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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Convergent Manufacturing of Large-Scale Components for Nuclear Applications, via Additive Manufacturing and Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy (PM)–hot isostatic pressing (PM-HIP) has long been recognized as a powerful route for producing fully dense, near net shape metallic components. By consolidating powders under high temperature and pressure, HIP provides isotropic properties, uniform microstructures, and scalability to complex geometries that are vital for sectors such as aerospace, energy, and nuclear power. Yet despite these advantages, the technology has remained constrained by costly trial and error canister fabrication, limitations of conventional forging, and incomplete knowledge about how the canister design influences final part properties. Additive manufacturing (AM), by contrast, thrives on design freedom and geometric flexibility but struggles with speed, scalability, and cost when applied to very large structures. The research presented in this report investigated how a convergent manufacturing approach, combining AM with PM-HIP, can merge the strengths of both technologies, leveraging AM’s flexibility for canister design and HIP’s consolidation capability to deliver reliable, large, and complex parts. The work progressed through three case studies that built on one another in scale and complexity. Small cylindrical canisters fabricated by conventional methods, laser powder bed fusion, and directed energy deposition were filled with stainless steel powders and subjected to HIP. The resulting parts demonstrated near-full density and mechanical properties on par with wrought stainless steel, showing for the first time that AM canisters can be a direct substitute for conventional ones without sacrificing quality. The next step involved a medium-scale, noncentrosymmetric T-valve, which is an enclosed, multibranch geometry that tested the limits of AM + PM-HIP integration. The T-valve achieved predictable shrinkage and uniform densification, confirming feasibility for enclosed designs. However, this study also revealed oxide inclusions and interfacial challenges at the AM + HIP boundary, underscoring the critical importance of controlling interface chemistry and employing robust, in situ strategies, such as melt pool monitoring and thermal monitoring, coupled with nondestructive evaluation techniques such as x-ray computed tomography. Finally, the effort culminated in fabricating a large-scale impeller weighing nearly 2000 lb and spanning 5 ft in diameter. Produced via multirobot wire arc AM and hot isostatic pressed to near-full density, the impeller validated industrial-scale feasibility. Predictive models closely matched experimental shrinkage, tensile properties were spatially uniform across the component, and the AM + PM-HIP interface proved mechanically sound despite the presence of oxide-decorated prior particle boundaries. This large-scale demonstration is a major milestone, showing that hybrid AM + PM‑HIP can reliably deliver components at reactor-relevant scales. Collectively, these studies charted a logical pathway: small-scale work built scientific confidence, medium-scale work highlighted opportunities and challenges, and large-scale work proved industrial impact. The overarching conclusion of this report is that AM + PM-HIP should not be seen as a replacement for forging but as a complementary pathway that provides the US with flexibility, resilience, and new options for manufacturing nuclear-grade components. Looking ahead, several directions emerge as critical to sustaining progress. Predictive modeling must become faster, more accessible, and more accurate, with digital twins and machine learning reducing reliance on trial and error. Powders and alloys must be optimized for HIP, with improved cleanliness, reduced oxides, and tailored chemistries that enhance creep, fatigue, and irradiation resistance. Interfaces between AM and HIP regions must be better engineered through coatings, machining strategies, and surface treatments to mitigate oxide formation and ensure reliable bonding to explore opportunities for HIP of targeted compositional parts, as well as multimaterial HIP cladding applications. Monitoring and nondestructive evaluation need to expand, incorporating multimodal sensors, x-ray computed tomography, and real-time data integration through platforms such as Pelican. At the same time, the pathway to industrial adoption requires techno-economic analysis, machinability studies, and qualification frameworks aligned with industry and regulatory standards. Finally, workforce and academic engagement must be strengthened. Programs that train technicians and engineers for US Navy and US Department of Energy manufacturing challenges should be paired with academic partnerships to support fundamental research, with open sharing of non-export-controlled data to accelerate innovation and build the next generation of experts. In conclusion, this report demonstrates that hybrid AM + PM-HIP is scientifically viable and strategically important. By combining the design agility of AM with the consolidation strength of HIP and embedding modeling, monitoring, and workforce development, this approach provided a transformative new capability for US manufacturing. The path forward is clear: hybrid AM + PM-HIP is not just a promising research direction but is also potentially an industrially relevant pathway that can reshape how nuclear-grade components are designed, qualified, and deployed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Benchmarking Correlation-Consistent Basis Sets for Frequency-Dependent Polarizabilities with Multiresolution Analysis

This paper presents the first converged frequency-dependent HF polarizability results for general molecules, on a set of 89 closed-shell atoms and molecules. The solver employs multiresolution analysis (MRA) in a multiwavelet basis to compute both ground and response states to a guaranteed precision, which are validated against independent numerical grid calculations on atoms and linear molecules. The MRA ground-state energies and response properties are used to evaluate results in correlation-consistent basis sets up to 5Z augmented with either single or double diffuse functions and core-polarization functions. Systematic trends are revealed through consideration of chemical composition as well as the use of machine learning to cluster convergence trends, the latter suggesting the possibility of learning and correcting basis-set error.

