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NASA NTRS2011

Early Oscillation Detection Technique for Hybrid DC/DC Converters

Oscillation or instability is a situation that must be avoided for reliable hybrid DC/DC converters. A real-time electronics measurement technique was developed to detect catastrophic oscillations at early stages for hybrid DC/DC converters. It is capable of identifying low-level oscillation and determining the degree of the oscillation at a unique frequency for every individual model of the converters without disturbing their normal operations. This technique is specially developed for space-used hybrid DC/DC converters, but it is also suitable for most of commercial and military switching-mode power supplies. This is a weak-electronic-signal detection technique to detect hybrid DC/DC converter oscillation presented as a specific noise signal at power input pins. It is based on principles of feedback control loop oscillation and RF signal modulations, and is realized by using signal power spectral analysis. On the power spectrum, a channel power amplitude at characteristic frequency (CPcf) and a channel power amplitude at switching frequency (CPsw) are chosen as oscillation level indicators. If the converter is stable, the CPcf is a very small pulse and the CPsw is a larger, clear, single pulse. At early stage of oscillation, the CPcf increases to a certain level and the CPsw shows a small pair of sideband pulses around it. If the converter oscillates, the CPcf reaches to a higher level and the CPsw shows more high-level sideband pulses. A comprehensive stability index (CSI) is adopted as a quantitative measure to accurately assign a degree of stability to a specific DC/DC converter. The CSI is a ratio of normal and abnormal power spectral density, and can be calculated using specified and measured CPcf and CPsw data. The novel and unique feature of this technique is the use of power channel amplitudes at characteristic frequency and switching frequency to evaluate stability and identify oscillations at an early stage without interfering with a DC/DC converter s normal operation. This technique eliminates the probing problem of a gain/phase margin method by connecting the power input to a spectral analyzer. Therefore, it is able to evaluate stability for all kinds of hybrid DC/DC converters with or without remote sense pins, and is suitable for real-time and in-circuit testing. This frequency-domain technique is more sensitive to detect oscillation at early stage than the time-domain method using an oscilloscope.

Wang, Bright L.↗

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 OSTI2023

3P Program: Phenotyping X Prediction = Productivity (Final Scientific/Technical Report)

The goal of the 3P Program was to establish integrated, real-time phenotyping and to analyze above- and below-ground plant architecture and total carbon partitioning and allocation to predict heterosis and develop superior crop hybrids by fully leveraging the Sorghum gene pool. There were two overarching themes: 1) the development of a new crop improvement approach utilizing advances in high-throughput phenotyping (HTP), computing, and genomics for public dissemination and 2) leveraging this platform for sorghum crop improvement and commercialization. The Clemson team worked on creating genomic resources and using both statistical learning and high-throughput phenotyping in genomics-assisted breeding. Research was broadly interested in the genetics of carbon partitioning, with the aim of improving crop performance and achieving sustainability. The technology and resources created can be readily found in the public domain and serve to advance scientific understanding of crop genomics and breeding. Genomic prediction was able to identify top crosses to be made, and a hybrid prediction pipeline is in place to drive year-over-year genetic gain. Roots have long been ignored by plant breeders and agronomists, not because they are unimportant but because they are hard to measure. This is an untapped white space of potential insight and innovation. To address this, Hi Fidelity Genetics developed the RootTracker to measure roots in the field on a continuous basis. A database system called RootTracker Tracker was developed to handle data coming from the RootTrackers. In using this device, valuable data was observed for plant breeding, hydrochemical development, and other agricultural biology applications. Carnegie Mellon’s goal was developing new techniques to generate high-resolution 3D models of plants from data collected in the field. The idea was that more useful and more informative phenotypes could be extracted by resolving small features, such as seeds and flowers, and that by modeling in 3D, the spatial structure of plants could be examined. To achieve this, multiple images collected by a new small format structured light stereo imager were fused together. A sorghum panicle modeling pipeline was developed to allow the collection and processing of data. Carolina Seed Systems is an agricultural technology company focused on decarbonizing the agricultural system. Their technology pipeline serves to drive fundamental progress towards creation and distribution of carbon negative crops. The genomic and the engineering technology developed through the 3P Program was leveraged to deliver both value and sustainability from the grower to the consumer. Promising sorghum hybrids were scaled up and commercialized. The overall goal of our research was to integrate, create, and deploy genetic and engineering concepts and technologies to enhance crop productivity in a sustainable fashion. The combination of public and private partners allowed the basic research and hypothesis testing to be quickly accelerated for commercial application by the companies yet maintained that the core framework and academic insights remain in the public domain for continued market disruption, competition, and innovation.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Optimizing first- and last-mile public transit services leveraging transportation network companies (TNC)

