a point absorber WEC device as a test platform, our proposed approach estimates sea states in real-time and subsequently adjusts PID controller gains to maximize energy extraction. Simulation results across diverse sea conditions demonstrate that our strategy eliminates the need for external wave monitoring equipment while maintaining power capture efficiency. The results show that our neural network-based control technique can improve power capture by 25.6% while significantly reducing system complexity. This approach offers a practical alternative for WEC deployments where direct wave measurements are either infeasible or cost prohibitive.

PIDcontrol↗
DOE OSTI2024

MLOps for Beam Controls

Machine learning operations (MLOps) is the standardization and streamlining of the ML development lifecycle to address the challenges associated with large-scale machine learning applications. The full MLOps pipeline consists of open-source tools: DataHub, MinIO and MLflow. It is being used for dataset management and model development to handle changing data dependencies, varying business needs, reproducibility, and diverse teams working with differing tools and skills. To demonstrate the completion of an MLOps pipeline for particle accelerator operations, we are deploying a simple script that computes settings for the Booster’s gradient magnet power supply. Once the demonstration is complete, we will develop and deploy ML-based optimization algorithms to improve Booster’s overall efficiency. This MLOps pipeline opens the gate to systematically develop and deploy ML applications for accelerator controls and diagnostics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

MLOps for Beam Controls

Machine learning operations (MLOps) is the standardization and streamlining of the ML development lifecycle to address the challenges associated with large-scale machine learning applications. The full MLOps pipeline consists of open-source tools: DataHub, MinIO and MLflow. It is being used for dataset management and model development to handle changing data dependencies, varying business needs, reproducibility, and diverse teams working with differing tools and skills. To demonstrate the completion of an MLOps pipeline for particle accelerator operations, we are deploying a simple script that computes settings for the Booster’s gradient magnet power supply. Once the demonstration is complete, we will develop and deploy ML-based optimization algorithms to improve Booster’s overall efficiency. This MLOps pipeline opens the gate to systematically develop and deploy ML applications for accelerator controls and diagnostics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

MLOps for Beam Controls

Machine learning operations (MLOps) is the standardization and streamlining of the ML development lifecycle to address the challenges associated with large-scale machine learning applications. The full MLOps pipeline consists of open-source tools: DataHub, MinIO and MLflow. It is being used for dataset management and model development to handle changing data dependencies, varying business needs, reproducibility, and diverse teams working with differing tools and skills. To demonstrate the completion of an MLOps pipeline for particle accelerator operations, we are deploying a simple script that computes settings for the Booster’s gradient magnet power supply. Once the demonstration is complete, we will develop and deploy ML-based optimization algorithms to improve Booster’s overall efficiency. This MLOps pipeline opens the gate to systematically develop and deploy ML applications for accelerator controls and diagnostics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Overview of the KSTAR experiments toward fusion reactor

The Korean Superconducting Tokamak Advanced Research has been focused on exploring the key physics and engineering issues for future fusion reactors by demonstrating the long pulse operation of high beta steady-state discharge. Advanced scenarios are being developed with the goal for steady-state operation, and significant progress has been made in high ℓ i , hybrid and high beta scenarios with β N of 3. In the new operation scenario called fast ion regulated enhanced (FIRE), fast ions play an essential role in confinement enhancement. GK simulations show a significant reduction of the thermal energy flux when the thermal ion fraction decreases and the main ion density gradient is reversed by the fast ions in FIRE mode. Optimization of 3D magnetic field techniques, including adaptive control and real-time machine learning control algorithm, enabled long-pulse operation and high-performance ELM-suppressed discharge. Symmetric multiple shattered pellet injections (SPIs) and real-time disruption event characterization and forecasting are being performed to mitigate and avoid the disruptions associated with high-performance, long-pulse ITER-like scenarios. Finally, the near-term research plan will be addressed with the actively cooled tungsten divertor, a major upgrade of the NBI and helicon current drive heating, and transition to a full metallic wall.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Initial testing of Alfvén eigenmode feedback control with machine-learning observers on DIII-D

