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DOE OSTI2024

Deep learning with plasma plume image sequences for anomaly detection and prediction of growth kinetics during pulsed laser deposition

Abstract Materials synthesis platforms that are designed for autonomous experimentation are capable of collecting multimodal diagnostic data that can be utilized for feedback to optimize material properties. Pulsed laser deposition (PLD) is emerging as a viable autonomous synthesis tool, and so the need arises to develop machine learning (ML) techniques that are capable of extracting information from in situ diagnostics. Here, we demonstrate that intensified-CCD image sequences of the plasma plume generated during PLD can be used for anomaly detection and the prediction of thin film growth kinetics. We develop multi-output (2 + 1)D convolutional neural network regression models that extract deep features from plume dynamics that not only correlate with the measured chamber pressure and incident laser energy, but more importantly, predict parameters of an auto-catalytic film growth model derived from in situ laser reflectivity experiments. Our results demonstrate how ML with in situ plume diagnostics data in PLD can be utilized to maintain deposition conditions in an optimal regime. Further, the predictive capabilities of plume dynamics on the kinetics of film growth or other film properties prior to deposition provides a means for rapid pre-screening of growth conditions for the non-expert, which promises to accelerate materials optimization with PLD.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Accurate and uncertainty-aware multi-task prediction of HEA properties using prior-guided deep Gaussian processes

Surrogate modeling techniques have become indispensable in accelerating the discovery and optimization of high-entropy alloys (HEAs), especially when integrating computational predictions with sparse experimental observations. This study systematically evaluates the training and testing performance of four prominent surrogate models—conventional Gaussian processes (cGP), Deep Gaussian processes (DGP), encoder-decoder neural networks for multi-output regression and eXtreme Gradient Boosting (XGBoost)—applied to a hybrid dataset of experimental and computational properties of the 8-component HEA system Al-Co-Cr-Cu-Fe-Mn-Ni-V. We specifically assess their capabilities in predicting correlated material properties, including yield strength, hardness, modulus, ultimate tensile strength, elongation, and average hardness under dynamic/quasi-static conditions, alongside auxiliary computational properties. The comparison highlights the strengths of hierarchical deep modeling approaches in handling heteroscedastic, heterotopic, and incomplete data commonly encountered in materials science. Our findings illustrate that combined surrogate models such as DGPs infused with machine-learned priors outperform other surrogates by effectively capturing inter-property correlations and by assimilating prior knowledge. This enhanced predictive accuracy positions the combined surrogate models as powerful tools for robust and data-efficient materials design.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Covariance Shaping Over Riemannian Manifolds for Massive MIMO Communication

Acquiring accurate instantaneous channel state information (CSI) is a challenging aspect of massive multi-input multi-output (MIMO) communication. Utilizing statistical information, such as channel covariance matrix, to design statistical beamforming vectors is robust when compared to instantaneous CSI. In this paper, we propose a novel MIMO covariance shaping scheme over Riemannian manifolds. It serves as an effective statistical beamforming solution to a number of close proximity user equipment (UE) that are undergoing substantial channel correlation. Proposed algorithm exploits the Hermitian positive definite nature of covariance matrices lying over Riemannian manifold. We introduce Wasserstein distance function as a Riemannian metric to measure distances between channel covariance matrices. Furthermore, K-means clustering technique is utilized to effectively identify the optimal shape of effective optimal covariance matrices. Our findings suggest that maximizing the geodesic distance between covariance matrices ultimately leads to a corresponding increase in the network throughput, as determined by the beamforming vector used to shape the covariance matrices. Simulation results validate that the proposed solution converges faster than Euclidean-based state-of-the-art, while maintaining the same computational complexity. Finally, the sum rate performance asymptotically achieves full capacity for two-UE case and more than 96% of the upper bound exhaustive search benchmark for multi-UE scenario.

