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DOE OSTI2025

Unpacking model inadequacy: The quantification of silver release from TRISO fuel by considering empirical and mechanistic approaches

Increasing adoption of the proposed tristructural isotropic (TRISO) particle fuel for both advanced and existing reactors makes it critical to assess and address any uncertainties and inadequacies of TRISO fission product release models. Model inadequacy stems from simplifications made to the computational model when compared to the experiments. The modeling and simulation efforts conducted using the BISON fuel performance code, along with the experimental campaigns carried out under the Advanced Gas Reactor Fuel Development and Qualification Program, afford a unique opportunity to conduct a rigorous modeling inadequacy assessment within the Bayesian uncertainty quantification (UQ) framework. Here, this study compares the standard Bayesian framework against the Kennedy-O'Hagan (KOH) framework, which explicitly represents modeling inadequacy, in regard to UQ for TRISO silver release models. For this purpose, both the traditional Arrhenius equation fitted to experimental data and the more advanced lower-length-scale (LLS)-informed model, which considers microstructure information, are independently considered. Applying the inverse UQ process on the AGR-2 and -3/4 datasets revealed modeling inadequacy to be the most dominant source of uncertainty. Experimental noise uncertainty is also significant; however, model parameter uncertainty can be considered negligible. Interestingly, both the Arrhenius equation and the LLS-informed model demonstrated similar levels of modeling inadequacy. For the forward predictive UQ, the KOH framework improved both the accuracy and quality of quantified uncertainties in comparison to the standard Bayesian framework. This is true for both the Arrhenius equation and the LLS-informed model. In comparing these modeling approaches, both demonstrated similar performance at the engineering scale, while the LLS-informed model expectedly outperformed the Arrhenius equation at the mesoscale. These conclusions highlight the importance of explicitly accounting for modeling inadequacy in the UQ process, and reinforce the need for continuous refinement of physics-based models in order to address the modeling inadequacy.

Advanced reactors↗

DOE OSTI2022

Uncertainty Quantification Framework for Predicting Material Response with Large Number of Parameters: Application to Creep Prediction in Ferritic-Martensitic Steels Using Combined Crystal Plasticity and Grain Boundary Models

This paper presents an uncertainty quantification (UQ) framework for the physics-based model prediction of material response with a large number of parameters. The application problem presented in this work is that of predicting creep in Grade 91 steel at 600°C. The material response is defined with a physically based microstructural model with constitutive equations emulating several observed phenomena in Grade 91 and embodied into an explicit geometry mesoscale finite element model for prior austenite grains and grain boundaries. Creep within the grains and in grain boundaries are represented by crystal plasticity for dislocation motion and a physics-based model for cavity growth and nucleation, respectively. The creep behavior of this material is influenced by several parameters, some of which have a wide range of variation based on experimental data. UQ combined with microstructural modeling can discover the core microstructural causes of experimental variability, leading to improved materials with lower variability in critical long-term material properties. In this study, we investigate the model's uncertainty to identify material properties that may be modified during production to increase creep life and analyze different components of the crystal plasticity model for improvements. For this purpose, a quantity of interest is defined as time to minimum creep rate, which correlates well to the creep failure of the material. A deep neural network model was trained and validated to be used as a surrogate for the finite element model. Then, a variance-based sensitivity analysis is performed on the surrogate model to find the Sobol indices of the input parameters in respect to the output quantity of interest. The Sobol indices are used to reduce the dimensionality of the model. Generalized polynomial chaos expansion is used on the reduced basis models to propagate the uncertainty from the input parameters to the quantity of interest using the deep neural network surrogate model. These results are benchmarked against uncertainty propagation using Monte Carlo simulations. In conclusion, the UQ performed through the reduced basis model captures almost all the uncertainty in the model with significantly fewer simulations, making it possible to perform the UQ directly via simulations with the finite element model rather than surrogate machine-learned models.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Bias Characterization, Vertical Interpolation, and Horizontal Interpolation for Distributed Wind Siting Using Mesoscale Wind Resource Estimates

