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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Foundations of machine learning for low-temperature plasmas: methods and case studies

Abstract Machine learning (ML) and artificial intelligence have proven to be an invaluable tool in tackling a vast array of scientific, engineering, and societal problems. The main drivers behind the recent proliferation of ML in practically all aspects of science and technology can be attributed to: (a) improved data acquisition and inexpensive data storage; (b) exponential growth in computing power; and (c) availability of open-source software and resources that have made the use of state-of-the-art ML algorithms widely accessible. The impact of ML on the field of low-temperature plasmas (LTPs) could be particularly significant in the emerging applications that involve plasma treatment of complex interfaces in areas ranging from the manufacture of microelectronics and processing of quantum materials, to the LTP-driven electrification of the chemical industry, and to medicine and biotechnology. This is primarily due to the complex and poorly-understood nature of the plasma-surface interactions in these applications that pose unique challenges to the modeling, diagnostics, and predictive control of LTPs. As the use of ML is becoming more prevalent, it is increasingly paramount for the LTP community to be able to critically analyze and assess the concepts and techniques behind data-driven approaches. To this end, the goal of this paper is to provide a tutorial overview of some of the widely-used ML methods that can be useful, amongst others, for discovering and correlating patterns in the data that may be otherwise impractical to decipher by human intuition alone, for learning multivariable nonlinear data-driven prediction models that are capable of describing the complex behavior of plasma interacting with interfaces, and for guiding the design of experiments to explore the parameter space of plasma-assisted processes in a systematic and resource-efficient manner. We illustrate the utility of various supervised, unsupervised and active learning methods using LTP datasets consisting of commonly-available, information-rich measurements (e.g. optical emission spectra, current–voltage characteristics, scanning electron microscope images, infrared surface temperature measurements, Fourier transform infrared spectra). All the ML demonstrations presented in this paper are carried out using open-source software; the datasets and codes are made publicly available. The FAIR guiding principles for scientific data management and stewardship can accelerate the adoption and development of ML in the LTP community.

Physics↗
DOE OSTI2022

Reinforcement Learning for Intelligent Building Energy Management System Control *

A building energy management system (BEMS) is a computer-based system designed to monitor and control a building's energy needs. Modern BEMS rely on the sensing and connectivity capabilities of Internet of Things (IoT) technology to intelligently adjust the energy consumption to reduce cost while respecting the consumers' preferences. Increasingly, control decisions are made based on predictions by models trained using supervised machine learning methods, which still requires control policies to be formulated in a rule-based fashion. When using reinforcement learning (RL) instead, control policies are learned by observing the utility in terms of cost and comfort associated with actions such as a change in the heating system's setpoint. The resulting RL-based controllers can capture not only the dynamics of the building and the associated electrical devices, but also fluctuations in electricity prices and user demand, avoiding the need to combine multiple predictive models with tailored control policies. This chapter will provide an overview of RL-based approaches for BEMS. After sketching the taxonomy of general RL methods, we discuss the implications of relying on the individual methods in a BEMS context. Existing work applying RL is presented along the key devices controlled by BEMS systems. Finally, we summarize the state-of-the-art and sketch limitations and open research directions.

Kotevska, Olivera↗
DOE OSTI2025

Benchmark microgravity experiments and computations for 3D dendritic-array stability in directional solidification

In this study, we present a comprehensive quantitative analysis of stability bands for dendritic arrays during directional solidification of a transparent succinonitrile-0.46 wt % camphor alloy, spanning a broad range of pulling velocities. Taking advantage of the microgravity environment aboard the International Space Station where most convection effects are suppressed, we obtain unique measurements that quantify the stable primary spacing range of spatially extended three-dimensional dendritic array structures under purely diffusive growth conditions. Through carefully designed velocity jump experiments and detailed examination of sub-grain boundary dynamics, we characterize key instabilities, including elimination and tertiary branching, shedding new light on the mechanisms governing dynamic dendritic spacing selection in extended 3D arrays. Phase field simulations are performed to characterize the stability limits of dendritic array structures for quantitative comparison with the flight experiments. Although the simulations capture general trends, significant deviations are noted at the upper stability boundary, indicating the influence of additional, unexplored factors. These findings contribute to a deeper understanding of dendritic growth dynamics and offer valuable benchmark data that could aid in refining predictive models and improving control of dendritic microstructures in metallurgical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Laser peening: A tool for additive manufacturing post-processing

