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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 55 records · Page 3

Enhanced accuracy through ensembling of randomly initialized auto-regressive models for dynamical systems

Computational mechanics simulations using traditional finite element methods (FEM) require prohibitively expensive computational resources for real-time engineering applications, design optimization, and digital twin implementations. While machine learning (ML) surrogate models offer significant computational speedups, autoregressive ML models for time-dependent mechanical systems suffer from error accumulation that compromises long-term prediction reliability - a critical concern for engineering applications where accuracy over extended time horizons is essential for safety and performance assessments. Here, we propose a deep ensemble framework specifically designed to address this challenge in computational mechanics applications, where multiple ML surrogate models with random weight initializations are trained in parallel and their predictions aggregated during inference. This approach leverages statistical diversity to maximize information gain from a fixed set of training data and to mitigate error propagation, while maintaining the computational efficiency that makes ML surrogates attractive for engineering practice. We validate the framework on three representative problems spanning critical areas of computational mechanics: stress field evolution in heterogeneous microstructures under complex loading (relevant to advanced materials design and composite analysis), planetary-scale shallow water dynamics (applicable to environmental and geotechnical engineering), and Gray-Scott reaction-diffusion systems (relevant to mass transport and chemical process engineering). Across all test cases, the ensemble approach demonstrates consistent error reduction of 15-33% compared to individual models. The codes for this work are available on GitHub (https://github.com/Graham-Brady-Research-Group/AutoregressiveEnsemble_SpatioTemporal_Evolution).

autoregressive prediction↗

Solving high-dimensional partial integral differential equations: The finite expression method

Partial integro-differential equations (PIDEs) have broad applications in the sciences, from electro-magnetism to options pricing. Here, in this paper, we introduce a new finite expression method (FEX) to solve PIDEs. This approach builds upon the original FEX and its inherent advantages with new advances: 1) A novel method of parameter grouping is proposed to reduce the number of coefficients in high-dimensional function approximation; 2) A Taylor series approximation method is implemented to significantly improve the computational efficiency and accuracy of the evaluation of the integral terms of PIDEs. The new FEX based method, denoted FEX-PG to indicate the addition of the parameter grouping (PG) step to the algorithm, provides both high accuracy and interpretable numerical solutions, with the outcome being an explicit equation that facilitates intuitive understanding of the underlying solution structures. These features are often absent in traditional methods, such as finite element methods (FEM) and finite difference methods, as well as in deep learning-based approaches. To benchmark our method against recent advances, we apply the new FEX-PG to solve benchmark PIDEs in the literature. In high-dimensional settings, FEX-PG exhibits strong and robust performance, achieving relative errors on the order of single precision machine epsilon, significantly outperforming existing approaches based on neural networks.

Combinatorial optimization↗

A multiscale model to understand the interface chemistry, contacts, and dynamics during lithium stripping

A reversible Li-metal electrode, paired with a solid electrolyte, is critical for attaining higher energy density and safer batteries beyond the current lithium-ion cells. A stable stripping process may be even harder to attain as the stripping process will remove Li-atoms from the surface, and naturally reduce surface contact area, if not self-corrected by other mechanisms, such as diffusion and plastic deformation under an applied external stack pressure. Here, we capture these mechanisms occurring at multiple length- and time- scales, i.e., interface interactions, vacancy hopping, and plastic deformation, by integrating density functional theory (DFT) simulations, kinetic Monte Carlo (KMC), and continuum finite element method (FEM). By assuming the self-affine nature of multiscale contacts, we predict the steady-state contact area as a function of stripping current density, interface wettability, and stack pressure. We further estimate the exponential increase of overpotential due to contact area loss to maintain the same stripping current density. We demonstrate that a lithiophilic interface requires less stack pressure to reach the same steady-state contact area fraction than a lithiophobic interface. A “tolerable steady-state” contact area loss for maintaining stable stripping is estimated at 20 %, corresponding to a 10 % increase in overpotential. To constrain contact loss within the tolerance, the required stack pressure is 0.1, 0.5, and 2 times the yield strength of lithium metal for three distinct interfaces, lithiophilic Li/lithium oxide(Li2O), Li/lithium lanthanum zirconium oxide(LLZO), and lithiophoblic Li/lithium fluoride(LiF), respectively. The modeling results agree with experiments on the impact of the stack pressure quantitatively, while the discrepancy in stripping rate sensitivity is attributed to the simplifying interface interaction in our simulations. Overall, this multiscale simulation framework demonstrates the importance of electrochemical-mechanical coupling in understanding the dynamics of the Li/SE interface during stripping.

