From Equations to Discovery: AI-Driven Parameter Space Navigation in Materials Science & Process Engineering
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From Equations to Discovery: AI-Driven Parameter Space Navigation in Materials Science & Process Engineering
Explore the source record for details and available documents.
organic↗
Multi‐hypothesis comparison of Farquhar and Collatz photosynthesis models reveals the unexpected influence of empirical assumptions at leaf and global scales
Abstract Mechanistic photosynthesis models are at the heart of terrestrial biosphere models (TBMs) simulating the daily, monthly, annual and decadal rhythms of carbon assimilation ( A ). These models are founded on robust mathematical hypotheses that describe how A responds to changes in light and atmospheric CO 2 concentration. Two predominant photosynthesis models are in common usage: Farquhar (FvCB) and Collatz (CBGB). However, a detailed quantitative comparison of these two models has never been undertaken. In this study, we unify the FvCB and CBGB models to a common parameter set and use novel multi‐hypothesis methods (that account for both hypothesis and parameter variability) for process‐level sensitivity analysis. These models represent three key biological processes: carboxylation, electron transport, triose phosphate use (TPU) and an additional model process: limiting‐rate selection. Each of the four processes comprises 1–3 alternative hypotheses giving 12 possible individual models with a total of 14 parameters. To broaden inference, TBM simulations were run and novel, high‐resolution photosynthesis measurements were made. We show that parameters associated with carboxylation are the most influential parameters but also reveal the surprising and marked dominance of the limiting‐rate selection process (accounting for 57% of the variation in A vs. 22% for carboxylation). The limiting‐rate selection assumption proposed by CBGB smooths the transition between limiting rates and always reduces A below the minimum of all potentially limiting rates, by up to 25%, effectively imposing a fourth limitation on A . Evaluation of the CBGB smoothing function in three TBMs demonstrated a reduction in global A by 4%–10%, equivalent to 50%–160% of current annual fossil fuel emissions. This analysis reveals a surprising and previously unquantified influence of a process that has been integral to many TBMs for decades, highlighting the value of multi‐hypothesis methods.
54 ENVIRONMENTAL SCIENCES↗
The development of an augmented machine learning approach for the additive manufacturing of thermoelectric materials
Through the integration of machine learning (ML) techniques alongside additive manufacturing (AM) experimentation, we demonstrate an iterative process to rapidly predict laser-material interactions and melt pool geometries throughout the build parameter space for a bismuth telluride thermoelectric (TE) material. In doing so, we determined process parameters that created crack-free, highly dense (>99 %) n-type bismuth telluride (Bi 2 Te 2.7 Se 0.3 ) parts through laser powder bed fusion (LPBF). Furthermore, the ML-assisted understanding of the processing space allowed for the identification of build parameters that successfully yielded geometrically enhanced Bi 2 Te 2.7 Se 0.3 parts with reduced build times and no increase in experimental effort.
36 MATERIALS SCIENCE↗
Technology Case Study: Economic, Sustainability, and Deployment Considerations for Sustainable Aviation Fuels Produced via Lignocellulosic Sugar Catalysis
This report presents a technology case study reflecting one exemplary representative pathway for the conversion of lignocellulosic sugars to sustainable aviation fuels (SAF) via aqueous phase reforming (APR) catalysis, considered within a broader integrated biorefinery framework based on biochemical processing operations. While far from the only option for converting sugars to SAF, this pathway was selected as a case study here based on its relatively high technology maturity and simplistic processing approach (avoiding complex separations or other equipment scalability challenges), coupled with the potential for high fuel yields and favorable costs/carbon intensities with opportunities for further near-term optimization. The report considers key process integration and engineering design considerations for a modeled hypothetical, nth-plant commercial biorefinery, reflecting a number of processing options and parameters envisioned to be achievable as future goals. Resultant outputs from Aspen Plus process simulations are evaluated through techno-economic and life cycle analyses (TEA and LCA), including implications for marginal cost of CO2 abatement and inclusion of currently-applicable policy incentives. Moving beyond base case configurations, a number of alternative scenarios are also evaluated for their ability to further improve economics, greenhouse gas (GHG) emissions, and marginal cost of abatement, highlighting a path to achieve deep decarbonization goals of more than 70% GHG reduction for SAF (with the potential to reach net-negative carbon intensities in some cases) under reasonable fuel production costs. The report also highlights future opportunities and gaps for further research on this technology pathway.