Additive manufacturing (AM) is rapidly moving from research to commercial applications due to its ability to produce geometric features difficult or impossible to generate by conventional machining. Fielded components need to endure fatigue loadings over long operational lifetimes. This work evaluates the ability of shot and laser peening to enhance the fatigue lifetime and strength of AM parts. As previously shown, peening processes induce beneficial microstructure and residual stress enhancement; this work takes a step to demonstrate the fatigue enhancement of peening including for the case of geometric stress risers as expected for fielded AM components. We present AM sample fatigue results with and without a stress riser using untreated baseline samples and shot and laser peening surface treatments. Laser peening is clearly shown to provide superior fatigue life and strength. We also investigated the ability of analysis to select laser peening parameters and coverage that can shape and/or correctively reshape AM components to a high degree of precision. We demonstrated this potential by shaping and shape correction using our finite element based predictive modeling and highly controlled laser peening.

42 ENGINEERING↗
DOE OSTI2026

Multi-machine validation of plasma initiation modelling and prospects for future devices: Predicting plasma initiation using only hardware design and control room input data

This paper reports on the generic prediction capability of full electromagnetic plasma initiation modelling with DYON, which was carried out for the first time in fusion research by the joint modelling of the International Tokamak Physics Activity—Integrating Operation Scenario group. The following devices were included in the experiment database: VEST (spherical torus, copper coils, Stainless steel wall, R/a = 0.3 m/0.2 m, V v = 3.7 m 3 ), MAST-U (spherical torus, copper coils, C wall, R/a = 0.7 m/0.5 m, V v = 55 m 3 ), EAST (conventional tokamak, superconducting coils, metallic wall, R/a = 1.85 m/0.5 m, V v = 38 m 3 ), DIII-D (conventional tokamak, copper coils, C wall, R/a = 1.67 m/0.65 m, V v = 35 m 3 ), and KSTAR (conventional tokamak, superconducting coils, C wall, R/a = 1.8 m/0.5 m, V v = 55 m 3 ). Despite the different hardware features of the devices, the required operating spaces of the loop voltage induction and prefill gas pressure for inductive plasma initiation in each device were successfully reproduced by the predictive simulations with DYON using only the individual hardware design and the control room input data for each discharge. This successful validation across multiple machines demonstrates that the full electromagnetic DYON modelling can capture the essential physics of inductive plasma initiation. The simulation settings commonly employed for all modelling and the modifications necessary to account for the discrepancies between individual devices are reported. Predictions for ITER based on the multi-machine validation indicate that a wide range of prefill gas pressures exists for the Townsend breakdown and the plasma burn-through (0.01–1.5 mPa).

DYON↗
DOE OSTI2026

Good practices for documenting AI-based studies on energy and buildings

Artificial intelligence has transformed building science research over the past decade, with applications spanning energy modeling, energy prediction, HVAC optimization and controls, fault detection, and occupancy modeling. However, many studies lack adequate documentation of datasets, algorithms, training procedures, and validation methods. Building science research faces additional challenges including inconsistent evaluation metrics, limited generalizability across building types, climates, and significant gaps between experimental studies and deployed systems. This communication provides practical guidance for good practices in documenting and publishing AI-based research following established standards from the computer science and machine learning communities. By adopting frameworks such as Datasheets for Datasets, Model Cards, and standardized reproducibility checklists, researchers can ensure their work meets the rigorous documentation standards necessary for reproducible, comparable, and impactful building science research.

