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Results for “Additive Process Modeling”

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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Two stochastic models useful in petroleum exploration

A model of the petroleum exploration process that tests empirically the hypothesis that at an early stage in the exploration of a basin, the process behaves like sampling without replacement is proposed along with a model of the spatial distribution of petroleum reserviors that conforms to observed facts. In developing the model of discovery, the following topics are discussed: probabilitistic proportionality, likelihood function, and maximum likelihood estimation. In addition, the spatial model is described, which is defined as a stochastic process generating values of a sequence or random variables in a way that simulates the frequency distribution of areal extent, the geographic location, and shape of oil deposits

Kaufman, G. M.↗
NASA NTRS1996

Advanced waste management technology evaluation

The purpose of this program is to evaluate the feasibility of steam reforming spacecraft wastes into simple recyclable inorganic salts, carbon dioxide and water. Model waste compounds included cellulose, urea, methionine, Igapon TC-42, and high density polyethylenes. These are compounds found in urine, feces, hygiene water, etc. The gasification and steam reforming process used the addition of heat and low quantities of oxygen to oxidize and reduce the model compounds.The studied reactions were aimed at recovery of inorganic residues that can be recycled into a closed biologic system. Results indicate that even at very low concentrations of oxygen (less than 3%) the formation of a carbonaceous residue was suppressed. The use of a nickel/cobalt reforming catalyst at reaction temperature of 1600 degrees yielded an efficient destruction of the organic effluents, including methane and ammonia. Additionally, the reforming process with nickel/cobalt catalyst diminished the noxious odors associated with butyric acid, methionine and plastics.

Couch, H.↗
DOE OSTI2025

A quality-agnostic combinatoric cost estimation model for large-format directed energy deposition metal additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) processes are amenable to synergistic combination into multi-process AM systems due to similar requirements for automation and energy sources. This work analyzes the economic performance of such DED AM systems from a quality-agnostic combinatoric standpoint with a model that calculates lowest-cost system combinations based on part geometry and process performance metrics. Common DED AM systems research focuses on a single process and does not consider the process, system, and application in the context of all possible system combinations (e.g., the combined set of process selection(s), motion system(s), and process hardware), leading to limited applicability of the resulting DED AM systems to cost-sensitive components such as those found in energy generation applications. The model developed herein incorporates the capital, material, and energy costs associated with DED AM system combinations into a predictive tool for estimating part and system cost, the output of which is intended to guide deployment of finite research and development resources towards DED AM system combinations with the lowest costs and greatest likelihood of economic impact. The DED AM systems identified by this framework may enable domestic production of the large conventionally cast and forged components necessary for energy generation.

Shanafield, Alexandra [ORNL]↗
DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Machine Learning Framework for Characterizing Processing–Structure Relationship in Block Copolymer Thin Films

The morphology of block copolymers (BCPs) critically influences material properties and applications. This work introduces a machine learning (ML)-enabled, high-throughput framework for analyzing grazing incidence small-angle X-ray scattering (GISAXS) data and atomic force microscopy (AFM) images to characterize BCP thin film morphology. A convolutional neural network was trained to classify AFM images by surface features, achieving 97% testing accuracy. Classified images were then analyzed to extract 2D grain size measurements from the samples in a high-throughput manner. ML models were trained to predict domain orientation based on processing parameters such as solvent ratio, additive type, and additive ratio. GISAXS-based properties were predicted with strong performances (R 2 > 0.75), while AFM-based property predictions were less accurate (R 2 < 0.60), likely due to the localized nature of AFM measurements compared to the bulk information captured by GISAXS. Beyond model performance, interpretability was addressed using SHapley Additive exPlanations (SHAP). SHAP analysis revealed that the additive ratio had the largest impact on morphological predictions, where additive provides the BCP chains with increased volume to rearrange into thermodynamically favorable morphologies. This interpretability helps validate model predictions and offers insight into parameter importance. Altogether, the presented framework combining high-throughput characterization and interpretable ML offers an approach to exploring and optimizing BCP thin film morphology across a broad processing landscape.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluating Large‐Storm Dominance in High‐Resolution GCMs and Observations Across the Western Contiguous United States