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

Hamiltonian learning using machine-learning models trained with continuous measurements

Here, we build upon recent work on the use of machine-learning models to estimate Hamiltonian parameters using continuous weak measurement of qubits as input. We consider two settings for the training of our model: (1) supervised learning, where the weak-measurement training record can be labeled with known Hamiltonian parameters, and (2) unsupervised learning, where no labels are available. The first has the advantage of not requiring an explicit representation of the quantum state, thus potentially scaling very favorably to a larger number of qubits. The second requires the implementation of a physical model to map the Hamiltonian parameters to a measurement record, which we implement using an integrator of the physical model with a recurrent neural network to provide a model-free correction at every time step to account for small effects not captured by the physical model. We test our construction on a system of two qubits and demonstrate accurate prediction of multiple physical parameters in both the supervised context and the unsupervised context. We demonstrate that the model benefits from larger training sets, establishing that it is “learning,” and we show robustness regarding errors in the assumed physical model by achieving accurate parameter estimation in the presence of unanticipated single-particle relaxation.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Adaptive Methods for Radial Basis Functions

Radial basis functions (RBFs) are a powerful tool for constructing high-order accurate reduced representations of scattered data in arbitrary dimension and on manifolds. We present a method of constructing data approximations in which we utilize a functional tail to capture a global background profile and a RBF neural network (NN) to capture the smaller-scale features. In the RBF NN the RBF centers, matrix shape parameters were selected adaptively for each RBF. We also utilized a geodesic notion of distance on the manifold on which the data lies, e.g., the spherical geodesic for data on the sphere. Although each of these ideas have been been investigated separately in previous works, their combination into a single algorithm is novel. We defined a machine learning problem in which these properties are learned to minimize the data reduction error. We demonstrate the algorithm for applications of scattered data reduction in the plane and on the sphere.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

SPIDARman: System-Level Physics-Informed Detection of Anomalies in Reactor Collected Data Considering Human Errors

In nuclear power plants (NPPs), anomalies arising from sensors or human errors (HEs) can undermine the performance and reliability of plant operations. Anomaly detection models can be employed to detect sensor errors and HEs. Additionally, physics-informed machine learning models can utilize the known physics of the system, as described by mathematical equations, to ensure that sensor values are consistent with physical laws. Hence, we propose SPIDARman: System-level Physics-Informed Detection of Anomalies in Reactor Collected Data Considering Human Errors, a holistic physics-informed anomaly detection approach based on generative adversarial networks (GANs) to detect anomalies in both automatically collected sensor data and manually collected surveillance data. Here we test our approach on data collected from a flow loop testbed, showcasing its potential to detect anomalies. Results demonstrate that the proposed model performs better than the baseline GAN-based models in detecting sensor and surveillance anomalies, suggesting the potential of physics-informed anomaly detection GAN models in NPPs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Stable Simulation of the Community Atmosphere Model Using Machine‐Learning Physical Parameterization Trained With Experience Replay

In recent years, machine learning (ML) models have been used to improve physical parameterizations of general circulation models (GCMs). A significant challenge of integrating ML models into GCMs is the online instability when they are coupled for long‐term simulation. We present a new strategy that demonstrates robust online stability when the physical parameterization package of an atmospheric GCM is replaced by a deep ML model. The method uses experience replay with a multistep training scheme of the ML model in which the model's own output at the previous time step is used in the training. Predicted physics tendencies in the replay buffer with the most recent errors in the training iterations are reused, making the ML model learn from its own errors. The training method reduces the gap between the offline and online environments of the ML model. The method is used to train the ML model as the physical parameterization of the Community Atmosphere Model (CAM5) with training data from the Multi‐scale Modeling Framework high resolution simulations. Three 6‐year online simulations of the CAM5 are carried out by using the ML physics package. The simulated spatial distributions of precipitation, surface temperature and zonally averaged atmospheric fields demonstrate overall better accuracy than that of the standard CAM5 and benchmark model even without the use of additional physical constraints or tuning. This work is the first to demonstrate a solution to address the online instability problem in climate modeling with ML physics by using experience replay.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Deep Learning Advances Arctic River Water Temperature Predictions

