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DOE OSTI2025

Effect of particle size and moisture on flow performance of loblolly pine anatomical fractions: Experimental findings and model predictions

The rising energy demand has highlighted biomass as a promising next-generation energy source. However, commercializing biomass-derived energy faces challenges, particularly in handling biomass feedstock. Factors like particle size, shape, moisture content, and surface roughness significantly impact biomass flowability. This study addresses a crucial knowledge gap by examining the effects of particle size and moisture content on the flow behavior and shear properties of different anatomical fractions of loblolly pine (Pinus taeda). The bulk shear behavior was examined using a Schulze ring shear tester, while flow performance was tested through gravity-driven flow experiments in a variable wedge-shape hopper. Results were incorporated into empirical and machine learning-based flow prediction models to evaluate their accuracy and limitations. The study found that samples with higher moisture content show higher unconfined yield strength. The critical arching distance increased with particle size, e.g., from approximately 13 and 33 mm for 2- and 6-mm whole chips, respectively at a 32-degree inclination angle. Conversely, the flow rate decreased for a given hopper opening as particle size increased. For instance, at a 60-mm hopper opening and a 32-degree inclination angle, the mass flow rates for 2- and 6-mm whole chips were 7.83 and 6.42 tonne/h, respectively. The empirical model consistently overpredicted the mass flow rate for all anatomical fractions, while the machine learning model more accurately predicted the central tendency of flow rate but was insensitive to varying tissue proportions. These novel findings provide comprehensive characterization of anatomical fractions, reveal significant combined effects of particle size and moisture content on biomass flow behavior, and demonstrate a better predictive accuracy of a machine learning model, all of which are useful for optimizing material handling strategies and biomass utilization technologies in the industry.

09 - BIOMASS FUELS↗

DOE OSTI2025

Self-Driving Microscopy for AI/ML-Enabled Physics Discovery and Materials Optimization

Materials are the bedrock of economy and foundation for all real-world technologies. The viability of space travel, grid energy storage, solar to fuels conversion, methane removal, and photovoltaic energy solutions hinge on the discovery and optimization of novel materials and rapid scaling toward manufacturing. The last 20 years have seen an exponential growth in the theoretical predictive capability for crystalline materials and small molecules. However, it is only in the last five years that we have seen the rapid expansion of high-throughput synthesis enabled by laboratory robotics and microfluidics, as well as a resurgence of combinatorial synthesis (Abolhasani and Kumacheva 2023; Epps and Abolhasani 2021; Jiang et al. 2022; Rajan 2008; Soldatov et al. 2021; Szymanski et al. 2023). Combinatorial synthesis, microfluidics, and ultimately dip-pen megalibraries have demonstrated the ability to “write” multicomponent nanomaterials at high throughput scale, generating millions of material examples in the 3D, 4D, and 5D composition spaces (Chen et al. 2016, 2019; Jibril et al. 2022).

36 MATERIALS SCIENCE↗

DOE OSTI2025

Dependence of Convective Cloud Microphysical Properties on Environmental Conditions during the TRACER and ESCAPE Field Campaigns: A Synergistic Approach of Observations, Machine Learning and Parcel Models

The sensitivity of convective clouds to aerosols and their interactions with environment, combined with limited observational constraints in parameterizations, introduces significant uncertainties in atmospheric models. Here, this study investigates the dependence of convective cloud microphysical properties on environmental conditions using a synergistic approach that combines unique observations from the TRACER and ESCAPE field campaigns, machine learning techniques, and parcel model simulations with a super-droplet microphysics scheme. A random forest algorithm identifies in-situ vertical velocity (w), temperature (T), and surface fine-mode aerosol mass concentration as the three most important environmental conditions influencing cloud properties including liquid water content (LWC), number concentration for particles with D max < 50 μm (N c ,<50), 50 μm ≤ D max ≤ 3000 μm (N c,50–3000 ), and droplet effective diameter (D e ). Results show that LWC, N c,<50 , and N c,50–3000 significantly increase with w in updrafts. Across w bins, as T decreases, LWC, D e , and N c,50–3000 increase, while N c,<50 decreases, which are closely linked to the distance above cloud bases. Warmer cloud bases yield higher LWC, greater N c,50–3000 , and smaller N c,<50 , while polluted environments produce greater N c,<50 . Parcel model simulations successfully replicate these observed dependencies. The simulation results indicate that warmer cloud bases enhance condensation generating larger droplets, and differences in droplet sizes are then amplified through collision-coalescence, resulting in a greater N c,50–3000 . Polluted conditions result in a greater N c,<50 primarily due to enhanced cloud condensation nuclei activation despite increased collision-coalescence rates compared to pristine conditions. This study provides observed quantitative patterns characterizing cloud microphysical properties as a function of key environmental parameters, offering valuable constraints for improving physics parameterizations and numerical models.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Seeing is Believing: Autonomous Microscopy and the Data Revolution in Materials Science [Slides]