Feng, Min↗

Diffusion Limit–Preserving Lumped DFEMs on AMR Meshes

Here, we present sweep-compatible, novel upwinding recipes for the bilinear discontinuous (BLD) finite element method (FEM) that allows lumped BLD to be used on adaptive mesh refinement (AMR) meshes for thick transport applications without adding additional degrees of freedom at hanging nodes that exist on refinement boundaries. We analyze the properties of the upwinding and lumping that are needed for BLD to get the thick diffusion limit on such meshes, present results demonstrating locking with the wrong recipe, and present results showing error convergence and robustness properties for two diffusive problems on a variety of AMR meshes.

42 ENGINEERING↗

Magnetic and Mechanical Analysis of Bi-2212 Rutherford Cable in a Cos-Theta Sub-Scale Dipole Coil

The U.S. Magnet Development Program (US-MDP) explores high-field accelerator magnets compatible with operational conditions beyond the limits of Nb$_3$Sn technology. The ongoing R&D High-Temperature Superconductors (HTS) suggests using Bi$_2$Sr$_2$CaCu$_2$O$_{8-x}$ (Bi-2212) as superconducting element. Bi-2212 Rutherford cables maintain a high critical current (I$_C$) when exposed to a large external magnetic field. However, Bi-2212 exhibits an oversensitive stress-strain response when subject to large Lorentz forces. This paper reports on the magnetic and mechanical analysis of the Bi-2212 cosine-theta insert being developed at Fermilab for a hybrid magnet composed of two external layers of Nb$_3$Sn and two internal layers of Bi-2212. We performed a FEM analysis of the insert to estimate the HTS stress state in the coil's strands under magnetic and mechanical loads.

43 PARTICLE ACCELERATORS↗

Exploring Structural Anisotropy in Amorphous Tb-Co via Changes in Medium-Range Ordering

Amorphous thin films grown by magnetron co-sputtering exhibit changes in atomic structure with varying growth and annealing temperatures. Structural variations influence the bulk properties of the films. Scanning nanodiffraction performed in a transmission electron microscope (TEM) is applied to amorphous Tb 17 Co 83 (a-Tb-Co) films deposited over a range of temperatures to measure relative changes in medium-range ordering (MRO). These measurements reveal an increase in MRO with higher growth temperatures and a decrease in MRO with higher annealing temperatures. The trend in MRO indicates a relationship between the growth conditions and local atomic ordering. By tilting select films, the TEM measures variations in the local atomic structure as a function of orientation within the films. The findings support claims that preferential ordering along the growth direction results from temperature-mediated adatom configurations during deposition, and that oriented MRO correlates with increased structural anisotropy, explaining the strong growth-induced perpendicular magnetic anisotropy found in rare earth–transition metal films. Beyond magnetic films, we propose the tilted FEM workflow as a method of extracting anisotropic structural information in a variety of amorphous materials with directionally dependent bulk properties, such as films with inherent bonding asymmetry grown by physical vapor deposition.

36 MATERIALS SCIENCE↗

The Use of Machine Learning Models for Predicting the Dielectric Strength of Gases

Technological advancements in high voltage systems have pushed sulfur hexafluoride (SF6) to its operational limits. Furthermore, this gas has other drawbacks including a high liquefaction temperature and a high global warming potential. Therefore, there has been an urgent need to find alternative gases with high dielectric strength (DS). In this work, density functional theory (DFT) is used to calculate molecular descriptors that are fed into an artificial neural network (ANN) and a random forest (RF). These machine learning (ML) models are then used to predict the DS for hundreds of molecules. A finite element model (FEM) is also used to calculate the electric field profile of multiple simple electrode geometries as the applied voltage to the system is increased. Results indicate that the random forest model has better generalization to unseen data than the neural network. The highest DS value predicted by the RF was 2.16 relative to the experimental DS of SF6. The results also demonstrate how choosing a gas with a higher DS and a geometry with minimal edges and corners can significantly increase the operating voltage of an electrical system. Due to its superior generalization, the RF represents the most promising path toward an accurate DS predictor once sufficient experimental data are available.

