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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Cross-domain digital twin architecture for predictive maintenance via machine learning and Large Language Models

This research introduces a comprehensive framework for creating and deploying a digital twin platform for continuous monitoring and predictive maintenance within industrial settings. Through utilizing advanced technologies, including Unreal Engine 5, Unity 3D, the Message Queue Telemetry Transport protocol, Random Forest machine learning algorithms, and Large Language Models (LLMs), we establish a platform that digitally reproduces physical equipment and translates digital controls into real-world actions. This facilitates preventive maintenance approaches and improves operational effectiveness. The digital twin platform gathers sensor data from operational equipment, analyzes it using machine learning, and delivers practical insights to prevent potential malfunctions and enhance equipment performance. Furthermore, the incorporation of a web portal enables efficient monitoring and access to historical data, educational materials, and equipment status information. Preliminary findings indicate that digital twins can transform industrial equipment management and maintenance methodologies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Optimization of simulated high-field side lower hybrid current drive coupling using machine learning predictions of scrape-off layer density

Lower hybrid current drive (LHCD) is a potential source of non-inductive off-axis current drive (CD) for tokamaks. Although LHCD has been successfully deployed on a number of tokamaks, it is highly sensitive to the scrape-off layer (SOL) conditions local to the LHCD launcher. Large gaps between the launcher and plasma core, SOL turbulence, or edge density perturbations due to edge-localized modes can hamper CD or cause large reflected power. These coupling issues in part motivated the installation of an LHCD launcher on the high-field side (HFS) of DIII-D. On the HFS, the SOL is less turbulent and more controllable compared to the low-field side. This quiescence may result in more predictable edge conditions and thus a more predictable CD. Here, in this work, HFS SOL reflectometry measurements are predicted from global plasma parameters using machine learning models. The SOL predictions coupled with the full-wave simulation of the LHCD launcher allow for the prediction of reflected power, directivity, and arcing risk before the discharge. Launcher performance is then optimized using multi-objective Bayesian optimization, finding the shot parameters that result in an optimal SOL density that maximizes CD while minimizing the risk of arcing. The predictions and optimizations of LHCD performance are then accelerated using a surrogate model of the full-wave LHCD simulation.

Bayesian optimization↗
DOE OSTI2024

In-Situ Species Concentration Measurements In Ammonia-Mix Flames Using Ftir Spectroscopy

Hydrogen and ammonia represent two carbon-free fuel sources that could be used in place of current fossil energy sources in combustion systems. To develop optimized ammonia combustion systems, validated modeling tools are needed. In the open literature, it has been shown that the complex chemistry associated with fuel-bound nitrogen contained in ammonia differs greatly from natural gas or hydrogen combustion. As a result, several new chemical kinetic mechanisms have been developed. Many of these mechanisms have been validated experimentally, however this has primarily focused on bulk parameters such as laminar flame speed and ignition delay time. Critically, high quality measurements of species concentrations are needed under controlled conditions which are easily represented by simple models. In this paper, direct, in-situ measurements of species concentrations and gas temperature are performed in a laminar flat-flame burner. This arrangement enables comparison with 1D model predictions, better isolating chemical kinetics from the fluid dynamics. Quantitative species concentrations are determined by absorption spectroscopy using an FTIR spectrometer. Fuel compositions representative of cracked ammonia (NH 3 /H 2 ) and ammonia-natural gas (NH 3 /CH 4 ) are considered for rich and lean equivalence ratios. A major focus of the paper is on the selection of spectral features for nitric oxide and ammonia and correcting for large amounts of baseline H 2 O absorption.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In-Situ Species Concentration Measurements in Ammonia-Mix Flames Using FTIR Spectroscopy

Hydrogen and ammonia represent two carbon-free fuel sources that could be used in place of current fossil energy sources in combustion systems. To develop optimized ammonia combustion systems, validated modeling tools are needed. In the open literature, it has been shown that the complex chemistry associated with fuel-bound nitrogen contained in ammonia differs greatly from natural gas or hydrogen combustion. As a result, several new chemical kinetic mechanisms have been developed. Many of these mechanisms have been validated experimentally, however this has primarily focused on bulk parameters such as laminar flame speed and ignition delay time. Critically, high quality measurements of species concentrations are needed under controlled conditions which are easily represented by simple models. In this paper, direct, in-situ measurements of species concentrations and gas temperature are performed in a laminar flat-flame burner. This arrangement enables comparison with 1D model predictions, better isolating chemical kinetics from the fluid dynamics. Quantitative species concentrations are determined by absorption spectroscopy using an FTIR spectrometer. Fuel compositions representative of cracked ammonia (NH3/H2) and ammonia-natural gas (NH3/CH4) are considered for rich and lean equivalence ratios. A major focus of the paper is on the selection of spectral features for nitric oxide and ammonia and correcting for large amounts of baseline H2O absorption.