A first of its kind fully data-driven system has been developed and implemented into the DIII-D plasma control system to detect and control Alfvén eigenmodes (AE) in real-time. Susceptibility to fast ion-induced AE is a challenge in fully non-inductive tokamak operation, which significantly reduces fast-particle confinement and results in degraded fusion gain. Controlling AEs in real-time to improve fast-ion confinement is, hence, important for future advanced tokamak fusion reactors. The models were implemented and tested in experiments which showed that neural networks (NN) are highly effective in detecting 5 types of AE (BAE, EAE, LFM, RSAE, TAE) using high resolution ECE. To estimate the neutron deficit, a NN has been trained that outputs the classical neutron rate using similar inputs to NUBEAM. Also a preliminary ML-based proportional control has been designed and gone through initial testing in experiment to use feedback-control on the neutral beam power to achieve desired amplitude of AE modes and neutron deficits. The effect of AEs on fast-ion confinement is measured by analysing the gap in classical neutron rate from the proposed NN-based NUBEAM and the measured neutron rate.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Performance Evaluation of Vertical Federated Machine Learning Against Adversarial Threats on Wide-Area Control System: Preprint

Federated machine learning (FL) is gaining significant popularity to develop cybersecurity solutions in power grids because of its advanced capability to support decentralized data handing at local devices, its privacy preservation, and its low-bandwidth requirement. However, the evolving adversarial machine learning (AML) threats raise significant concerns for the cybersecurity of FL architectures. The FL-based split neural network (SplitNN) achieves high performance through the decentralized training of local neural network models while preserving data privacy across multiple entities. In this paper, we propose a methodology for evaluating the performance of a vertical FLbased anomaly detector against different types of AML attacks, including denial-of-service attacks, adversarial data injection attacks, and replay attacks on the trained local models deployed in the grid network. For a case study, we consider the modified IEEE 13-bus system, and we develop SplitNN-based binary and multiclass classification models to detect, locate, and identify different types of data integrity attacks on the volt-watt control with two pooling layers: maximum pooling and AvgPool. Our experimental results, computed through performance metrics, reveal that the severity of these AML attacks varies with the integrated pooling mechanism, the type of classification model, and the nature of the cyberattack. Further, the AML attacks negatively impacted the prediction time per sample for the pretrained SplitNN during the online testing.

adversarial threats↗
DOE OSTI2025

Xopt and Badger: a machine learning ecosystem for real-time accelerator control and optimization

Machine learning (ML)-based black-box optimization algorithms have demonstrated significant improvements in accelerator optimization speed, often by orders of magnitude. However, deploying these algorithms in real-time facility control remains challenging due to the specialized expertise and infrastructure required. To bridge this gap, we introduce the Xopt ecosystem, a versatile suite of tools designed to make advanced ML-based optimization accessible to the broader accelerator community. This ecosystem includes Xopt, a modular Python framework that facilitates the integration of ML-based optimization algorithms with arbitrary control problems, and Badger, a graphical user interface built on top of Xopt, which enables seamless deployment of ML algorithms in real-time control systems. The Xopt ecosystem has been successfully applied towards solving challenging real-time control problems at leading international accelerator facilities, including SLAC, LBNL, Argonne, Fermilab, BNL, DESY, and ESRF, demonstrating its effectiveness in real-world optimization tasks. In this presentation, we provide an overview of Xopt’s capabilities and illustrate its impact through case studies from SLAC accelerator facilities including LCLS, LCLS-II, and FACET-II.

Roussel, Ryan [SLAC]↗
DOE OSTI2025

Safe Physics-Informed Machine Learning for Dynamics and Control

This tutorial paper focuses on safe physics-informed machine learning in the context of dynamics and control, providing a comprehensive overview of how to integrate physical models and safety guarantees. As machine learning techniques enhance the modeling and control of complex dynamical systems, ensuring safety and stability remains a critical challenge, especially in safety-critical applications like autonomous vehicles, robotics, medical decision-making, and energy systems. We explore various approaches for embedding and ensuring safety constraints, including structural priors, Lyapunov and Control Barrier Functions, predictive control, projections, and robust optimization techniques. Additionally, we delve into methods for uncertainty quantification and safety verification, including reachability analysis and neural network verification tools, which help validate that control policies remain within safe operating bounds even in uncertain environments. The paper includes illustrative examples demonstrating the implementation aspects of safe learning frameworks that combine the strengths of data-driven approaches with the rigor of physical principles, offering a path toward the safe control of complex dynamical systems.

