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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Using AMReX's Embedded Boundaries to Support MFIX-Exa’s Geometry Capabilities

MFIX-Exa is an AMReX-based application used for the simulation of chemically reacting multiphase flows inside reactors. The reactor geometry is mostly a combination of primitive shapes such as cylinders, cubes and spheres of varying dimensions connected together with potentially a lot of dead space between them. Additionally, the reactors may have particle-laden jets introduced at different parts of their geometry to enhance reactant mixing. This talk presents how MFIX-Exa uses OpenSCAD’s csg format to allow users to define the embedded boundary (EB) geometry and how it supports specifying inflow through certain sections of the EB. The talk will describe how MFIX-Exa leverages the EB features of grid-pruning, restart files and redistribution. Finally, the talk goes over some capabilities which are currently not available in MFIX-Exa but planned for the future, such as moving parts of the reactor geometry.

embedded boundaries↗
DOE OSTI2025

Thermomechanics coupling to Monte Carlo particle transport on unstructured mesh geometries using Cardinal

Geometry deformation due to thermal expansion influences neutron transport in many systems. Studying this phenomenon involves coupling models for neutronics, thermal hydraulics, and solid mechanics. To enable high fidelity modeling of these coupled physics, new capabilities were introduced in Cardinal, coupling OpenMC Monte Carlo particle transport models with MOOSE thermomechanical physics on unstructured moving-mesh geometries. In this work, we present a fully open-source capability leveraging on-the-fly mesh skinning to automatically regenerate OpenMC geometry, which allows multiphysics feedback from temperature, density, and geometry changes. The new capability is verified using an analytic benchmark slab problem, which couples S 2 neutron transport with thermal conduction, convective boundary conditions, Doppler-broadened cross sections, and nonlinear thermal expansion effects along the heated slab. Cardinal reproduces the analytic solutions for the neutron flux, heating, k eff , and temperature with demonstrated convergence in various error terms including mesh resolution and cross section temperature library spacing. For the nominal benchmark conditions and with a fine mesh, maximum relative errors for neutron flux, temperature, and heating are lower than 1%, while errors in integral quantities such as k eff and slab length are within 1 pcm and 48 µm, respectively. This work (i) presents a new numerical approach to thermomechanics coupling with OpenMC models, (ii) is the first (to our knowledge) to utilize a mechanical partial differential equation (PDE) solution to solve the (Griesheimer and Kooreman, 2022) analytic benchmark, and (iii) develops this verified capability within an open-source package.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Consistent solutions of the radiation diffusion equation in spherical and cylindrical geometries

We have extended the radiation diffusion model of Hammer and Rosen [Phys. Plasmas 10, 1829 (2003)] to diverging spherical and cylindrical geometries. The effect of curvilinear geometry on the supersonic, expanding wavefront increases as the internal radius of a spherical or cylindrical shell approaches zero. Small spherical geometries are important for modeling systems at the size scale of inertial confinement fusion capsules, at these scales existing quasi-analytic models for planar geometry significantly disagree with the results of simulation. With this method, the benefits of rapid iteration can be applied to common spherical systems at much smaller length scales. We present comparisons between numerical diffusion solutions and the analytic model to give ranges of applicability for the model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Modeling Multi-View Impedance-Based Cross-Geometry SOH Estimator for Li-ion Batteries

Abstract: Accurately estimating battery’s State of Health (SOH) remains challenging when models must generalize across cell designs and operating conditions. Most Electrochemical Impedance Spectroscopy (EIS)-based approaches either (i) hand-engineer a few Nyquist-plot features for shallow models—fast but does not generalize across geometries—or (ii) learn directly from Nyquist plots with deep networks, which removes manual feature extraction, yet still limited to a single plot type. As a result, cross-geometry robustness and deployability on constrained Internet of Things (IoT) devices remain open problems. We propose a compact Convolutional Neural Network (CNN) (∼ 10k parameters) that takes multi-representation EIS inputs—Nyquist (real/imaginary) and phase–magnitude (|Z|/ϕ) stacked as four channels, so the model can learn complementary degradation signatures while remaining small enough for fast inference. We build a dataset from cyclic aging of two geometries (LG INR18650MJ1 cylindrical cells and LIR2032 coin cells), acquire EIS every ten cycles from 10 kHz to 10 mHz (10 points/decade), and evaluate with leave-one-cell-out testing strategy. We further study fusion vs. single-representation inputs and assess feasibility for on-device deployment (e.g., NVIDIA Jetson device). The results show that training on multiple EIS representations improves SOH estimation accuracy and cross-geometry generalization compared to single-representation models, which uses only Nyquist or phase–magnitude plots. This design targets accurate, generalizable SOH prediction without manual feature engineering while enabling practical real-time use.

