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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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DOE OSTI2020

CRADA Final Report: Open Microgrid Platform

Current microgrid control technology is mostly proprietary, expensive, and inflexible. An open-source, vendor-neutral, publish-subscribe controller will significantly lower the barrier to entry for new technologies and market entrants: inverter, battery, and load control manufacturers; cloud and services providers; and energy aggregators. An OpenFMB controller can significantly reduce the acquisition, integration, and ongoing operating and maintenance costs and increase revenue opportunities for energy producers and consumers. It allows distributed energy resource (DER) owners to replace individual DER components as richer-function, lower-cost devices become available or to incorporate new forecast and optimization algorithms as they are developed. A standard, secure, full-function DER field controller will also provide a low-cost means for grid operators to effectively manage the variability and uncertainty of solar photovoltaics (PV). Under the terms of this CRADA, ORNL has worked with Open Energy Solutions (OES) to advance the transition of ORNL’s existing open-source microgrid controller into a platform geared toward mainstream implementation. Using a more prevalent and memory-safe programming language, Rust, OES has converted ORNL’s current generation on-grid optimization into an application more suitable for industry use. The results of the ported optimization were analyzed by inputting the same arguments in both the current-generation and next-generation optimizers and verifying that the results were equivalent.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Matrix-free preconditioning for high-order H (curl) discretizations

The greater arithmetic intensity of high-order finite element discretizations makes them attractive for implementation on next-generation hardware, but assembly of high-order finite element operators as matrices is prohibitively expensive. As a result, the development of general algebraic solvers for such operators has been an open research challenge. Fast matrix-free application of high-order operators has received significant attention in the literature in the context of Poisson-type problems, but preconditioners and solvers for inverting more general operators are not very well-developed. In this paper, we consider the problem of preconditioning a definite Maxwell operator at high polynomial order without assembling a matrix. We show that given efficient preconditioners for high-order H 1 finite element problems on the same mesh, efficient H(curl) preconditioners can be constructed in an auxiliary space framework. We demonstrate the resulting preconditioners in a practical setting with tensor-product basis functions on an unstructured mesh of quadrilaterals. Overall, our approach uses a sparsified H 1 solver constructed on a low-order mesh of the nodal points of the underlying high-order space, and we show that the resulting H(curl) preconditioner is effective at very high polynomial orders for two-dimensional model problems with complicated geometry, varying piecewise constant coefficients, and curved elements. The resulting preconditioner scales with nearly optimal O(p d+1 ) floating point operation count and optimal O(p d ) memory transfer requirements, outperforming existing Maxwell preconditioners in the high-order regime.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2013

A modified Monte Carlo 'local importance function transform' method

The Local Importance Function Transform (LIFT) method uses an approximation of the contribution transport problem to bias a forward Monte-Carlo (MC) source-detector simulation [1-3]. Local (cell-based) biasing parameters are calculated from an inexpensive deterministic adjoint solution and used to modify the physics of the forward transport simulation. In this research, we have developed a new expression for the LIFT biasing parameter, which depends on a cell-average adjoint current to scalar flux (J{sup *}/{phi}{sup *}) ratio. This biasing parameter differs significantly from the original expression, which uses adjoint cell-edge scalar fluxes to construct a finite difference estimate of the flux derivative; the resulting biasing parameters exhibit spikes in magnitude at material discontinuities, causing the original LIFT method to lose efficiency in problems with high spatial heterogeneity. The new J{sup *}/{phi}{sup *} expression, while more expensive to obtain, generates biasing parameters that vary smoothly across the spatial domain. The result is an improvement in simulation efficiency. A representative test problem has been developed and analyzed to demonstrate the advantage of the updated biasing parameter expression with regards to solution figure of merit (FOM). For reference, the two variants of the LIFT method are compared to a similar variance reduction method developed by Depinay [4, 5], as well as MC with deterministic adjoint weight windows (WW). (authors)

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2019

An Integrated Risk Assessment Process for Digital Instrumentation and Control Upgrades of Nuclear Power Plants

