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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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The software provides machine learning analysis and visualization to detect patterns in epigenetic data, including conventional machine learning and statistical methods, and open-source packages like pyBigWig (https://github.com/deeptools/pyBigWig) for data processing. The software is written in python, it uses some python libraries.
We present MLstructureMining, a machine learning tool that identifies a structural model from an experimental pair distribution function. We show how the method can be used for structure analysis of both crystalline and nanocrystalline materials.
This project is directed at improving the efficiency and productivity of the existing installed US machine tool base by correcting a fundamental system-wide flaw in the existing programmable machine tool infrastructure. The project will catalyze a shift from a geometry-only mindset to a geometry -and-machine -performance mindset. The project will lead to a dramatic overhaul of the existing ecosystem for programming of Computer Numerically Controlled (CNC) machine tools, and will result in energy savings, cost savings, reduced scrap, and improved competitiveness of US manufacturers.
Abstract With the onset and rapid growth of smart manufacturing, there is a constant increase in the demand for automation technologies to enhance productivity while providing uninterrupted, cost‐efficient, and resilient machining. Traditional manufacturing systems, however, suffer from several losses due to machine faults and degradation. Specifically, tool wear directly impacts the precision and quality of the milled parts, which causes an increase in the scrap production. Hence, more attempts are required to meet the desired quota of successful parts, which in turn results in wasted material, longer delays, further tool degradation, and higher energy, machining, and labor costs. As such, this paper develops a multi‐objective optimization framework to generate the optimal control set points (e.g., feed rate and width of cut) that minimize the total cost of machining operations resulting from multiple contradictory cost functions (e.g., material, energy, tardiness, machining, labor, and tool) in the presence of tool wear. Notably, we estimate the total expected cost in dollars, which provides automatic and intuitive weighting in this multi‐objective formulation. The optimization framework is tested on a high‐fidelity face milling model that has been validated on real data from industry. Results show significant dollar savings of up to as compared to the default control scheme.
Abstract In this research, we propose an Error Separation Technique (EST) based on optical fiber sensors for on-machine straightness error measurement. Two fiber optic Fabry–Pérot interferometers have been developed serving as two displacement sensors. The displacement distance is computed according to the reflected spectrum from interferometers, which can achieve a sub-micrometer resolution. The two-point method has been employed to separate the straightness error of the slides and the profile error of a fine-polished standard block. The spacing distance between two interferometers is determined by the diameter of optical fibers so that the EST's resolution has the potential to reach the sub-millimeter scale. In the experiment, the straightness error has been measured on a commercially available computer numerical control machine tool, and the measurement has been conducted on its x-axis. The spacing distance between two optical fiber sensors is 1.5 mm which equals the EST's resolution along the machine tool's x-axis. The separated profile error of the measured standard block is around 30 µm which has been verified by a high precision Coordinate Measurement Machine (CMM). The magnitude of the separated straightness error is around 40 µm. This technique is flexible and simple to be conducted, which can contribute to the micro-machine tool calibration and other straightness error applications.
Clean energy has become an increasingly important consideration in today’s power systems. As the push for clean energy continues, many coal-fired power plants are being decommissioned in favor of renewable power sources such as wind and solar. However, the intermittent nature of renewables means that dynamic load following traditional power systems is crucial to grid stability. With high flexibility and fast response at a wide range of operating conditions, gas turbine systems are poised to become the main load following component in the power grid. Yet, rapid changes in load can lead to fluid flow instabilities in gas turbine power systems. These instabilities often lead to compressor surge and stall, which are some of the most critical problems facing the safe and efficient operation of compressors in turbomachinery today. Although the topic of compressor surge and stall has been extensively researched, no methods for early prediction have been proven effective. This study explores the utilization of machine learning tools to predict compressor stall. The long short-term memory (LSTM) model, a form of recurrent neural network (RNN), was trained using real compressor stall datasets from a 100 kW recuperated gas turbine power system designed for hybrid configuration. Two variations of the LSTM model, classification and regression, were tested to determine optimal performance. The regression scheme was determined to be the most accurate approach, and a tool for predicting compressor stall was developed using this configuration. Overall, results show that the tool is capable of predicting stalls 5–20 ms before they occur. With a high-speed controller capable of 5 ms time-steps, mitigating action could be taken to prevent compressor stall before it occurs.