Bakr, Ahmed [The University of Alabama (UA)]↗
DOE OSTI2025

A Block-Structured Adaptive Mesh Framework to Solve Radiation Transfer Equation in Irregular Embedded Geometries

Radiation transport arises in various scientific, industrial, and medical fields, and understanding its effect in applications is needed to make accurate predictions, safety assessments and performance optimizations. Solving the Radiation Transport Equation (RTE) is challenging due to its integro-differential nature, which involves both differential and integral terms. The differential term describes the change in radiation intensity due to absorption and emission, while the integral term accounts for scattering. The accurate modeling of radiation is further complicated in many applications due to the complex, irregular geometries. Various methods exist for solving the RTE, including the zonal, Monte Carlo, spherical harmonics, discrete ordinates, and finite volume methods. Traditional mesh-based approaches, which rely on structured or unstructured meshes, struggle with irregular geometries due to: a) the difficulty of conforming structured grids to irregular domains, b) challenges in enforcing boundary conditions correctly, and c) the additional computational cost of unstructured mesh methods. This work presents a second-order accurate method for solving the RTE in irregular geometries. The radiation intensity is discretized using the finite-volume method in both spatial and angular directions on regular Cartesian grid blocks. Leveraging the block-structured adaptive mesh refinement (AMR) framework provided by AMReX, our method refines the grid locally to reduce spatial discretization error, ensuring a converged numerical solution while minimizing computational costs elsewhere. A two-stage deferred correction approach is employed: First, a first-order discretization on grid blocks is solved using an algebraic multigrid method in HYPRE. Second, a correction term is applied explicitly to achieve second-order accuracy. The correction term is calculated by approximating the radiation flux on cell faces using a Total Variation Diminishing (TVD) scheme. This approach ensures quick convergence of the multigrid method while preserving higher-order accuracy of the numerical solution. Irregular geometries are resolved as embedded boundaries (EB), resulting in both cut cells and regular cells. In cut cells, we modify the fluxes using face fractions and incorporate additional contributions from EB boundary conditions. To ensure higher-order convergence near the EB interface, the correction term is modified by interpolating the radiation intensity to fictitious ghost points. The implementation takes advantage of modern supercomputers by leveraging AMReX’sMPI/X parallelization strategy where X can be MPI or a GPU accelerator including CUDA, HIP and DPC++. We validate our solver using classical test cases, both with and without EB, demonstrating accuracy and efficiency. Additionally, we analyze the impact of adaptive mesh refinement on solution accuracy and computational cost, highlighting the advantages of our approach for high-resolution radiation transport simulations.

computational fluid dynamics (CFD)↗
DOE OSTI2025

Understanding Geometry and Microstructure Interactions In LPBF By Linking Lab Scale Studies To Real Part Case Examples

The mechanical properties derived from simple tensile tests are uniquely important in the design and qualification of load bearing metallic components. The tensile properties in standards for wrought metallic materials are generally accessible for design and simulation engineers, but this is not the case for additively manufactured metals. This work investigates the influence of tensile specimen geometry on the mechanical properties of laser powder bed fusion (LPBF) additively manufactured Ti-6Al-4V, particularly in relation to properties measured from specimens excised from an exemplar part. A comprehensive analysis was conducted across various specimen geometries, considering factors such as thermal history, cross-sectional area, shape, and surface roughness. Key findings reveal that sample size, particularly cross-sectional area, significantly affects reported tensile properties, with ASTM E8 flat and round specimens exhibiting differences in elastic modulus (13%), yield strength (17%), ultimate tensile strength (UTS) (14%), and elongation to failure (11%). Additionally, surface roughness was found to have a limited impact on ASTM round geometries, but it becomes critical in thin-walled and small high-throughput samples. The ASTM flat samples closely matched the properties of samples excised from the exemplar part, underscoring the necessity of testing witness samples that accurately represent end-use conditions. Furthermore, mechanical properties of samples built within the stitch zone of the exemplar part demonstrated reduced ductility, highlighting the importance of laser alignment and qualification in multi-laser additive manufacturing processes. Overall, this study emphasizes the need for careful consideration of specimen geometry and testing conditions to ensure accurate reporting of mechanical properties in LPBF Ti-6Al-4V.