Machine intelligence has the potential to revolutionize materials science, enabling autonomous synthesis, self-driving characterization, and accelerated modeling. However, despite the promise, successful implementation of these methods in day-to-day research remains a challenge. This talk will delve into the reasons behind this, exploring how truly intelligent experiments are hindered by opaque experiment control, a lack of domain-specific models, and human-centric design. Through a focus on the characterization of next-generation microelectronics and energy storage materials, I will share insights from both successful and failed attempts to implement machine intelligence. We will then explore the next steps necessary to unlock the full potential of machine intelligence in materials science, creating a future where intelligent systems work seamlessly alongside researchers to drive innovation and discovery.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Universal Electronic‐Structure Relationship Governing Intrinsic Magnetic Properties in Permanent Magnets

An electronic-structure-centered perspective is presented on permanent-magnet (PM) design, highlighting two key levers, that is, saturation magnetization (M s ), governed by 3d-band filling and exchange physics, and magnetocrystalline anisotropy energy (MAE), arising from spin-orbit coupling (SOC) on anisotropic orbital populations. Reviewing current practices, including DFT-based MAE/J ij extraction, atomistic-spin and micromagnetic modeling, and high-throughput machine learning (ML) pipelines, three bottlenecks limiting predictive discovery is identified that is i) electronic-structure accuracy for small MAE (sensitive to functional choice, Hubbard U, and many-body effects), ii) finite-temperature and kinetic realism (phonon/magnon renormalization, ordering kinetics), and iii) descriptor and multiscale decoupling (lack of SOC-weighted and orbital-resolved fingerprints). Deep dives into the electronic-structure of Nd─Fe─B and Fe─N show how these fingerprints govern magnetic performance, motivating DFT- and quantum-mechanics-based descriptors for discovery. Unbiased, structure-driven exploration, coupled with high-throughput simulations, ML, generative AI, and reasoning models, accelerates candidate identification and propagates insights across scales. Addressing supply-chain risks, on future needs of designing “critical-element-free” magnets with tailored microstructure and high energy products is emphasized. By integrating electronic fingerprints, AI reasoning, and multiscale modeling, a practical roadmap is provided for rare-earth-lean or rare-earth free, high-performance, sustainable PMs.

Singh, Prashant [Ames Laboratory, and Iowa State U↗

NASA NTRSDate not supplied

Hourly Carbon Fluxes Estimation Using the GOES Advanced Baseline Imager (ABI) Data Over the Conterminous USA

Tremendous efforts by Fluxnet scientists over the past few decades have made thousands of site-years of carbon flux observations available for advancing our understanding of carbon cycling in terrestrial ecosystems. One of key Fluxnet measurements is net ecosystem exchange (NEE) as it is directly related to carbon budget of terrestrial ecosystems. However, carbon flux estimation studies using satellite remote sensing have focused mainly on daily Gross Primary Production (GPP). The satellite based carbon flux estimation used the polar orbiting satellite sensors (e.g., Moderate Resolution Imaging Spectroradiometer (MODIS)), which allow us to observe target regions only once during the day. Because daily NEE is close to zero value, the carbon flux models using the polar orbiting satellite data have not been well used for NEE estimation. The new generation of geostationary satellite sensors (e.g., GOES Advanced Baesline Imager (ABI) and Himawari Advanced Himawari Imager (AHI)) provide frequent observations, often less than every 10 minutes. Here, we use GOES ABI data to estimate hourly NEE over the conterminous USA. We used the Terrestrial Observation Prediction System (TOPS) model for estimating hourly NEE. TOPS is a diagnostic ecosystem process model that simulates the fluxes of carbon and water through vegetation in response to climate variability. For the climate input, we developed hourly climate data using the same algorithm with NASA Earth Exchange Gridded Daily Meteorology (NEX-GDM) datasets based on machine learning techniques. The hourly climate data includes precipitation, maximum temperature, minimum temperature, dew point temperature, and, in particular, solar radiation that is directly derived from the Geostationary observations. The spatial patterns of ecosystem parameters used in TOPS are optimized using satellite Solar Induced Fluorescence (SIF) data. The high frequency GPP estimations from geostationary satellite sensors make it comparable to the instantaneous SIF data than daily GPP. We also used Fluxnet data for optimization of model parameters and the validation of the output. The derived data addresses the diurnal dynamics of carbon cycling at large scales and should help in reducing the uncertainties in carbon budget studies.