Bedick, Clinton↗
DOE OSTI2025

A Roadmap for the Future of Systems Biology in Cancer Research

Cancer systems biology seeks to understand how cancer arises as a system of interconnected molecules, cells, and tissues, with the goal of understanding, predicting, and controlling the disease. In the last decade, the field has rapidly grown as advances in experimental, computational, and analytic technologies have improved our ability to capture and recapitulate the complexities of cancer at multiple scales. However, the field’s promise to understand how specific molecular changes give rise to altered cancer outcomes remains incompletely fulfilled. Fortunately, an opportunity exists to accelerate progress by better coordinating modeling and data-gathering efforts across the cancer systems biology community. This will create the foundation for building accurate, multiscale cancer models that can better predict and identify improved therapeutic interventions. Here, in this study, we outline some of the current challenges in cancer systems biology research, how they can be addressed, and actions that the community can take to accelerate progress in the field.

Modeling & Simulation↗
DOE OSTI2024

Validation of new and existing methods for time-domain simulations of turbulence and loads

We seek to obtain a second-by-second match between the simulated and measured structural loads of a utility-scale wind turbine. To obtain the one-to-one load simulations, we start with the furthest upstream component of the modeling chain: the turbulent inflow. We consider new and existing methods to generate constrained-turbulence flow fields. The new method is based on large-eddy simulations (LES) and machine learning (ML). The existing methods include Kaimal-based TurbSim and the superstatistical wind field model. The inflow measurements used to constrain these simulations are obtained with a nacelle-mounted scanning lidar. We compare the flow fields for the different inflow simulation approaches and validate their associated load predictions against measurements collected in the Rotor Aero-dynamics, Aeroelastics, and Wake (RAAW) field campaign. We find that the rotor-position control developed for this study is key in enabling the time match between measurements and simulations. When this control approach is used, the load simulation performance tracks with the inflow simulation fidelity, with LES+ML yielding errors ≤ 4% for the damage-equivalent loads of flapwise bending moment, and tower fore-aft bending moments.

17 WIND ENERGY↗
DOE OSTI2024

Harnessing dimethyl ether with ultra-low-grade heat for scaling-resistant brine concentration and fractional crystallization

Solvent-driven separations may enable scalable concentration of hypersaline brines, supporting a circular resource economy from the extraction of lithium and rare earth elements from spent battery and magnet leachates. This work analyses a novel solvent-driven water extraction (SDWE) system employing dimethyl ether (DME) and ultra-low-grade heat for brine concentration and fractional crystallization. SDWE exploits DME’s unique properties: (1) a low dielectric constant that promotes water solubility over charged solutes by a factor of 10 3 , and (2) a high volatility that facilitate efficient DME reconcentration with ultra-low-grade heat. The techno-economic viability of SDWE is assessed with a computational framework that encompasses a liquid–liquid separator and a solvent concentrator. We integrate the extended universal quasichemical model with the virial equation of state to predict the compositions of the complex three-phase DME-water mixture at vapor–liquid and liquid–liquid equilibrium. Subsequently, we optimize the thermodynamic and economic performance of SDWE, by controlling the interstage flash pressure, heat source temperature, and the number of concentrating stages. DME-based SDWE concentrates an input saline feed to 5.5 M and regenerates over 99 % of the DME using ultra-low-grade heat below 50 °C, with a DME/water selectivity ratio of 125. Here our calculations reveal that optimal performance is achieved at interstage flash pressures of 0.4 – 0.5 bar for heat source temperatures between 323–373 K, with improved exergetic efficiencies at lower temperatures. At a heat source temperature of 323 K and an interstage pressure of 0.489 bar, DME-driven SDWE achieves an optimal thermodynamic efficiency of 20.5 % and a projected specific cost of US$ 1.93 m -3 . These specific costs suggest that SDWE is competitive with commercialized thermal distillation technologies, while mitigating the traditional risks associated with scaling in heat and mass exchangers with hypersaline brines.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Concurrent measurement of strain and chemical reaction rates in a calcite grain pack undergoing pressure solution: Evidence for surface-reaction controlled dissolution