36 MATERIALS SCIENCE↗
NASA NTRS1973

A study of engine variable geometry systems for an advanced high subsonic long range commercial aircraft

Several variable geometry high Mach inlet concepts, aimed at meeting a system noise objective of 15 EPNdB below FAR part 36, for a long range, Mach 0.9 advanced commercial transport are assessed and compared to a fixed geometry inlet with multiple splitters. The effects of a variable exhaust nozzle (mixed exhaust engine) on noise, inlet geometry requirements, and economics are also presented. The best variable geometry inlet configuration identified is a variable cowl design which relies on a high throat Mach number for additional inlet noise suppression only at takeoff, and depends entirely on inlet wall treatment for noise suppression at approach power. Relative economic penalties as a function of noise level are also presented.

Compagnon, M. A.↗
NASA NTRS1979

Interfacial geometry and D-variation effects in two-phase systems

Numerical solutions of the governing diffusion equation for two-phase concentration dependent diffusion coefficients are examined. Solutions were also calculated for planar, cylindrical, and spherical geometries to compare the effect of interface geometries with those caused by concentration-dependent diffusion coefficients, and two methods of averaging D were considered to determine the best averaging method for different types of D-variations. The effects of interface-location criteria on mass conservation and convergence of interface location, diffusion coefficient variation in the alpha and beta-phases of a two-phase binary alloy system, effect of D(alpha) variation in a cylindrical couple on beta-phase thickness, and geometry and D-variation effects on the degree of homogenization were determined. It is concluded that typical D(alpha)-variations can have a greater influence on the kinetics of interdiffusion than the geometry.

Tenney, D. R.↗
NASA NTRS1982

Aircraft geometry verification with enhanced computer generated displays

A method for visual verification of aerodynamic geometries using computer generated, color shaded images is described. The mathematical models representing aircraft geometries are created for use in theoretical aerodynamic analyses and in computer aided manufacturing. The aerodynamic shapes are defined using parametric bi-cubic splined patches. This mathematical representation is then used as input to an algorithm that generates a color shaded image of the geometry. A discussion of the techniques used in the mathematical representation of the geometry and in the rendering of the color shaded display is presented. The results include examples of color shaded displays, which are contrasted with wire frame type displays. The examples also show the use of mapped surface pressures in terms of color shaded images of V/STOL fighter/attack aircraft and advanced turboprop aircraft.

Cozzolongo, J. V.↗
NASA NTRS1982

Slab-geometry Nd:glass laser performance studies

It is noted that slab-geometry solid-state lasers potentially provide significant performance improvements relative to conventional rod-geometry lasers. Experimental measurements that use an Nd:glass test-bed slab laser are presented. A comparison is made between the results and computer-model predictions of the slab-geometry approach. The computer model calculates and displays the temperature and stress fields in the slab, and on the basis of these predicts birefringence and index-of-refraction distributions. The effect that these distributions have on optical propagation is determined in a polarization-sensitive ray-tracing section of the model. Calculations are also made of stress-induced surface curvature and the resulting focusing effects. The measurements are found to be in good agreement with the computer-model predictions. It is concluded that the slab configuration offers significant laser-performance advantages in comparison with the traditional rod-laser geometry.