Much like their counterparts in utility-scale wind energy, developers of industrial, small-scale and distributed wind turbine deployments need to understand and accurately characterize the wind resource to properly assess the power generation and financial ramifications during siting and planning. National Renewable Energy Laboratory’s WIND (Wind Integration National Dataset) Toolkit (WTK) provides a best-in-class wind resource dataset generated using the Weather Research and Forecasting (WRF) model. This dataset includes parameters such as the wind speed, wind direction, and temperature at various heights, plus atmospheric stability near the surface. This data is available at 2-km spatial resolution and five-minute temporal resolution across 7 years, from 2007 to 2013 through a publicly accessible API interface. The Tools Assessing Performance (TAP) project seeks to extend this dataset to allow long term resource estimates and leverage it to better equip distributed wind equipment manufacturers, owner-operators, and installation professionals with better tools for practical siting applications. In this report, we present the results from our investigation within the TAP project focused on characterization of bias in WTK-based wind speed estimates and evaluation of vertical and horizontal interpolation techniques. We discuss the tradeoffs between different techniques and their combinations, as well as describe the lower bounds we determine for the studied validation errors. While the specific estimates we present are specific to WTK and the validation dataset we have chosen for this investigation (NREL's Wind Resource Meteorological Database), the overall analysis and the studied techniques are general enough to be applied to a broader set of wind datasets, both simulation-based and observational.

17 WIND ENERGY↗

DOE OSTI2019

Shortening the Design and Certification Cycle for Additively Manufactured Materials by Improved Mesoscale Simulations and Validation Experiments: Fiscal Year 2019 Status Report.

This report outlines the fiscal year (FY) 2019 status of an ongoing multi-year effort to develop a general, microstructurally-aware, continuum-level model for representing the dynamic response of material with complex microstructures. This work has focused on accurately representing the response of both conventionally wrought processed and additively manufactured (AM) 304L stainless steel (SS) as a test case. Additive manufacturing, or 3D printing, is an emerging technology capable of enabling shortened design and certification cycles for stockpile components through rapid prototyping. However, there is not an understanding of how the complex and unique microstructures of AM materials affect their mechanical response at high strain rates. To achieve our project goal, an upscaling technique was developed to bridge the gap between the microstructural and continuum scales to represent AM microstructures on a Finite Element (FE) mesh. This process involves the simulations of the additive process using the Sandia developed kinetic Monte Carlo (KMC) code SPPARKS. These SPPARKS microstructures are characterized using clustering algorithms from machine learning and used to populate the quadrature points of a FE mesh. Additionally, a spall kinetic model (SKM) was developed to more accurately represent the dynamic failure of AM materials. Validation experiments were performed using both pulsed power machines and projectile launchers. These experiments have provided equation of state (EOS) and flow strength measurements of both wrought and AM 304L SS to above Mbar pressures. In some experiments, multi-point interferometry was used to quantify the variation is observed material response of the AM 304L SS. Analysis of these experiments is ongoing, but preliminary comparisons of our upscaling technique and SKM to experimental data were performed as a validation exercise. Moving forward, this project will advance and further validate our computational framework, using advanced theory and additional high-fidelity experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Co-Occurring Atmospheric Features and Their Contributions to Precipitation Extremes

Object-based identification algorithms for atmospheric features are commonly utilized to attribute global precipitation. This study employs a systematic approach to examine feature co-occurrences and their relationships to mean and extreme precipitation. Four features are identified using existing data sets for atmospheric rivers (ARs), mesoscale convective systems (MCSs), low-pressure systems (LPSs), and fronts (FTs). Often, a single atmospheric phenomenon satisfies the criteria set by multiple feature identification algorithms, yielding an association between precipitation and multiple features. Over the extra-tropics, the number of features attributed to a single event typically increases with precipitation intensity. Over two-thirds of the precipitation is from co-occurring features, with a considerable fraction related to AR-FT co-occurrences. Over the tropics, about one-quarter of precipitation is associated with co-occurring features, with LPS-MCS co-occurrences contributing substantially in monsoon regions. MCSs are the leading single-feature contributors over tropical land and oceans. In the extra-tropics, FTs, ARs, and their co-occurrences account for over half of the total precipitation over oceans. AR-FT-MCS and FT-MCS co-occurrences contribute to extremes (precipitation exceeding the 95th percentile) over both oceans (over 30%) and land (over 20%). Any combination of features involving MCSs shows a larger contribution to high percentiles of precipitation intensity. A case analysis indicates that AR-FT-MCS co-occurrences exhibit convective instability and deep vertical motion, suggesting that the feature trackers and reanalysis are capturing physics relevant to both convective and frontal systems. The results here emphasize the need for simultaneous identifications of multiple features when attributing precipitation to atmospheric phenomena.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