Mileski, Matthew [AFIT]↗

Structural Analysis of Multilayer Tapered Canted-Cosine-Theta Superconducting Magnet for the Interaction Region of Electron Ion Collider

The electron ion collider (EIC) will collide high energy and highly polarized hadron and electron beams with luminosities up to 10 34 cm -2 s -1 . The magnet designs at the interaction region (IR) are challenging due to the close proximity of the hadron and electron beams. A canted cosine theta (CCT) quadrupole magnet was designed due to the space restrictions at the IR. The CCT magnet has a tapered aperture, which allows higher gradients at the interaction point (IP) side of the magnet. The tapered geometry makes the magnet not symmetrical along the axial direction. In conclusion, to validate the design in terms of the mechanical strength and the allowed deformations, a detailed structural mechanical analysis for the tapered CCT quadrupole magnet has been carried out using the finite element method (FEM) considering both the shrinking due to cool down and the electromagnetic force on the conductors.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Structural Analysis of a Serpentine Superconducting Magnet for the Interaction Region of the Electron Ion Collider

The electron ion collider (EIC) is under design to collide the high energy and highly polarized hadron with electron beams with luminosities up to 10 34 cm −2 s −1 . The superconducting magnet designs at the interaction region (IR) are quite challenging due to the close proximity of the hadron and electron beams. Several serpentine types of superconducting magnets have been designed due to the space restrictions at the IR. Here, to validate the designs in terms of the mechanical strength, structural integrity, as well as the allowed deformations, a detailed structural mechanical analysis for a 12-layer superconducting quadrupole serpentine magnet (Q1BpR) in the rear side hadron beams has been carried out using the finite element method (FEM) considering the pretension stress, shrinking due to cool down, and the electromagnetic force on the conductors. Anisotropy material properties and individual roving tension have been considered. The electro-magnetic (EM) simulations were performed using COMSOL, confirmed with RAT, the structural mechanical analysis were performed using COMSOL by considering the contact elements.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Numerical Simulation of Irradiation Induced Swelling for STAR 4.1 Blanket

Here, this article presents the preliminary results of FEM implementation of irradiation-induced swelling, hardening, and creep effect using ANSYS user programmable features (UPFs) applied to material properties. The first liquid metal breeding blanket model for STAR 4.1 tokamak as a part of the virtual prototyping system is under development at Princeton Plasma Physics Laboratory (PPPL). Intense neutron irradiation produces significant changes in the physical and mechanical properties of Fe-(8%–9%)Cr-based reduced activation ferritic martensitic (RAFM) steels. An ANSYS model of the breeding blanket was built to involve these irradiation-induced material property changes with neutron fluence distribution mapped from the MCNP model. Simulation results show that significant structure deformation forms from nuclear swelling, stress, and plastic strain arising from DPA gradient through wall thickness. The material degradation effect is not negligible. This modeling feature can either assist in analyzing the structural behaviors with the influence of nuclear swelling or provide guidance to design the structure to withstand irradiation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

The Shape Factor for Pits and Its Impact on Pit Stability

This study employs the finite element method (FEM) to predict the impact of pit shape on pit stability via shape factors of various pit geometries relevant to localized corrosion. Lower values of the shape factor indicate an increased ease in maintaining pit stability. Analyzed geometries include undercut pits, bispherical pit-within-pit structures, and covered pits with perforated (lacy) covers. The effect of the water layer thickness, transport properties of the electrolyte inside and outside the pit, and cathode location on the pit shape factor were also explored. Results show that occluded pits exhibit lower shape factors than open ones, with disk-shaped pits decreasing further as c/r ratio and occlusion angle increase. The findings also suggest minimal influence from a secondary pit if the primary remains active. An equation is presented that quantifies the impact of lacy covers, revealing significant shape factor value reduction. Additionally, high salt concentrations inside pits have a limited stabilizing effect compared to geometry, while thin water layers and adjacent cathodic/sinks reduce pit stability.

Shehi, A. (ORCID:0009000271548041)↗

Seismic Contingency Auto Generator

This code takes in premade earthquake scenario XML files from USGS, power grid data, and converts them into a contingency file (.con file) that can be used by power grid solvers. Within the .con file are a number (Specified by the user) of contingencies that have randomly failed power transformers based on their likelihood of failure and peak ground acceleration (PGA) value around the transformer. The transformers' likelihood of failure was calculated based on a variety of finite element modeling on various transformer designed for specific transformer voltage classes. Parameters from these FEM were used to create generic fragility curves for transformers within a specific voltage class, which correspond with earthquake PGA values to produced a probability of failure for a given earthquake scenario. More refined versions of this process, such as specifying specific transformer design categories within a voltage class, could also be applied in future iterations of the software.