The accelerated warming in the Arctic poses serious risks to freshwater ecosystems by altering streamflow and river thermal regimes. However, limited research on Arctic River water temperatures exists due to data scarcity and the absence of robust methodologies, which often focus on large, major river basins. To address this, we leveraged the newly released, extensive AKTEMP data set and advanced machine learning techniques to develop a Long Short-Term Memory (LSTM) model. By incorporating ERA5-Land reanalysis data and integrating physical understanding into data-driven processes, our model advanced river water temperature predictions in ungauged, snow- and permafrost-affected basins in Alaska. Our model outperformed existing approaches in high-latitude regions, achieving a median Nash-Sutcliffe Efficiency of 0.95 and root mean squared error of 1.0°C. The LSTM model learned air temperature, soil temperature, solar radiation, and thermal radiation—factors associated with energy balance—were the most important drivers of river temperature dynamics. Soil moisture and snow water equivalent were highlighted as critical factors representing key processes such as thawing, melting, and groundwater contributions. Glaciers and permafrost were also identified as important covariates, particularly in seasonal river water temperature predictions. Our LSTM model successfully captured the complex relationships between hydrometeorological factors and river water temperatures across varying timescales and hydrological conditions. This scalable and transferable approach can be potentially applied across the Arctic, offering valuable insights for future conservation and management efforts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Accelerating Discovery of Atomistic Defects via Machine Learning

The quantification of defects such as vacancies in crystalline structures is a cornerstone of materials science research. Traditional efforts often rely on manual detection, a process that is time-intensive, prone to human error, and challenging to scale. Here we leverage machine learning (ML) methods to identify and quantify vacancies within a crystalline lattice, aiming to expedite detection while improving accuracy. Additionally, we explore the transferability of these ML techniques, identifying characteristics of atomistic imaging data that complicate this task. We show how the integration of ML can drive innovation, providing a powerful tool that will play an increasingly crucial role in the future of materials science.

2D materials↗
DOE OSTI2026

A Hybrid Biophysical‐Machine Learning Framework for Diurnal Surface Energy Flux Estimation Using Proximal Sensing

Thermal infrared-based remote sensing of surface energy fluxes has traditionally relied on high spatial resolution satellite data with revisit frequencies on the order of weeks. In this study, we evaluate a biophysics-based analytical surface energy balance model for predicting latent energy ( LE ) and sensible heat ( H ) fluxes using proximal sensing observations. The Surface Temperature Initiated Closure (STIC1.2) model has been extensively validated across a wide range of spatial and temporal scales using various satellite-derived thermal infrared data sets. Here we extend this validation by applying STIC at sub-hourly temporal resolution over multiple growing seasons for four distinct agricultural systems. We further develop and evaluate novel STIC variants that incorporate machine learning (ML) techniques to eliminate the need for surface energy balance observations, specifically net radiation and soil heat flux, thereby enhancing model applicability in data-sparse settings. The integration of a ML component to estimate surface available energy is shown to have strong predictive performance for both LE (R 2 = 0.81–0.94) and H (R 2 = 0.46–0.72) across all agricultural systems examined here, demonstrating the potential of hybrid biophysical-machine learning approaches for surface energy balance modeling with minimal data requirements. This study concludes with a novel application of explainable machine learning (exML) to diagnose sources of model error. This exML framework attributes residual prediction errors to both model input variables and environmental drivers not explicitly included in the simulation experiments. This approach provides a new pathway for improving model design and integrating previously overlooked yet influential variables into future model iterations.

evapotranspiration↗
DOE OSTI2026

Data for: A hybrid biophysical-machine learning framework for diurnal surface energy flux estimation using proximal sensing

Thermal-based remote sensing of surface energy fluxes has traditionally relied on high spatial resolution satellite data with revisit frequencies on the order of weeks. In this study, we evaluate a biophysics-based analytical surface energy balance model for predicting latent energy (LE) and sensible heat (H) fluxes using proximal sensing observations. The Surface Temperature Initiated Closure (STIC1.2) model has been extensively validated across a wide range of spatial and temporal scales using various satellite-derived thermal datasets. Here we extend this validation by applying STIC at sub-hourly temporal resolution over multiple growing seasons for four distinct agricultural systems. We further develop and evaluate novel STIC variants that incorporate machine learning (ML) techniques to eliminate the need for specific surface energy balance observations, specifically net radiation and soil heat flux, thereby enhancing model applicability in data-sparse settings. The integration of an ML component to estimate surface available energy is shown to have strong predictive performance for both LE (R2 = 0.81-0.94) and H (R2 = 0.46-0.72) across all agricultural systems examined here, demonstrating the potential of hybrid biophysical – machine learning approaches for surface energy balance modeling with minimal data requirements. This study concludes with a novel application of explainable machine learning (exML) to diagnose sources of model error. This exML framework attributes residual prediction errors to both model input variables and environmental drivers not explicitly included in the simulation experiments. This approach provides a new pathway for improving model design and integrating previously overlooked yet influential variables into future model iterations.