How does vertical wind shear influence entrainment in squall lines?

The influence of vertical wind shear on updraft entrainment in squall lines is not well understood. To address this knowledge gap, a suite of high-resolution idealized numerical model simulations of squall lines were run in various vertical wind shear (hereafter “shear”) environments to study the effects of shear on entrainment in deep convective updrafts. Low-level horizontal mass flux into the leading edge of the cold pool was strongest in the simulations with the strongest low-level shear. These simulations consequently displayed wider updrafts, less entrainment-driven dilution, and larger buoyancy than the simulations with comparatively weak low-level shear. An analysis of vertical accelerations along trajectories that passed through updrafts showed larger net accelerations from buoyancy in the simulations with stronger low-level shear, which demonstrates how less entrainment-driven dilution equated to stronger updrafts. Additionally, the effects of upper-level shear on entrainment and updraft vertical velocities were generally less pronounced than the effects of low-level shear. We argue that in addition to the outflow boundary-shear interactions and their effect on updraft tilt established by previous authors, decreased entrainment-driven dilution is yet another beneficial effect of strong low-level shear on squall line updraft intensity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Surface and subsurface oceanographic features drive forage fish distributions and aggregations: Implications for prey availability to top predators in the US Northeast Shelf ecosystem

Abstract Forage fishes are a critical food web link in marine ecosystems, aggregating in a hierarchical patch structure over multiple spatial and temporal scales. Surface‐level forage fish aggregations (FFAs) represent a concentrated source of prey available to surface‐ and shallow‐foraging marine predators. Existing survey and analysis methods are often imperfect for studying forage fishes at scales appropriate to foraging predators, making it difficult to quantify predator–prey interactions. In many cases, general distributions of forage fish species are known; however, these may not represent surface‐level prey availability to predators. Likewise, we lack an understanding of the oceanographic drivers of spatial patterns of prey aggregation and availability or forage fish community patterns. Specifically, we applied Bayesian joint species distribution models to bottom trawl survey data to assess species‐ and community‐level forage fish distribution patterns across the US Northeast Continental Shelf (NES) ecosystem. Aerial digital surveys gathered data on surface FFAs at two project sites within the NES, which we used in a spatially explicit hierarchical Bayesian model to estimate the abundance and size of surface FFAs. We used these models to examine the oceanographic drivers of forage fish distributions and aggregations. Our results suggest that, in the NES, regions of high community species richness are spatially consistent with regions of high surface FFA abundance. Bathymetric depth drove both patterns, while subsurface features, such as mixed layer depth, primarily influenced aggregation behavior and surface features, such as sea surface temperature, sub‐mesoscale eddies, and fronts influenced forage fish diversity. In combination, these models help quantify the availability of forage fishes to marine predators and represent a novel application of spatial models to aerial digital survey data.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Improved multiphysics model of the High Temperature Engineering Test Reactor for the simulation of loss-of-forced-cooling experiments

We present a multiphysics model of the High Temperature Engineering Test Reactor for comparison with past and predict future loss-of-forced-cooling (LOFC) experiments. The approach selected combines (1) 3-D full-core superhomogenization-corrected neutronics, (2) 3-D full-core homogenized or semi-heterogeneous heat transfer (macroscale), (3) 2-D axisymmetric fuel rod heat transfer (mesoscale), and (4) 1-D thermal-hydraulics channels. Although large sensitivities remain and the available experimental data are insufficient for use in a rigorous validation exercise, the overall transient behavior is successfully reproduced. The novelty of our work includes (1) a new macroscale-mesoscale heat transfer coupling approach relying on gap conductance to drastically speed up numerical convergence by two orders of magnitude, (2) determination of a radial effective thermal conductivity that yields reasonably close results between the homogenized and semi-heterogeneous macroscale thermal models, and (3) a preliminary study of the reactor's early behavior following a LOFC event, thus enabling further assessment of numerical models against fission power measurements.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Climatology of Linear Mesoscale Convective System Morphology in the United States based on Random Forests Method