Most of the existing nuclear power plants (NPPs) in the world rely on traditional analog instrumentation and control (I&C) systems for monitoring, control, and protection functions. With the industrial base largely moving to digital systems, the operation and maintenance of plants involves managing issues including lack of needed analog spare parts, increasing maintenance costs, and the loss of vendor support. Compared with existing analog I&C systems, digital I&C systems have significant functional advantages, such as reliable system performance in terms of accuracy and computational capability, high data handling and storage capabilities to fully measure and display operating conditions, and improved capabilities (e.g., fault tolerance, self-testing, signal validation, process system diagnostics). Therefore, the U.S. nuclear power industry has initiated the replacement of existing, aging analog systems with digital I&C technology, and is developing new designs for advanced plants using digital systems in integrated control rooms to provide modern control and protection systems. However, the qualification of digital I&C systems remains a challenge, especially the issue of software common cause failure (CCF), which has been difficult to address. A CCF is the malfunction of two or more plant components or functions due to a single failure source. CCFs have the potential to generate unanalyzed events or sequences that may not be bounded by previous plant accident analyses, therefore, to challenge the plant safety. Existing analyses on CCF in I&C systems are mainly focusing on hardware failures. With the application and upgrades of new digital I&C systems, software CCFs due to design flaws have become a potential threat to plant safety considering most redundancy designs are using the similar digital platforms or software in the operating and application systems. With complex multi-layer redundancy designs to meet the single failure criterion, these I&C safety systems are of a particular concern in the U.S. Nuclear Regulatory Commission (NRC) licensing procedures. Therefore, there is a need to develop an integrated risk assessment strategy with digital CCF and plant transient responses considered to assure the long-term safety and reliability of vital digital systems and reduce uncertainties in costs, time, and support integration of digital systems in the plant. The overall goal of this project is to deliver a strong technical basis to support effective, licensable, and secure digital I&C technologies for the digital upgrades to existing NPPs. To deal with the expensive licensing justifications from regulatory insights, this technical basis is instructive for nuclear vendors and utilities to effectively lower the costs associated with digital compliance and speed-up industry advances by: (1) defining an integrated risk-informed analysis process for digital I&C upgrades including hazard analysis, reliability analysis, and consequence analysis; (2) applying systematic and risk-informed tools to address CCFs and quantify responding failure probabilities for digital I&C technologies; (3) evaluating the impact of digital failures at the individual level, system level, and plant level; and (4) providing insights and suggestions on designs to manage the risks, thus to support the development, licensing, and deployment of advanced digital I&C technologies on NPPs. Upgrading digital I&C (safety and non-safety related) systems in existing NPPs within a cost-effective and regulatory acceptable way offers the foremost means of performance improvements and cost-reductions for existing NPPs. One key outcome of this project is to perform plant-specific risk assessment to provide a sustainable scientific support for enabling industry to balance the digital-related risks, costs, reliability, and safety.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Head and Neck Margin Reduction With Adaptive Radiation Therapy: Robustness of Treatment Plans Against Anatomy Changes

Purpose: We set out to investigate loss of target coverage from anatomy changes in head and neck cancer patients as a function of applied safety margins and to verify a cone beam computed tomography (CBCT)–based adaptive strategy with an average patient anatomy to overcome possible target underdosage. Methods and Materials: For 19 oropharyngeal cancer patients, volumetric modulated arc therapy treatment plans (2 arcs; simultaneous integrated boost, 70 and 54.25 Gy; 35 fractions) were automatically optimized with uniform clinical target volume (CTV)–to–planning target volume margins of 5, 3, and 0 mm. We applied b-spline CBCT–to–computed tomography (CT) deformable registration to allow recalculation of the dose on modified CT scans (planning CT deformed to daily CBCT following online positioning) and dose accumulation in the planning CT scan. Patients with deviations in primary or elective CTV coverage >2 Gy were identified as candidates for adaptive replanning. For these patients, a single adaptive intervention was simulated with an average anatomy from the first 10 fractions. Results: Margin reduction from 5 mm to 3 mm to 0 mm generally led to an organ-at-risk (OAR) mean dose (D{sub mean}) sparing of approximately 1 Gy/mm. CTV shrinkage was mainly seen in the elective volumes (up to 10%), likely related to weight loss. Despite online repositioning, substantial systematic errors were present (>3 mm) in lymph node CTV, the parotid glands, and the larynx. Nevertheless, the average increase in OAR dose was small: maximum of 1.2 Gy (parotid glands, D{sub mean}) for all applied margins. Loss of CTV coverage >2 Gy was found in 1, 3, and 7 of 73 CTVs, respectively. Adaptive intervention in 0-mm plans substantially improved coverage: in 5 of 7 CTVs (in 6 patients) to <2 Gy of initially planned. Conclusions: Volumetric modulated arc therapy head and neck cancer treatment plans with 5-mm margins are robust for anatomy changes and show a modest increase in OAR dose. Margin reduction improves OAR sparing with approximately 1 Gy/mm at the expense of target coverage in a subgroup of patients. Patients at risk of CTV underdosage >2 Gy in 0-mm plans may be identified early in treatment using dose accumulation. A single intervention with an average anatomy derived from CBCT effectively mitigates discrepancies.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2016