09 BIOMASS FUELS↗
Physicochemical properties of digital light processing 3D-Printed alumina and mullite ceramics
Alumina ceramics fabricated using conventional techniques such as uniaxial pressing or injection molding are popular due to their low density, excellent insulation, and mechanical properties. However, these methods often limit the fabrication of complex geometries with high dimensional accuracy due to tooling constraints and limited design freedom. To overcome these limitations, this study employed Digital Light Processing (DLP) additive manufacturing (AM), which enables the production of precise structures. In addition, the optimization of sintering parameters to enhance the densification and performance of alumina and mullite ceramics was investigated, with a specific focus on how varying sintering temperatures and hold times affect part shrinkage, geometric accuracy, and material integrity. Flexural strength of both alumina and mullite specimens was clearly influenced by the way the layers was stacked. When layers were arranged across the direction of the applied load (Z = 4; XZ), the strength was higher than when they were stacked along the same direction as the load (Z = 3; XY). Weibull analysis based on these results showed high modulus values across all samples, indicating good reliability in the flexural strength measurements. This reliability, combined with the clear influence of sintering parameters, highlights how processing conditions effect the material properties and mechanical performance of parts produced through DLP additive manufacturing. In conclusion, these findings open new avenues for ceramic AM across various applications, enhancing the potential for innovation in fields such as aerospace, biomedical engineering, and energy.
36 MATERIALS SCIENCE↗
Nanometer-Scale Acoustic Wave Packets Generated by Stochastic Core-Level Photoionization Events
We demonstrate that the absorption of femtosecond hard x-ray pulses excites quasispherical, high-amplitude, and high-wave-vector coherent acoustic phonon wave packets using an all hard-x-ray pump-probe scattering experiment. The time- and momentum-resolved diffuse scattering signal is consistent with an ensemble of 3D strain wave packets induced by the rapid electron cascade dynamics following photoionization at uncorrelated excitation centers. We quantify key parameters of this process, including the localization size of the stress field and the photon energy conversion efficiency into elastic energy. The parameters are determined by the photoelectron and Auger electron cascade dynamics, as well as the electron-phonon interaction. In particular, we obtain the localization size of the observed strain wave packet to be 1.5 and 2.5 nm for bulk SrTiO 3 and KTaO 3 single crystals, respectively. The results provide crucial information on the mechanism of x-ray energy deposition into matter and shed light on the shortest collective length scales accessible to coherent acoustic phonon generation using x-ray excitation. Published by the American Physical Society 2024
36 MATERIALS SCIENCE↗
Predictive modeling of a subcritical pulverized-coal power plant for optimization: Parameter estimation, validation, and application
As renewable power generation deployment increases, fossil fuel plants are increasingly required to operate more flexibly. Many coal-fired power plants were originally designed to operate at base load and do not operate optimally at partial load. Predictive first-principles plant-wide models can be employed to identify opportunities for flexibility improvements and diagnose low-load operating issues. This paper describes the application of the Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES) to model and optimize flexible power plant operations. The key benefits of using IDAES are that it provides an open-source, fully equation-oriented modeling framework for efficient modular model construction, reuse, and customization, together with a mathematical optimization framework leveraging powerful, state-of-the-art solvers. The process systems engineering workflow from predictive process simulation to parameter estimation, model validation, and plant optimization is applicable to a variety of existing and next-generation energy systems as well as other chemical and environmental processes. Here, to demonstrate this capability, a physics-based, steady-state model was developed to improve full- and part-load performance of the Escalante Generating Station, a 245 MWe (net) subcritical pulverized coal-fired power plant owned and operated by Tri-State Generation and Transmission Association. Specifically, sixty-nine model parameters were simultaneously estimated from several months of operating data enabling prediction of flow rates, temperatures, pressures, and steam quality throughout the plant. The validated model was leveraged by Escalante to reduce the minimum operating load from 90 MW to 50 MW by diagnosing a low-load water-hammer issue, enabling coal usage and emissions reductions during periods of low power demand. Additionally, opportunities for heat rate reduction (i.e., efficiency improvement) through a steeper sliding-pressure approach to load-following and optimization of other boiler operating variables were also identified and quantified. For example, a potential efficiency improvement of 0.7 percentage points was observed at half-load operation.
01 COAL, LIGNITE, AND PEAT↗
Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study
Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.