This study uses machine learning methods, specifically the random forest (RF), on a radar-based mesoscale convective system (MCS) tracking dataset to classify the five types of linear MCS morphology in the contiguous United States during the period 2004-2016. The algorithm is trained using radar- and satellite-derived spatial and morphological parameters, and reanalysis environmental information from 5-26yr manually identified nonlinear and five linear MCS modes. The algorithm is then used to automate the classification of linear MCSs over 8 years with high accuracy, providing a systematic, long-term climatology of linear MCSs. Results reveal that nearly 40% of MCSs are classified as linear MCSs, in which half of the linear events belong to the type of system having a leading convective line. The occurrence of linear MCSs shows large annual and seasonal variations. On average, 113 linear MCSs occur annually during the warm season (through March to October), with most of these events clustered from May through August in the central eastern Great Plains. MCS characteristics, including duration, propagation speed, orientation, and system cloud size, have large variability among the different linear modes. The systems having a trailing convective line and the systems having a back-building area of convection typically move more slowly and have higher precipitation rate, and thus have higher potential in producing extreme rainfall and flash flooding. Analysis of the environmental conditions associated with linear MCSs show that the storm-relative flow is of most importance in determining the organization mode of linear MCSs.

Cui, Wenjun↗

DOE OSTI2022

Electrophoretic Deposition of Platinum Nanoparticles using Ethanol-Water Mixtures Significantly Reduces Neural Electrode Impedance

We report platinum electrodes are critical components in many biomedical devices, an important example being implantable neural stimulation or recording electrodes. However, upon implantation, scar tissue forms around the electrode surface, causing unwanted deterioration of the electrical contact. We demonstrate that sub-monolayer coatings of platinum nanoparticles (PtNPs) applied to 3D neural electrodes by electrophoretic deposition (EPD) can enhance the electrode's active surface area and significantly lower its impedance. In this work we use ethanol-water mixtures as the EPD solvent, in contrast to our previous studies carried out in water. We show that EPD coating in 30 vol.% ethanol improves the device's electrochemical performance. Computational mesoscale multiparticle simulations were for the first time applied to PtNP-on-Pt EPD, revealing correlations between ethanol concentration, electrochemical properties, and coating homogeneity. Thereto, this optimum ethanol concentration (30 vol.%) balances two opposing trends: (i) the addition of ethanol reduces water splitting and gas bubble formation, which benefits surface coverage, and (ii) increased viscosity and reduced permittivity occur at high ethanol concentrations, which impair the coating quality and favoring clustering. A seven-fold increase in active surface area and significantly reduced in vitro impedance of the nano-modified neural stimulation electrode surfaces highlight the influence of ethanol-water mixtures in PtNP EPD.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Mechanisms of heat flux across the Southern Greenland continental shelf in 1/10° and 1/12° ocean/sea ice simulations

The increased presence of warm Atlantic water on the Greenland continental shelf has been connected to the accelerated melting of the Greenland Ice Sheet, particularly in the southwest and southeast shelf regions. Results from two high-resolution coupled ocean-sea ice simulations that utilized either the 1/10-degree Parallel Ocean Program (POP) or the 1/12-degree HYbrid Coordinate Ocean Model (HYCOM) are used to understand the flux of heat on and off the southern Greenland shelf. The analysis reveals that the region of greatest heat flux onto the shelf is southeast Greenland. On the southwestern shelf, heat is mainly exported from the shelf to the interior basins. We identify differences in the shelf break current structure and on-shelf heat content between the two simulations. Just south of the Denmark strait, there is a seasonally persistent pattern of multi-day variability in the cross-shelf heat flux in both simulations. In the POP simulation, this high-frequency signal results in net on-shore heat flux. In the HYCOM simulation, the signal is weaker and results in net off-shelf heat flux. This variability is consistent with Denmark Strait Overflow eddies traveling along the shelf break.

