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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 397 records · Page 22

Benchmarking large language models for materials synthesis: The case of atomic layer deposition

In this work, we introduce an open-ended question benchmark, ALDbench, to evaluate the performance of large language models (LLMs) in materials synthesis, and, in particular, in the field of atomic layer deposition, a thin film growth technique used in energy applications and microelectronics. Our benchmark comprises questions with a level of difficulty ranging from the graduate level to domain expert current with the state of the art in the field. Human experts reviewed the questions along the criteria of difficulty and specificity, and the model responses along four different criteria: overall quality, specificity, relevance, and accuracy. We ran this benchmark on an instance of OpenAI’s GPT-4o. The responses from the model received a composite quality score of 3.7 on a 1–5 scale, consistent with a passing grade. However, 36% of the questions received at least one below average score. An in-depth analysis of the responses identified at least five instances of suspected hallucination. Finally, we observed statistically significant correlations between the difficulty of the question and the quality of the response, the difficulty of the question and the relevance of the response, the specificity of the question, and the accuracy of the response as graded by the human experts. Furthermore, this emphasizes the need to evaluate LLMs across multiple criteria beyond difficulty or accuracy.

Artificial intelligence↗

Parallel simulation via SPPARKS of on-lattice kinetic and Metropolis Monte Carlo models for materials processing

Abstract SPPARKS is an open-source parallel simulation code for developing and running various kinds of on-lattice Monte Carlo models at the atomic or meso scales. It can be used to study the properties of solid-state materials as well as model their dynamic evolution during processing. The modular nature of the code allows new models and diagnostic computations to be added without modification to its core functionality, including its parallel algorithms. A variety of models for microstructural evolution (grain growth), solid-state diffusion, thin film deposition, and additive manufacturing (AM) processes are included in the code. SPPARKS can also be used to implement grid-based algorithms such as phase field or cellular automata models, to run either in tandem with a Monte Carlo method or independently. For very large systems such as AM applications, the Stitch I/O library is included, which enables only a small portion of a huge system to be resident in memory. In this paper we describe SPPARKS and its parallel algorithms and performance, explain how new Monte Carlo models can be added, and highlight a variety of applications which have been developed within the code.

36 MATERIALS SCIENCE↗

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Developing thermal protection systems (TPS) for future space vehicles involves an extensive design and test cycle. A key component of the cycle is determining margins for a safe design that rely on confidence in the performance of the TPS. Predicting the complicated multiphysics phenomena that occur during atmospheric entry requires high-fidelity modeling tools. To this end, the Porous-material Analysis Toolbox based on OpenFOAM (PATO) has been developed. PATO is an open-source software for computing material response of reactive porous materials submitted to high-temperature environments. Recent applications of PATO include computation of the full heatshield 3D material response from the Mars Science Laboratory atmospheric entry and ablation during arc jet testing. Current efforts are underway to loosely couple PATO with other discipline specialized codes including hypersonic computational fluid dynamics (CFD) to assess the effects of pyrolysis-gas blowing into the boundary layer and computational solid mechanics to address modeling of mechanical erosion. Surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation are also being added.

Thermal Protection Systems↗

Material Response Modeling of Ablative Thermal Protection Systems using PATO

Developing thermal protection systems (TPS) for future space vehicles involves an extensive design and test cycle. A key component of the cycle is determining margins for a safe design that rely on confidence in the performance of the TPS. Predicting the complicated multiphysics phenomena that occur during atmospheric entry requires high-fidelity modeling tools. To this end, the Porous-material Analysis Toolbox based on OpenFOAM (PATO) has been developed. PATO is an open-source software for computing material response of reactive porous materials submitted to high-temperature environments. Recent applications of PATO include computation of the full heatshield 3D material response from the Mars Science Laboratory atmospheric entry and ablation during arc jet testing. Current efforts are underway to loosely couple PATO with other discipline specialized codes including hypersonic computational fluid dynamics (CFD) to assess the effects of pyrolysis-gas blowing into the boundary layer and computational solid mechanics to address modeling of mechanical erosion. Surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation are also being added.