Geostationary satellite↗

DOE OSTI2024

Autonomous Inverter Controls for Resilient and Secure Grid Operation: Vector Control Design for Grid Forming

The project addresses both fundamental and practical challenges of GFM/GFL inverter control for the power grids with high inverter based resources (IBRs) penetration. A data- driven modeling technique is applied to accurately model dynamics of PWM inverters, including electromagnetic-transient (EMT). Systematic and integrative designs of grid- forming (GFM) and grid-following (GFL) primary controls are developed to guarantee system performance under either normal or abnormal operating conditions without violating constraints. This modeling and control framework provides black-start capability in case of an outage without relying on rotating generators, and its secondary control is also shown to enhance resilience against cyber-physical attacks.

14 SOLAR ENERGY↗

DOE OSTI2024

Toward Accelerating Discovery via Physics-Driven and Interactive Multifidelity Bayesian Optimization

Both computational and experimental material discovery bring forth the challenge of exploring multidimensional and often nondifferentiable parameter spaces, such as phase diagrams of Hamiltonians with multiple interactions, composition spaces of combinatorial libraries, processing spaces, and molecular embedding spaces. Often these systems are expensive or time consuming to evaluate a single instance, and hence classical approaches based on exhaustive grid or random search are too data intensive. This resulted in strong interest toward active learning methods such as Bayesian optimization (BO) where the adaptive exploration occurs based on human learning (discovery) objective. However, classical BO is based on a predefined optimization target, and policies balancing exploration and exploitation are purely data driven. In practical settings, the domain expert can pose prior knowledge of the system in the form of partially known physics laws and exploration policies often vary during the experiment. Here, we propose an interactive workflow building on multifidelity BO (MFBO), starting with classical (data-driven) MFBO, then expand to a proposed structured (physics-driven) structured MFBO (sMFBO), and finally extend it to allow human-in-the-loop interactive interactive MFBO (iMFBO) workflows for adaptive and domain expert aligned exploration. These approaches are demonstrated over highly nonsmooth multifidelity simulation data generated from an Ising model, considering spin–spin interaction as parameter space, lattice sizes as fidelity spaces, and the objective as maximizing heat capacity. Detailed analysis and comparison show the impact of physics knowledge injection and real-time human decisions for improved exploration with increased alignment to ground truth. Here, the associated notebooks allow to reproduce the reported analyses and apply them to other systems.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Artificial Intelligence and Machine Learning Support for Probabilistic Fracture Mechanics

In this research, artificial intelligence and machine learning (ML) methods are used to search an uncertain parameter space more efficiently for the most important inputs with respect to response sensitivities. These methods are applied to the Extremely Low Probability of Rupture (xLPR) probabilistic fracture mechanics code used at the U.S. Nuclear Regulatory Commission (NRC) in support of nuclear regulatory research. This report documents two separate but related sub-tasks: (1) ranking important uncertain input features with respect to target outputs, determined by convergence in confidence intervals for increasing sample sizes using simple random sampling; and (2) implementation of a reduced-order surrogate model for fast, approximate sample generation. Unoptimized readily available off-the-shelf ML models were used in both sub-tasks.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2024

Low-Cost Sensor Performance Intercomparison, Correction Factor Development, and 2+ Years of Ambient PM2.5 Monitoring in Accra, Ghana