Vaagensmith, Bjorn [Idaho National Laboratory (INL↗

Application of physics-informed neural networks (PINNs) solution to coupled thermal and hydraulic processes in silty sands

Abstract The accurate modeling of water and heat transport in soils is crucial for both geo-environmental and geothermal engineering. Traditional modeling methods are problematic because they require well-defined boundaries and initial conditions. Recently, physics-informed neural networks (PINNs), which incorporate partial differential equations (PDEs) to solve forward and inverse problems, have attracted increasing attention in machine learning research. In this study, we applied PINNs to tackle hydraulic and thermal transport coupling forward problems in silty sands. A fully connected deep neural network was utilized for training. This neural network model leverages automatic differentiation to apply the governing equations as constraints, based on the mathematical approximations established by the neural network itself. We conducted forward problems and compared the solutions derived from PINNs with those from Finite Element Method (FEM) simulations. The forward problem results demonstrate the PINNs model’s capability in predicting hydraulic transport, heat transport, and thermal–hydraulic coupling in silty sands under various boundary conditions. The PINNs exhibited great performance in simulating the thermal–hydraulic coupling problem. The accuracy of the PINNs solutions shows its potential for simulation in geotechnical engineering.

Feng, Yuan↗

Strain-concentration for fast, compact photonic modulation and non-volatile memory

A critical figure of merit (FoM) for electro-optic (EO) modulators is the transmission change per voltage, d T / d V . Conventional approaches in wave-guided modulators maximize d T / d V via a high EO coefficient or longer light-material interaction lengths but are ultimately limited by material losses and nonlinearities. Optical and RF resonances improve d T / d V at the cost of spectral non-uniformity, especially for high- Q optical cavity resonances. Here, we introduce an EO modulator based on piezo-strain-concentration of a photonic crystal cavity to address both trade-offs: (i) it eliminates the trade-off between d T / d V and waveguide loss—i.e., enhancement of the resonance tuning efficiency d v c / d V for the fixed EO coefficient, waveguide length, and cavity Q —and (ii) at high DC strains it exhibits a non-volatile (NV) cavity tuning Δ v c ,NV for passive memory and programming of multiple devices into resonance despite fabrication variations. The device is fabricated on a scalable silicon nitride-on-aluminum nitride platform. We measure d v c / d V =177±1MHz/V, corresponding to Δ v c =40±0.32GHz for a voltage spanning ±120V with an energy consumption of δ U /Δ v c =0.17nW/GHz. The modulation bandwidth is flat up to ω BW,3dB /2 π =3.2±0.07MHz for broadband DC-AC and 142±17MHz for resonant operation near a 2.8 GHz mechanical resonance. Optical extinction up to 25 dB is obtained via Fano-type interference. Strain-induced beam-buckling modes are programmable under a “read-write” protocol with a continuous, repeatable tuning range of 5±0.25GHz, allowing for storage and retrieval, which we quantify with mutual information of 2.4 bits and a maximum non-volatile excursion of 8 GHz. Using a full piezo-optical finite-element-model (FEM) we identify key design principles for optimizing strain-based modulators and chart a path towards achieving performance comparable to lithium niobate-based modulators and the study of high strain physics on-chip.

Wen, Y. Henry (ORCID:0009000685423628)↗

Modeling of Bi-2212 strand and Rutherford cable in a dipole coil insert

The U.S. Magnet Development Program (US-MDP) explores high-field accelerator magnets compatible with op- erational conditions beyond the limits of Nb3Sn technology. The ongoing R&D High-Temperature Superconductors (HTS) suggests using Bi2Sr2CaCu2O8−x (Bi-2212) as superconducting element. Bi-2212 Rutherford cables maintain a high critical current (IC ) when exposed to a large external magnetic field. However, Bi-2122 exhibits an oversensitive stress-strain response when subject to large Lorentz forces. This paper reports on the magnetic and mechanical analysis of the Bi-2212 cosine-theta insert being developed at Fermilab for a hybrid magnet composed of 2 external layers of Nb3Sn and 2 internal layers of Bi-2212. We performed a FEM analysis of the insert to estimate the HTS stress state in the coil s strands under magnetic and mechanical loads.

D'Agliano, A.↗

Near-net shaping of high-density, complex, spatially-tailored ceramics for extreme environments

The purpose of this subcontract is for LLNL to collaborate with the Subcontractor (UCSB) in the areas of binder jet additive manufacturing (BJAM), hot pressing (HP), finite element modeling (FEM), and multi-material sintering studies. LLNL wants to further develop its hot pressing, AM, and modeling capabilities through LLNL’s Early Career Faculty Program. This work will focus on developing a method to hot press complex-shaped ceramic parts through the co-deposition of a structural/functional ceramic and sacrificial mold material in one assembly via multi-material binder jet printing. The method aims to produce dense, near-net shaped parts with applications relevant to a wide variety of fields including aerospace, defense, and energy.