Eggleston, J. M.↗
NASA NTRSDate not supplied

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

vaned diffuser↗
NASA NTRSDate not supplied

Experimental and Numerical Investigation of the NASA High Efficiency Centrifugal Compressor Vaned Stage Geometry and Aerodynamic Performance

Since its inception in the early 2010s, the NASA High Efficiency Centrifugal Compressor (HECC) has been enigmatic for the propulsion research community: experimental data and numerical simulations of the stage have generally not aligned in their quantifications of performance metrics. Typically, the fault for these disagreements is assigned to the numerical simulations as the simulations are models, and models are inherently incomplete representations of the experiment. This “incompleteness” may manifest in assumptions regarding roughness or heat transfer, simplifications of the flow path (i.e., neglecting bleed flows), or the oft-scapegoated turbulence model. In the case of HECC, recent work showed unexpected discrepancies between the intended impeller geometry defined in the design report (termed Design-Intent) and the manufactured impeller used in the experimental campaigns (termed As-Manufactured). That work used numerical simulations to establish that the geometric differences between the Design-Intent and As-Manufactured impellers were significant enough to result in drastically different performance predictions for the HECC vaneless diffuser configuration. The Design-Intent impeller simulations over predicted the performance relative to the experiment, whereas the As-Manufactured simulations better represented the experimental data, both in terms of one-dimensional performance metrics and spanwise flow profiles. This effort expands on that work by examining in detail the geometry and aerodynamic performance of the HECC vaned diffuser configuration. Further differences between the Design-Intent and As-Manufactured geometries have been discovered in the vaned diffuser and exit guide vanes, and these differences are documented herein. The summations of the geometric differences for all of the components were used to create two numerical models of HECC vaned diffuser configuration: the Design-Intent simulations which are generated from the original geometry definitions given in the design report and the As-Manufactured simulations which are the best available representation of the manufactured compressor hardware used in the experimental test campaigns. In congruence with the earlier vaneless diffuser work, the numerical predictions of the Design-Intent choked mass flow rate, total pressure ratio, and efficiency were notably greater than that of the As-Manufactured simulations. To increase confidence in the experimental dataset, measurements from a recent test campaign conducted in 2024 are used to validate the original experimental data acquired from 2012 to 2014 with good repeatability overall, especially considering the passage of time and differences in the data acquisition systems between the test campaigns. Both numerical simulations were then extensively evaluated against the experimental data. The As-Manufactured simulations provided better estimates of the stage performance than the Design-Intent cases in terms of most performance metrics. Nonetheless, more detailed results still show opportunities for improvement. Despite a more accurate representation of the physical hardware, characterization of the impeller work input remains a challenge even for rigorously developed numerical models.

centrifugal compressor↗
DOE OSTI2025

Power Flow Geometry and Approximation

Here, the power flow equations are important in numerous power systems problems of practical interest which consider alternating current power flow (ACPF) physics. Perhaps the most well studied being the alternating current optimal power flow problem (ACOPF), seeking to optimize the operation of an electric power system. Due to their non-linearity, problems which include the power flow equations are typically challenging, particularly in optimization. Interestingly, the set of solutions to the power flow equations forms a smooth manifold. As a result, differential geometry can be used to describe and analyze this set of equations. This approach has proven effective in several engineering applications (e.g., solving ACOPF and analyzing the solution space boundary). Central to the success of this approach is an understanding of the power flow manifold's geometry. In this work, we develop the geometric and topological properties of this manifold using concepts from differential geometry. After demonstrating the convenience of this manifold's representation as a function's graph, computational methods are emphasized: we develop retractions, error bounds for linear approximation, and formulas for evaluating the Riemannian metric (including associated objects such as geodesics and the curvature tensor). Scalar curvature and the second fundamental form play a new role in quantifying the quality of linear approximations, like the popular direct current approximation. All functions are implemented in Julia and available in an online repository. Proofs are included for completeness.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
DOE OSTI2025

Exascale granular microstructure reconstruction in 3D volumes of arbitrary geometries with generative learning