One dimensional spatial resolution optimization on a hybrid low field MRI-gamma detector

Hybrid systems like Positron Emission Tomography/Magnetic Resonance Imaging (PET/MRI) and MRI/gamma camera, offer advantages combining the resolution and contrast capability of MRI with the better contrast and functional information of nuclear medicine techniques. However, the radiation detectors are expensive and need an electronic set-up, which can interfere with the MRI acquisition process or viceversa. In order to improve these drawbacks, in this work it is presented the design of a low field NMR system made up of permanent magnets compatible with a gamma radiation detector based on gel dosimetry. The design is performed using the software FEMM for estimation of the magnetic field, and GEANT4 for the physical process involved in radiation detection and effect of magnetic field. The homogeneity in magnetic field is achieved with an array of NbFeB magnets in a linear configuration with a separation between the magnets, minimizing the effect of Compton back scattering compared with a no-spacing linear configuration. The final magnetic field in the homogeneous zone is ca. 100 mT. In this hybrid proposal, although the gel detector do not have spatial resolution per se, it is possible to obtain a dose profile (1D image) as a function of the position by using a collimator array. As a result, the gamma detector system described allows a complete integrated radiation detector within the low field NMR (lfNMR) system. Finally we present the better configuration for the hybrid system considering the collimator parameters such as height, thickness and distance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

A framework and tool for designing cost-effective, resilient, and circular net-zero supply chains under uncertainty with an application to multilayer plastic films

While 55% of Fortune 500 companies have committed to achieving net-zero emissions and/or zero-waste operations by 2035, only 2% are currently on track, revealing a critical gap between ambition and action. Designing supply chains that reduce both emissions and waste is a complex non-intuitive, multi-objective challenge, compounded by the high costs of new technologies and the need for resilient, profitable solutions. This paper aims to address this challenge by presenting a generic framework and multi-objective optimization formulation for designing cost-effective, circular, and resilient supply chains under uncertainty, implemented through a user-friendly decision-support tool with intuitive data visualization capabilities, enabling communication of results to both technical and non-technical stakeholders. We demonstrate the application of this framework in the context of multilayer plastic films (barrier films), which are widely used in food packaging and composite materials. The model quantifies trade-offs across three objectives: minimizing global warming potential, maximizing circularity, and minimizing cost. A key contribution of this work is the explicit modeling of technological resilience, the ability of supply chains to maintain function under disruption. In the cost-minimization case, the resilience constraint makes the design approximately three times more expensive in the short-term metric, but shifts the system from relying on a single recovery pathway to a portfolio of four recovery pathways, improving the robustness of the optimization solution under uncertainty. Lastly, we introduce TranZero, a decision-support tool that integrates material flow analysis, hotspot identification, and optimization-based scenario planning to support net-zero and circularity decisions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Accelerating Ab Initio Simulation via Nested Monte Carlo and Machine Learned Reference Potentials