Agricultural Sciences↗
DOE OSTI2025

A methodology for decay heat characterization in molten salt reactors

Accurate decay heat prediction in molten salt reactors (MSRs) faces dual challenges: complex operational uncertainties and the need for interpretable models compatible with engineering workflows. This work presents a hybrid machine learning and segmented polynomial methodology that addresses both requirements through three key innovations. First, a modular data architecture encodes MSR-specific operational parameters (power density: 1-100 W cm -3 , humidity: 0-0.1 wt %, air ingress: 0-0.1 mol %) with uncertainty-aware temporal discretization spanning 15 orders of magnitude. Second, region-optimized machine learning models achieve 92.3 % root mean square error (RMSE) reduction over conventional polynomials while maintaining physical interpretability through automated piecewise equation generation. Third, dual front-end interfaces accelerate safety analyses — a Jupyter environment enables researchers to explore 10,000+ parameter combinations via interactive widgets, while a Streamlit web application reduces design iteration cycles through production-grade visualization tools. Operational deployment demonstrates prediction times of only a couple hundred milliseconds for 10 4 years decay profiles, enabling real-time optimization of spent fuel container designs.

42 - ENGINEERING↗
DOE OSTI2024

When ancient numerical demons meet physics-informed machine learning: adjoint-based gradients for implicit differentiable modeling

Recent advances in differentiable modeling, a genre of physics-informed machine learning that trains neural networks (NNs) together with process-based equations, have shown promise in enhancing hydrological models' accuracy, interpretability, and knowledge-discovery potential. Current differentiable models are efficient for NN-based parameter regionalization, but the simple explicit numerical schemes paired with sequential calculations (operator splitting) can incur numerical errors whose impacts on models' representation power and learned parameters are not clear. Implicit schemes, however, cannot rely on automatic differentiation to calculate gradients due to potential issues of gradient vanishing and memory demand. Here we propose a “discretize-then-optimize” adjoint method to enable differentiable implicit numerical schemes for the first time for large-scale hydrological modeling. The adjoint model demonstrates comprehensively improved performance, with Kling–Gupta efficiency coefficients, peak-flow and low-flow metrics, and evapotranspiration that moderately surpass the already-competitive explicit model. Therefore, the previous sequential-calculation approach had a detrimental impact on the model's ability to represent hydrological dynamics. Furthermore, with a structural update that describes capillary rise, the adjoint model can better describe baseflow in arid regions and also produce low flows that outperform even pure machine learning methods such as long short-term memory networks. The adjoint model rectified some parameter distortions but did not alter spatial parameter distributions, demonstrating the robustness of regionalized parameterization. Despite higher computational expenses and modest improvements, the adjoint model's success removes the barrier for complex implicit schemes to enrich differentiable modeling in hydrology.

58 GEOSCIENCES↗
DOE OSTI2025

An Assessment of the Error Due to Computing Waste Isolation Pilot Plant Porosity Using the Porosity Response Surface Approach

The Waste Isolation Pilot Plant Performance Assessment (WIPP PA) must predict the likelihood that radionuclides will escape into the biosphere via mechanisms that depend on geohydraulic flow. Ideally, one would predict the geohydraulic flow using coupled geohydraulic and geomechanical simulations, but such coupled simulations are not computationally tractable. Instead, Sandia has historically used a look-up table of porosities for a given fluid pressure and time, called the porosity response surface, but this approach can introduce porosity errors because it largely ignores the porosity’s dependence on the past fluid pressure history. This report discusses efforts to quantify these porosity errors for both the legacy and new porosity response surfaces. Six hundred different fluid pressure histories were fed through the legacy/new geomechanical model and the legacy/new porosity response surface to generate six hundred porosity error histories. The error associated with the legacy porosity surface was substantial, while the error associated with the new porosity surface was typically small, except when fluid pressures exceeded the lithostatic pressure at the repository. In response to the errors at high pressures, a preliminary study of the WIPP PA’s sensitivity to these porosity errors was conducted. The study found that reducing the porosity errors at high pressures negligibly affected predictions of radionuclide releases. Finally, an initial machine-learned model for porosity was developed. This ML model significantly reduced the porosity error at high pressures, but sizable errors remained, so more development is necessary before coupling an ML model to the geohydraulic model.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