Particulate matter air pollution is a leading cause of global mortality, particularly in Asia and Africa. Addressing the high and wide-ranging air pollution levels requires ambient monitoring, but many low- and middle-income countries (LMICs) remain scarcely monitored. To address these data gaps, recent studies have utilized low-cost sensors. These sensors have varied performance, and little literature exists about sensor intercomparison in Africa. By colocating 2 QuantAQ Modulair-PM, 2 PurpleAir PA-II SD, and 16 Clarity Node-S Generation II monitors with a reference-grade Teledyne monitor in Accra, Ghana, we present the first intercomparisons of different brands of low-cost sensors in Africa, demonstrating that each type of low-cost sensor PM2.5 is strongly correlated with reference PM2.5, but biased high for ambient mixture of sources found in Accra. When compared to a reference monitor, the QuantAQ Modulair-PM has the lowest mean absolute error at 3.04 μg/m3, followed by PurpleAir PA-II (4.54 μg/m3) and Clarity Node-S (13.68 μg/m3). We also compare the usage of 4 statistical or machine learning models (Multiple Linear Regression, Random Forest, Gaussian Mixture Regression, and XGBoost) to correct low-cost sensors data, and find that XGBoost performs the best in testing (R2: 0.97, 0.94, 0.96; mean absolute error: 0.56, 0.80, and 0.68 μg/m3 for PurpleAir PA-II, Clarity Node-S, and Modulair-PM, respectively), but tree-based models do not perform well when correcting data outside the range of the colocation training. Therefore, we used Gaussian Mixture Regression to correct data from the network of 17 Clarity Node-S monitors deployed around Accra, Ghana, from 2018 to 2021. We find that the network daily average PM2.5 concentration in Accra is 23.4 μg/m3, which is 1.6 times the World Health Organization Daily PM2.5 guideline of 15 μg/m3. While this level is lower than those seen in some larger African cities (such as Kinshasa, Democratic Republic of the Congo), mitigation strategies should be developed soon to prevent further impairment to air quality as Accra, and Ghana as a whole, rapidly grow.

Humidity↗

NASA NTRSDate not supplied

BRAINSTACK – A Platform for Artificial Intelligence & Machine Learning Collaborative Experiments on a Nano-Satellite

As space missions continue to become more ambitious, complex, and distant to Earth, the need for advanced on-board intelligent decision making to guide everything from mission operations to fault detection and recovery has become a major front of space research. While the prevalence of research on such Artificial Intelligence / Machine Learning (AI/ML) modules has exploded, the capacity to experimentally validate such modules in space in a rapid and inexpensive format has not. To this end, the Nano Orbital Workshop (NOW) group at NASA Ames Research Center has been at the forefront of performing initial flight evaluation tests of ‘commercially’ available AI/ML computational platforms via the TechEdSat (TES-n) flight series as part of what is programmatically referred to as the BRAINSTACK. BRAINSTACK will provide an orbital AI/ML evaluation laboratory where computational experiments are pre-loaded into memory prior to launch, and then executed as desired during the mission, with results reported back and program tweaks or new data sets uploaded as needed. Processors selected as part of the BRAINSTACK are of ideal size, packaging, and power consumption for easy integration into a cube satellite structure. These experiments have included the evaluation of small, high-performance GPUs and more recently, neuromorphic processors in LEO operations. Neuromorphic processors are of particular interest due to their superior computational power efficiency over GPUs. The first TES-n flight test of an Intel first-generation Loihi neuromorphic processor launched on January 13, 2022 and continues to operate in orbit despite almost no space environment modifications. The Intel Loihi Gen-1 is characterized by a 14nm 128-core Spiking Neural Network (SNN) able to support on-chip training. This experiment utilized a Loihi packaged in the ‘Kapoho Bay’ USB module, providing a relatively straight-forward interface to the bus avionics system. The Kapoho Bay was in turn managed by a host Intel Pentium single-board computer to handle scheduling of the AI/ML application payloads, and communications with the satellite vehicle manager. The recently released Intel Loihi Gen-2, able to support integer-valued spike payloads and produced using 7nm process, will form part of the basis of the evolving BRAINSTACK in the upcoming three TES-n/NOW flights. Additionally, it is planned to measure the radiation environment these processors experience to understand any degradation or computational artifacts caused by long term space radiation exposure on these novel architectures. This evolving flexible and collaborative environment involving various research teams across NASA and other organizations is intended to be a convenient orbital test platform from which many anticipated future space AI/ML applications may be initially tested.

