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DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2024

HAPPA: A Modular Platform for HPC Application Resilience Analysis with LLMs Embedded

High-performance computing (HPC) systems are increasingly vulnerable to soft errors, which pose significant challenges in maintaining computational accuracy and reliability. Predicting the resilience of HPC applications to these errors is crucial for robust code protection and detailed resilience analysis. In this study, we present HAppA, a modular platform designed for HPC Application Resilience Analysis. Embedding Large Language Models (LLMs), HAppA addresses understanding the context information of long code sequences typical in HPC applications. HAppA implements a novel code representation module that chunks the code into fixed-size segments and aggregates the embeddings of these segments. Three aggregation methods have been explored: MeanPooling, MaxPooling, and LSTM-based techniques. We built a DAtaset for REsilience analysis using Fault Injection (FI), named DARE. Using our DARE dataset, HAppA is trained for regression prediction tasks. Our evaluation results demonstrate the predictive accuracy of HAppA compared to other models, particularly noting that the LSTM-based aggregation method -- HAppA-LSTM -- achieves a mean squared error (MSE) of 0.078 for SDC prediction, surpassing the existing state-of-the-art PARIS model, which recorded an MSE of 0.1172. Additionally, HAppA with the KeyBERT model extracts a list of keywords representing the source code. A comprehensive importance analysis of these keywords further elucidates the code patterns contributing to the error rate. These findings highlight the effectiveness of HAppA in analyzing the resilience of HPC applications and establish a new benchmark for predictive accuracy in resilience.

Jiang, Hailong [Kent State University]↗

DOE OSTI2021

OPERATING EXPERIENCE AND ITS RELATIONSHIP TO EMBEDDED DIGITAL DEVICES IN SAFETY SYSTEMS

Interest in embedded digital devices (EDDs) for monitoring and providing control of components is increasing and the added functionality digital brings such as diagnostics, displays, control functions is welcomed in both the nuclear and other industries. As a result, pure analog-based components continue to disappear from the industrial I&C marketplace. Equipment with EDDs, also known by related terms such as smart devices, intelligent devices, and digital devices of limited functionality, can include sensors, breakers, priority logic modules, time delay relays, pumps, valve actuators, motor control centers, and uninterruptible power supplies. Not only is equipment consisting of analog and older digital technology being replaced with commercial grade products containing EDDs, but EDDs can also be retrofitted to work with existing components. EDDs may be installed physically within a component, such as in a relay. There are also external devices that some would not consider an EDD, but that operate in almost all technical ways identically to one internal to a component such as in a valve controller. In fact, the digital portions may be located hundreds of feet from the actual component.Due to the potential of being used in an identical manner and without alteration from their application in other industries, operating experience (OpE) for EDDs may be much more applicable than in the case of other more system level devices. Clear separation and independence of functionality provided with EDDs may also allow greater applicability of existing OpE from industry for changes that can be shown not to affect its safety function. However, OpE also demonstrates issues with different conditions between other industries and nuclear power plants, such as issues with undeclared changes or undeclared digital devices and the new failure modes they may introduce, issues with the reporting of OpE in industry, and a lack of transparency into OpE for EDDs.Understanding and addressing these issues will be key in the future use of EDDs in nuclear power plants, but failure rate data is difficult to obtain for EDDs, and lessons learned from the use of EDDs are difficult to collect and identify.Key words: embedded digital device, smart device, operating experience, failure modes

Muhlheim, Michael↗

DOE OSTI2023

Substrate-embedded metal meshes for ITO-free organic light emitting diodes

Organic light-emitting diodes (OLEDs) have great potential for use in large-area display and lighting applications, but their widespread adoption for large areas is hindered by the high cost and insufficient performance of indium tin oxide (ITO) anodes. In this study, we introduce an alternative anode material – a silver mesh embedded in glass – to facilitate production of large-area OLEDs. We present a facile, scalable manufacturing technique to create high aspect ratio micromeshes embedded in glass to provide the planar geometry needed for OLED layers. Our phosphorescent green OLEDs achieve a current efficiency of 51.4 cd/A at 1000 cd/m 2 and reach a slightly higher external quantum efficiency compared to a standard ITO/glass reference sample. Notably, these advancements are achieved without any impact on the viewing angle of the OLEDs. These findings represent a promising advancement towards ITO-free, high-efficiency OLEDs for various high performance, large-area applications, such as lighting and displays.