Thermal Protection Systems↗

Discretization effects in the finite element simulation of seismic waves in elastic and elastic-plastic media

Presented here is a numerical investigation that (re-)appraises standard rules for space/time discretization in seismic wave propagation analyses. Although the issue is almost off the table of research, situations are often encountered where (established) discretization criteria are not observed and inaccurate results possibly obtained. In particular, a detailed analysis of discretization criteria is carried out for wave propagation through elastic and elastic-plastic media. The establishment of such criteria is especially important when accurate prediction of high-frequency motion is needed and/or in the presence of highly non-linear material models. Current discretization rules for wave problems in solids are critically assessed as a conditio sine qua non for improving verification/validation procedures in applied seismology and earthquake engineering. For this purpose, the propagation of shear waves through a 1D stack of 3D finite elements is considered, including the use of wide-band input motions in combination with both linear elastic and non-linear elastic-plastic material models. The blind use of usual rules of thumb is shown to be sometimes debatable, and an effort is made to provide improved discretization criteria. Possible pitfalls of wave simulations are pointed out by highlighting the dependence of discretization effects on time duration, spatial location, material model and specific output variable considered.

58 GEOSCIENCES↗

Study of materials performance model for aircraft interiors

A demonstration version of an aircraft interior materials computer data library was developed and contains information on selected materials applicable to aircraft seats and wall panels, including materials for the following: panel face sheets, bond plies, honeycomb, foam, decorative film systems, seat cushions, adhesives, cushion reinforcements, fire blocking layers, slipcovers, decorative fabrics and thermoplastic parts. The information obtained for each material pertains to the material's performance in a fire scenario, selected material properties and several measures of processability.

Leary, K.↗

Generalizing the Gurson model using symbolic regression and transfer learning to relax inherent assumptions

Abstract To generate material models with fewer limiting assumptions while maintaining closed-form, interpretable solutions, we propose using genetic programming based symbolic regression (GPSR), a machine learning (ML) approach that describes data using free-form symbolic expressions. To maximize interpretability, we start from an analytical, derived material model, the Gurson model for porous ductile metals, and systematically relax inherent assumptions made in its derivation to understand each assumption’s contribution to the GPSR model forms. We incorporate transfer learning methods into the GPSR training process to increase GPSR efficiency and generate models that abide by known mechanics of the system. The results show that regularizing the GPSR fitness function is critical for generating physically valid models and illustrate how GPSR allows a high level of interpretability compared with other ML approaches. The method of systematic assumption relaxation allows the generation of models that address limiting assumptions found in the Gurson model, and the symbolic forms allow conjecture of decreased material strength due to void interaction and non-symmetric void shapes.

36 MATERIALS SCIENCE↗

Higher-order factorization machine for accurate surrogate modeling in material design

Efficient and robust optimization is important in material science for identifying optimal structural parameters and enhancing material performance. Surrogate-based active learning algorithms have recently gained great attention for their ability to efficiently navigate large, high-dimensional design spaces. Among surrogate models, 2 nd -order factorization machine (FM) models are widely employed as the surrogate model in active learning algorithms due to their balance between simplicity and effectiveness. However, their quadratic nature limits their capacity to capture complex, higher-order interactions among variables, often leading to suboptimal solutions. To overcome this limitation, we propose an active learning scheme integrating a 3 rd -order FM model, capable of modeling three-variable interactions and more intricate relationships in material systems. We comprehensively evaluate the surrogate modeling performance of the 3 rd -order FM case using various objective functions. Furthermore, we examine the optimization reliability and efficiency of the 3 rd -order FM-based active learning in a real-world material design task (e.g., nanophotonic structures for transparent radiative cooling). Our study shows that the 3 rd -order FM outperforms the 2 nd -order model in both surrogate accuracy and optimization performance, highlighting higher-order models’ promises for material design and optimization problems.

Factorization machine↗

HydraGNN_GFM_FineTuning4Materials v1.0

This repository enables fine-tuning of the HydraGNN Predictive GFM 2026 — an open-source ensemble of pre-trained graph foundation models for atomistic materials modeling, developed at Oak Ridge National Laboratory. The GFM 2026 is freely available and downloadable via Globus from the OLCF Data Constellation (DOI: 10.13139/OLCF/2562660). Starting from these pre-trained weights, this repository provides a complete transfer learning pipeline for adapting the GFM ensemble to domain-specific molecular and materials property prediction tasks. It includes: 1) Utilities for ensemble fine-tuning with task-specific output heads 2) Example pipelines for eight widely-used materials and molecular datasets 3) Tools for model adaptation and head configuration 4) Data preprocessing utilities for each supported dataset 5) Benchmarking and evaluation scripts

Ungerboeck, Linda↗

Hydrostatic Stress Effects Incorporated Into the Analysis of the High-Strain-Rate Deformation of Polymer Matrix Composites