As a corollary of the rapid advances in computing, ab initio simulation is playing an increasingly important role in modeling materials at the atomic scale. Two strategies are possible, ab initio Monte Carlo (AIMC) and molecular dynamics (AIMD) simulation. The former benefits from exact sampling from the correct thermodynamic distribution, while the latter is typically more efficient with its collective all-atom coordinate updates. In this study, using a relatively simple test model comprised of helium and argon, we show that AIMC can be brought up to, and even above, the performance levels of AIMD via a hybrid nested sampling/machine learning (ML) strategy. Here, ML provides an accurate classical reference potential (up to three-body explicit interactions) that can pilot long collective Monte Carlo moves that are accepted or rejected in toto à la nested Monte Carlo (NMC); this is in contrast to the single move nature of a naive implementation. Our proposed method only requires a small up front expense from evaluating the ab initio energies and forces of (100) random configurations for training. Importantly, our method does not totally rely on the trained, assuredly imperfect, interaction. We show that high performance and exact sampling at the desired level of theory can be realized even when the trained interaction has appreciable differences from the ab initio potential. Remarkably, at the highest levels of performance realized via our approach, a pair of statistically uncorrelated atomic configurations can be generated with (1) ab initio calculations.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2017

User-Centered Evaluation of Visual Analytics

Visual analytics systems are becoming very popular. More domains now use interactive visualizations to analyze the ever-increasing amount and heterogeneity of data. More novel visualizations are being developed for more tasks and users. We need to ensure that these systems can be evaluated to determine that they are both useful and usable. A user-centered evaluation for visual analytics needs to be developed for these systems. While many of the typical human-computer interaction (HCI) evaluation methodologies can be applied as is, others will need modification. Additionally, new functionality in visual analytics systems needs new evaluation methodologies. There is a difference between usability evaluations and user-centered evaluations. Usability looks at the efficiency, effectiveness, and user satisfaction of users carrying out tasks with software applications. User-centered evaluation looks more specifically at the utility provided to the users by the software. This is reflected in the evaluations done and in the metrics used. In the visual analytics domain this is very challenging as users are most likely experts in a particular domain, the tasks they do are often not well defined, the software they use needs to support large amounts of different kinds of data, and often the tasks last for months. These difficulties are discussed more in the section on User-centered Evaluation. Our goal is to provide a discussion of user-centered evaluation practices for visual analytics, including existing practices that can be carried out and new methodologies and metrics that need to be developed and agreed upon by the visual analytics community. The material provided here should be of use for both researchers and practitioners in the field of visual analytics. Researchers and practitioners in HCI and interested in visual analytics will find this information useful as well as a discussion on changes that need to be made to current HCI practices to make them more suitable to visual analytics. A history of analysis and analysis techniques and problems is provided as well as an introduction to user-centered evaluation and various evaluation techniques for readers from different disciplines. The understanding of these techniques is imperative if we wish to support analysis in the visual analytics software we develop. Currently the evaluations that are conducted and published for visual analytics software are very informal and consist mainly of comments from users or potential users. Our goal is to help researchers in visual analytics to conduct more formal user-centered evaluations. While these are time-consuming and expensive to carryout, the outcomes of these studies will have a defining impact on the field of visual analytics and help point the direction for future features and visualizations to incorporate. While many researchers view work in user-centered evaluation as a less-than-exciting area to work, the opposite is true. First of all, the goal is user-centered evaluation is to help visual analytics software developers, researchers, and designers improve their solutions and discover creative ways to better accommodate their users. Working with the users is extremely rewarding as well. While we use the term “users” in almost all situations there are a wide variety of users that all need to be accommodated. Moreover, the domains that use visual analytics are varied and expanding. Just understanding the complexities of a number of these domains is exciting. Researchers are trying out different visualizations and interactions as well. And of course, the size and variety of data are expanding rapidly. User-centered evaluation in this context is rapidly changing. There are no standard processes and metrics and thus those of us working on user-centered evaluation must be creative in our work with both the users and with the researchers and developers.

intelligence analysis↗
DOE OSTI2020

Machine learning for nonintrusive model order reduction of the parametric inviscid transonic flow past an airfoil

