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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Software Tools Ecosystem Project (STEP) Midyear Report CY2025

This document provides a technical project report for the first six months of 2025 for the Software Tools Ecosystem Project (STEP). The mission of STEP is to enable critical software tools to proactively adapt to emerging platform technologies (such as new accelerators, storage devices, network technologies, and smart devices) and emerging application use cases (such as advanced machine learning and workflow frameworks) so that they continue to meet the needs of scientific computing and provide a strong foundation for future Advanced Scientific Computing Research activities. Our challenges include the wide breadth of our stakeholders and rapidly evolving platform technology dependencies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

A Scientist-in-the-Loop Data Analytics Framework for Intelligent Simulation Model Tuning and Validation

This project developed a scientist-in-the-loop data analytics framework for intelligent simulation model tuning and validation, targeting the Weather Research and Forecasting (WRF) model and its solar energy variant, WRF-Solar-BNL. Domain experts, such as climate scientists, depend on large-scale numerical simulations for knowledge discovery and decision-making, yet the complexity of parameter tuning and the disconnect between automated optimization and domain expertise pose significant challenges. We extended an interactive visual analytics framework that enables domain experts to observe and intervene in the computational steering process by identifying disagreements between the simulation model, surrogate model, and the expert’s domain knowledge. Using Bayesian Optimization with Gaussian Process Regression as the surrogate model, our system allows users to probe parameter relationships, analyze correlation patterns, and adjust tuning parameters in real time. We developed use cases for solar irradiance forecasting through sustained collaboration with Brookhaven National Laboratory, resolving critical model configuration challenges and achieving meaningful reductions in prediction error. The project supported one PhD student, one MS student, and eight undergraduate students across three Data Science Capstone projects, resulting in one master’s thesis.

Dasgupta, Aritra [New Jersey Institute of Technolo↗
DOE OSTI2026

Software Tools Ecosystem Project (STEP): CY2025 Annual Report

This document provides a technical project report for the Software Tools Ecosystem Project (STEP) during calendar year 2025. The mission of STEP is to enable critical software tools to proactively adapt to emerging platform technologies (such as new accelerators, storage devices, network technologies, and smart devices) and emerging application use cases (such as advanced machine learning and workflow frameworks) so that they continue to meet the needs of scientific computing and provide a strong foundation for future Advanced Scientific Computing Research activities.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Expandable Log Analyzing Framework

Prior to my internship, I was informed that a previous intern had built a tool to analyse MongoDB logs and look for invalid access attempts, which served as a great reference point for my project. I was initially tasked with expanding on her prototype and filling in the gaps such as integrating it with the main monitoring tool the lab uses. Eventually, the scope grew, expanding to support other databases and a growing collection of tools. I organized the framework around an observer pattern, meaning one point in the program sending updates to the rest of the framework. Every time a log was read and parsed, it was sent to be processed by the tools, using the type of event as a means to determine which tools should get a chance to act on the log. This decouples the tools from the log reader, making future updates and additions much easier. The framework processes MongoDB logs at ~135,000 entries per second and PostgreSQL logs at ~170,500 entries per second, accurately detecting anomalies such as slow queries and connections from unknown addresses. This framework serves to fill gaps in database monitoring tools currently implemented at the lab, such as tracking failed authentication for PostgreSQL and MongoDB which had very minimal or none before this framework. National labs such as Fermilab hold sensitive data and valuable computing resources, making them attractive targets. Monitoring intrusion attempts on databases is made much easier by this comprehensive monitoring suite.