Hong, Tianzhen [Lawrence Berkeley National Laborat↗
DOE OSTI2026

Combining Generative Modeling and Advanced Control for Building Scenario Generation

Buildings make up a large portion of energy consumption in the U.S. today. Understanding their energy consumption patterns can improve their efficiency, but requires detailed models that rely on incomplete or unknown information. Previous work has shown that artificial intelligence (AI) can be used to predict missing information and even suggest upgrades to improve building efficiency. However, building upgrades may require undesirable upfront costs. Oppositely, advanced control could improve building efficiency with negligible upfront cost. To explore the tradeoffs between these two approaches, in this work we propose a workflow to compute optimal temperature setpoint schedules to minimize energy consumption and operational cost. Results show that modifying the temperature setpoints in a building using model predictive control (MPC) can effectively reduce its energy consumption and operational cost. This optimal operation cannot fully meet a desired goal. However, we show that by considering MPC in addition to component upgrades, a desired goal can be met with significantly less upfront costs.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Robust control of the current profile and plasma energy in EAST

Integrated control of the toroidal current density profile, or alternatively the q-profile, and plasma stored energy is essential to achieve advanced plasma scenarios characterized by high plasma confinement, magnetohydrodynamics stability, and noninductively driven plasma current. The q-profile evolution is closely related to the evolution of the poloidal magnetic flux profile, whose dynamics is modeled by a nonlinear partial differential equation (PDE) referred to as the magnetic-flux diffusion equation (MDE). The MDE prediction depends heavily on the chosen models for the electron temperature, plasma resistivity, and non-inductive current drives. To aid control synthesis, control-oriented models for these plasma quantities are necessary to make the problem tractable. However, a relatively large deviation between the predictions by these control-oriented models and experimental data is not uncommon. For this reason, the electron temperature, plasma resistivity, and non-inductive current drives are modeled for control synthesis in this work as the product of an “uncertain” reference profile and a nonlinear function of the different auxiliary heating and current-drive (H&CD) source powers and the total plasma current. The uncertainties are quantified in such a way that the family of models arising from the modeling process is able to capture the q-profile and plasma stored energy dynamics from a typical EAST shot. A control-oriented nonlinear PDE model is developed by combining the MDE with the “uncertain” models for the electron temperature, plasma resistivity, and non-inductive current drives. This model is then rewritten into a control framework to design a controller that is robust against the modeled uncertainties. The resulting controller utilizes EAST's H&CD powers and total plasma current to regulate the q profile and plasma stored energy even when mismatches between modeled and actual dynamics are present. The effectiveness of the controller is demonstrated through nonlinear simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Field Validation of Wake Steering Control with Wind Direction Variability: Preprint

Wake steering is a type of wind farm control strategy wherein upstream turbines are misaligned with the wind direction to redirect their wakes away from downstream turbines, increasing overall wind plant power. Wake steering is often analyzed assuming steady mean wind directions across the wind farm. However, in practice, the wind direction varies considerably over time because of large-scale weather phenomena. Wind direction variability causes wake steering controllers to increase power production less than predicted by steady state models, but more robust wake steering strategies can be designed that account for variable wind conditions. This paper compares the achieved yaw offsets and power gains from two 2-turbine wake steering experiments at a commercial wind farm with model predictions using the FLOw Redirection and Induction in Steady State (FLORIS) control-oriented model, assuming both fixed and variable wind directions. The impact of wind direction variability is modeled by including wind direction and yaw uncertainty in the FLORIS calculations. The field results match the trends predicted assuming wind direction variability. Specifically, the yaw offsets achieved in the intended control regions are lower than desired, resulting in less power gain, while a slight loss in power occurs for wind directions outside of the intended control region because of unintentional yaw misalignment. The agreement between the model and field results suggests that the wind direction variability model can be used to design wake steering controllers that are more robust to variable wind conditions present in the field.