42 ENGINEERING↗

DOE OSTI2022

A Stability Analysis Tool for Bulk Power Systems Using Black-Box Models of Inverter-based Resources

This paper presents a small-signal stability analysis tool for large-scale power systems with high penetration of inverter-based resources (IBRs). Firstly, a network transfer function matrix (NTFM), which represents the information of the system topology, transmission lines, loads, IBRs locations, etc., is derived to model the entire power system network. Secondly, small-signal perturbation method is applied to obtain the sequence impedance/admittance responses of IBRs considering the frequency cross-coupling effects. With the obtained NTFM as well as IBRs' models, a multi-input, multi-output (MIMO) feedback system is constructed, and the generalized Nyquist criterion (GNC)-based stability method is employed to analyze the stability of the entire power system. Different testing cases based on a modified IEEE-14 bus system are leveraged to verify the proposed stability analysis tool.

Sun, Dongsen↗

DOE OSTI2026

A Unified Design Theory for Multi-Port Polyphase Transformers Enabling Scalable Power-Multiplexed EV Fleet Charging Systems

This paper presents a unified analytical design theory for multi-port polyphase transformers, targeting scalable and isolated high-power Electric Vehicle (EV) fleet charging systems with power multiplexing capability. As fleet electrification accelerates, conventional one-to-one charger architectures face significant challenges in infrastructure cost, peak power demand, and low utilization of installed power electronics. Power-multiplexed charging architectures, which dynamically distribute power from a shared pool of converter modules across multiple vehicles, have emerged as a promising solution. However, such architectures require scalable, isolated multi-port power interfaces capable of routing energy among multiple inputs and outputs, whose design remains complex and dependent on iterative modeling. To address this gap, the proposed theory provides closed-form expressions for self-inductance, leakage inductance, and mutual coupling terms for arbitrary multi-phase, multi-port transformer structures. The formulation enables direct synthesis of isolated multi-input and multi-output resonant converter systems without reliance on geometry-specific finite-element analysis or extensive parameter extraction. This capability is particularly critical for power-multiplexed systems, where modular converter structures must interface with multiple vehicles while maintaining galvanic isolation and flexible power allocation. The effectiveness of the proposed framework is demonstrated through the design of a 360 kW multi-phase system operating over a 700–900 VDC input and 400–1250 VDC output range. PLECS simulation results confirm accurate prediction of system behavior and validate the applicability of the approach to multi-port, power-multiplexed charging scenarios. The proposed method significantly reduces design complexity while enabling scalable, cost-effective, and fully utilized EV fleet charging infrastructure.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2023

A Stability Analysis Tool for Bulk Power Systems Using Black-Box Models of Inverter-Based Resources

This paper presents a small-signal stability analysis tool for large-scale power systems with high penetration of inverter-based resources (IBRs). Firstly, a network transfer function matrix (NTFM), which represents the information of the system topology, transmission lines, loads, IBRs locations, etc., is derived to model the entire power system network. Secondly, small-signal perturbation method is applied to obtain the sequence impedance/admittance models of the block-box IBRs considering the frequency cross-coupling effects. With the obtained NTFM as well as IBR models, a multi-input, multi-output (MIMO) feedback system is constructed, and the generalized Nyquist criterion (GNC)-based stability method is employed to analyze the stability of the entire power system. Furthermore, based on the developed stability analysis method, sensitivity analysis is conducted on an unstable case to identify which parameter has a high impact on the system stability. As a result, different test cases based on a modified IEEE 14- bus system as well as a reduced 240-bus WECC system are studied to verify the proposed stability analysis tool.