Procedures for modeling the effect of high strain rate on composite materials are needed for designing reliable composite engine cases that are lighter than the metal cases in current use. The types of polymer matrix composites that are likely to be used in such an application have a deformation response that is nonlinear and that varies with strain rate. The nonlinearity and strain rate dependence of the composite response is primarily due to the matrix constituent. Therefore, in developing material models to be used in the design of impact-resistant composite engine cases, the deformation of the polymer matrix must be correctly analyzed. However, unlike in metals, the nonlinear response of polymers depends on the hydrostatic stresses, which must be accounted for within an analytical model. An experimental program has been carried out through a university grant with the Ohio State University to obtain tensile and shear deformation data for a representative polymer for strain rates ranging from quasi-static to high rates of several hundred per second. This information has been used at the NASA Glenn Research Center to develop, characterize, and correlate a material model in which the strain rate dependence and nonlinearity (including hydrostatic stress effects) of the polymer are correctly analyzed. To obtain the material data, Glenn s researchers designed and fabricated test specimens of a representative toughened epoxy resin. Quasi-static tests at low strain rates and split Hopkinson bar tests at high strain rates were then conducted at the Ohio State University. The experimental data confirmed the strong effects of strain rate on both the tensile and shear deformation of the polymer. For the analytical model, Glenn researchers modified state variable constitutive equations previously used for the viscoplastic analysis of metals to allow for the analysis of the nonlinear, strain-rate-dependent polymer deformation. Specifically, we accounted for the effects of hydrostatic stresses. An important discovery in the course of this work was that the hydrostatic stress effects varied during the loading process, which needed to be accounted for within the constitutive equations. The model is characterized primarily by shear data, with tensile data used to characterize the hydrostatic stress effects.

Goldberg, Robert K.↗

Mechanics of Structure Genome-Based Nonlinear Shell Analysis

In this paper, a mechanics of structure genome (MSG)-based nonlinear shell theory is introduced. The theory uses an implicit algorithm combining the Euler’s and Newton’s method that can be applied for shell modeling as well as 3D homogenization. This theory has been implemented into the general-purpose constitutive modeling code SwiftComp, which was originally developed for linear analyses. For the convenience of implementing different nonlinear material models, the SwiftComp user material (SCUMAT), which has a similar interface to the Abaqus user subroutine UMAT, is developed. The capability of the MSG-based nonlinear shell is validated with numerical examples with different material models. A 2-step nonlinear homogenization, with a micromechanics step and a shell analysis step, is demonstrated.

Yufei Long↗

Application of Probabilistic Analysis to Aircraft Impact Dynamics

Full-scale aircraft crash simulations performed with nonlinear, transient dynamic, finite element codes can incorporate structural complexities such as: geometrically accurate models; human occupant models; and advanced material models to include nonlinear stressstrain behaviors, laminated composites, and material failure. Validation of these crash simulations is difficult due to a lack of sufficient information to adequately determine the uncertainty in the experimental data and the appropriateness of modeling assumptions. This paper evaluates probabilistic approaches to quantify the uncertainty in the simulated responses. Several criteria are used to determine that a response surface method is the most appropriate probabilistic approach. The work is extended to compare optimization results with and without probabilistic constraints.

Lyle, Karen H.↗

Application of Probability Methods to Assess Crash Modeling Uncertainty

Full-scale aircraft crash simulations performed with nonlinear, transient dynamic, finite element codes can incorporate structural complexities such as: geometrically accurate models; human occupant models; and advanced material models to include nonlinear stress-strain behaviors, and material failure. Validation of these crash simulations is difficult due to a lack of sufficient information to adequately determine the uncertainty in the experimental data and the appropriateness of modeling assumptions. This paper evaluates probabilistic approaches to quantify the effects of finite element modeling assumptions on the predicted responses. The vertical drop test of a Fokker F28 fuselage section will be the focus of this paper. The results of a probabilistic analysis using finite element simulations will be compared with experimental data.

Lyle, Karen H.↗

Application of Probability Methods to Assess Crash Modeling Uncertainty

Full-scale aircraft crash simulations performed with nonlinear, transient dynamic, finite element codes can incorporate structural complexities such as: geometrically accurate models; human occupant models; and advanced material models to include nonlinear stress-strain behaviors, and material failure. Validation of these crash simulations is difficult due to a lack of sufficient information to adequately determine the uncertainty in the experimental data and the appropriateness of modeling assumptions. This paper evaluates probabilistic approaches to quantify the effects of finite element modeling assumptions on the predicted responses. The vertical drop test of a Fokker F28 fuselage section will be the focus of this paper. The results of a probabilistic analysis using finite element simulations will be compared with experimental data.