Fluid flow in the transonic regime finds relevance in aerospace engineering, particularly in the design of commercial air transportation vehicles. Computational fluid dynamics models of transonic flow for aerospace applications are computationally expensive to solve because of the high degrees of freedom as well as the coupled nature of the conservation laws. While these issues pose a bottleneck for the use of such models in aerospace design, computational costs can be significantly minimized by constructing special, structure-preserving surrogate models called reduced-order models. In this work, we propose a machine learning method to construct reduced-order models via deep neural networks and we demonstrate its ability to preserve accuracy with a significantly lower computational cost. In addition, our machine learning methodology is physics-informed and constrained through the utilization of an interpretable encoding by way of proper orthogonal decomposition. Application to the inviscid transonic flow past the RAE2822 airfoil under varying freestream Mach numbers and angles of attack, as well as airfoil shape parameters with a deforming mesh, shows that the proposed approach adapts to high-dimensional parameter variation well. Notably, the proposed framework precludes the knowledge of numerical operators utilized in the data generation phase, thereby demonstrating its potential utility in the fast exploration of design space for diverse engineering applications. Comparison against a projection-based nonintrusive model order reduction method demonstrates that the proposed approach produces comparable accuracy and yet is orders of magnitude computationally cheap to evaluate, despite being agnostic to the physics of the problem.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

WE-D-204-06: An Open Source ImageJ CatPhan Analysis Tool

Purpose: The CatPhan is a popular QA device for assessing CT image quality. There are a number of software options which perform analysis of the CatPhan. However, there is often little ability for the user to adjust the analysis if it isn’t running properly, and these are all expensive options. An open source tool is an effective solution. Methods: To use the software, the user imports the CT as an image sequence in ImageJ. The user then scrolls to the slice with the lateral dots. The user then runs the plugin. If tolerance constraints are not already created, the user is prompted to enter them or to use generic tolerances. Upon completion of the analysis, the plugin calls pdfLaTex to compile the pdf report. There is a csv version of the report as well. A log of the results from all CatPhan scans is kept as a csv file. The user can use this to baseline the machine. Results: The tool is capable of detecting the orientation of the phantom. If the CatPhan was scanned backwards, one can simply flip the stack of images horizontally and proceed with the analysis. The analysis includes Sensitometry (estimating the effective beam energy), HU values and linearity, Low Contrast Visibility (using LDPE & Polystyrene), Contrast Scale, Geometric Accuracy, Slice Thickness Accuracy, Spatial resolution (giving the MTF using the line pairs as well as the point spread function), CNR, Low Contrast Detectability (including the raw data), Uniformity (including the Cupping Effect). Conclusion: This is a robust tool that analyzes more components of the CatPhan than other software options (with the exception of ImageOwl). It produces an elegant pdf and keeps a log of analyses for long-term tracking of the system. Because it is open source, users are able to customize any component of it.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

SparseMaps—A systematic infrastructure for reduced-scaling electronic structure methods. III. Linear-scaling multireference domain-based pair natural orbital N-electron valence perturbation theory

Multi-reference (MR) electronic structure methods, such as MR configuration interaction or MR perturbation theory, can provide reliable energies and properties for many molecular phenomena like bond breaking, excited states, transition states or magnetic properties of transition metal complexes and clusters. However, owing to their inherent complexity, most MR methods are still too computationally expensive for large systems. Therefore the development of more computationally attractive MR approaches is necessary to enable routine application for large-scale chemical systems. Among the state-of-the-art MR methods, second-order N-electron valence state perturbation theory (NEVPT2) is an efficient, size-consistent, and intruder-state-free method. However, there are still two important bottlenecks in practical applications of NEVPT2 to large systems: (a) the high computational cost of NEVPT2 for large molecules, even with moderate active spaces and (b) the prohibitive cost for treating large active spaces. In this work, we address problem (a) by developing a linear scaling “partially contracted” NEVPT2 method. This development uses the idea of domain-based local pair natural orbitals (DLPNOs) to form a highly efficient algorithm. As shown previously in the framework of single-reference methods, the DLPNO concept leads to an enormous reduction in computational effort while at the same time providing high accuracy (approaching 99.9% of the correlation energy), robustness, and black-box character. In the DLPNO approach, the virtual space is spanned by pair natural orbitals that are expanded in terms of projected atomic orbitals in large orbital domains, while the inactive space is spanned by localized orbitals. The active orbitals are left untouched. Our implementation features a highly efficient “electron pair prescreening” that skips the negligible inactive pairs. The surviving pairs are treated using the partially contracted NEVPT2 formalism. A detailed comparison between the partial and strong contraction schemes is made, with conclusions that discourage the strong contraction scheme as a basis for local correlation methods due to its non-invariance with respect to rotations in the inactive and external subspaces. A minimal set of conservatively chosen truncation thresholds controls the accuracy of the method. With the default thresholds, about 99.9% of the canonical partially contracted NEVPT2 correlation energy is recovered while the crossover of the computational cost with the already very efficient canonical method occurs reasonably early; in linear chain type compounds at a chain length of around 80 atoms. Calculations are reported for systems with more than 300 atoms and 5400 basis functions.