Optics↗

DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗

DOE OSTI2024

Embedded High-Temperature Sensors: Enhancing Thermoelectrical Performance with Refractory Composites Gradient Layers

To monitor the stability of various energy and manufacturing systems, sensors capable of operating at temperatures exceeding 1000 °C in diverse environments for extended durations are essential. However, under harsh conditions, degradation of sensing materials is a concern that can be controlled by embedding the sensors into refractory oxides. Doped-LaCrO3 based composites are excellent candidates for high-temperature sensing applications due to their good thermoelectrical properties. However, chemical reactivity between the conductive phase and the refractory oxides can decrease the performance of the sensors. In this work, it was devised gradient-type protective layers safeguarding conductive phases within embedded thermocouples, which were fabricated and characterized by X-Ray Diffraction for phase development analysis, Scanning Electron Microscopy and Energy-dispersive X-ray spectroscopy for microstructure and cationic interdiffusion kinetics, long-term thermoelectric testing was completed up to 1400 °C. The enhanced performance of these novel sensors addresses a critical limitation, rendering them viable for long-term high-temperature applications.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Templates for Risk Informed Assurance with Curvature Embeddings (TRACE)

We investigate recovery of geometric structure from networks embedded in manifolds with spatially varying curvature, extending the constant-curvature framework of Lubold et al. (2023). Our work supports cascade risk assessment in critical infrastructure through the Templates for Risk-informed Assurance with Curvature Embeddings (TRACE) framework. Simulations on a bi-modal Gaussian surface show that constant-curvature methods yield weighted averages shaped by clique patterns, while hierarchical clustering identifies distinct regimes. Localized estimation, however, reveals boundary contamination in transitional regions. To address heterogeneity, we develop distance metrics for graphs with edge and node features, proving their metric validity, and validate them via deterministic graph generation from canonical tilings. We further propose a diffusion-based anomaly detection approach that treats networks as glued manifolds, using curvature discontinuities to detect structural anomalies. Employing the carré-du-champ operator and scalar curvature, we achieve robust anomaly discrimination, demonstrated on the Singapore Water Treatment (SWaT) dataset with joint network-traffic and sensor features. Integration with TRACE reveals how curvature shapes cascade dynamics: positive curvature impedes, while negative curvature accelerates propagation. This geometric perspective provides interpretable risk metrics and visualization tools for critical infrastructure managers. While full validation remains ongoing, our contributions establish a rigorous foundation for geometric analysis of network resilience and cascade vulnerability.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

The Twins Embedding of Type Ia Supernovae. I. The Diversity of Spectra at Maximum Light

In this work, we study the spectral diversity of Type Ia supernovae (SNe Ia) at maximum light using high signal-to-noise spectrophotometry of 173 SNe Ia from the Nearby Supernova Factory. We decompose the diversity of these spectra into different extrinsic and intrinsic components, and we construct a nonlinear parameterization of the intrinsic diversity of SNe Ia that preserves pairings of "twin"SNe Ia. We call this parameterization the "Twins Embedding."Our methodology naturally handles highly nonlinear variability in spectra, such as changes in the photosphere expansion velocity, and uses the full spectrum rather than being limited to specific spectral line strengths, ratios, or velocities. We find that the time evolution of SNe Ia near maximum light is remarkably similar, with 84.6% of the variance in common to all SNe Ia. After correcting for brightness and color, the intrinsic variability of SNe Ia is mostly restricted to specific spectral lines, and we find intrinsic dispersions as low as ~0.02 mag between 6600 and 7200 Å. With a nonlinear three-dimensional model plus one dimension for color, we can explain 89.2% of the intrinsic diversity in our sample of SNe Ia, which includes several different kinds of "peculiar"SNe Ia. A linear model requires seven dimensions to explain a comparable fraction of the intrinsic diversity. We show how a wide range of previously established indicators of diversity in SNe Ia can be recovered from the Twins Embedding. In a companion article, we discuss how these results can be applied to the standardization of SNe Ia for cosmology.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Kinematic Evidence for an Embedded Planet in the IM Lupi Disk