42 ENGINEERING↗
A real-time distributed solid oxide electrolysis cell (SOEC) model for cyber-physical simulation
System integration and dynamic operability between SOEC and balance-of-plant (BoP) components are major technical challenges before realizing rapid load following of SOEC systems. Cyber-physical simulation (CPS) is a leading-edge digital engineering approach and is regarded as the next step beyond Digital Twins. CPS approach can be used to research SOEC system integration and develop dynamic controls prior to actual pilot testing without using a real SOEC. To seamlessly couple with BoP hardware and access non-observable operational parameters (e.g., local temperature gradient) during transients, a distributed one-dimensional (1D) real-time SOEC model was developed. Its real-time execution was demonstrated for 20 to 640 nodes at the fixed time step of 5 ms. A higher excess air ratio enabled smaller local temperature gradients on SOEC solid materials and faster transients upon current density step change from 0.15 to 0.55 A cm -2 . During the transients, the magnitude of the peak temperature gradient nearly doubled in 10 s from -3.5 to -5.9 °C cm -1 . This represents a significant operating risk that can impact the dynamic operability of SOEC systems. In addition, the local temperature gradient was found to change directions on all nodes in SOEC solid materials, with the greatest impact on the upstream nodes. The SOEC model was also tested at the thermal neutral voltage using actual process air flow parameters as variable model inputs. Variable process air temperatures were found to induce alternating local temperature gradients on SOEC solid materials. These are new operational mechanisms for SOEC degradation relevant for load following operational modes yet distinct from previous reports. To mitigate these unfavorable features, the SOEC can be operated at voltages that are slightly (±20 mV) deviated from the thermal neutral voltage. Here, the corresponding net thermal energy change was less than 1.6% of the electric power consumption. This 1D real-time SOEC model established the basis of cyber-physical simulation of SOEC hybrid systems.
24 POWER TRANSMISSION AND DISTRIBUTION↗
PrOMMiS Tutorial
This is a tutorial on using parameter estimation and process optimization in PrOMMiS. The tutorials are publicly available in the GitHub repository. The presentation attached guides through the flow of the three different tutorials. The tutorials are presented as follows: i) Parameter estimation of oxalate precipitation, ii) Optimization of precipitation model, and iii) Optimization of full process.
critical minerals and materials↗
Real-Time Nitrate Ion Monitoring with Poly(3,4-ethylenedioxythiophene) (PEDOT) Materials
Nitrate (NO 3 ) pollution in groundwater, caused by various factors both natural and synthetic, contributes to the decline of human health and well-being. Current techniques used for nitrate detection include spectroscopic, electrochemical, chromatography, and capillary electrophoresis. It is highly desired to develop a simple cost-effective alternative to these complex methods for nitrate detection. Therefore, a real-time poly (3,4-ethylenedioxythiophene) (PEDOT)-based sensor for nitrate ion detection via electrical property change is introduced in this study. Vapor phase polymerization (VPP) is used to create a polymer thin film. Variations in specific parameters during the process are tested and compared to develop new insights into PEDOT sensitivity towards nitrate ions. Through this study, the optimal fabrication parameters that produce a sensor with the highest sensitivity toward nitrate ions are determined. With the optimized parameters, the electrical resistance response of the sensor to 1000 ppm nitrate solution is 41.79%. Furthermore, the sensors can detect nitrate ranging from 1 ppm to 1000 ppm. The proposed sensor demonstrates excellent potential to detect the overabundance of nitrate ions in aqueous solutions in real time.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Particle Markov Chain Monte Carlo Approach to Inference in Transient Surface Kinetics
Here, in this work, we develop a novel Bayesian approach to study the adsorption and desorption of CO onto a Pd(111) surface, a process of great importance in natural sciences. The motivation for this work comes from the recent availability of time-resolved infrared spectroscopy data and the need for model interpretability and uncertainty quantification in chemical processes. The objective is to learn the relevant parameters that characterize the process: coverage with time, rate constants, activation energies, and pre-exponential factors. Our approach consists of three main schemes: (i) a problem design and probabilistic model for the whole system, (ii) a particle Markov chain Monte Carlo sampler to learn the hidden coverages and rate constant parameters, and (iii) two Bayesian formulations to infer the activation energies and pre-exponential factors. The flexibility of the Bayesian framework allows for uncertainty quantification where possible and integration of mathematical constraints in the model to reflect the system physically. We found that our results for the activation energies and pre-exponential factor are in agreement with those reported in the experimental literature, independently, and we provide discussions on the advantages and disadvantages as well as applicability to other systems.
36 MATERIALS SCIENCE↗
XRFtomo
Based on [1], XRFtomo brings together a variety of image processing tools used for preparing, processing and reconstructing 3D renditions of samples imaged using a synchrotron-based x-ray fluorescence (XRF) microprobe or nanoprobe at the Advanced Photon Source (APS). This software bridges the gap between data acquisition and visualization by providing tools to adjust for misalignment in the imaging process and tools for running reconstructions[2], all with the use of a GUI or command line. XRFtomo accepts .h5 files processed through MAPS[3] and it outputs reconstructed cross-sections, projections, sinograms, metadata, and a configuration file with last-used parameters for rapid processing the next time the program is launched. These images serve as inputs for other 3D visualization software for generating volumetric renderings and animations.