Reconstructing 3D granular microstructures within volumes of arbitrary geometries from limited 2D image data is crucial for predicting the material properties, as well as performances of structural components accounting for material microstructural effects. We present a novel generative learning framework that enables exascale reconstruction of granular microstructures within complex 3D geometric volumes. Building upon existing transfer learning techniques using pre-trained convolutional neural networks (CNN), we introduce several key innovations to overcome the difficulties inherent in arbitrary geometries. Our framework incorporates periodic boundary conditions using circular padding techniques, ensuring continuity and representativeness of the reconstructed microstructures. We also introduce a novel seamless transition reconstruction (STR) method that creates statistically equivalent transition zones to integrate multiple pre-existing 3D microstructure volumes. Based on STR, we propose a cost-effective strategy for reconstructing microstructures within complex geometric volumes, minimizing computational waste. Validation through numerical experiments using kinetic Monte Carlo simulations demonstrates accurate reproduction of grain statistics, including grain size distributions and morphology. A case study involving the reconstruction of a 4-blade propeller microstructure illustrates the method’s capability to efficiently handle complex geometries. In conclusion, the proposed framework significantly reduces computational demands while maintaining high reconstruction quality, paving the way for scalable microstructure reconstruction in materials design and analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies

Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.

42 ENGINEERING↗
DOE OSTI2025

Co-optimization of fuel properties, combustion system geometry, and injection strategy for conventional diesel fuel

Here, studies have shown that fuel properties can impact an engine’s operation in several ways, including ignition delay, sooting tendency, mixture formation, and combustion temperature. In mixing-controlled compression ignition (MCCI) engines, the fuel system design and piston bowl geometry significantly affect combustion performance and emissions. Based on current information, it is difficult to draw conclusions about fuel property effects and sensitivities. The central fuel hypothesis approach used in the US Department of Energy Co-Optima program has worked well for spark ignition fuels: identifying critical fuel property ranges is sufficient to screen fuel blends that are expected to maximize efficiency and reduce pollutant emissions. However, for MCCI-relevant fuels, the information gained from past studies is not sufficient to build such a merit function or to allow for performing a similar screening of fuel blends. It is hypothesized that a co-optimization of a fuel’s physical and chemical properties, combustion system geometry, and injection strategy could leverage synergies between the effects of the fuel properties and geometries, resulting in improved performance over state-of-the-art. A machine learning–assisted unconstrained global optimization algorithm was used to explore a design space comprising 23 independent variables. The results show that physical property effects were minimal even for large variations in fuel properties, and the only interaction effect that was observed was the effect of varied fuel density parameters on fuel/air mixture formation. Nevertheless, these interactions were not sufficient in magnitude to significantly affect optimization results. Therefore, analysis of the results suggests that fuel physical properties cannot be leveraged in a co-optimization context to increase engine efficiency.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Robustness of the smartpixels classifier for different simulated sensor geometries and non-ideal detector conditions

Pixel tracking detectors at upcoming collider experiments will see unprecedented charged-particle densities. Real-time data reduction on the detector will enable higher granularity and faster readout, possibly enabling the use of the pixel detector in high-rate online event selection, such as the ATLAS or CMS first-level trigger systems. This data reduction can be accomplished with a neural network (NN) in the readout chip bonded with the sensor that recognizes and rejects tracks with low transverse momentum (p T ) based on the geometrical shape of the charge deposition (“cluster”). To design viable detectors for deployment, the dependence of the NN as a function of the sensor geometry, external magnetic field, irradiation, and noise must be understood. In this paper, we present first studies of the efficiency and data reduction for planar pixel sensors exploring these parameters. For the CMS HL-LHC sensor geometry, we obtain a signal efficiency of (91.9 ± 0.7)% and a data reduction of (29.7 ± 1.0)%. A smaller sensor pitch in the bending direction improves the p T discrimination, but a larger pitch can be partially compensated with detector thickness. Any accumulated radiation damage also changes the cluster shape, reducing the signal efficiency compared to the baseline by approximately 30–60% in absolute terms, but nearly all of the performance can be recovered through retraining of the network and updating the weights. Finally, the impact of noise was investigated, and retraining the network on noise-injected datasets was found to maintain performance within 6% of the baseline network trained and evaluated on noiseless data. •ASIC-compatible track-momentum classifier is robust in realistic detector conditions.•About 90% signal efficiency and 30% data reduction per layer for CMS HL-LHC geometry.•Single-layer signal efficiency increases for smaller pixel pitch or thicker sensors.•Performance with noise or after radiation damage mostly recovered by retraining.

Shekar, Danush [Illinois U., Chicago] (ORCID:00000↗