Clark, Dylan [Unlisted, IL]↗
DOE OSTI2026

Expandable Log Analyzing Framework

Prior to my internship, I was informed that a previous intern had built a tool to analyse MongoDB logs and look for invalid access attempts, which served as a great reference point for my project. I was initially tasked with expanding on her prototype and filling in the gaps such as integrating it with the main monitoring tool the lab uses. Eventually, the scope grew, expanding to support other databases and a growing collection of tools. I organized the framework around an observer pattern, meaning one point in the program sending updates to the rest of the framework. Every time a log was read and parsed, it was sent to be processed by the tools, using the type of event as a means to determine which tools should get a chance to act on the log. This decouples the tools from the log reader, making future updates and additions much easier. The framework processes MongoDB logs at ~135,000 entries per second and PostgreSQL logs at ~170,500 entries per second, accurately detecting anomalies such as slow queries and connections from unknown addresses. This framework serves to fill gaps in database monitoring tools currently implemented at the lab, such as tracking failed authentication for PostgreSQL and MongoDB which had very minimal or none before this framework. National labs such as Fermilab hold sensitive data and valuable computing resources, making them attractive targets. Monitoring intrusion attempts on databases is made much easier by this comprehensive monitoring suite.

Clark, Dylan [Unlisted, IL]↗
DOE OSTI2025

Hybrid Energy-Powered Electrochemical Direct Ocean Capture Model

Offshore synthetic fuel production and marine carbon dioxide removal can be enabled by direct ocean capture, which extracts carbon dioxide from the ocean that then can be used as a feedstock for fuel production or sequestered underground. To maximize carbon capture, plants require a variety of low-carbon energy sources to operate, such as variable renewable energy. However, the impacts of variable power on direct ocean capture have not yet been thoroughly investigated. To facilitate future deployments, a generalizable model for electrodialysis-based direct ocean capture plants is created to evaluate plant performance and electricity costs under intermittent power availability. This open-source Python-based model captures key aspects of the electrochemistry, ocean chemistry, post-processing, and operation scenarios under various conditions. To incorporate realistic energy supply dynamics and cost estimates, the model is coupled with the National Renewable Energy Laboratory’s H2Integrate tool, which simulates hybrid energy system performance profiles and costs. This integrated framework is designed to provide system-level insights while maintaining computational efficiency and flexibility for scenario exploration. Initial evaluations show similar results to those predicted by the industry, and demonstrate how a given plant could function with variable power in different deployment locations, such as with wind energy off the coast of Texas and with wind and wave energy off the coast of Oregon. The results suggest that electrochemical systems with greater tolerances for power variability and low minimum power requirements may offer operational advantages in variable-energy contexts. However, further research is needed to quantify these benefits and evaluate their implications across different deployment scenarios.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Database-Agnostic Log Analysis and Monitoring Framework

Prior to my internship, I was informed that a previous intern had built a tool to analyse MongoDB logs and look for invalid access attempts, which served as a great reference point for my project. I was initially tasked with expanding on her prototype and filling in the gaps such as integrating it with the main monitoring tool the lab uses. Eventually, the scope grew, expanding to support other databases and a growing collection of tools. I organized the framework around an observer pattern, meaning one point in the program sending updates to the rest of the framework. Every time a log was read and parsed, it was sent to be processed by the tools, using the type of event as a means to determine which tools should get a chance to act on the log. This decouples the tools from the log reader, making future updates and additions much easier. The framework processes MongoDB logs at ~135,000 entries per second and PostgreSQL logs at ~170,500 entries per second, accurately detecting anomalies such as slow queries and connections from unknown addresses. This framework serves to fill gaps in database monitoring tools currently implemented at the lab, such as tracking failed authentication for PostgreSQL and MongoDB which had very minimal or none before this framework. National labs such as Fermilab hold sensitive data and valuable computing resources, making them attractive targets. Monitoring intrusion attempts on databases is made much easier by this comprehensive monitoring suite.