First-mile last-mile (FMLM) mobility services that connect riders to public transit can lead to improved transit accessibility and network efficiency if such services are convenient and reliable. However, many current FMLM services are inefficient and costly because they are inflexible (e.g., fixed supply of shuttles) and do not leverage collected data for optimized decision making. At the same time, new forms of shared mobility can provide added flexibility and real-time analytics to FMLM systems when carefully integrated. This study evaluates performance and cost implications of public/private coordination between transit shuttles and transportation network companies (TNC) in the FMLM context. A real-time operations model was developed to simulate daily operations for an existing FMLM system using real-world demand data. Three supply strategies were tested with varying levels of flexibility: (1) Status Quo (two 23-passenger on-demand shuttles), (2) Hybrid (one 23-passenger on-demand shuttle + TNC), and (3) TNC Only (exclusively use TNC services). Results indicated that the added flexibility of the Hybrid service design (using shuttles and TNCs) improved service performance (a 7.7% improvement), reduced daily operating costs (– 6.0%), and improved service reliability (95th percentile travel times decreased by up to 40% during peak periods). In addition, the Hybrid service design was more robust to variations in demand. Here, the Hybrid service was significantly cheaper to operate (– 31.6%) at reduced demand levels (50% of normal), and improved service performance (a 10.2% improvement) when demand levels were increased (150% of normal). These findings emphasize the importance of flexibility in FMLM service designs, especially when demand is sparse and variable.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Towards fast and accurate predictions of radio frequency power deposition and current profile via data-driven modelling: applications to lower hybrid current drive

Three machine learning techniques (multilayer perceptron, random forest and Gaussian process) provide fast surrogate models for lower hybrid current drive (LHCD) simulations. A single GENRAY/CQL3D simulation without radial diffusion of fast electrons requires several minutes of wall-clock time to complete, which is acceptable for many purposes, but too slow for integrated modelling and real-time control applications. The machine learning models use a database of more than 16 000 GENRAY/CQL3D simulations for training, validation and testing. Latin hypercube sampling methods ensure that the database covers the range of nine input parameters ( $n_{e0}$ , $T_{e0}$ , $I_p$ , $B_t$ , $R_0$ , $n_{\|}$ , $Z_{{\rm eff}}$ , $V_{{\rm loop}}$ and $P_{{\rm LHCD}}$ ) with sufficient density in all regions of parameter space. The surrogate models reduce the inference time from minutes to $\sim$ ms with high accuracy across the input parameter space.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Towards fast, accurate predictions of RF simulations via data-driven modeling: Forward and lateral models

Three machine learning techniques (multilayer perceptron, random forest, and Gaussian process) provide fast surrogate models for lower hybrid current drive (LHCD) simulations. A single GENRAY/CQL3D simulation without radial diffusion of fast electrons requires several minutes of wall-clock time to complete, which is acceptable for many purposes, but too slow for integrated modeling and real-time control applications. More accurate simulations with fast electron diffusion are even slower, requiring multiple hours of run time with parallel processing. The machine learning models use a database of 16,000+ GEN-RAY/CQL3D simulations for training, validation, and testing. Latin hypercube sampling methods implemented in πScope ensure that the database covers the range of 9 input parameters (n e0 , T e0 , I p , B t , R 0 , n ∥︀ , Z e f f , V loop , P LHCD ) with sufficient density in all regions of parameter space. The surrogate models reduce the computation time from minutes-hours to ms with high accuracy across the input parameter space. Data-driven surrogate models also allow for solving inverse and “lateral” problems. A surrogate model for the inverse problem maps from a desired current drive or power deposition profile to a set of input parameters that would result in such a profile, while a surrogate model for the lateral problem maps from a measured experimental quantity such as hard x-ray emission to a current drive or power deposition profile. In conclusion, the πScope database creation workflow is flexible and applicable to other RF simulation codes such as TORIC.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Stability-Constrained Learning for Frequency Regulation in Power Grids With Variable Inertia