42 ENGINEERING↗

DOE OSTI2022

Wavelet and Deep-Learning-Based Approach for Generation System Problematic Parameters Identification and Calibration

Accurate models of generation systems are critical for maintaining reliable and secure grid operations. In this paper, a novel and systematic approach is proposed to identify and calibrate the generation system problematic parameters using continuous wavelet transform (CWT) and advanced deep-learning technology. The phasor measurement unit (PMU) data are used through “event playback” to check whether the parameter calibration is required, and if yes, a group of suspicious parameters will be identified as the primary problematic parameter candidates (PPCs). These primary PPCs are randomly perturbed to generate the event playback simulation data, which are used by the CWT and convolutional neural networks (CNNs) to further narrow down the primary PPCs into a smaller set of candidates. Then, the identified candidates are perturbed again to generate massive event playback simulation data for training a parameter calibration neural network. Here, we designed a multi-output neural network structure to find the mappings between the perturbed parameters and the simulation data using both CNN and long short-term memory (LSTM) models. Finally, the well-trained and tested CNN-LSTM model is used to estimate the accurate value of the suspicious parameters with actual PMU measurements. The proposed CNN-LSTM network can accurately and reliably estimate the generation-system problematic parameters, and has better performance when compared to other machine-learning methods, such as the multilayer perceptron network and the conditional variational autoencoder method. The accuracy and effectiveness of the proposed approach have been validated through simulation and real-world data.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Iterative Stability Enforcement in Adaptive Antoulas–Anderson Algorithms for \({\boldsymbol{\mathcal{H}_2}}\) Model Reduction

This paper presents an extension of the Adaptive-Antoulas-Anderson (AAA) algorithm for rational modelling. Specifically, our new stable multi-input multi-output AAA (smiAAA) algorithm builds rational approximations of multi-input signals with a common set of stable poles. A new methodology is presented for iteratively enforcing stability constraints on the poles. We demonstrate the strengths of this approach compared to the stability enforcement in the FastAAA algorithm. Results using the smiAAA algorithm are compared with the commonly used Vector Fitting algorithm and the more recently published RKFIT algorithm. Vector Fitting and RKFIT both require the user to input the number of poles to use in the approximations. If the final approximation is not accurate enough, the user must re-start Vector Fitting or RKFIT with a larger number of poles and/or a new starting location for the poles. In contrast, the smiAAA algorithm is designed to allow the user to simply input the desired accuracy of the approximations, and the necessary number of poles is detected automatically. This permits users to produce approximations of a desired accuracy with no knowledge about the underlying order of the system being approximated, preventing the algorithm from ever needing to be rerun. An additional feature for preventing extraneous poles from being returned by AAA is also discussed. The cause of these extraneous poles is efficiently detected and removed by our presented methodology. In conclusion, the examples presented demonstrate that smiAAA can efficiently produce approximations of similar or better accuracy than Vector Fitting and RKFIT while requiring less input from the user.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

BOOTS: Bayesian Optimization for Optimal Test Selection

BOOTS is a package for optimal selection of candidate operating points in large-scale manufacturing applications. It is designed to optimally select operating points to maximize predicted values of product quality and resource efficiency according to a data-driven model. The package is based on the use of a multi-input multi-output (MIMO) Gaussian process model to describe the relationships between inputs (operating points) and outputs (product quality and resource efficiency). This package does not provide any site- or process-specific information.

Villez, Kris [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2025

UBW (USLCI-Brightway2) [SWR-25-169]

Life cycle inventory (LCI) data are critical for robust life cycle assessment (LCA), yet many widely used datasets such as the U.S. Life Cycle Inventory (USLCI) are not natively compatible with advanced modeling frameworks like Brightway2. This work presents an automated pipeline to transform USLCI data into a fully functional Brightway2 project. The workflow performs systematic data cleaning, resolves duplicate process and exchange identifiers, and applies allocation to multi-output processes. Technosphere and biosphere flows are harmonized through unit conversions and a bridge mapping to the biosphere3 database, with comprehensive logging of missing flows and cutoff issues. The resulting Brightway2 database is validated using matrix diagnostics to ensure consistency of the technosphere, and is benchmarked via life cycle impact assessment (LCIA) methods such as ReCiPe and IPCC GWP. Outputs include reproducible CSV exports of corrected processes, elementary flows, characterization factors, and LCIA results, alongside backup utilities for project sharing. This pipeline lowers barriers for integrating USLCI data into open-source LCA workflows, enabling reproducible, validated LCA inventories within the Brightway 2 framework.