Drgona, Jan↗
DOE OSTI2024

Machine learning for reducing noise in RF control signals at industrial accelerators

Industrial particle accelerators typically operate in dirtier environments than research accelerators, leading to increased noise in RF and electronic systems. Furthermore, given that industrial accelerators are mass produced, less attention is given to optimizing the performance of individual systems. As a result, industrial accelerators tend to underperform their own hardware capabilities. Improving signal processing for these machines will improve cost and time margins for deployment, helping to meet the growing demand for accelerators for medical sterilization, food irradiation, cancer treatment, and imaging. Our work focuses on using machine learning techniques to reduce noise in RF signals used for pulse-to-pulse feedback in industrial accelerators. Here we review our algorithms and observed results for simulated RF systems, and discuss next steps with the ultimate goal of deployment on industrial systems.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Fast Machine Learning for Quantum Control of Microwave Qudits on Edge Hardware

Quantum optimal control is a promising approach to improve the accuracy of quantum gates, but it relies on complex algorithms to determine the best control settings. CPU or GPU-based approaches often have delays that are too long to be applied in practice. It is paramount to have systems with extremely low delays to quickly and with high fidelity adjust quantum hardware settings, where fidelity is defined as overlap with a target quantum state. Here, we utilize machine learning (ML) models to determine control-pulse parameters for preparing Selective Number-dependent Arbitrary Phase (SNAP) gates in microwave cavity qudits, which are multi-level quantum systems that serve as elementary computation units for quantum computing. The methodology involves data generation using classical optimization techniques, ML model development, design space exploration, and quantization for hardware implementation. Our results demonstrate the efficacy of the proposed approach, with optimized models achieving low gate trace infidelity near $10^{-3}$ and efficient utilization of programmable logic resources.

Sanders, Flor [Columbia U.]↗
DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2026

Enabling integrated AI control on DIII-D: a control system design with state-of-the-art experiments

We present the design and application of a general algorithm for Prediction And Control using MAchiNe learning (PACMAN) in DIII-D. Machine learning (ML)-based predictors and controllers have shown great promise in achieving regimes in which traditional controllers fail, such as tearing mode (TM) free scenarios, ELM-free scenarios and stable advanced tokamak conditions. The architecture presented here was deployed on DIII-D to facilitate the end-to-end implementation of advanced control experiments, from diagnostic processing to final actuation commands. This paper describes the detailed design of the algorithm and explains the motivation behind each design point. We also describe several successful ML control experiments in DIII-D using this algorithm, including a reinforcement learning controller targeting advanced non-inductive plasmas, a wide-pedestal quiescent H-mode ELM predictor, an Alfvén Eigenmode controller, a Model Predictive Control plasma profile controller and a state-machine TM predictor-controller. There is also discussion on guiding principles for real-time ML controller design and implementation.

machine learning↗
DOE OSTI2024

A tutorial review of machine learning-based model predictive control methods

Abstract This tutorial review provides a comprehensive overview of machine learning (ML)-based model predictive control (MPC) methods, covering both theoretical and practical aspects. It provides a theoretical analysis of closed-loop stability based on the generalization error of ML models and addresses practical challenges such as data scarcity, data quality, the curse of dimensionality, model uncertainty, computational efficiency, and safety from both modeling and control perspectives. The application of these methods is demonstrated using a nonlinear chemical process example, with open-source code available on GitHub. The paper concludes with a discussion on future research directions in ML-based MPC.

Wu, Zhe [Department of Chemical and Biomolecular E↗
DOE OSTI2025

Detecting Masquerade Attacks in Controller Area Networks Using Graph Machine Learning

Modern vehicles rely on a myriad of electronic control units (ECUs) interconnected via controller area networks (CANs) for critical operations. Despite their ubiquitous use and reliability, CANs are susceptible to sophisticated cyberattacks, particularly masquerade attacks, which inject false data that mimic legitimate messages at the expected frequency. These attacks pose severe risks such as unintended acceleration, brake deactivation, and rogue steering. Traditional intrusion detection systems (IDS) often struggle to detect these subtle intrusions due to their seamless integration into normal traffic. This paper introduces a novel framework for detecting masquerade attacks in the CAN bus using graph machine learning (ML). We hypothesize that the integration of shallow graph embeddings with time series features derived from CAN frames enhances the detection of masquerade attacks. We show that by representing CAN bus frames as message sequence graphs (MSGs) and enriching each node with contextual statistical attributes from time series, we can enhance detection capabilities across various attack patterns compared to using graph-based features only. Our method ensures a comprehensive and dynamic analysis of CAN frame interactions, improving robustness and efficiency. Extensive experiments on the ROAD dataset validate the effectiveness of our approach, demonstrating statistically significant improvements in the detection rates of masquerade attacks compared to a baseline that uses graph-based features only as confirmed by Mann-Whitney U and Kolmogorov-Smirnov tests (p < 0.05) .

Marfo, William [Univ. of Texas, El Paso, TX (Unite↗