Abstract Extreme precipitation events are projected to increase in frequency across much of the land‐surface as the global climate warms, but such projections have typically relied on coarse‐resolution (100–250 km) general circulation models (GCMs). The ensemble of HighResMIP GCMs presents an opportunity to evaluate how a more finely resolved atmosphere and land‐surface might enhance the fidelity of the simulated contribution of large‐magnitude storms to total precipitation, particularly across topographically complex terrain. Here, the simulation of large‐storm dominance, that is, the number of wettest days to reach half of the total annual precipitation, is quantified across the western United States (WUS) using four GCMs within the HighResMIP ensemble and their coarse resolution counterparts. Historical GCM simulations (1950–2014) are evaluated against a baseline generated from station‐observed daily precipitation (4,803 GHCN‐D stations) and from three gridded, observationally based precipitation data sets that are coarsened to match the resolution of the GCMs. All coarse‐resolution simulations produce less large‐storm dominance than in observations across the WUS. For two of the four GCMs, bias in the median large‐storm dominance is reduced in the HighResMIP simulation, decreasing by as much as 62% in the intermountain west region. However, the other GCMs show little change or even an increase (+28%) in bias of median large‐storm dominance across multiple sub‐regions. The spread in differences with resolution amongst GCMs suggests that, in addition to resolution, model structure and parameterization of precipitation generating processes also contribute to bias in simulated large‐storm dominance.

Environmental Sciences & Ecology↗
DOE OSTI2024

Uncertainty Propagation from Experiment Measurements to Modeling Approaches: A Case for SMR Steam Entrainment Testing

To license new and advanced reactor designs, regulators must be convinced that their unique safety cases—relative to existing large scale reactors—have been adequately addressed by the designed reactor protection systems. In water cooled small modular reactors (SMRs), droplet entrainment in steam flow has significant implications on the progression of accident scenarios due to its compact design features, which requires representative test data applicable to SMR designs. Computer code, modeling and simulation (M&S) tools and models require adequate verification, assessment, and qualification. This includes M&S results validation against scaled empirical data within allowable uncertainty bands to gain regulatory approvals during the various stages of reactor system design, demonstration, and commercialization. However, measurement uncertainty within the empirical datasets and test data applicability ranges requires careful consideration of M&S inputs (i.e., boundary conditions, and initial conditions), and verification and validation efforts. This study focuses on uncertainty quantification in designing scaled test facilities for SMR applications with appropriate measurements and a standard data-reduction method to estimate thermal hydraulics characteristics parameters that incorporate physics phenomena of interest. In addition, this study supports the evaluation model development and assessment process using M&S that interfaces with advanced computing tools and digital twin capabilities. This will allow synchronization between experiment and modeling approaches for droplet entrainment testing and analysis, improving diagnostics, prognostics, and decision-making to accelerate regulatory approval.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Strategic Petroleum Reserve Cavern Leaching Monitoring CY24

This report provides an analysis of the effects of raw water leaching at the U.S. SPR using the Sandia Solution Mining Code (SANSMIC). A new version of the code has been established in the past year (implemented in Python and C++ code) and was used for this annual report. Additionally, the setup, running, and post-processing of leaching modeling has now been streamlined into a single Python notebook environment for each cavern run.

58 GEOSCIENCES↗
NASA NTRS1989

Design of LQG controllers with reduced parameter sensitivity

A method is presented for improving the tolerance of LQG controllers to parameter errors. The improvement is achieved by introducing terms reflecting the structure of the errors into the LQR cost function and the process and measurement noise models. Adjusting the sizes of these additional terms permits a tradeoff between robustness and nominal performance.

Lin, J. Y.↗
NASA NTRS2010

Interactions Between Mineral Dust, Climate, and Ocean Ecosystems

Over the past decade, technological improvements in the chemical and physical characterization of dust have provided insights into a number of phenomena that were previously unknown or poorly understood. In addition, models are now incorporating a wider range of physical processes, which will allow us to better quantify the climatic and ecological impacts of dust. For example, some models include the effect of dust on oceanic photosynthesis and thus on atmospheric CO 2 (Friedlingstein et al. 2006). The impact of long-range dust transport, with its multiple forcings and feedbacks, is a relatively new and complex area of research, where input from several disciplines is needed. So far, many of these effects have only been parameterized in models in very simple terms. For example, the representation of dust sources remains a major uncertainty in dust modeling and estimates of the global mass of airborne dust. This is a problem where Earth scientists could make an important contribution, by working with climate scientists to determine the type of environments in which easily erodible soil particles might have accumulated over time. Geologists could also help to identify the predominant mineralogical composition of dust sources, which is crucial for calculating the radiative and chemical effects of dust but is currently known for only a few regions. Understanding how climate and geological processes control source extent and characterizing the mineral content of airborne dust are two of the fascinating challenges in future dust research.