Pressure solution is inferred to be a significant contributor to sediment compaction and lithification, especially in carbonate sediments. For a sediment deforming primarily by pressure solution, the compaction rate should be directly related to the rate of calcite dissolution, transport along grain contacts, and calcite reprecipitation. Previous experimental work has shown that there is evidence that deformation in wet calcite grain packs is consistent with control by pressure solution, but considerable ambiguity remains regarding the rate limiting mechanism. We present the results of laboratory compaction experiments designed to directly measure calcite dissolution and precipitation rates (recrystallization rates) concurrently with strain rate to test whether measured rates are consistent with predicted rates both in absolute magnitude and time evolution. Recrystallization rates are measured using trace element chemistry (Sr/Ca, Mg/Ca) and isotopes (87Sr/86Sr) of fluids flowing slowly through a compacting grain pack as it is being triaxially compressed. Imaging techniques are used to characterize the grain contacts and strain effects in the post-experiment grain pack. Our data show that calcite recrystallization rates calculated from all three geochemical parameters are in approximate agreement and that the rates closely track strain rate. The geochemically inferred rates are close to predicted rates in absolute magnitude. Uncertainty in grain contact dimensions makes distinguishing between surface reaction control and diffusion control difficult. Measured reaction rates decrease faster than predicted from standard pressure solution creep flow laws. This inconsistency may indicate that calcite dissolution rates at grain contacts are more complex, and more time-dependent, than suggested by geometric models designed to predict grain contact stresses.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Arctic shrub expansion generates regional variation in litter decomposition by altering litter quality and the decomposition environment

Abstract The expansion of deciduous shrubs into the graminoid‐dominated arctic tundra is expected to alter litter decomposition by changing litter quality and local abiotic and biotic conditions. However, it remains unclear how shrub expansion will affect litter decomposition at regional scales, where macroclimate is expected to be the dominant regulator of decomposition. To determine the relative influence of macroclimate and local controls on regional patterns of litter mass loss and nitrogen release, we conducted two hierarchical litter decomposition experiments across spatial scales. We decomposed leaf and root litter from a prominent graminoid ( Eriophorum vaginatum ) and three genera of deciduous shrubs ( Betula , Alnus and Salix ) for 1 year within replicated plots at five sites spanning a 160 km latitudinal gradient in northern Alaska. Using Eriophorum litter as a substrate, we found that macroclimate was the primary regulator of mass loss but had opposing effects on leaf and root litter. As summer temperature increased along the latitudinal gradient (11.9 to 13.9°C), leaf litter mass loss increased by 20% whereas root litter mass loss decreased by 33%. Leaf nitrogen release also increased with summer temperature. Conversely, root nitrogen release was controlled by the vegetation type of the decomposition environment. Using different shrub litters as substrates, we found that litter quality and its interaction with soil microclimate and macroclimate controlled decomposition. Overall, shrub root litters decomposed faster than Eriophorum root litter, losing 53% more mass and 190% more nitrogen across all sites and decomposition environments. For leaf litter, however, patterns varied by litter genus, with Salix losing more mass and Betula and Alnus losing less mass than Eriophorum . Our findings demonstrate that shrub expansion in the Arctic can regulate leaf and root litter decomposition at the regional scale through its effects on local controls, primarily litter quality. Ongoing increases in shrub cover are likely to accelerate the turnover of root litter carbon and nitrogen pools in tundra ecosystems. Therefore, including shrub‐related processes in Earth system models will improve our ability to predict regional‐scale litter decomposition and its effects on carbon and nutrient cycling in a warming Arctic. Read the free Plain Language Summary for this article on the Journal blog.