The increasing penetration of converter-based renewable generation has resulted in faster frequency dynamics, and low and variable inertia. As a result, there is a need for frequency control methods that are able to stabilize a disturbance in the power system at timescales comparable to the fast converter dynamics. This paper proposes a combined linear and neural network controller for inverter-based primary frequency control that is stable at time-varying levels of inertia. We model the time-variance in inertia via a switched affine hybrid system model. We derive stability certificates for the proposed controller via a quadratic candidate Lyapunov function. We test the proposed control on a 12-bus 3-area test network, and compare its performance with a base case linear controller, optimized linear controller, and finite-horizon Linear Quadratic Regulator (LQR). Our proposed controller achieves faster mean settling time and over 50% reduction in average control cost across 100 inertia scenarios compared to the optimized linear controller. Unlike LQR which requires complete knowledge of the inertia trajectories and system dynamics over the entire control time horizon, our proposed controller is real-time tractable, and achieves comparable performance to LQR.

data-driven control↗

DOE OSTI2020

A Hybrid-Learning Algorithm for Online Dynamic State Estimation in Multimachine Power Systems

With the increasing penetration of distributed generators in the smart grids, having knowledge of rapid real-time electromechanical dynamic states has become crucial to system stability control. Conventional Supervisory Control and Data Acquisition (SCADA)-based dynamic state estimation (DSE) techniques are limited by the slow sampling rates, while the emerging phasor measurement units (PMUs) technology enables rapid real-time measurements at network nodes. Using generator bus terminal voltages, we propose a hybrid-learning DSE (HL-DSE) algorithm to estimate the synchronous machine rotor angle and speed in real time. The HL-DSE takes the power system model into account and trains neuroestimators with real-time data in an online manner. Compared with traditional DSE methods, the HL-DSE overcomes limitations by using a data-driven approach in conjunction with the physical power system model. The time efficiency, accuracy, convergence, and robustness of the proposed algorithm are tested under noises and fault conditions in both small- and large-scale test systems. Simulation results show that the proposed HL-DSE is much more computationally efficient than widely used Kalman filter (KF)-based methods while maintaining comparable accuracy and robustness. In particular, HL-DSE is over 100 times faster than square-root unscented KF (SR-UKF) and 80 times faster than extended KF (EKF). The advantages and challenges of the HL-DSE are also discussed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Scheduler Modeling of Distributed Energy Resources for Providing Ancillary Services

Distribution energy resources (DERs) have been integral components of modern power systems, and their capability to provide grid services has been widely studied. To promote the deployment of these resources in providing grid services in real-world utility operations, this paper proposes a day-ahead scheduler model for a distribution system connected DER plant. A certain amount of generation capacity of this DER plant is reserved for frequency services, and some ancillary services for the distribution system-including peak load reduction, voltage regulation, and power factor control-are integrated into the model. The model is tested on a real-world distribution system. From the simulation results, the energy and reserve schedule of the solar photovoltaic (PV) unit and battery energy storage system (BESS) can be determined, and voltage and power factor are well maintained. Additionally, in order to demonstrate the specific characteristics of the co-located and hybrid operation modes for the PV and BESS, these two modes are analyzed both theoretically and through real-time simulation. Simulation results show that most of PV's variability is transferred to the net power in the co-located mode, whereas it is transferred to the BESS in the hybrid mode. This proposed scheduler model and the comparison of co-located and hybrid modes can provide practical guidance for the applications of DER plant in the real-world utility.