Gasso, Santiago↗
NASA NTRS2014

Investigation into the Use of the Concept Laser QM System as an In-Situ Research and Evaluation Tool

The NASA Marshall Space Flight Center (MSFC) is using a Concept Laser Fusing (Cusing) M2 powder bed additive manufacturing system for the build of space flight prototypes and hardware. NASA MSFC is collecting and analyzing data from the M2 QM Meltpool and QM Coating systems for builds. This data is intended to aide in understanding of the powder-bed additive manufacturing process, and in the development of a thermal model for the process. The QM systems are marketed by Concept Laser GmbH as in-situ quality management modules. The QM Meltpool system uses both a high-speed near-IR camera and a photodiode to monitor the melt pool generated by the laser. The software determines from the camera images the size of the melt pool. The camera also measures the integrated intensity of the IR radiation, and the photodiode gives an intensity value based on the brightness of the melt pool. The QM coating system uses a high resolution optical camera to image the surface after each layer has been formed. The objective of this investigation was to determine the adequacy of the QM Meltpool system as a research instrument for in-situ measurement of melt pool size and temperature and its applicability to NASA's objectives in (1) Developing a process thermal model and (2) Quantifying feedback measurements with the intent of meeting quality requirements or specifications. Note that Concept Laser markets the system only as capable of giving an indication of changes between builds, not as an in-situ research and evaluation tool. A secondary objective of the investigation is to determine the adequacy of the QM Coating system as an in-situ layer-wise geometry and layer quality evaluation tool.

Bagg, Stacey↗
NASA NTRS2017

Microphysics in Goddard Multi-Scale Modeling Systems

Advances in computing power allow atmospheric prediction and general circulation models to be run at progressively finer scales of resolution, using increasingly more sophisticated physical parameterizations. The representation of cloud microphysical processes is one of key components of these models. In addition, over the past decade both research and operational numerical weather prediction models have started using more complex microphysical schemes that were originally developed for high-resolution cloud-resolving models (CRMs). In the paper, we described different microphysics schemes that are used in Goddard Multi-scale Modeling System. There are three major models, Goddard Cumulus Ensemble (GCE), NASA Unified Weather Research Forecast (NU-WRF) and Multi-scale Modeling Framework (MMF) model, in this modeling system. The microphysics schemes are Goddard three class ice (3ICE) and four class (4ICE) scheme, Morrison two moments (2M) 3ICE, Colorado State University Regional Atmospheric Modeling System (RAMS) 2M five class ice (5ICE) and spectral bin microphysics schemes. The performance of these schemes are examined and compared with radar and satellite observation. In addition, the inter-comparison with different microphysics schemes are conducted. Current and future observations needed for microphysics schemes evaluation as well as major characteristics of current microphysics are discussed.

Tao, W.-K.↗
NASA NTRS2018

Cassini In-Flight Navigation Adaptations

In the nearly two decades of Cassini flight, adaptations to navigation processes were applied as characteristics unique to Cassini were identified and spacecraft configuration changes were implemented. Additionally, operational experience was leveraged into more efficient processes, better modeling, and more robust contingency strategies. Trajectory adjustments were implemented to allow further investigation of surprising science discoveries meriting more attention. Unique analyses were performed to determine how to best accomplish atypical science observations while maintaining acceptable risk levels. Descriptions of the most significant adaptations are organized according to the affected navigation subsystems: trajectory design, orbit determination, optical navigation, and maneuver design.

Wagner, Sean↗
NASA NTRS2016

The Evolution of the NASA Commercial Crew Program Mission Assurance Process

In 2010, the National Aeronautics and Space Administration (NASA) established the Commercial Crew Program (CCP) in order to provide human access to the International Space Station and low Earth orbit via the commercial (non-governmental) sector. A particular challenge to NASA has been how to determine that the Commercial Provider's transportation system complies with programmatic safety requirements. The process used in this determination is the Safety Technical Review Board which reviews and approves provider submitted hazard reports. One significant product of the review is a set of hazard control verifications. In past NASA programs, 100% of these safety critical verifications were typically confirmed by NASA. The traditional Safety and Mission Assurance (S&MA) model does not support the nature of the CCP. To that end, NASA S&MA is implementing a Risk Based Assurance process to determine which hazard control verifications require NASA authentication. Additionally, a Shared Assurance Model is also being developed to efficiently use the available resources to execute the verifications.