Vozzo, Justin T. [Department of Natural Resources ↗
DOE OSTI2026

Continental-Scale Controls on Hyporheic Respiration Revealed by Knowledge-Guided Machine Learning

Hyporheic zone sediments regulate organic matter turnover and in-stream respiration, yet controls on sediment respiration remain poorly constrained across heterogeneous river networks, limiting prediction of stream metabolism and carbon processing at continental scales. Here, we integrate observations from ~90 river corridors across the United States in the WHONDRS consortium with a knowledge-guided machine learning (KGML) framework that couples thermodynamic rate theory with machine learning to identify dominant controls on hyporheic respiration. Diagnostic analyses show that organic matter concentration and thermodynamic favorability define an upper bound on respiration potential, whereas biological catalytic capacity and physical accessibility jointly govern realized respiration rates through interaction effects. To represent unmeasurable accessibility constraints, we use the mechanistic model as a scaffold for KGML, allowing machine learning to target residual structure not explained by process theory. This hybrid framework improves predictive skill relative to both the mechanistic model alone and fully data-driven models while preserving interpretability. These results indicate that variability in hyporheic respiration is largely mechanistically structured and demonstrate how integrating process theory with explainable AI enhances predictive performance while enabling scalable synthesis of river corridor observations.

Zheng, Jianqiu↗
DOE OSTI2024

Predicting the tensile and compressive modulus of electrospun fiber mat‐reinforced hydrogels using the Halpin–Tsai equations

Abstract The reinforcement of mechanically‐weak hydrogels to yield composites with increased stiffness, strength, or toughness is a well‐established approach. In particular, introducing electrospun nanofibers into hydrogels is a common strategy for biomedical applications, as the resulting hierarchical structure mimics biology and allows for control over fiber diameter and alignment and tuning of mechanical properties. However, further study of the link between the constituent materials and the mechanical properties of the composite is uncommon. One potential model to understand the mechanical properties of fiber‐reinforced hydrogels involves the Halpin–Tsai equations, which relate the modulus values of the fibers and hydrogel matrix and the fiber volume fraction, to the modulus of the composite. To assess the application of this model to fiber‐reinforced hydrogels, predicted values were compared with experimental values from mechanical testing of a poly(ethylene glycol) (PEG) matrix reinforced with an electrospun polycaprolactone (PCL) fiber mat. Although the equations described these systems well in tension, providing a facile approach to identify a fiber volume fraction that will achieve a desired modulus, the Halpin–Tsai approach was less successful under compression. This study motivates additional investigation of the role of structural features of hydrogel composites in determining mechanical properties to enable design of materials for specific applications.

Polymer Science↗
DOE OSTI2024

Going beyond BEM with BEM: an insight into dynamic inflow effects on floating wind turbines

Blade element momentum (BEM) theory is the backbone of many industry-standard wind turbine aerodynamic models. To be applied to a broader set of engineering problems, BEM models have been extended since their inception and now include several empirical corrections. These models have benefitted from decades of development and refinement and have been extensively used and validated, proving their adequacy in predicting aerodynamic forces of horizontal-axis wind turbine rotors in most scenarios. However, the analysis of floating offshore wind turbines (FOWTs) introduces new sets of challenges, especially if new-generation large and flexible machines are considered. In fact, due to the combined action of wind and waves and their interaction with the turbine structure and control system, these machines are subject to unsteady motion and thus unsteady inflow on the wind turbine's blades, which could put BEM models to the test. Consensus has not been reached on the accuracy limits of BEM in these conditions. This study contributes to the ongoing research on the topic by systematically comparing four different aerodynamic models, ranging from BEM to computational fluid dynamics, in an attempt to shed light on the unsteady aerodynamic phenomena that are at stake in FOWTs and whether BEM is able to model them appropriately. Simulations are performed on the UNAFLOW 1:75 scale rotor during imposed harmonic surge and pitch motion. Experimental results are available for these conditions and are used for baseline validation. The rotor is analyzed in both rated operating conditions and low wind speeds, where unsteady aerodynamic effects are expected to be more pronounced. Results show that BEM, despite its simplicity, can adequately model the aerodynamics of FOWTs in most conditions if augmented with a dynamic inflow model.