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

Incorporating corrosion design constraints in desalination process optimization: A case study in mechanical vapor compression

Corrosion is an expensive and complex challenge for desalination, yet current design approaches do not explicitly account for corrosion mechanisms in process modeling and technoeconomic analysis. Here, to address this gap, we present a workflow for incorporating corrosion design constraints directly into desalination process optimization models. We develop surrogate models for general and localized corrosion metrics as functions of temperature, pH, salinity, dissolved oxygen, and material using data from OLI Systems’ Corrosion Analyzer. We then integrate these surrogates as corrosion design constraints in a cost-optimization MVC model that minimizes the levelized cost of water (LCOW). For a case study of mechanical vapor compression (MVC) treating seawater across a range of recoveries, we find dissolved oxygen (DO) is the dominant driver of localized corrosion, and thus of cost-optimal material choice and operating conditions. Reducing the DO from 8 mg/L to 0.5 mg/L reduces the LCOW by 15-35%, informing the breakeven costs for implementing DO removal or selecting highly corrosion-resistant alloys. This framework is broadly applicable across corrosion types, materials, and components and enables desalination process design that minimizes capital costs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

AI-Enabled Discovery and Physics-Based Optimization of Energy Efficient Processing Strategies for Advanced Turbine Alloys (Final Technical Report)

In this project, the multi-organizational team of academic and industrial researchers from the University of Kentucky an aerospace and energy generation OEM partner has leveraged novel Digital Process Twin (DPT) models of process/structure interactions (i.e., process-induced surface integrity) to advance a paradigm of fully integrated computational materials engineering (ICME). Using efficient process models as the core of a digital process simulator for a reinforcement learning algorithm, the team has integrated industrial data and metrics of structure/performance/energy relationships and manufacturing-related energy metrics to optimize dynamic processing parameters for significantly improved life-cycle energy efficiency of advanced γ-TiAl low-pressure turbine (LPT) alloys, as indicated by a set of design relevant parameters (e.g., residual stresses and scrap rate). The key objective and anticipated outcome of the project was at least a 10% reduction in life-cycle embodied energy for a recently developed, γ-TiAl low-pressure turbine (LPT) alloy and nickel-based superalloy Inconel 718, through the adoption of the proposed AI-enabled process optimization approach. The final project outcomes significantly exceeded this original target, realizing manufacturing-related energy efficiency improvements of more than 130% for TiAl and up to 80% for Inconel 718. Rather than following the prevailing and highly inefficient empirical paradigm, the proposed study demonstrated the feasibility of adopting a digital, physics-based process design and optimization paradigm. The recurring need for manual intervention, rework, reinspection causes significant production bottlenecks and unnecessary expense associated with delivering the requisite component quality. The OEM partner, and turbine industry in general, expect to reap significant cost and resource savings if an AI-optimized set of parameters can be applied to specific machining operations. The technical scope of the proposed project involved the paving of a realistic path towards model-based and AI-enabled Integrated Computational Materials Engineering (ICME), and away from inefficient empirical process optimization and legacy manufacturing practices, which are no longer able to efficiently process novel high-performance turbine alloy materials. The project team will address the fundamental knowledge gap that currently exists within the ICME paradigm with respect to the process/structure/performance/energy impacts of finishing processes. While significant resources have been devoted to the ‘early stages’ of manufacturing, such as alloy design, primary and secondary processing, finishing processes have not been adequately integrated within ICME. To provide an actionable path towards model-based finishing process design (e.g., machining, burnishing, grinding, polishing), we will employ a novel AI-enabled process optimization paradigm, based on a computationally efficient, physics-based process simulator. Through limited experimental work to calibrate and validate our process simulator model via an advanced in-situ characterization technique and process optimization via reinforcement learning, the project will seek to demonstrate a viable alternative to the inefficient ‘legacy’ processing strategies, empirical testing and broad scope machining learning approaches, all of which fail to adequately consider complex process physics. The project team has identified an intermetallic γ-TiAl LPT alloy, which is currently being used as part of the OEM partner’s advanced gas turbine designs. This particular alloy poses significant manufacturing challenges during finishing operations, which limit the degree to which the current turbine design can be manufactured in an energy- and cost-efficient manner. Empirical testing and numerical modeling efforts to optimize processing parameters for γ-TiAl have not been able to resolve these manufacturing challenges, so the proposed physics-based AI-enabled optimization technology would offer a truly novel and transformative capability. The multi-organizational team of academic and industry experts from the UKY and the OEM partner will work together closely to demonstrate the analytical and experimental critical function and characteristic proof of concept of this novel approach.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Robust Parameter Design on Dual Stochastic Response Models With Constrained Bayesian Optimization