17 WIND ENERGY↗
DOE OSTI2022

Development and assessment of a reactor system prognosis model with physics-guided machine learning

Autonomous control systems provide recommendations to help operators in decision-making during plant operations ranging from normal operation to accident management. An important step of autonomous control is prognosis. In nuclear engineering domain, prognosis is the process of predicting future conditions of a system or equipment based on present signs and symptoms of a fault. The prognosis model allows predicting future reactor states for possible candidate control strategies so that the outcomes can be evaluated to determine the best control strategy. The prognosis model requires representing direct relationships between the symptoms and the predictions. In nuclear engineering, computational simulations are approximate representations of the operation of the real system. However, prognosis with computational simulations requires high computation power and time due to possible large number of scenarios. Necessary computation resources can be reduced with machine learning (ML) approach for fast predictions by building a surrogate function using the simulation data. A critical issue is, ML models are ignorant of physical knowledge, and these models approximate statistical relationships between the system variables. This ignorance can produce results that are inconsistent with physical laws, even if an optimal result is achieved from a mathematical point of view. Physics-guided machine learning (PGML) is an approach to tackle this issue. Here, this work formulates and illustrates a framework to guide development and assessment of the ML-based prognosis model for autonomous control systems. The development of the prognosis model considers the training of a ML model which consists of optimizing many aspects of the ML approach. The assessment of the prognosis model considers training data limitations and uncertainties of the ML approach. Prognosis models with standalone ML and PGML are developed and assessed on the loss-of-flow scenario of Experimental Breeder Reactor II. The results indicate that PGML based prognosis model has the best performance compared to other prognosis models.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Biomanufacturing and Scale-Up: Pathways to Biochemicals, Biofuels, and Biomaterials

Advancing the bioeconomy requires the development of large-scale microbial bioprocesses capable of converting waste carbon streams into biofuels, biochemicals, and biomaterials at industrially relevant scales. While biomanufacturing has been successfully demonstrated at the laboratory scale for a wide range of chemicals, only a few have reached industrial-scale production. This is partly due to the inherent complexity of microbial systems, which rely on living cells with intricate metabolic pathways that are highly sensitive to environmental changes, making large-scale production difficult to optimize and predict. As a result, scaling-up bioprocesses remains a high-stakes challenge that requires deeper exploration. This involves integrating feedstock and microbial selection, upstream and downstream processes, and computational modelling, among other research efforts. Bulk and specialty chemicals derived from biological processes also face competition from fossil-based production routes, which have been refined through decades of technological advancements. While biologically derived molecules may offer more environmentally friendly production pathways than traditional chemical manufacturing, their widespread adoption depends on achieving cost parity-or superiority-relative to fossil-based methods. This emphasizes the importance of holistic research, including techno-economic analyses and life cycle assessments, to ensure both economic viability and environmental sustainability. This editorial and special issue explores state-of-the-art strategies for converting waste carbon sources into valuable products. It discusses how enzymes, single microbes (e.g., extremophiles), and microbiomes (e.g., through division of labor) can be integrated with upstream and downstream process innovations-such as consolidated bioprocessing and in situ product recovery-to improve the efficiency and scalability of biomanufacturing. The editorial further highlights the role of computational modelling in understanding, predicting, and controlling bioprocess performance across scales, and concludes by emphasizing the importance of techno-economic modelling to identify technologies that can move to market.

09 BIOMASS FUELS↗
DOE OSTI2021

Neural network model of the multi-mode anomalous transport module for accelerated transport simulations

Here, a neural network version of the Multi-Mode Anomalous Transport Module, known as MMMnet, has been developed to calculate plasma turbulent diffusivities in DIII-D with a calculation time suitable for control applications. MMMnet uses a simple artificial neural network structure to predict the ion thermal, electron thermal, and toroidal momentum diffusivities while reproducing Multi-Mode Model (MMM) data with good accuracy and keeping the calculation time as a fraction of that associated with MMM. Model-based control techniques require models with fast calculation times, making many existing physics-oriented predictive codes unsuitable. The control-oriented predictive code COTSIM (Control Oriented Transport SIMulator) calculates the most significant plasma dynamics in response to the different actuators while running at a speed useful for control design. In order to achieve this calculation speed, COTSIM often relies on scaling laws and control-level models. Replacing some of these scaling laws and control-level models with neural network versions of more complex physics-level models has the potential of increasing the range of validity and the level of accuracy of COTSIM without compromising its computational speed. In this work, MMMnet is integrated into COTSIM to improve the turbulent diffusivity predictions, which will in turn improve the prediction accuracy associated with the dynamics of many plasma properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

A Four-Layer Cyber-Physical Security Model for Electric Machine Drives Considering Control Information Flow