17 WIND ENERGY↗
DOE OSTI2025

Uncertainty-Guided Prediction Horizon of Phase-Resolved Ocean Wave Forecasting Under Data Sparsity: Experimental and Numerical Evaluation

Accurate short-term wave forecasting is critical for the safe and efficient operation of marine structures that rely on real-time, phase-resolved ocean wave information for control and monitoring purposes (e.g., digital twins). These systems often depend on environmental sensors (e.g., waverider buoys, wave-sensing LIDAR). Challenges arise when upstream sensor data are missing, sparse, or phase-shifted due to drift. This study investigates the performance of two machine learning models, time-series dense encoder (TiDE) and long short-term memory (LSTM), for forecasting phase-resolved ocean surface elevations under varying degrees of data degradation. We introduce the τ-trimming algorithm, which adapts the prediction horizon based on uncertainty thresholds derived from historical forecasts. Numerical wave tank (NWT) and wave basin experiments are used to benchmark model performance under short- and long-term data masking, spatially coarse sensor grids, and upstream phase shifts. Results show under a 50% probability of upstream data loss, the τ-trimmed TiDE model achieves a 46% reduction in error at the most upstream target, compared to 22% for LSTM. Furthermore, phase misalignment in upstream data introduces a near-linear increase in forecast error. Under moderate model settings, a ±3 s misalignment increases the mean absolute error by approximately 0.5 m, while the same error is accumulated at ±4 s using the more conservative approach. These findings inform the design of resilient, uncertainty-aware wave forecasting systems suited for realistic offshore sensing environments.

42 ENGINEERING↗
DOE OSTI2024

Physics-informed State-space Neural Networks for transport phenomena

This work introduces Physics -informed State -space neural network Models (PSMs), a novel solution to achieving real-time optimization, flexibility, and fault tolerance in autonomous systems, particularly in transportdominated systems such as chemical, biomedical, and power plants. Traditional data -driven methods fall short due to a lack of physical constraints like mass conservation; PSMs address this issue by training deep neural networks with sensor data and physics -informing using components' Partial Differential Equations (PDEs), resulting in a physics -constrained, end -to -end differentiable forward dynamics model. Further, through two in silico experiments - a heated channel and a cooling system loop - we demonstrate that PSMs offer a more accurate approach than a purely data -driven model. In the former experiment, PSMs demonstrated significantly lower average root -mean -square errors across test datasets compared to a purely data -driven neural network, with reductions of 44 %, 48 %, and 94 % in predicting pressure, velocity, and temperature, respectively. Beyond accuracy, PSMs demonstrate a compelling multitask capability, making them highly versatile. In this work, we showcase two: supervisory control of a nonlinear system through a sequentially updated state -space representation and the proposal of a diagnostic algorithm using residuals from each of the PDEs. The former demonstrates PSMs' ability to handle constant and time -dependent constraints, while the latter illustrates their value in system diagnostics and fault detection.

42 ENGINEERING↗
DOE OSTI2026

Quantum fate of the Choptuik naked singularity

Classical critical collapse provides a dynamical route from smooth initial data to a naked singularity, representing a sharper violation of predictability than ordinary black hole singularities. We argue that this distinction is erased by quantum backreaction. Building on the semiclassical interior analysis, where quantum self-energy of the collapsing matter generates a universal growing mode and a finite mass gap, we study the exterior naked singularity region that determines global visibility in the Einstein-scalar system. We analyze controlled exterior models in both $2+1$ and $3+1$ dimensions. In the former, smooth matching and physical boundary conditions analytically select a vacuum polarization state, whose backreaction cloaks the classically naked region by a quantum trapped branch. In the latter, numerical horizon tracing shows that near a quantum-shifted threshold the exterior develops finite-mass marginally trapped surfaces rather than a zero-mass naked endpoint. These results suggest a global quantum picture in which the Choptuik naked singularity shares the fate of an ordinary black hole singularity: quantum effects push the putative Cauchy horizon behind a quantum-generated horizon, thereby reducing the loss of predictability to the standard black hole evaporation problem.