A physics-based ensemble machine-learning approach to identifying a relationship between lightning indices and binary lightning hazard

To convert lightning indices generated by numerical weather prediction experiments into binary lightning hazard, a machine-learning tool was developed. This tool, consisting of parallel multilayer perceptron classifiers, was trained on an ensemble of planetary boundary layer schemes and microphysics parameterizations that generated four different lightning indices over 1 week. In a subsequent week, the multi-physics ensemble was applied and the machine-learning tool was used to evaluate the accuracy. Unintuitively, the machine-learning tool performed better on the testing dataset than the training dataset. Much of the error may be attributed to mischaracterizing the convection. The combination of the machine learning model and simulations could not differentiate between cloud-to-cloud lightning and cloud-to-ground lightning, despite being trained on cloud-to-ground lightning. It was found that the simulation most representative of the local operational model was the most accurate simulation tested.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Coefficient-to-Basis Network: a fine-tunable operator learning framework for inverse problems with adaptive discretizations and theoretical guarantees

We propose a Coefficient-to-Basis Network (C2BNet), a novel framework for solving inverse problems within the operator learning paradigm. C2BNet efficiently adapts to different discretizations through fine-tuning, using a pre-trained model to significantly reduce computational cost while maintaining high accuracy. Unlike traditional approaches that require retraining from scratch for new discretizations, our method enables seamless adaptation without sacrificing predictive performance. Furthermore, we establish theoretical approximation and generalization error bounds for C2BNet by exploiting low-dimensional structures in the underlying datasets. Our analysis demonstrates that C2BNet adapts to low-dimensional structures without relying on explicit encoding mechanisms, highlighting its robustness and efficiency. To validate our theoretical findings, we conducted extensive numerical experiments that showcase the superior performance of C2BNet on several inverse problems. The results confirm that C2BNet effectively balances computational efficiency and accuracy, making it a promising tool to solve inverse problems in scientific computing and engineering applications.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Heisenberg-limited Hamiltonian learning for interacting bosons

We develop a protocol for learning a class of interacting bosonic Hamiltonians from dynamics with Heisenberg-limited scaling. For Hamiltonians with an underlying bounded-degree graph structure, we can learn all parameters with root mean square error ϵ using ${\mathcal{O}}(1/\epsilon )$ total evolution time, which is independent of the system size, in a way that is robust against state-preparation and measurement error. In the protocol, we only use bosonic coherent states, beam splitters, phase shifters, and homodyne measurements, which are easy to implement on many experimental platforms. A key technique we develop is to apply random unitaries to enforce symmetry in the effective Hamiltonian, which may be of independent interest.

computer science↗
DOE OSTI2026

Hyperdimensional computing for image classification (HDC) v1.0

This is an implementation of the hyperdimensional computing technique to classify images. It consists of a python script that trains the system for a set of images from a set of images (dataset) specified by the user. This training produces hardware configuration parameters and description vectors that are then loaded into the hardware description part of the project. The hardware description consists of hardware described in Verilog (a well known language for this purpose) that is synthesizable and can be implemented in a real chip. This hardware received the training information generated by python, and then is able to accept images to produce answers for each image on which category (class) from the pre-=trained ones the image belongs to. The hardware and python training scripts are configurable and documented. The advantage of hyperdimensional computing is its robustness to errors and the easy capability for online learning (refining the training during inference slowly over time), which this implementation supports.

Michelogiannakis, Georgios [Lawrence Berkeley Nati↗
DOE OSTI2024

Group-theoretic error mitigation enabled by classical shadows and symmetries

Abstract Estimating expectation values is a key subroutine in quantum algorithms. Near-term implementations face two major challenges: a limited number of samples required to learn a large collection of observables, and the accumulation of errors in devices without quantum error correction. To address these challenges simultaneously, we develop a quantum error-mitigation strategy called symmetry-adjusted classical shadows , by adjusting classical-shadow tomography according to how symmetries are corrupted by device errors. As a concrete example, we highlight global U(1) symmetry, which manifests in fermions as particle number and in spins as total magnetization, and illustrate their group-theoretic unification with respective classical-shadow protocols. We establish rigorous sampling bounds under readout errors obeying minimal assumptions, and perform numerical experiments with a more comprehensive model of gate-level errors derived from existing quantum processors. Our results reveal symmetry-adjusted classical shadows as a low-cost strategy to mitigate errors from noisy quantum experiments in the ubiquitous presence of symmetry.

Zhao, Andrew (ORCID:0000000202990277)↗