Despite the IEEE Power Electronics Society (PELS) establishing Technical Committee 10 on Design Methodologies with a focus on the cyber-physical security of power electronics systems, a holistic design methodology for addressing security vulnerabilities remains underdeveloped. This gap largely stems from the limited integration of computer science and power/control engineering studies in this interdisciplinary field. Addressing the inadequacy of unilateral cyber or control perspectives, this article presents a novel four-layer cyber-physical security model specifically designed for electric machine drives. Central to this model is the innovative control information flow (CIF) model, residing within the control layer, which serves as a pivotal link between the cyber layer's vulnerable resources and the physical layer's state-space models. By mapping vulnerable resources to control variable space and tracing attack propagation, the CIF model facilitates accurate impact predictions based on tainted control laws. The effectiveness and validity of this proposed model are demonstrated through hardware experiments involving two typical cyber-attack scenarios, underscoring its potential as a comprehensive framework for multidisciplinary security strategies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2014

FN-DFE: Fuzzy-Neural Data Fusion Engine for Enhanced State-Awareness of Resilient Hybrid Energy System

Resiliency and improved state-awareness of modern critical infrastructures, such as energy production and industrial systems, is becoming increasingly important. As control systems become increasingly complex, the number of inputs and outputs increase. Therefore, in order to maintain sufficient levels of state-awareness, a robust system state monitoring must be implemented that correctly identifies system behavior even when one or more sensors are faulty. Furthermore, as intelligent cyber adversaries become more capable, incorrect values may be fed to the operators. To address these needs, this paper proposes a Fuzzy-Neural Data Fusion Engine (FN-DFE) for resilient state-awareness of control systems. The designed FN-DFE is composed of a three-layered system consisting of: 1) traditional threshold based alarms, 2) anomalous behavior detector using self-organizing fuzzy logic system, and 3) artificial neural network based system modeling and prediction. The improved control system state-awareness is achieved via fusing input data from multiple sources and combining them into robust anomaly indicators. In addition, the neural network based signal predictions are used to augment the resiliency of the system and provide coherent state-awareness despite temporary unavailability of sensory data. The proposed system was integrated and tested with a model of the Idaho National Laboratory’s (INL) hybrid energy system facility know as HYTEST. Experimental results demonstrate that the proposed FN-DFE provides timely plant performance monitoring and anomaly detection capabilities. It was shown that the system is capable of identifying intrusive behavior significantly earlier than conventional threshold based alarm systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Slag Management of Carbon Feedstock Used in Gasification FY17 TCF between Eastman Chemical and NETL (Final Report)

NETL, in collaboration with Eastman Chemical Corp (Kingsport, TN), targeted the joint evaluation and refinement of a slag management program developed by NETL (NETL IP, patent applied for) to control gasifier slag properties formed from ash in individual or combinations of different coal-based carbon feedstock materials and specific slag modifiers used in gasification. Slag forms from mineral or organic-metallic impurities in the carbon feedstock that melt at the high temperatures of gasification, coalescing to form a liquid (slag) that must flow from the gasifier. Slag additives, also known as slag modifiers, are often added to the carbon feedstock to modify the ash chemistry and achieve desired slag flow properties at target temperatures used in gasification. If slag does not flow from a gasifier, its buildup within the gasification chamber will cause either gasifier shutdown to physically remove the slag (consuming time and damaging the protective refractory lining), or the gasification temperature must be increased to lower slag viscosity so it can flow from the gasifier, leading to greater refractory wear/corrosion, along with increased fouling and downstream component wear. Because of these issues, gasification is typically targeted at the lowest temperature possible where slag will flow in a controlled manner (a temperature range called T100 for the lowest temperature, with T250 being the highest temperature where the slag has achieved the desired fluidity). That temperature range also needs to yield a desired syngas composition, highlighting the importance of knowing and being able to control carbon feedstock slag viscosity and the temperature of thermal breakdown of the carbon feedstock. Slag viscosity varies with changes in the gasification chamber temperature, oxygen partial pressure, and slag chemistry. The slag model work with Eastman Chemical targeted predicting and controlling molten coal ash slag behavior at specific gasification conditions. The final goal of the refined model was to develop/refine the NETL slag model so a gasifier operator would be able to predict slag behavior prior to purchasing or using a carbon feedstock and control slag properties once a carbon feedstock is being gasified, allowing a gasifier user to determine what mineral additives or blends of different carbon materials would be needed to achieve desired slag properties at targeted gasification conditions. For a given carbon feedstock and desired gasification condition, the actual gasification cost and slag behavior would be able to be predicted using the slag management program in advance of purchasing or using the carbon feedstock – allowing accurate control of slag ash behavior in real time. As part of the TCF project work with Eastman Chemical, the viscosity of several ash compositions of interest to them would be measured and used to populate the slag model, along with a large database of historical slag temperature, chemistry, and viscosity information they possess – information that would in-crease the predictive accuracy of the slag management model with slag ash chemistry of interest to them. As part of the model evaluation and refinement, the predictive model and its database will be installed on computers at Eastman Chemical and used to manage slag properties in a gasifier during real-time operation of their gasifier. In summary, success of the slag management program at Eastman Chemical would support its use by other gasifier operators to manage slag chemistry and properties over other desired gasification temperature ranges, allowing greater process control and efficiency of their carbon feedstock conversion during gasification.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Real-Time Automated pH Control within Batch Processes Relying on Raman pH Measurement