FOS: Physical sciences↗
DOE OSTI2024

Data Driven Commercial Building Energy Code Compliance and Technology Inventory for New York City

Building Performance Standards (BPS) are gaining national traction. A BPS will require new processes in the design, construction, and operation of buildings that take the occupants into account and enable predictive analysis to ensure compliance with current and future GHG emissions caps. In New York City, most buildings over 25,000 square feet will be regulated by a BPS starting in 2024, regardless of whether it is new construction permitted under current energy codes or an existing building. This research is one of the first to begin the evaluation of a long-term series of building policies in the context of an open data ecosystem, in cooperation with city agencies. Existing building policies enacted in NYC have ranged from building energy benchmarking and labeling to energy audits to the regulation of GHG emission in buildings. Through the development of a dataset related to building technologies and energy consumption, this project can help to evaluate if meaningful conclusions can be drawn for the data that has been largely self-reported in compliance with city regulations. This project will also provide lessons learned from a deep dive into these types of datasets to provide best practices for municipalities or states seeking to embark on policies like those enacted in NYC. In addition, a Building Automation System (BAS) Stretch Standard of Care (SSOC) for owners, designers, and building operators will enable the measurement and predictive analysis of energy consumption and GHG emissions at the plant, system, or component level, in anticipation of regulated GHG limits on buildings based on energy use. The SSOC is expected to be suitable for use on a national level. The primary feature of an SSOC is a standardized format for a set of BAS points that can be used to control and to gather data from individual plants, systems, or components that are related to building energy consumption. This project examined how measurements compare to prescriptive or simulation-based energy code targets, finding little correlation between predictive 8760-hour energy modeling and actual energy consumption for a small sample (n=27) of buildings constructed after 2015. Other analysis found that, while large multifamily housing (MFH) buildings showed a general trend similar to predicted reductions in energy use from the implementation of model commercial energy codes, this trend was not evident in the office, K-12 school, and hotel use groups in NYC. No upward or downward trends in energy consumption were found when buildings were grouped by size. Energy audit data were analyzed and it appears that there is bias by audit company on measures recommended to clients. Further research should be performed to cross-analyze this with other attributes, such as building size, vintage, and number of stories. Analysis found that for 281 buildings that were permitted and completed after 2015 and had submitted benchmarking data in 2022, between 81% and 96% (by use group) were found to be in compliance with the 2024 to 2029 NYC BPS emission caps, and between 55% and 89% were in compliance with the 2030-2034 caps. This work is beneficial to the public in helping policymakers and building stakeholders better understand the wide-ranging implications of a BPS.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Pressure Gain, Stability, and Operability of Methane/Syngas Based RDEs Under Steady and Transient Conditions (Final Project Report)

The scope of this work addresses key issues associated with losses associated with the detonation wave and other processes internal to the RDE operation, as well as it develops modeling tools for the evaluation of these losses and exhaust emissions in RDEs. The main challenge in studying RDEs is that RDE performance is highly reliant on the specifics of the design so much so that simple/canonical systems alone cannot provide useful engineering information, but practical RDE designs are sufficiently complex and involve extreme operational environments that detailed access either experimentally (laser diagnostics, for instance) or computationally (direct numerical simulations) are as yet to become practical. To overcome this challenge, we have conducted a combined experimental/simulation/analytical study investigating key phenomena that control the characteristics of operation of RDEs. As a result, the study has developed tools and methods that can be used to evaluate performance and design approaches using reduced-physics models, with the assumptions validated using detailed simulations, and the model prediction tested using experimental observations. The specific objectives of the research were: (1) Develop and demonstrate a low-loss fully axial injection concept, taking advantage of stratification effects to alter the detonation structure and position the wave favorably within the combustor; (2) Obtain stability and operability characteristics of an RDE across operating conditions to aid in the development of operability and performance rules for the operations of other systems; and (3) Develop quantitative metrics for performance gain as well as quantitative description of the loss mechanisms through a combination of diagnostics development, reduced-order modeling, and detailed simulations. The work conducted here has made contribution on design of low-loss inlets that has broad application within the power generation industry for use with pressure gain combustion. The operability and stability of different designs, while focusing on axial air inlet designs, has been analyzed. The effect of nozzle and injection conditions was studied. Models and simulations of exhaust emissions, focusing on NOx emission has been developed and used to investigate how operation of the RDE affect NOx production using Lagrangian analysis of RDE simulations. This work has built on previous programs, with the goal of further understanding operation of RDEs and elevate the readiness of design consideration. In addition, a suite of diagnostic and modeling tools have been developed to obtain quantitative metrics on performance based on measurements, which can be readily transferred to other experimental configurations.

08 HYDROGEN↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