58 GEOSCIENCES↗

DOE OSTI2024

Observed Variability in Convective Cell Characteristics and Near-Storm Environments across the Sea- and Bay-Breeze Fronts in Southeast Texas

Abstract During the DOE Atmospheric Radiation Measurement (ARM) Tracking Aerosol Convection Interactions Experiment (TRACER) IOP spanning June–September 2022, two fixed ARM sites and a mobile team concurrently sampled the airmass heterogeneity across sea- and bay-breeze fronts around the greater Houston metropolitan region. Here, we quantify the spatiotemporal variability between maritime (coastal/bay side of breeze fronts) and continental (inland side of breeze fronts) air masses over 15 IOP days characterized by strong sea-breeze forcing. We analyze environmental profile data from 177 radiosondes and use S- and C-band radar data to track and quantify the variability in attributes of more than 2300 shallow and transitioning cells across different air masses. The composite analysis of environmental profiles indicates that during the early afternoon, the sea-breeze maritime air mass exhibits lower convective available potential energy (CAPE) than the bay-breeze maritime air mass. As the sea breeze advances inland with time, CAPE within the maritime air mass exceeds that of the continental air mass to the north of the breeze fronts. In general, maritime cells have a larger mean composite reflectivity and cell widths than continental cells; however, the response varies between shallow and transitioning cells. Mean composite 20-dB Z echo-top heights, however, are similar across air masses for both shallow and transitioning cells. The continental and maritime inflow air mass for transitioning cells has significantly different mean values for mixed-layer entrainment CAPE, lifted condensation level, level of free condensation, boundary layer depth, and diluted equilibrium level. For shallow cells, only total precipitable water shows a significant difference. Significance Statement The greater Houston metropolitan area is a natural laboratory for understanding the individual impacts of background meteorology and aerosols on convective clouds. Due to its proximity to the Gulf Coast and Galveston Bay, the Houston region experiences a diurnal precipitation cycle in the summer, driven by convection triggered from sea- and bay-breeze fronts. These fronts act as a boundary between air masses with distinct thermodynamic and environmental characteristics. Convergence along these fronts and interactions between storm outflow and the fronts facilitate convection initiation in different mesoscale air masses. This study quantifies the heterogeneity among these air masses while investigating their influence on cloud microphysics. We find that the effect of airmass heterogeneity is more pronounced for the bulk microphysical properties in shallow clouds.

Sharma, Milind↗

DOE OSTI2025

Using ARM Observations to Evaluate Process-Interactions in MCS Simulations Across Scales (Final Progress Report)

This project, funded by DOE Atmospheric System Research (DE-SC0020050), focused on improving the representation of mesoscale convective systems (MCSs) in numerical weather and climate models by leveraging high-resolution observations from the DOE Atmospheric Radiation Measurement (ARM) program. The research aimed to evaluate model sensitivities to grid spacing, microphysics, and planetary boundary layer (PBL) schemes, with a particular emphasis on improving convection parameterization for high-resolution modeling. Findings from this work highlight several key advancements. Model validation against ARM radar wind profiler data from the Southern Great Plains (SGP) and Manaus (MAO) sites revealed systematic biases in simulated convective mass flux profiles, leading to the development of an observationally constrained evaluation framework for diagnosing and improving model performance. Sensitivity analyses demonstrated that the representation of Amazonian MCSs was highly dependent on PBL scheme selection, while mid-latitude MCSs were more strongly influenced by microphysics parameterizations. A series of high-resolution WRF simulations, ranging from 4 km to 125 m grid spacing, provided insight into the behavior of convective drafts across scales. While updraft properties converged at sub-kilometer resolutions, biases in downdraft intensity persisted even at the finest resolution tested, emphasizing the need for further refinements in model physics. Additionally, comparisons of MCS vertical structures between mid-latitude and tropical environments revealed stronger updrafts and larger mass flux in mid-latitude MCSs, providing critical insights for improving climate model representations of storm-scale dynamics. The project’s findings have already contributed to advancing numerical modeling capabilities, particularly in WRF, MPAS, ICON, and DOE’s SCREAM model, by refining how convective processes are represented in high-resolution climate simulations. Results were disseminated through peer-reviewed publications, conference presentations, and ARM/ASR Research Highlights, engaging the broader scientific community. The project also provided valuable training opportunities for two postdoctoral researchers, who played central roles in model development, analysis, and dissemination of results. Their work contributed to several publications and conference presentations, helping prepare them for careers in atmospheric modeling. By improving the simulation of MCSs, this research directly supports the development of next-generation climate models capable of more accurately representing extreme precipitation and convective processes. The insights gained will inform future improvements in convective parameterization and guide the design of high-resolution weather and climate simulations, ultimately enhancing the reliability of climate projections and weather forecasts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