Artificial Intelligence↗

NASA NTRSDate not supplied

BRAINSTACK – A Platform for Artificial Intelligence & Machine Learning Collaborative Experiments on a Nano-Satellite

Artificial Intelligence↗

DOE OSTI2024

Extreme sparsification of physics-augmented neural networks for interpretable model discovery in mechanics

Data-driven constitutive modeling with neural networks has received increased interest in recent years due to its ability to easily incorporate physical and mechanistic constraints and to overcome the challenging and time-consuming task of formulating phenomenological constitutive laws that can accurately capture the observed material response. However, even though neural network-based constitutive laws have been shown to generalize proficiently, the generated representations are not easily interpretable due to their high number of trainable parameters. Sparse regression approaches exist that allow for obtaining interpretable expressions, but the user is tasked with creating a library of model forms which by construction limits their expressiveness to the functional forms provided in the libraries. Here, in this work, we propose to train regularized physics-augmented neural network-based constitutive models utilizing a smoothed version of $L^0$-regularization. This aims to maintain the trustworthiness inherited by the physical constraints, but also enables interpretability which has not been possible thus far on any type of machine learning-based constitutive model where model forms were not assumed a priori but were actually discovered. During the training process, the network simultaneously fits the training data and penalizes the number of active parameters, while also ensuring constitutive constraints such as thermodynamic consistency. We show that the method can reliably obtain interpretable and trustworthy constitutive models for compressible and incompressible hyperelasticity, yield functions, and hardening models for elastoplasticity, using synthetic and experimental data. This work aims to set a new paradigm for interpretable machine learning models in the broad area of solid mechanics where low and limited data is available along with prior knowledge of physical constraints that the learned maps need to obey. This paradigm can potentially be extended to a broader spectrum of scientific exploration.

Data-driven constitutive models↗

DOE OSTI2026

Mechanical behaviour of additively manufactured metals

Additive manufacturing is reshaping the production of engineering components in diverse industries, such as the automotive, aerospace, defense, and biomedical sectors, by offering unprecedented design flexibility. The non-equilibrium processing conditions of additive manufacturing generate materials with unique microstructures and tailored mechanical properties that are often unattainable through conventional routes. This review focuses on recent advances in additively manufactured metals that demonstrate distinctive mechanical behaviors, including strength-ductility synergy, microstresses and gradient plasticity, fracture and fatigue resistance, and high-temperature creep performance. Here, we examine the mechanisms and micromechanical effects arising from the heterogeneous microstructures fabricated by additive manufacturing, to guide the design of a wide range of high-performance structural materials. Furthermore, we discuss critical research needs and emerging opportunities in process control, alloy design, advanced characterization, high-fidelity computational modeling, and machine learning aimed at achieving exceptional mechanical properties in additively manufactured metals.

Additive Manufacturing↗

DOE OSTI2026

Platform for Automated Anomaly Detection in the Mercury Process System at the Target System in the Spallation Neutron Source

The Spallation Neutron Source (SNS) at Oak Ridge National Laboratory accelerates proton beams, which are directed toward a mercury target to generate the world’s most intense neutron beams via spallation. The target system consists of several interconnected subsystems and accounts for a major share of the facility’s overall downtime. Early detection of anomalies in the target system response can thus provide the possibility of taking corrective actions to reduce downtime. Accelerator facilities have largely focused on the beam side for data-driven fault prognostics. On the target side, SNS relies on operational shift technicians (OSTs), who respond to alarms and manually flag anomalies onto the System Tracking and Reliability (STAR) platform. This paper presents one of the first studies of using machine learning (ML) to automate anomaly detection in the target system. The study focused on the mercury process system as the first use case and employed reconstruction-based anomaly detection on minutely sampled time series signals. The pipeline was integrated into the STAR platform to autonomously rank and flag anomalies every week. The STAR platform provides a user interface for the OSTs to evaluate the flagged anomalies, thereby incorporating human feedback.