Ghosh, Tapajyoti [National Laboratory of the Rocki↗

DOE OSTI2023

Development of a dynamical model and energy analysis for wheel loader

The objective of this paper is to develop a fully integrated model for the wheel loader, including the subsystem dynamics of the engine, drivetrain, working circuit, steering circuit, and vehicle. It leads to a high-order strongly nonlinear system, and all state variables are coupled together to form a Multi-Input and Multi-Output (MIMO) system. A control architecture is proposed to decouple the MIMO system into several Single-Input and Single-Output (SISO) systems. Here, a tracking problem has been formulated to validate this fully integrated model with the field test data. The accuracy of the model is verified by the 2.3% difference between the measured and simulated fuel consumption. Meanwhile, an energy distribution analysis is conducted to reveal the energy consumption and energy loss of each portion of the wheel loader. Such a model can be used to plan the working pattern, guide the driving habits of human operators, or refine the underlying architecture, leading to the ultimate goal of reducing total fuel consumption and improving productivity.

42 ENGINEERING↗

DOE OSTI2023

MASK4 Test Campaign for Sandia WaveBot Device

This data and report details the findings from a wave tank test focused on production of useful work of a wave energy converter (WEC) device. The experimental system and test were specifically designed to validate models for power transmission throughout the WEC system. Additionally, the validity of co-design informed changes to the power take-off (PTO) were assessed and shown to provide the expected improvements in system performance. These data describe the "MASK4" wave tank test of the Sandia WaveBot device. The WaveBot device has been tested a number of times in different permutations at the US Navy's Maneuvering and Sea Keeping (MASK) basin. Each test in this series is referred to as MASK1, MASK2, etc. The WaveBot device was first tested in one degree of freedom (heave) in 2016. This MASK1 test focused primarily on system identification and modeling. After MASK1, major modifications were performed to improve the overall real-time control and measurement system, improve the heave drive train, and add surge and pitch degrees of freedom. The second set of testing, which was broken up in to two stages: MASK2A and MASK2B, focused on bench testing and closed-loop control performance as well as nonlinear modeling. MASK3 then focused on multi-input, multi-output modeling and control for maximization of electrical power. The attached report presents the results from MASK4, which focuses on detailed modeling of the power conversion chain and validation co-design principles by way of the introduction of a magnetic spring. The test log, report, and data from the MASK4 test of the WaveBot augmented with a tunable magnetic spring. Processing codes can be found at the Github link below.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Towards Z-Next: The Integration of Theory, Experiments, and Computational Simulation in a Bayesian Data Assimilation Framework

Making reliable predictions in the presence of uncertainty is critical to high-consequence modeling and simulation activities, such as those encountered at Sandia National Laboratories. Surrogate or reduced-order models are often used to mitigate the expense of performing quality uncertainty analyses with high-fidelity, physics-based codes. However, phenomenological surrogate models do not always adhere to important physics and system properties. This project develops surrogate models that integrate physical theory with experimental data through a maximally-informative framework that accounts for the many uncertainties present in computational modeling problems. Correlations between relevant outputs are preserved through the use of multi-output or co-predictive surrogate models; known physical properties (specifically monotoncity) are also preserved; and unknown physics and phenomena are detected using a causal analysis. By endowing surrogate models with key properties of the physical system being studied, their predictive power is arguably enhanced, allowing for reliable simulations and analyses at a reduced computational cost.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Application of FARM to an IES scenario within the FORCE ecosystem