Clark, Dylan [Unlisted, US, IL; Fermilab]↗
DOE OSTI2025

Knowledge graph-aided Bayesian active learning for top- K genetic interaction discovery

In silico methods for predicting the effects of multi-gene perturbations hold great promise for advancing functional genomics, computational drug discovery, and disease modeling. However, the development of these predictive algorithms for mammalian systems has been hampered by limited datasets and high experimental costs. In this study, we present a Bayesian active learning framework designed to discover pairwise host gene knockdowns that effectively inhibit viral proliferation in an in vitro HIV-1 infection model. Our method leverages a biological knowledge graph as side information and employs a computationally efficient batch diversification approach. We evaluated this framework using a dataset of viral load measurements obtained from multi-day dual-gene depletion experiments, encompassing all possible pairwise knockdowns of over 350 host genes associated with HIV infection. We demonstrate that our framework rapidly identifies the most effective gene knockdown pairs for reducing viral load. Furthermore, we show that incorporating side information enhances performance during the early stages of active learning (low data regime), while our batch diversification strategy significantly boosts performance in later stages (high data regime). This framework is general and can be adapted to explore gene interactions in other contexts, such as synthetic lethality prediction and mapping epistatic effects across quantitative trait loci.

Computational biology and bioinformatics↗
DOE OSTI2026

A tensor train-based isogeometric solver for large-scale 3D poisson problems

We introduce a three-dimensional (3D), fully tensor train (TT) assembled isogeometric analysis (IGA) framework, TT-IGA, for solving partial differential equations (PDEs). Our method reformulates IGA discrete operators into TT format, enabling efficient compression and computation. Geometry evaluations use the original NURBS description at sampling points and TT approximation is applied to geometry-derived coefficient fields and discrete operators. We demonstrate the effectiveness of the proposed TT-IGA framework on the three-dimensional Poisson equation, achieving substantial reductions in memory and computational cost without compromising solution quality.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Virtual Engineering: Python framework for engineering process design

Virtual Engineering (VE) is a Python software framework designed to accelerate the research and development of engineering processes that are fundamentally defined by multiple unit operations executed in series. VE supports a wide variety of different multi-physics models and integrates them to simulate a complete end-to-end process. To automate the execution of this model sequence, VE provides (i) a robust method to communicate between models, (ii) a high-level, user-friendly interface to set model parameters and enable optimization, and (iii) an overall model-agnostic approach that allows new computational units to be swapped in and out of workflows. Although the VE framework was developed to support the biochemical conversion of biomass to fuel, we have designed each component to easily accommodate new domains and unit models.

09 BIOMASS FUELS↗
DOE OSTI2026

FitCache: A Transparent Drop-In Framework for Multi-Tier Caching to Accelerate Distributed Deep Learning Workloads

Training in Deep learning (DL) remains highly compute- and data-intensive, with I/O becoming a critical bottleneck as models and datasets scale. Recent studies report that data loading can dominate training time, especially on large-scale HPC systems with shared parallel file systems (PFS). Existing caching approaches either rely on single-tier designs or require intrusive modifications to training pipelines, limiting their portability and effectiveness. In this work, we present FitCache, a transparent drop-in framework for multi-tier caching to accelerate distributed DL training by coordinating fast local memory (e.g., DRAM, Persistent Memory (PMem)) and NVMe as hierarchical caches atop PFS. Our design adapts to hardware diversity, i.e., if NVMe is missing, memory transparently acts as a caching tier, ensuring stable performance. FitCache transparently intercepts I/O requests and issues concurrent fetches across all tiers, returning data from the fastest responder without centralized metadata or static redirection paths. FitCache adapts to dynamic workloads and heterogeneous clusters while maintaining POSIX compatibility. Experiments on Frontier (2048 GPUs) and smaller research clusters show that FitCache reduces training time by up to 40% and per-batch I/O latency by up to 71.6% compared to Lustre Orion PFS, offering a drop-in solution for scalable DL training.