In engineering system design, minimizing the variations of the quality measurements while guaranteeing their overall quality up to certain levels, namely the robust parameter design (RPD), is crucial. Recent works have dealt with the design of a system whose response-control variables relationship is a deterministic function with a complex shape and function evaluation is expensive. In this work, we propose a Bayesian optimization method for the RPD of stochastic functions. Dual stochastic response models are carefully designed for stochastic functions. The heterogeneous variance of the sample mean is addressed by the predictive mean of the log variance surrogate model in a two-step approach. We establish an acquisition function that favors exploration across the feasible and optimality-improvable regions to effectively and efficiently solve the stochastic constrained optimization problem. Further, the performance of our proposed method is demonstrated by the extensive numerical and case studies. Note to Practitioners-Many manufacturing processes involve undesirable variations, which create variations in the final products. For example, many emerging manufacturing processes, such as nanomanufacturing, involve complex physical and chemical dynamics and transformation, creating variations in the manufacturing output. In such processes, it is crucial to design the manufacturing processes or products so that they have minimum variations in their quality. Meanwhile, it is also important to maintain the overall quality of the designed processes or products. Furthermore, acquiring data from many advanced manufacturing processes is often very costly, especially in the designing stage. In this work, we propose a data-driven method that automatically finds the best setting of manufacturing processes or products with the minimum variations of quality and a given constraint on the average quality satisfied. Our proposed method is used before conducting every experiment; It analyzes the historical data from previous experiments and provides a setting to be used in the next experiment. Our proposed method efficiently utilizes the historical data, and thus finds the best robust setting by conducting only a small number of experiments.