Marin, Fabrico↗
Non-Equilibrium Processes, Stability, Design and Control of Pulsed Plasmas for Materials Processing
The energy and angle of impact of ions, interspersed with fluxes of neutral radicals, on the surface of wafers during plasma materials processing are critical parameters for the fabrication of microelectronic devices, nanostructure materials and biocompatible materials. This sensitivity extends to nearly all applications of plasmas to materials processing and surface modification. Low temperature plasmas for plasma materials processing have traditionally used continuously excited plasmas. However, pulsed plasma processing is an enabling technology for achieving finer resolution of microelectronics fabrication and for producing unique surface properties in a wide range of applications. This research project is addressing fundamental plasma physics issues in materials processing – the control of pulsed plasmas and the means for optimizing plasma produced reactant fluxes.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Spotlight SAR Data Collection Geometry from ECEF Coordinates
High-performance spotlight Synthetic Aperture Radar (SAR) requires measurement of the radars motion during the synthetic aperture. A convenient coordinate frame for motion measurement is often not the convenient coordinate frame for motion compensation during the SAR data generation and image formation processing. A convenient frame for radar motion measurement is the Earth-Centered Earth-Fixed (ECEF) coordinate frame, whereas spotlight SAR processing typically require s polar coordinates from a selected Scene Reference Point (SRP). This report presents the conversion from ECEF coordinates to appropriate parameters for SAR processing.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
CCF Parameter Estimations, 2020 Update
This report documents the quantitative results of the common-cause failure (CCF) data collection effort (which included data through 2020) and summarizes the results of the parameter estimation quantification process performed on CCF data in the U.S. Nuclear Regulatory Commission (NRC) CCF database. This is the 2020 update to NUREG/CR-5497, updating data and parameter estimations for CCFs. This release, CCF Parameter Estimation 2020, reflects the CCF data contained within the CCF database, https://rads.inl.gov/Pages/CCF.aspx, by executing (in August 2021) the CCF query rules in the folder SPAR Rules 2020. The data covers the period from 1/1/2006 to 12/31/2020, the most recent 15-year period in which data are available. The use of the most recent rolling 15-year data in parameter estimation differs from previous updates, in which 1/1/1997 was used as the starting date (e.g., 1/1/1997 to 12/31/2015 for the 2015 update, 1/1/1997 to 12/31/2012 for the 2012 update). The new date range (i.e., the most recent 15-year period), was selected for this CCF update so as to be consistent with the date range chosen for the component reliability parameter estimation, and with the effort to include sufficient data for analysis while simultaneously reflecting the most recent industry performance. These results are appropriate for use in probabilistic risk assessment (PRA) studies, including the Standardized Plant Analysis Risk (SPAR) models of commercial nuclear power plants (NPPs) in the U.S. This update may be referred as: U.S. Nuclear Regulatory Commission, "CCF Parameter Estimations, 2020 Update," https://nrcoe.inl.gov/publicdocs/CCF/ccfparamest2020.pdf, November 2021.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Integrated Process Testing of MSR Salt Spill Accidents
Part of the licensing process for new nuclear reactors requires vendors to assess the potential consequences of identified accident scenarios using accident progression modeling. The accident scenario that will likely be evaluated by all molten salt reactor (MSR) developers is a spill of radionuclide-bearing fuel salt onto the reactor containment floor (i.e., a salt spill accident). The development of accident progression models requires experimental data to inform which processes to incorporate, to enable the calculation of parameters to model these processes, and to validate the model predictions. The data should quantify the sensitivities of key processes (e.g., molten salt spreading, heat transfer, containment structure corrosion, radionuclide vaporization, and aerosol generation) towards the initial conditions of the spill, the ambient environment, and the features of the containment. In addition, results from integrated process tests that quantify coupled processes are required to validate systems-level models. This report documents results from integrated process tests conducted on simulated molten salt spill accidents. The generated experimental data simultaneously quantify the heat transfer behavior of the spilled salt, compositional changes to the bulk salt, and the release of surrogate fission products from the spilled salt as aerosol particles. All tests that were conducted used FLiNaK doped with surrogate fission products, and the variables that were evaluated included the initial salt temperature and the concentration of surrogate fission products present in the salt. The major accomplishments of this work include identifying surrogate fuel salt compositions that provide insight into the dispersal behavior of radionuclides of potential significance to the source term, employing previously developed methods and measurement techniques to simultaneously measure key processes, generating data on the coupled processes of molten salt heat transfer and surrogate fission product release as aerosol particles, demonstrating new test methods for real-time monitoring of the flow rate of the spill and aerosol size quantification in an argon atmosphere, and developing a mass transfer model for cesium and iodine release from molten FLiNaK to provide insight into aerosol formation by vapor condensation. The same methodology applied herein can be employed to study different salt compositions of interest to MSR developers, different environmental conditions, and other variables that are relevant to postulated accident scenarios. The insights gained from these integrated process tests conducted at a laboratory scale will be incorporated into future integral effects tests conducted at an engineering scale.
20 FOSSIL-FUELED POWER PLANTS↗