Abstract We test the hypothesis that an embedded giant planet in the IM Lupi protostellar disk can produce velocity kinks seen in CO line observations as well as the spiral arms seen in scattered light and continuum emission. We inject planets into 3D hydrodynamics simulations of IM Lupi, generating synthetic observations using Monte Carlo radiative transfer. We find that an embedded planet of 2–3 M Jup can reproduce non-Keplerian velocity perturbations, or “kinks”, in the 12 CO J = 2–1 channel maps. Such a planet can also explain the spiral arms seen in 1.25 mm dust continuum emission and 1.6 μ m scattered-light images. We show that the wake of the planet can be traced in the observed peak velocity map, which appears to closely follow the morphology expected from our simulations and from analytic models of planet–disk interaction.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Ab Initio Many Body Quantum Embedding and Local Correlation in Crystalline Materials using Interpolative Separable Density Fitting

We present an efficient implementation of ab initio many-body quantum embedding and local correlation methods for infinite periodic systems through translational symmetry adapted interpolative separable density fitting, an approach which reduces the scaling of the calculations to only linear with the number of k-points. Employing this methodology, we compute correlated ground-state coupled cluster energies within density matrix embedding and local natural orbital correlation frameworks for both weakly and strongly correlated solids, using up to 1000 k-points. By extrapolating the local correlation domains and k-point sampling we further obtain estimates of the full coupled cluster with singles, doubles, and perturbative triples ground-state energies in the thermodynamic limit.

Chemical Physics (physics.chem-ph)↗

NASA NTRS1973

Analysis of embedded shock waves calculated by relaxation methods.

The requirements for uniqueness of the calculated jump conditions across embedded shock waves are investigated for type-dependent difference systems used in transonic flow studies. A mathematical analysis shows that sufficient conditions are (1) the equations should be differenced in conservative form and (2) a special difference operator should be used when switching from a hyperbolic to an elliptic operator. The latter results in a consistency condition on the integral equations, rather than the differential, at these points. Calculated jump conditions for several embedded and detached shock waves are analyzed in the physical and hodograph planes. Comparisons are made with previous results, a time-dependent calculation, and data.

Murman, E. M.↗

NASA NTRS1978

Tools for Embedded Computing Systems Software

A workshop was held to assess the state of tools for embedded systems software and to determine directions for tool development. A synopsis of the talk and the key figures of each workshop presentation, together with chairmen summaries, are presented. The presentations covered four major areas: (1) tools and the software environment (development and testing); (2) tools and software requirements, design, and specification; (3) tools and language processors; and (4) tools and verification and validation (analysis and testing). The utility and contribution of existing tools and research results for the development and testing of embedded computing systems software are described and assessed.

Source record↗

NASA NTRS1980

Axisymmetric elastodynamic response from normal and radial impact of layered composites with embedded penny-shaped cracks

A method is developed for the dynamic stress analysis of a layered composite containing an embedded penny-shaped crack and subjected to normal and radial impact. Quantitatively, the time-dependent stresses near the crack border can be described by the dynamic stress intensity factors. Their magnitude depends on time, on the material properties of the composite and on the relative size of the crack compared to the composite local geometry. Results obtained show that, for the same material properties and geometry of the composite, the dynamic stress intensity factors for an embedded (penny-shaped) crack reach their peak values within a shorter period of time and with a lower magnitude than the corresponding dynamic stress factors for a through-crack.