42 ENGINEERING↗
DOE OSTI2024

LEED: A Lightwave Energy-Efficient Datacenter

The Lightwave Energy-Efficient Datacenter (LEED) program is a disruptive “green-field” approach that provides a quantum leap in the energy efficiency of datacenters. LEED’s fundamental value proposition is that a novel and re-architected optical network—RotorNet— can deliver “more bandwidth per buck” as well as unique system-level attributes that significantly improve overall datacenter energy efficiency and performance. LEED has developed three system-level testbeds. The first testbed uses calibrated hardware and software power measurements to determine server energy efficiency as a function of network bandwidth and workload. These measurements have shown that increasing network communications bandwidth dramatically increases server energy efficiency providing a realistic path to the overall ENLITENED program goal of doubling the number of transactions per joule. The second testbed demonstrates key hardware: a prototype low-loss, high-port count optical “selector switch”. This switch was fabricated, racked, and tested. Measured switch characteristics include loss, bandwidth, crosstalk, switch time, system-level switch time (including the transceivers), and bit error rate. The third testbed demonstrates a fully working and manufactured pinwheel design which dramatically lowers the cost of design, while delivering high switch radix and low reconfiguration times. The LEED project has tied these three novel photonic switch prototypes together with production servers and software through the development of a novel FPGA-based NIC platform called Corundum. Corundum ensures that the packet-switched protocols supported by commodity operating systems and devices can interface with the Rotor switch design. The LEED group has used this combined hardware and software prototype to characterize applications running at a commercially relevant scale. The project has used a combination of enhanced optical modulation amplitude (OMA) modulators, broadband multiplexers and demultiplexers, avalanche photodiodes, and a novel burst-mode receivers to enable the insertion of LEED-developed optical switches without the need for expensive optical amplification. Our modeling has shown that measured LEED-developed device characteristics can achieve link characteristics of 2 pJ/bit including both transceivers and the Rotor switch. In summary, the LEED program has demonstrated a credible and practical path, through novel hardware and software, to realize the program objectives of ENLITENED. The net result will ensure that the United States maintains its strength in the crucial sector of Information Technology, which is vital to both our economic security and our national security.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Speeding-up fuzzing through directional seeds

Abstract Fuzzing is an automated process for discovering inputs in a program that may trigger unexpected behavior. Today, fuzzing has become a standard practice for the discovery of bugs and security vulnerabilities. However, the main issue with such practices is that the exploration of the input space of programs can often be prohibitively expensive. Therefore, several alternative fuzzing strategies have been introduced during the last few years. Some fuzzing techniques rely on human expertise to provide a plausible set of initial input examples, namely, seeds. However, the process of handcrafting seeds for fuzzing purposes often becomes strenuous for humans as it requires a deeper understanding of the Program-Under-Test (PUT). Also, the use of known inputs to programs often does not trigger vulnerable program behavior or may not reach potentially vulnerable code locations. To address those issues, we propose a seed generation framework that enables Human-In-The-Loop (HITL) directed fuzzing where the human assumes a more active role in the creation of seeds that can penetrate and assess desired locations of the PUT. Our proposed framework uses Symbolic Execution (SE) to generate seeds that exercise paths to target program locations. Moreover, our framework enables the visualization of the explored execution paths in the binary of the PUT for the generated seeds. We evaluated our approach on a set of 12 carefully designed C programs with diverse characteristics that mimic real-world programs. The experimental results show the effectiveness of the proposed approach in improving the performance of standard fuzzing tools such as the American Fuzzy Lop ("Image missing" <#comment/> ). Specifically, our solution can generate seeds that substantially enhance the performance of the fuzzer, achieving speedups ranging from $$1.46\times $$ 1.46 × to $$68.53\times $$ 68.53 × for branch conditions, $$1.39\times $$ 1.39 × to $$254.62\times $$ 254.62 × for branch depths, $$14,879.59\times $$ 14 , 879.59 × to $$30,295.88\times $$ 30 , 295.88 × for branch widths over traditional seeds. Additionally, the speedup increases with the number of target function ranging from $$12,260\times $$ 12 , 260 × to $$22,856.07\times $$ 22 , 856.07 × over traditional seeds while only requiring less than 15 seconds on average for the seed generation step.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

An information-matching approach to optimal experimental design and active learning

The efficacy of mathematical models heavily depends on the quality of the training data, yet collecting sufficient data is often expensive and challenging. Many modeling applications require inferring parameters only as a means to predict other quantities of interest (QoI). Because models often contain many unidentifiable (sloppy) parameters, QoIs often depend on a relatively small number of parameter combinations. Therefore, we introduce an information-matching criterion based on the Fisher information matrix to select the most informative training data from a candidate pool. This method ensures that the selected data contain sufficient information to learn only those parameters that are needed to constrain downstream QoIs. It is formulated as a convex optimization problem, making it scalable to large models and datasets. Here, we demonstrate the effectiveness of this approach across various modeling problems in diverse scientific fields, including power systems and underwater acoustics. Finally, we use information-matching as a query function within an active learning (AL) loop for materials science applications. In all these applications, we find that a relatively small set of optimal training data can provide the necessary information for achieving precise predictions. These results are encouraging for diverse future applications, particularly AL in large machine-learning models.

Materials science↗