14 SOLAR ENERGY↗

DOE OSTI2024

Dynamic Control of Sodium Cold Trap Purification Temperature Using LSTM System Identification

This study investigates the dynamic regulation of the sodium cold trap purification temperature at Argonne National Laboratory’s liquid sodium test facility, employing long short-term memory (LSTM) system identification techniques. The investigation introduces an innovative hybrid approach by integrating model predictive control (MPC) based on first principles dynamic models with a multi-step time–frequency LSTM model in predicting the temperature profiles of a sodium cold trap purification system. The long short-term memory–model predictive controller (LSTM-MPC) model employs a sliding window scheme to gather training samples for multi-step prediction, leveraging historical data to construct predictive models that capture the non-linearities of the complex system dynamics without explicitly modeling the underlying physical processes. The performance of the LSTM-MPC and MPC were evaluated through simulation experiments, where both models were assessed on their capacity to maintain the cold trap temperature within predefined set-points while minimizing deviations and overshoots. Results obtained show how the data-driven LSTM-MPC model demonstrates stability and adaptability. In contrast, the traditional MPC model exhibits irregularities, particularly evident as overshoots around set-point limits, which can potentially compromise its effectiveness over long prediction time intervals. The findings obtained offer valuable insights into integrating data-driven techniques for enhancing real-time monitoring systems.

LSTM-MPC↗

DOE OSTI2022

Towards Fast and Accurate Predictions of Radio Frequency Power Deposition and Current Profile via Data-driven Modeling

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1984

Real-time hybrid computer simulation of a small turboshaft engine and control system

The development of an analytical model of a small turboshaft engine designed for helicopter propulsion systems is described. The model equations were implemented on a hybrid computer system to provide a real time nonlinear simulation of the engine performance over a wide operating range. The real time hybrid simulation of the engine was used to evaluate a microprocessor based digital control module. This digital control module was developed as part of an advanced rotorcraft control program. After tests with the hybrid engine simulation the digital control module was used to control a real engine in an experimental program. A hybrid simulation of the engine's electrical hydromechanical control system was developed. This allowed to vary the fuel flow and torque load inputs to the hybrid engine simulation for simulating transient operation. A steady-state data and the experimental tests are compared. Analytical model equations, analog computer diagrams, and a digital computer flow chart are included.

Hart, C. E.↗

NASA NTRS2007

Hybrid Automated Diagnosis of Discrete/Continuous Systems

A recently conceived method of automated diagnosis of a complex electromechanical system affords a complete set of capabilities for hybrid diagnosis in the case in which the state of the electromechanical system is characterized by both continuous and discrete values (as represented by analog and digital signals, respectively). The method is an integration of two complementary diagnostic systems: (1) beacon-based exception analysis for multi-missions (BEAM), which is primarily useful in the continuous domain and easily performs diagnoses in the presence of transients; and (2) Livingstone, which is primarily useful in the discrete domain and is typically restricted to quasi-steady conditions. BEAM has been described in several prior NASA Tech Briefs articles: "Software for Autonomous Diagnosis of Complex Systems" (NPO-20803), Vol. 26, No. 3 (March 2002), page 33; "Beacon-Based Exception Analysis for Multimissions" (NPO-20827), Vol. 26, No. 9 (September 2002), page 32; "Wavelet-Based Real-Time Diagnosis of Complex Systems" (NPO-20830), Vol. 27, No. 1 (January 2003), page 67; and "Integrated Formulation of Beacon-Based Exception Analysis for Multimissions" (NPO-21126), Vol. 27, No. 3 (March 2003), page 74. Briefly, BEAM is a complete data-analysis method, implemented in software, for real-time or off-line detection and characterization of faults. The basic premise of BEAM is to characterize a system from all available observations and train the characterization with respect to normal phases of operation. The observations are primarily continuous in nature. BEAM isolates anomalies by analyzing the deviations from nominal for each phase of operation. Livingstone is a model-based reasoner that uses a model of a system, controller commands, and sensor observations to track the system s state, and detect and diagnose faults. Livingstone models a system within the discrete domain. Therefore, continuous sensor readings, as well as time, must be discretized. To reason about continuous systems, Livingstone uses monitors that discretize the sensor readings using trending and thresholding techniques. In development of the a hybrid method, BEAM results were sent to Livingstone to serve as an independent source of evidence that is in addition to the evidence gathered by Livingstone standard monitors. The figure depicts the flow of data in an early version of a hybrid system dedicated to diagnosing a simulated electromechanical system. In effect, BEAM served as a "smart" monitor for Livingstone. BEAM read the simulation data, processed the data to form observations, and stored the observations in a file. A monitor stub synchronized the events recorded by BEAM with the output of the Livingstone standard monitors according to time tags. This information was fed to a real-time interface, which buffered and fed the information to Livingstone, and requested diagnoses at the appropriate times. In a test, the hybrid system was found to correctly identify a failed component in an electromechanical system for which neither BEAM nor Livingstone alone yielded the correct diagnosis.