Anomaly detection↗

NASA NTRS2015

Application of Data Cubes for Improving Detection of Water Cycle Extreme Events

As part of an ongoing NASA-funded project to remove a longstanding barrier to accessing NASA data (i.e., accessing archived time-step array data as point-time series), for the hydrology and other point-time series-oriented communities, "data cubes" are created from which time series files (aka "data rods") are generated on-the-fly and made available as Web services from the Goddard Earth Sciences Data and Information Services Center (GES DISC). Data cubes are data as archived rearranged into spatio-temporal matrices, which allow for easy access to the data, both spatially and temporally. A data cube is a specific case of the general optimal strategy of reorganizing data to match the desired means of access. The gain from such reorganization is greater the larger the data set. As a use case of our project, we are leveraging existing software to explore the application of the data cubes concept to machine learning, for the purpose of detecting water cycle extreme events, a specific case of anomaly detection, requiring time series data. We investigate the use of support vector machines (SVM) for anomaly classification. We show an example of detection of water cycle extreme events, using data from the Tropical Rainfall Measuring Mission (TRMM).

water cycle extreme events↗

NASA NTRS2023

An Ensemble Neural Network Model for Predicting Rare-Earth Oxide and Silicate Heat Capacities at High Temperature

In this work, a neural network model was developed to predict the constant pressure heat capacity for materials in the rare-earth oxide—silica material space. Several model architectures were trained and tested on heat capacity data generated from first-principles density functional theory calculations. Hyperparameter optimization was performed, and the optimal model was selected for heat capacity predictions. The optimal model architecture was found to have a root-mean-squared error of 5.12 ± 3.37 J/mol-K. The optimal model architecture was then used in a bagging ensemble model trained using the leave-one-group-out method to provide error estimates for model predictions. The out-of-bag score for the ensemble model was 0.997. The predicted heat capacities agree well with the DFT and experimental results and were computed orders of magnitude faster than DFT simulations. Machine learning shows the potential to provide a suitable surrogate model for thermochemical property predictions for candidate environmental barrier coating materials but refining of input material features and model architectures could further improve accuracy for these models.

environmental barrier coatings↗

NASA NTRSDate not supplied

SPHINX: An SEP Model Validation Infrastructure developed through Community Challenges and the SEP Scoreboards

Solar Energetic Particle (SEP) events are interesting from a scientific perspective as they are the product of a broad set of physical processes from the corona out through the extent of the heliosphere, and provide insight into processes of particle acceleration and transport that are widely applicable in astrophysics. From the operations perspective, SEP events pose a radiation hazard for aviation, electronics in space, and human space exploration, in particular for missions outside of the Earth’s protective magnetosphere including to the Moon and Mars (Whitman et al 2022). For these reasons, SEP modelers have developed a rich and diverse set of models with a wide variety of aims. Some models probe the basic physics at the heart of particle acceleration and transport. Others produce fast statistical forecasts or employ disruptive new techniques like Machine Learning with the goal to assist end users in making operational decisions. To enable a consistent and quantitative understanding of SEP model performance, a generalized, automated validation infrastructure, called SPHINX, is being developed at NASA SRAG in close collaboration with NASA CCMC, NASA M2M, NOAA SWPC, and BIRA-IASB. This infrastructure has been built up through a multi-year community challenge. Starting in 2018 at the SHINE workshop, an effort was launched through SHINE, ISWAT, and ESWW to encourage quantitative, comprehensive, and consistent validation of SEP models. This effort has defined a set of challenge SEP events with the aim of generating quantitative comparisons between forecasts and observations and a set of challenge “non-events” to assess false alarms. In 2023, these challenge lists have been extended to statistically significant numbers with a prescribed set of rules for producing forecasts and supported through the dedicated SEPVAL working meetings. The participation of the research community has allowed the infrastructure to validate all the types of outputs being produced by SEP models. In parallel, the SPHINX code is being applied to real time forecasts submitted to the SEP Scoreboards, ensuring that the validation infrastructure can interpret forecasts produced in an operational scenario and provide metrics meaningful for operations. Upon completion, SPHINX and its interactive user interface, SPHINX-Web, will be made available for public use.

space weather↗