The Influence of Soil Properties on Sea-Breeze Circulations in the Southeast U.S.

Sea-breeze circulations (SBCs) are common weather phenomena at and near coastal regions. They form because of a thermal gradient between the land surface at the coast and the sea surface. In a mid-day regime, a “thermal low” generated at the warm coast will lead to rising air motion, creating a wind shift coming from the sea near the surface displacing the coastal air. A “return flow” moving back towards the sea is generated by upper-level divergence because of the rising motion from the thermal low. SBCs propagate and serve as a method of urban pollutant dispersion in the Los Angeles region of California and are constrained to the coast due to the topography of surrounding mountains serving as a boundary for further inland propagation. Within the northeast U.S. SBCs are seen in the warm season but tend to remain coastally bound due to Coriolis distortion over long distances. Within the southeast U.S. (SEUS), the paradigmatic example of SBCs occurs over the Florida peninsula, where thunderstorms form on a nearly daily occurrence due to the convergence of SBCs from the east and west sides of the peninsula. However, there are further examples of sea-breezes in the SEUS that warrant study. Within the region bordering the SEUS and the Mid-Atlantic, just east of the southern Appalachian Mountains, warm-season SBCs form at the coast of Georgia and the Carolinas. Relatively flat topography ~150-200km inland allows for mostly unimpeded inland SBC propagation. Through visual analysis, Viner et al. catalogued several SBCs that propagated as far inland as the Central Savannah River Area surrounding Augusta, Georgia. Wermter et al. found that while the land-sea thermal gradient at the coast can influence coastal SBC genesis, the inland-coastal thermal gradient over the land is the primary influencer on the speed and depth of inland propagation of SBCs in this region. Additionally, soil moisture itself is a known correlative factor to sea-breeze formation, as it influences the soil temperature and the thermal gradient needed for SBC genesis and inland penetration. Physick determined that higher latent heat fluxes associated with wetter soil dampen the land-sea thermal gradient and suppress the formation of a SBC. Physick determined that higher latent heat fluxes associated with wetter soil dampen the land-sea thermal gradient and suppress the formation of a SBC. Conversely, drier soil enhances the thermal gradient and promotes SBC formation. However, while there is an inverse relationship between soil moisture and SBCs, higher soil moisture can actually promote more convective rainfall following a SBC if it does not significantly impact the thermal gradient. While the relationship between soil moisture and SBC formation has been conceptually explored and modeled numerically, there is a research gap in observed connections. The Soil Moisture Active Passive (SMAP) satellite mission has been operational since 2015 and has been used to create high-resolution re-analytical Level 4 (L4) datasets of soil moisture and soil temperature at different soil depths: the surface (0-5cm) and rootzone (0-1m). The surface soil temperature effectively acts as the “skin temperature” of the surface at these levels, and a spatial map of the land-sea as well as the coastal-inland thermal gradients can be represented. SMAP data are also assimilated in some atmospheric models such at the High Resolution Rapid Refresh (HRRR) mesoscale model. We propose leveraging the use of SMAP products to fill in spatial gaps left by weather and mesonet stations within the SEUS region, as well as assessing the effectiveness of utilizing SMAP products towards SBC forecasting in both deterministic and machine learning (ML) models.

58 GEOSCIENCES↗

DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