This paper presents the integration of wire-arc additive manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) into a machine tool to create a retrofit hybrid computer numeric control (CNC) machine tool. GMAW, along with other direct energy deposition systems, has the capacity to deposit material faster than the excess thermal energy can dissipate. This results in the need to allow the part to cool between consecutive layers, which is the most time-consuming part of the additive process. Finite element analysis (FEA) was used in conjunction with monitored build plate surface temperatures during deposition samples to improve adequate dwell time prediction and to develop a cooling system. A deposition was completed where no dwell time was used and the build plate along with the machine table temperatures were monitored. A second deposition was completed where only one bead was deposited and the traverse speed was increased. The GMAW welder was mounted on a 3-axis CNC machine where two square deposition samples were completed. A FEA model was designed and verified using the monitored samples. The model will be used to determine improved depositions speeds and whether forced cooling would allow for an increased deposition rate without structural failure. It was determined the FEA software can be used to accurately model and predict the thermal response of WAAM AM components.
In this work, we develop novel physics-based and machine learning computational techniques to predict fundamental properties of metallic systems that affect radiation damage behavior in reactor structural materials. Oftentimes, atomistic predictions of engineering alloys simplify chemical compositions to a single element to reduce computational cost and complexity, introducing large sources of uncertainty and potentially missing important behavior. In addition, engineering alloys such as SS 316 are particularly challenging to simulate with first principles methods because of the additional degrees of freedom introduced by magnetic natures of the constituent elements, and very little data of this type exists within the literature. These novel methods aim to improve the qualitative prediction of radiation damage in engineering alloys by more accurately simulating their compositions, both by accelerating the computations and by developing novel analyses.
This study is focusing on leveraging the system design tools set for the next-generation solid oxide fuel cell (SOFC) based natural gas fuel cell (NGFC) system. Conventionally, system design and optimization of NGFC systems rely heavily on traditional reduced order model (ROM) techniques and designers’ experience level. For overcoming the technical barriers of system design, multiple multi-physics models and machine learning (ML) tools have been utilized to automate the conceptual design process and enhance the reliability of solutions for the NGFC system. The proposed tools set includes a physics-informed ML tool for automated ROM construction that leverages advances in deep neural networks to significantly reduce ROM prediction error for the NGFC power island compared to traditional approaches. The constructed physics-informed ML ROM can be used in system design, and optimization tools set Institute for the Design of Advanced Energy Systems (IDAES) Process Systems Engineering (PSE) framework. The tools set also provides a user-friendly graphic user interface built within Jupyter Notebooks, and the complete tools set is open-source public available.
In a Computer Numerical Controlled (CNC) finishing process, the target material removal from an optical surface is guided by the convolution between the influence function of a machine tool and its dwell time at certain points over the surface. To reduce dynamics stressing and increase machining efficiency, the dwell time must be converted to varying velocities, which are the actual inputs to the machine tool controller. Conventionally, the conversion assumed constant acceleration and relied on linear motion interpolation, which caused discontinuities in velocities. This unsmooth motion affects the material removal distribution, and, thus, the accuracy of the finished surface shape. Many modern CNC machines support the smoother, cubic-polynomial interpolated Position-Velocity-Time (PVT) motion mode; however, the conventional scheduler may fail to provide suitable velocities for the PVT. Here in this study answers this challenge by proposing a novel PVT-based velocity scheduler that achieves smooth motion while considering CNC dynamic limits. Firstly, the principle of the PVT is explained, and the PVT-based velocity scheduler is formulated. Secondly, a quadratic programming is used to optimize the velocities by imposing the CNC dynamic constraints and the C 1 continuities (zeroth and first derivatives are continuous) simultaneously. Thirdly, the smoothness and accuracy of the scheduled velocities are studied on different kinds of tool paths via simulation. Finally, a sub-0.3 nm level surface finishing experiment using ion beam figuring is demonstrated to verify the feasibility of the proposed method. The PVT-based scheduler and simulator code is open-sourced.
Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process toolpath does not account for geometric discrepancies caused by the previous AM step, which leads to increased production times and tool wear, particularly when wire-based directed energy deposition (DED) is used as the AM process. This work discusses a methodology for approximating a part’s surface topology using on-machine contact probing and formulating an optimized SM toolpath using the surface topology approximation. Three different geometric surface approximations were used: triangular, trapezoidal, and a hybrid of both. SM toolpaths were created using each geometric approximation and assessed according to three objectives: reducing total machining time, reducing surface roughness, and reducing cutting force. Different prioritization scenarios of the optimization goals were also investigated. The optimal surface approximation that yielded the most improvement in the optimization was determined to be the hybrid surface topology approximation. Furthermore, it was shown that when the machining time or cutting force optimization goals were prioritized, there was little improvement in the other optimization goals.
This paper describes the workforce development activities supported by America’s Cutting Edge (ACE), a national initiative for machine tool technology development and advancement. ACE is supported by the Department of Defense Industrial Base Analysis and Sustainment (IBAS) program from the Office of Industrial Policy. Both the online and in-person components of the computer numerically controlled (CNC) machining and metrology training programs are summarized and participation information is provided.
In this 25 minute presentation, we showcase our open source “GeoThermalCloud” tool for identifying hidden geothermal resources using a publicly available dataset for southwestern New Mexico. The presenters include Bulbul Ahmmed and Luke Frash. All of the visuals use source material from LA-UR approved publications and this work falls under the Earth Sciences DUSA. The code shown in this video is already released with LANL approval in open source format on GitHub and DockerHub. The audio in this video includes only material on the topics of geothermal energy and machine learning applied to geothermal energy. The primary machine learning method used is LANL’s Non-negative Matrix Factorization “NMFk” method. Modeling work also mentions LANL’s Geothermal Design Tool “GeoDT” which is another approved open source code that has been released by LANL. This work was performed for DOE Geothermal Technologies Office (DE-EE-3.1.8.1). The host for the released video is intended to be YouTube or a suitable perpetual data repository such as GDR.
We report the overarching hypothesis of this study was that temporal microbial potentiometric sensor (MPS) signal patterns could be used to predict changes in commonly monitored water quality parameters by using artificial intelligence/machine learning tools. To test this hypothesis, the study first examines a proof of concept by correlating between MPS's signals and high algae concentrations in an algal cultivation pond. Then, the study expanded upon these findings and examined if multiple water quality parameters could be predicted in real surface waters, like irrigation canals. Signals generated between the MPS sensors and other water quality sensors maintained by an Arizona utility company, including algae and chlorophyll, were collected in real time at time intervals of 30 min over a period of 9 months. Data from the MPS system and data collected by the utility company were used to train the ML/AI algorithms and compare the predicted with actual water quality parameters and algae concentrations. Based on the composite signal obtained from the MPS, the ML/AI was used to predict the canal surface water's turbidity, conductivity, chlorophyll, and blue-green algae (BGA), dissolved oxygen (DO), and pH, and predicted values were compared to the measured values. Initial testing in the algal cultivation pond revealed a strong linear correlation (R 2 = 0.87) between mixed liquor suspended solids (MLSS) and the MPSs' composite signals. The Normalized Root Mean Square Error (NRMSE) between the predicted values and measured values were <6.5%, except for the DO, which was 10.45%. The results demonstrate the usefulness of MPSs to predict key surface water quality parameters through a single composite signal, when the ML/AI tools are used conjunctively to disaggregate these signal components. The maintenance-free MPS offers a novel and cost-effective approach to monitor numerous water quality parameters at once with relatively high accuracy.
Temperature-based methods have been developed to infer 1D vertical exchange flux between a stream and the subsurface. Current analyses rely on fitting physically based analytical and numerical models to temperature time series measured at multiple depths to infer daily average flux. These methods have seen wide use in hydrologic science despite strong simplifying assumptions including a lack of consideration of model structural error or the impacts of multidimensional flow or the impacts of transient streambed hydraulic properties. We performed a “perfect-model experiment” investigation to examine whether regression trees, with and without gradient boosting, can extract sufficient information from model-generated subsurface temperature time series, with and without added measurement error, to infer the corresponding exchange flux time series at the streambed surface. Using model-generated, synthetic data allowed us to assess the basic limitations to the use of machine learning; further examination of real data is only warranted if the method can be shown to perform well under these ideal conditions. We also examined whether the inherent feature importance analyses of tree-based machine learning methods can be used to optimize monitoring networks for exchange flux inference.
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GSA (Geological Society of America) Connects 2022, Denver CO, October 7-10, 2022