Lyle, Karen H.↗

Fragmentation analysis of a bar with the Lip-field approach

The Lip-field approach was introduced in Moës and Chevaugeon (2021) as a new way to regularize softening material models. It was tested in 1D quasistatic in Moës and Chevaugeon (2021) and 2D quasistatic in Chevaugeon and Moës (2021): this paper extends it to 1D dynamics, on the challenging problem of dynamic fragmentation. The Lip-field approach formulates the mechanical problem to be solved as an optimization problem, where the incremental potential to be minimized is the non-regularized one. Spurious localization is prevented by imposing a Lipschitz constraint on the damage field. Here, the displacement and damage field at each time step are obtained by a staggered algorithm, that is the displacement field is computed for a fixed damage field, then the damage field is computed for a fixed displacement field. Indeed, these two problems are convex, which is not the case of the global problem where the displacement and damage fields are sought at the same time. The incremental potential is obtained by equivalence with a cohesive zone model, which makes material parameters calibration simple. A non-regularized local damage equivalent to a cohesive zone model is also proposed. It is used as a reference for the Lip-field approach, without the need to implement displacement jumps. These approaches are applied to the brittle fragmentation of a 1D bar with randomly perturbed material properties to accelerate spatial convergence. Both explicit and implicit dynamic implementations are compared. Favorable comparison to several analytical, numerical and experimental references serves to validate the modeling approach.

36 MATERIALS SCIENCE↗

Kinetics of Failure in an Elastic Peridynamic Material

The dynamic behavior of an elastic peridynamic material with a nonconvex bond potential is studied. In spite of the material’s inherently unstable nature, initial value problems can be solved using essentially the same techniques as with conventional materials, both analytically and numerically. In a suitably constructed material model, small perturbations grow exponentially over time until the material fails. Additionally, the time for this growth is computed explicitly for a stretching bar that passes from the stable to the unstable phase of the material model. This time to failure represents an incubation time for the nucleation of a crack. The finiteness of the failure time in effect creates a rate dependence in the failure properties of the material. Thus, the unstable nature of the elastic material leads to a rate effect even though it does not contain any terms that explicitly include a strain rate dependence.

36 MATERIALS SCIENCE↗

Kinetics of Failure in an Elastic Peridynamic Material

The dynamic behavior of an elastic peridynamic material with a nonconvex bond potential is studied. In spite of the material's inherently unstable nature, initial value problems can be solved using essentially the same techniques as with conventional materials. In a suitably constructed material model, small perturbations grow exponentially over time until the material fails. The time for this growth is computed explicitly for a stretching bar that passes from the stable to the unstable phase of the material model. This time to failure represents an incubation time for the nucleation of a crack. The finiteness of the failure time in effect creates a rate dependence in the failure properties of the material. Thus, the unstable nature of the elastic material leads to a rate effect even though it does not contain any terms that explicitly include a strain rate dependence.

36 MATERIALS SCIENCE↗

Component level modeling of materials degradation for insights into operational flexibility of Existing Coal Power Plants

Increasingly, coal-fired power plants are required to balance power grids by compensating for the variable electricity supply from renewable energy sources. Fossil-fueled power plants, originally designed to be base loaded, will increasingly need to operate on a load following or cyclic basis. This demanding requirement for operational flexibility needs insights into accelerated material degradation arising due to the harsh operating conditions (e.g., fatigue, early oxide exfoliation due to stresses) along with current damage mechanisms (fireside corrosion, creep and erosion) observed in service. Our research objective is to develop component level modeling toolkit for materials-based degradation for two key mechanisms that can accelerate with cyclic operations. In more detail, this includes the fireside corrosion/steam oxidation/erosion/creep/fatigue of superheaters/reheaters and steam pipework and also the water droplet erosion/ fatigue of last stage steam turbine blades degradation mechanisms, that demand routine and sometimes unplanned maintenance and repair. The innovation is in developing a computational fluid dynamics/finite element (CFD/FE) modeling toolkit for the component level models of the boilers and low-pressure steam turbines in coal power plants that can tackle multidisciplinary failure mechanisms occurring concurrently for extreme environment materials. Lifetime assessment in such environments also needs to account for the unit-specific analyses, operational history and fuel feedstock; this can only be obtained by destructive analysis of components. This, in turn, enables validation of the model toolkits utilizing service feedback data, improving the probability of time/temperature dependent life prediction.

20 FOSSIL-FUELED POWER PLANTS↗