Sih, G. C.↗

NASA NTRS1983

A conservative type-dependent full potential method for the treatment of supersonic flows with embedded subsonic regions

A nonlinear method based on the full potential equation in conservation form, cast in an arbitrary coordinate system, has been developed to treat predominantly supersonic flows with embedded subsonic regions. This type of flow field occurs frequently near the fuselage-canopy junction area and wing leading edge regions for a moderately swept fighter configuration. The method uses the theory of characteristics to accurately monitor the type-dependent flow field. A conservative switching scheme is developed to transition from the supersonic marching algorithm to a subsonic relaxation procedure, and vice versa. An implicit approximate factorization scheme is employed to solve the finite-differenced equation. Results are shown for a few configurations, including a wing-body-wake realistic fighter model having embedded subsonic regions.

Shankar, V.↗

NASA NTRS1983

Embedded cavity drag in steady and unsteady flows

The numerical solution of the laminar boundary-layer flow over an embedded cavity is studied. The purpose is to examine the relevant drag characteristics of laminar cavity flow. The solution field is obtained in terms of velocity and vorticity variables, with the stream function and pressure derivable from the directly computed variables. An analysis and comparison is made among four square cavities, ranging in size from 0.25 to 1.00 boundary-layer thicknesses deep. The dominant flow features are examined in the vicinity of the cavity by means of the stream function and iso-vorticity contours. The dominant physics in the overall drag characteristics of the flow is examined by an analysis of the pressure and wall shear stress distributions in the cavity, and upstream and downstream of the cavity. Pressure forces and frictional forces in, and in the vicinity of, the cavity are determined. Stress relaxation distances, both upstream and downstream of the cavity, are calculated and analyzed. The flow dynamics of the boundary-layer flow over an embedded cavity is summarized. Finally, the relevance of the results to the control of flow separation in such flows is discussed.

Gatski, T. B.↗

NASA NTRS1984

The embedded operating system project

This progress report describes research towards the design and construction of embedded operating systems for real-time advanced aerospace applications. The applications concerned require reliable operating system support that must accommodate networks of computers. The report addresses the problems of constructing such operating systems, the communications media, reconfiguration, consistency and recovery in a distributed system, and the issues of realtime processing. A discussion is included on suitable theoretical foundations for the use of atomic actions to support fault tolerance and data consistency in real-time object-based systems. In particular, this report addresses: atomic actions, fault tolerance, operating system structure, program development, reliability and availability, and networking issues. This document reports the status of various experiments designed and conducted to investigate embedded operating system design issues.

Campbell, R. H.↗

NASA NTRS1984

Embedded cavity drag in steady and unsteady flows

The numerical solution of the laminar boundary-layer flow over an embedded cavity is studied. The purpose of the study is to examine the relevant drag characteristics of laminar cavity flow. The solution field is obtained in terms of velocity and vorticity variables, with the stream function and pressure derivable from the directly computed variables. An analysis and comparison is made among four square cavities, ranging in size from 0.25 to 1.00 boundary-layer thicknesses deep. The dominant flow features are examined in the vicinity of the cavity by means of the stream function and iso-vorticity contours. The dominant physics in the overall drag characteristics of the flow is examined by an analysis of the pressure and wall shear stress distributions in the cavity, and upstream and downstream of the cavity. Pressure forces and frictional forces in, and in the vicinity of, the cavity are determined. Stress relaxation distances, both upstream and downstream of the cavity, are calculated and analyzed. The flow dynamics of the boundary-layer flow over an embedded cavity is summarized. Finally, the relevance of the present results to the control of flow separation in such flows is discussed.

Gatski, T. B.↗

NASA NTRS1984

Observations of an ionization ridge containing an embedded O-B cluster in the G10.2-0.3 H II region of W31

VLA radio maps at 5-GHz of the G10.2-0.3 H II region in the W31 complex reveal an extended ionization ridge of dimensions 5.7 x 2.9 sq pc at an assumed distance of 7 kpc. In the ridge, 21 dense clumps have been found with characteristic emission measures of about a million pc/cm to the 6th and electron densities greater than 1000/cu cm, suggesting embedded stars. From estimates of the number of Lyman continuum photos required to support the radio structure, spectral types in the ridge are found which range from B0.5 to O6. The observed radio structure cannot be explained by excitation from a single embedded source, or by expansion of shock-heated gas into the interstellar medium.

Woodward, C. E.↗