The FARM (Feasible Actuator Range Modifier) software module is a component of the RAVEN-based FORCE framework for analysis of Integrated Energy Systems (IES). FARM supports the HERON software module in the evaluation of the optimal dispatch by evaluating feasible set-points for the different IES unit components. Set-points are required to satisfy limits on both production variables (i.e., the variables to be optimized such as the electrical power, the hydrogen production rate, etc.) and process variables tied to the service life of equipment (e.g., steam flowrate, vessel pressure, turbine firing temperature, etc.). This problem is addressed by adopting a two-stage approach. First, the HERON power dispatcher determines set-points that meet the constraints on the former variables (e.g., power levels and power ramp rate limits). These constraints are called explicit constraints. Then, FARM adjusts these set-points to ensure the respect of the limits on the latter variables given the knowledge of the system physics acquired through machine learning algorithms. These constraints are called implicit constraints. From this standpoint, FARM constitutes a bridge between the HERON power dispatcher that adopts a simplified description of the IES unit (low-resolution physics) and the HYBRID high-fidelity models (high-resolution physics). The original version of the FARM software module (FARM-Alpha) was released by Argonne National Laboratory in January 2021. In the latest version of the code released in July 2022 (FARM-Delta), the Reference Governor (RG) algorithm was upgraded to a Multi-Input Multi-Output version from its original Single-Input Single-Output form. The RG algorithm acts to enforce constraints. With this improvement an IES unit is now treated as a single dynamic system from the standpoint of control. The crosstalk among components in an IES unit is now fully considered thereby ensuring a true optimization is obtained for those units that have multiple set-points. In this report, the capabilities of FARM-Delta operating within the FORCE ecosystem are demonstrated for an IES test case. The specific configuration of IES unit for this case was selected by the IES team with consultation from the Advanced Reactor IES Expert Group. A full TEA analysis that invoked HERON, HYBRID, FARM, and RAVEN was performed and serves to demonstrate how the latest modification to FARM algorithms (i.e., state variable selection, state-space matrices derivation, set-point verification) can shape setpoints that might otherwise compromise the health of equipment through accelerated wear and tear. In this specific test case, it was demonstrated that these algorithms ensure a more efficient utilization of steam resources to be shared by two different subsystems, namely Balance of Plant (BOP) and High-Temperature Steam Electrolysis (HTSE). Finally, some code improvements that can further enhance the user-friendliness are suggested.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Creation of Multiple Effect Evaporator and Combined Cycle Modelica Modules, and Optimization of Potable Water Generation from Saltwater Sources (Final Technical Report)

Modelica models for a Heat Recovery Steam Generator (HRSG) and Multiple Effect Evaporator have been developed. These models have been validated against results from literature and from an actual cogeneration system on the campus of NC State University. The models are capable of connecting to other components to create multi-input, multi-output energy systems with storage, also known as integrated energy systems. An existing 35 MW gas turbine model is connected to the HRSG model created for this project to produce 9 bar steam. The high pressure steam feeds a backpressure steam turbine from the library to generate additional electric power. 2 bar steam leaves the turbine to supply an 8 effect MEE to generate water for a community. As part of the effort, three research papers were submitted (two published in ANS Proceedings and one submitted to Applied Energy).

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Model predictive control for robust quantum state preparation

A critical engineering challenge in quantum technology is the accurate control of quantum dynamics. Model-based methods for optimal control have been shown to be highly effective when theory and experiment closely match. Consequently, realizing high-fidelity quantum processes with model-based control requires careful device characterization. In quantum processors based on cold atoms, the Hamiltonian can be well-characterized. For superconducting qubits operating at milli-Kelvin temperatures, the Hamiltonian is not as well-characterized. Unaccounted for physics (i.e., mode discrepancy), coherent disturbances, and increased noise compromise traditional model-based control. This work introduces model predictive control (MPC) for quantum control applications. MPC is a closed-loop optimization framework that (i) inherits a natural degree of disturbance rejection by incorporating measurement feedback, (ii) utilizes finite-horizon model-based optimizations to control complex multi-input, multi-output dynamical systems under state and input constraints, and (iii) is flexible enough to develop synergistically alongside other modern control strategies. We show how MPC can be used to generate practical optimized control sequences in representative examples of quantum state preparation. Specifically, we demonstrate for a qubit, a weakly-anharmonic qubit, and a system undergoing crosstalk, that MPC can realize successful model-based control even when the model is inadequate. These examples showcase why MPC is an important addition to the quantum engineering control suite.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