Hu, Guangxing [ORNL] (ORCID:0009000283203614)↗
DOE OSTI2025

EJFAT Scientific Perspective

Presented new computing model to the test by deploying the EJFAT system alongside a data-stream processing framework running the production-level CLAS12 event reconstruction application. In this experiment, a continuous stream of CLAS12 Level-1 identified events was processed in real-time using the EJFAT load balancer, distributing the workload across 90 computing nodes located across the U.S. This marks the first-ever large-scale, real-time distributed data stream processing experiment, demonstrating that scientific data-streaming pipelines can efficiently scale across four dimensions, thanks to EJFAT’s advanced hardware and software capabilities.

Gyurjyan, Vardan [Thomas Jefferson National Accele↗
DOE OSTI2024

Assessing Accelerator Library Integration in MOOSE

MOOSE is a general purpose open source multiphysics framework supporting native finite element and finite volume discretizations as well and wrapping other libraries providing arbitrary computational capabilities. Due to its generality, it has experienced significant success. However, with recent changes in the landscape of computer architectures, most notably the growth of GPU computing, MOOSE must assess new technologies or else risk alienating customers interested in the benefits these technologies can offer. In that vein we have assessed multiple accelerator libraries developed through the ECP project, including Kokkos, libCEED, and MFEM, and present our evaluation of these libraries as candidates for incorporation into the MOOSE framework.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Tuning Two-Dimensional Phthalocyanine Dual Site Metal–Organic Framework Catalysts for the Oxygen Reduction Reaction

Metal-organic frameworks (MOFs) offer an interesting opportunity for catalysis, particularly for metal-nitrogen-carbon (M-N-C) motifs by providing an organized porous structural pattern and well-defined active sites for the oxygen reduction reaction (ORR), a key need for hydrogen fuel cells and related sustainable energy technologies. Here, in this work, we leverage electrochemical testing with computational models to study the electronic and structural properties in these systems and their relationship to ORR activity and stability based on dual transitional metal centers. These consists of two M1 metals with amine nodes coordinated to a single M2 metal with a phthalocyanine linker, where M1/M2 = Co, Ni, or Cu. Co-based metal centers, in particular Ni-Co, demonstrate the highest overall activity of all nine tested MOFs. Computationally, we identify the dominance of Co-sites, relative higher importance of the M2 site, and the role of layer M1 interactions on the ORR activity. Selectivity measurements indicate that M1 sites of MOFs, particularly Co, exhibits lowest (< 4%), and Ni demonstrates highest (>46%) two-electron selectivity, in good agreement with computational studies. Direct in-situ stability characterization, measuring dissolved metal ions, and calculations, using an alkaline stability metric, confirm that Co is the most stable metal in the MOF, while Cu exhibits notable instability at the M1. Overall, this study reveals how atomistic coupling of electronic and structural properties affects the ORR performance of dual site MOF catalysts and opens new avenues for tunable design and future development of these systems for practical electrochemical applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

A Permanently Porous Chalcogen-Bonded Organic Framework

The nature of connectivity between constituent atomic or molecular building blocks is fundamental in shaping the properties and functionality of materials. The extrapolation of emergent interatomic interactions to enable functional materials has driven transformative technological advancements. However, the bonding interactions used in material design have been largely static since the emergence of dynamic covalent chemistry ~30 years ago. Here we demonstrate that non-covalent chalcogen bonding (Ch-bonding) is a distinct mode of interatomic connectivity for constructing functional materials by design. This is established by leveraging self-complementary assembly of 1,2,5-telluradiazole moieties to construct a honeycomb-type permanently porous Ch-bonded organic framework, assembled and stabilized solely through non-covalent Te...N contacts. Empirical and computational studies of electronic structure, structural healing and lattice dynamics highlight the pi-type electronic communication, controlled assembly and modulated lattice dynamics in Trip3Tez-I arising directly from the unique nature of the Te...N Ch-bonding that holds substantial implications for next generation crystalline semiconductors. In addition to introducing a distinct class of permanently porous frameworks, this work establishes Ch-bonding as a programmable molecular tool for constructing functional materials with distinct properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