Nuclear fission is an energy source that can provide consistent power with very low associated carbon emissions. However, management of the used nuclear fuel is an important aspect of the application of nuclear power. Recycling of useful components from used fuel is an attractive option, but this involves chemical processing of the fuel. Possible chemical separation technologies that might be used in this regard are sensitive to solution pH. Raman spectroscopy is a promising technique for monitoring the pH of solutions in real time. Classical pH probes are too fragile to be used in the harsh environments encountered in nuclear fuel processing. Raman probes are robust and can withstand these harsh environments to track pH. Coupled with chemometric analysis, the demonstration of the use of Raman spectroscopy to track and predict the pH in carboxylate-buffered systems is made possible. Utilizing this spectroscopy in conjunction with Programmable Logic Controllers mimics industrial control systems used in many modern industrial settings. This showcases a pragmatic approach toward leveraging Raman spectroscopy and chemometric model outputs as inputs for a real-time control system. The model to predict pH created by chemometrics proved to be successful in tracking pH. The optimal pH for TALSPEAK extraction of lanthanides and actinides from aqueous solution is known to proceed in a narrow pH range of around pH = 2.8 ± 0.1. This study uses Raman optical monitoring and automated control to return and maintain solution pH within this range after acid or base perturbations move the solution pH well outside this region. Root-mean-square errors show that pH changes measured using Raman spectroscopy on the batch process solution are reliably measured and used to automatically correct and maintain solution pH. Measurement of solution pH tracks favorably with electrochemical pH probe comparison measurements. As a result, the ability to showcase Raman spectroscopy paired with chemometrics analysis acts as a durable, better alternative data source compared to traditional pH probes to optimize the separation efficiency in the used nuclear fuel processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Error analysis of a hybrid control drum worth model

This paper presents a perturbation-based model for control drum worth prediction which employs both physics-based and statistics-based components. Control drums, or control shims, are cylindrical in shape and span the axial length of the core. A portion of the cylinder is coated in neutron absorbing material and the drum can rotate to introduce the absorbing material to the body of the core to reduce reactivity. The model can be expensive to create due to the requirement for full-core Monte Carlo eigenvalue calculations. Therefore, it is important to analyze how the errors in Monte Carlo calculated k{sub eff} used for model training affect model performance. It was found that the error in predicted criticalities could average to 70 pcm in the most complex form of the model and 215 pcm in the simplest form of the model. Furthermore, it was found that the Monte Carlo uncertainty in quantities calculated with Serpent used to train the models had minimal impact on the error observed from the model. Lastly, one of the forms of the hybrid model could be trained in considerably less computational time if the Monte Carlo calculations were run to higher uncertainty in k{sub eff} with a small penalty to model performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