MOOSE ProbML: Parallelizable Probabilistic Machine Learning and Uncertainty Quantification Capabilities

The Multiphysics Object Oriented Simulation Environment (MOOSE) is a widely used open- source finite element software for performing multiphysics multiscale simulations in a massively parallel fashion. Recently, the computational team at Idaho National Laboratory (INL) has implemented Probabilistic Machine Learning (ProbML) capabilities in MOOSE—in a parallelized fashion—and enable active learning with large-scale computational models for tasks such as surrogate model development, scale bridging, forward/inverse uncertainty quantification (UQ), Bayesian optimization, etc. This presentation summarizes these developments in MOOSE along with demonstrations on several real applications relevant to nuclear energy. At the fundamental level, samplers like Monte Carlo/Latin Hypercube, variance reduction, parallelized Markov Chain Monte Carlo (MCMC) support uncertainty propagation in both forward and inverse settings. These samplers can be integrated with the Gaussian processes (GP) suite in MOOSE, which offer several variants like scalar GPs, multi-output GPs, and deep GPs, to enable active learning. These GPs can be tuned using gradient-based optimization methods like Adam and its variants or gradient-free methods like the elliptical slice sampler (a variant of MCMC adept under Gaussian settings) for more complex covariance kernels or likelihoods whose gradient computations can be cumbersome. A variety of batch acquisition functions permit parallelized evaluation of the computational model and support different learning objectives with high efficiency like Bayesian inference, global surrogate development, optimization, etc. Furthermore, libtorch integration supports training, evaluation, and re-training of neural networks and other complex machine learning models in active learning settings. The impacts of these developments are shown on several real applications: (1) nuclear fuel inverse UQ and model inadequacy assessment using the Kennedy O’Hagan framework; (2) uncertainty aware surrogate modeling for additive manufacturing to predict field quantities; (3) nuclear reactor rare events analysis; and (4) complex fluid flow prediction using a global surrogate with quantified prediction uncertainty. Finally, the outlook of MOOSE ProbML is discussed for both outer-loop and inner-loop computations in the broad view to accelerate fuels and materials qualification, address gaps in knowledge and data, and assess new reactor/fuel systems.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Structural response reconstruction using a system-equivalent singular vector basis

Here, this paper develops a novel method for reconstructing the full-field response of structural dynamic systems using sparse measurements. The singular value decomposition is applied to a frequency response matrix relating the structural response to physical loads, base motion, or modal loads. The left singular vectors form a non-physical reduced basis that can be used for response reconstruction with far fewer sensors than existing methods. The contributions of the singular vectors to measured response are termed singular-vector loads (SVLs) and are used in a regularized Bayesian framework to generate full-field response estimates and confidence intervals. The reconstruction framework is applicable to the estimation of single data records and power spectral densities from multiple records. Reconstruction is successfully performed in configurations where the number of SVLs to identify is less than, equal to, and greater than the number of sensors used for reconstruction. In a simulation featuring a seismically excited shear structure, SVL reconstruction significantly outperforms modal FRF-based reconstruction and successfully estimates full-field responses with as few as two uniaxial accelerometers. SVL reconstruction is further verified in a simulation featuring an acoustically excited cylinder. Finally, response reconstruction and uncertainty quantification are performed on an experimental structure with three shaker inputs and 27 triaxial accelerometer outputs.

42 ENGINEERING↗