36 MATERIALS SCIENCE↗

R&D to Ensure a Scientific Basis for Qualification Tests and Standards (Final Report)

Project return on investment in a photovoltaic (PV) system depends increasingly on maintaining high energy yields, and the system lifetime is a major factor in levelized cost of electricity (LCOE). Thus, the rate of PV deployment and the success of these assets depends upon reliable long-term power generation. The overarching objective of this program is to improve photovoltaic (PV) module reliability via development of tests and standards. Where reliability problems or risk are discovered, we can design tests to ensure that these liabilities don't affect future generations of products. Customers can use these tests to understand which products are susceptible to certain degradation mechanisms, and manufacturers can use the tests to design unwanted characteristics out of their products. The work under this program identifies PV reliability needs, performs characterization that provides scientific understanding of targeted degradation mechanisms, and translates those data into practical and predictive test protocols and standards. Major accomplishments include: A model for polarization-type potential induced degradation (PID-p) was developed and validated against experimental data. NREL is currently leading a new edition of IEC 62804-1 for PID detection. PID-p can cause large losses in current and voltage for some module designs on cloudy days. Finite element modeling (FEM) and experiment was used to determine when cells crack in a module. It was shown that cells in landscape orientation are much more likely to crack than those on portrait orientation. Shortly thereafter, the first products with portrait-oriented cells were introduced. Studies of how to test for light and elevated temperature degradation (LeTID) culminated with the publication of IEC TS 63342. Software to predict the progression of LeTID was developed, validated, and made publicly available. Field validated tests and international standards for durability of PV module coatings abrasion, backsheets, and encapsulants were developed. Examples are IEC 62788-1-1, IEC 62788-2 ED2, IEC TS 62788-7-2, IEC 62788-7-3 ED1, IEC 63209-2. NREL led the development a high-temperature testing technical specification, and published guidelines that enable installers to determine whether higher-temperature testing is needed, simply based on location and mounting configuration. In a number of our case studies, variations in the bills of materials or workmanship have been associated with variations in reliability. These observations emphasize the importance of quality assurance to reliability. A framework for criticality (i.e. Pareto) analysis was developed and published. The framework helps us and other researchers determine what problems should be addressed for reliability research to have the biggest industry impact. NREL continues to participate actively in international standards development and stakeholder engagement activities, including organizing an annual PV Reliability Workshop. These activities are important for ensuring we address issues that are relevant and timely, and that we convey our results to those who may benefit.

14 SOLAR ENERGY↗

Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion (Final Scientific/Technical Report)

This report summarizes the technical accomplishments of the four-year research project “Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion” (Award No. DE-FE0032092), conducted at Howard University and the University of Houston (subawardee) from September 2021 to August 2025. The project successfully achieved all four major objectives: 1. 3D Structural Characterization – Developed 3D optical imaging and mechanical sectioning methods to characterize catalyst distribution and support morphology in nickel foam substrates. Successfully reconstructed 3D geometries and imported them into COMSOL Multiphysics for electromagnetic simulations. 2. EM Hotspot Simulation – Created all-frequency stable electromagnetic formulations and 3D nodal discontinuous Galerkin (NDG) methods for coupled electromagnetic-thermal-fluid problems in multiscale catalytic media. Demonstrated stable solutions from DC to microwave frequencies. 3. Multiphysics Coupling – Developed multiscale simulation methods coupling FEM electromagnetic solvers with thermal transport equations. Reactive molecular dynamics (ReaxFF MD) simulations were performed to investigate catalytic reaction mechanisms at the atomistic level. Demonstrated electromagnetic-thermal co-simulation capabilities for porous catalyst structures. 4. System Optimization – Designed and optimized EM-assisted catalytic systems using nickel foam and carbon foam structures, demonstrating significant temperature increases due to microwave heating. Observed and characterized plasma generation in carbon fiber catalysts. Investigated multiple reaction chamber geometries for improved microwave energy deposition. The project produced significant scientific contributions including 15+ peer-reviewed publications, trained multiple Ph.D. students and undergraduate researchers, and advanced the understanding of microwave-assisted hydrogen production from fossil fuels.

08 HYDROGEN↗