Mission Assurance↗
DOE OSTI2026

Microstructure Validation of Graph Theory Model-Derived Cooling Rates in the Wire Arc Additive Manufacturing of ER70S-6 Steel

Wire arc additive manufacturing (WAAM) enables high-rate fabrication of large metallic components, but spatial variations in thermal history can lead to microstructural heterogeneity that requires efficient process models to evaluate. This study evaluates whether cooling rates extracted from a graph theory model (GTM)-based thermal simulation are consistent with the microstructural evolution observed in an ER70S-6 WAAM wall. Thermal histories from the model were analyzed at selected build heights, and cooling rates were extracted from the final thermal excursion through the austenite phase field. Microstructures at corresponding locations were characterized using electron backscatter diffraction (EBSD) to quantify grain size distributions, and pearlite interlamellar spacing was used as an additional indicator of cooling behavior. The modeled cooling rates were highest near the substrate and generally decreased with build height, consistent with the observed reduction in the fine grain fraction and the progressive shift in the grain size distribution as build height increased. Pearlite spacing trends also supported the modeled cooling rate variation. These results indicate that GTM-derived thermal histories can be post-processed into metallurgically meaningful cooling rate estimates for WAAM steel builds and linked to dataset specific empirical grain size distribution relationships for process–thermal history–microstructure assessment.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Wasserstein normalized autoencoder for anomaly detection

A novel anomaly detection algorithm is presented. The Wasserstein normalized autoencoder (WNAE) is a normalized probabilistic model that minimizes the Wasserstein distance between the learned probability distribution—a Boltzmann distribution where the energy is the reconstruction error of the autoencoder (AE)—and the distribution of the training data. This algorithm has been developed and applied to the identification of semivisible jets—conical sprays of visible standard model (SM) particles and invisible dark matter states—with the CMS experiment at the CERN LHC. Trained on jets of particles from simulated SM processes, the WNAE is shown to learn the probability distribution of the input data in a fully unsupervised fashion, such that it effectively identifies new physics jets as anomalies. The model exhibits stable, convergent training and recovers strong classification performance for a wide range of signals against the selected background process, for which a standard AE fails because of outlier reconstruction. In addition, the model improves upon standard normalized autoencoders while remaining fully agnostic to the signal. The WNAE directly tackles the problem of outlier reconstruction, a common failure mode of autoencoders in anomaly detection tasks.

Hayrapetyan, Aram [Yerevan Phys. Inst.]↗
NASA NTRS2003

Computational Analysis of Cryogenic Flow Through a Control Valve

The initial efforts to develop the capability to model valves used in rocket engine component testing at Stennis Space Center are documented. An axisymmetric model of a control valve with LN2 as the working fluid was developed. The goal was to predict the effect of change in the plug/sear region of the valve prior to testing. The valve flow coefficient was predicted for a range of plug positions. Verification of the calculations was carried out to quantify the uncertainty in the numerical answer. The modeled results compared well qualitatively to experimental trends. Additionally, insights into the flow processes in the valve were obtained. Benefits from the verification process included the ability to use coarser grids and insight into ways to reduce computational time by using double precision accuracy and non-integer grid ratios. Future valve modeling activities will include shape optimization of the valve/seat region and dynamic grid modeling.

Danes, Russell↗
NASA NTRS2004

Turnaround Time Modeling for Conceptual Rocket Engines

Recent years have brought about a paradigm shift within NASA and the Space Launch Community regarding the performance of conceptual design. Reliability, maintainability, supportability, and operability are no longer effects of design; they have moved to the forefront and are affecting design. A primary focus of this shift has been a planned decrease in vehicle turnaround time. Potentials for instituting this decrease include attacking the issues of removing, refurbishing, and replacing the engines after each flight. less, it is important to understand the operational affects of an engine on turnaround time, ground support personnel and equipment. One tool for visualizing this relationship involves the creation of a Discrete Event Simulation (DES). A DES model can be used to run a series of trade studies to determine if the engine is meeting its requirements, and, if not, what can be altered to bring it into compliance. Using DES, it is possible to look at the ways in which labor requirements, parallel maintenance versus serial maintenance, and maintenance scheduling affect the overall turnaround time. A detailed DES model of the Space Shuttle Main Engines (SSME) has been developed. Trades may be performed using the SSME Processing Model to see where maintenance bottlenecks occur, what the benefits (if any) are of increasing the numbers of personnel, or the number and location of facilities, in addition to trades previously mentioned, all with the goal of optimizing the operational turnaround time and minimizing operational cost. The SSME Processing Model was developed in such a way that it can easily be used as a foundation for developing DES models of other operational or developmental reusable engines. Performing a DES on a developmental engine during the conceptual phase makes it easier to affect the design and make changes to bring about a decrease in turnaround time and costs.

Nix, Michael↗