Park, Han↗

NASA NTRS2011

Improvements to the Ionizing Radiation Risk Assessment Program for NASA Astronauts

To perform dosimetry and risk assessment, NASA collects astronaut ionizing radiation exposure data from space flight, medical imaging and therapy, aviation training activities and prior occupational exposure histories. Career risk of exposure induced death (REID) from radiation is limited to 3 percent at a 95 percent confidence level. The Radiation Health Office at Johnson Space Center (JSC) is implementing a program to integrate the gathering, storage, analysis and reporting of astronaut ionizing radiation dose and risk data and records. This work has several motivations, including more efficient analyses and greater flexibility in testing and adopting new methods for evaluating risks. The foundation for these improvements is a set of software tools called the Astronaut Radiation Exposure Analysis System (AREAS). AREAS is a series of MATLAB(Registered TradeMark)-based dose and risk analysis modules that interface with an enterprise level SQL Server database by means of a secure web service. It communicates with other JSC medical and space weather databases to maintain data integrity and consistency across systems. AREAS is part of a larger NASA Space Medicine effort, the Mission Medical Integration Strategy, with the goal of collecting accurate, high-quality and detailed astronaut health data, and then securely, timely and reliably presenting it to medical support personnel. The modular approach to the AREAS design accommodates past, current, and future sources of data from active and passive detectors, space radiation transport algorithms, computational phantoms and cancer risk models. Revisions of the cancer risk model, new radiation detection equipment and improved anthropomorphic computational phantoms can be incorporated. Notable hardware updates include the Radiation Environment Monitor (which uses Medipix technology to report real-time, on-board dosimetry measurements), an updated Tissue-Equivalent Proportional Counter, and the Southwest Research Institute Radiation Assessment Detector. Also, the University of Florida hybrid phantoms, which are flexible in morphometry and positioning, are being explored as alternatives to the current NASA computational phantoms.

Semones, E. J.↗

NASA NTRS2019

Real-Time Modeling of Thermal Interactions in Cryogenic Ball Bearings

Based on the integration of classical differential equations of motion of bearing elements, a real-time dynamic simulation of ball bearing performance is coupled with simultaneous modeling of thermal interactions between the bearing elements. The transient heat generations are time averaged over a significantly larger time step before they are used to compute the changes in bearing temperature fields. Such an averaging algorithm eliminates the numerical difficulties associated with simultaneous integration of mechanical thermal differential equations with vastly different time scales. Under stable operation, the step change in temperatures at each thermal time step converges to a steady-state solution. Following is a list of accomplishments in the present investigation: (1) A real-time dynamic performance of both 440C and hybrid ball bearings in a LOX environment is modeled in both transient and steady-state time domains, as the inner race accelerates to a prescribed operating speed. (2) The frictional interactions at the ball to race contacts are modeled by experimentally measured traction coefficients as a function of slide-to-roll ratios. (3) Bearing heat generation, as defined by the heat transferred to circulating LOX, is validated against experimental values determined by measured LOX temperatures under prescribed pressures and flow rates. The predicted heat generation is in good agreement with the experimental values. (4) The steady-state solutions are shown to be independent of initial conditions. This establishes convergence of the numerical integration of a differential equation of motion of the bearing elements. (5) Churning and drag losses in the circulating LOX constitutes the majority of bearing heat generation under the experimental test conditions. (6) The heat dissipated in frictional interactions in hybrid bearings is significantly lower in hybrid bearings in comparison to that simulated in all-steel bearings, while the churning and drag losses are relatively unchanged.

Gupta, P. K.↗