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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

EPA GHG certification of medium- and heavy-duty vehicles: Development of road grade profiles representative of US controlled access highways

In collaboration with the U.S. Environmental Protection Agency and the U.S. Department of Energy, the National Renewable Energy Laboratory has conducted a national analysis of road grade characteristics experienced by U.S. medium- and heavy-duty trucks on controlled access highways. These characteristics have been developed using TomTom's commercially available street map and road grade database. Using the TomTom national road grade database, national statistics on road grade and hill distances were generated for the U.S. network of controlled access highways. These statistical distributions were then weighted using data provided by the U.S. Environmental Protection Agency for activity of medium- and heavy-duty trucks on controlled access highways. Here, the national activity-weighted road grade and hill distance distributions were then used as targets for development of a handful of sample grade profiles potentially to be used in the U.S. Environmental Protection Agency's Greenhouse Gas Emissions Model certification tool as well as in dynamometer testing of medium- and heavy-duty vehicles and their powertrains.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Key Insights: Interconnecting Behind-the-Meter Microgrids

This technical brief explores the interconnection challenges and evolving standards associated with behind-the-meter (BTM), facility-scale microgrids. It clarifies key functions related to customer microgrids and backup systems while addressing critical questions regarding certification coverage, operational impacts, customer relationships, and testing requirements for BTM microgrid systems. The document emphasizes the need for updated standards and additional witness testing to ensure safe and effective microgrid operation as well as improved grid integration and compliance with power quality standards.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Nuclear Materials Packaging, Transportation, and Systems Analysis Group Software Quality Assurance Plan: ANSYS Mechanical Finite Element Analysis Software Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic, and electromagnetic simulation capabilities. ANSYS has two main programs, which use the same solvers: (1) Mechanical APDL (ANSYS Design Parametric Language), a Fortran-based coding platform, and (2) ANSYS Workbench, which uses a graphical user interface to aid in finite element analysis implementation. This plan covers both APDL and Workbench. The ANSYS computer program is a large-scale, multipurpose finite element program that can be used to solve several classes of engineering analyses. The analysis capabilities of ANSYS include the ability to solve static and dynamic structural analyses, steady-state and transient heat transfer problems, mode-frequency and buckling eigenvalue problems, static or time-varying magnetic analyses, and various types of field and coupled-field applications. The program contains many special features that allow nonlinearities or secondary effects such as plasticity, large strain, hyperelasticity, creep, swelling, large deflections, contact, stress stiffening, temperature dependency, material anisotropy, and radiation to be included in the solution. As ANSYS has been developed, other special capabilities such as substructuring, submodeling, random vibration, kinetostatics, kinetodynamics, free convection fluid analysis, acoustics, magnetics, piezoelectrics, coupled-field analysis, and design optimization have been added to the program. These capabilities contribute further to making ANSYS a multipurpose analysis tool for varied engineering disciplines. The ANSYS program has been in commercial use for over 50 years and has been used extensively in the aerospace, automotive, construction, electronic, energy services, manufacturing, nuclear, plastics, oil, and steel industries. Additionally, many consulting firms and hundreds of universities have used ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. Ansys design analysis software is the first created within a quality system with ISO 9001 certification, the internationally accepted quality standard. Product development, testing, maintenance and support processes also meet the United States Nuclear Regulatory Commission's quality requirements, as they have for nearly four decades. The Quality Assurance Service Agreement is suitable for the customers working in the nuclear industry who need to meet specific federal regulations including 10CRF50 Appendix B and provisions of 10CFR21. ANSYS has retained its original International Organization for Standardization (ISO) 9001 accreditation certificate since1995-05-04, It’s current certificate is valid until 2027-05-29.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
DOE OSTI2016

Superconducting focusing lenses for the SSR-1 cryomodule of PXIE test stand at Fermilab

Five solenoid-based focusing lenses designed for use inside the SSR1 cryomodule of the PXIE test stand at Fermilab have been fabricated and tested. In addition to a focusing solenoid, each lens is equipped with a set of windings that generate magnetic field in the transverse plane and can be used in the steering dipole mode or as a skew quadrupole corrector. The lenses will be installed between superconducting cavities in the cryomodule, so getting sufficiently low fringe magnetic field was one of the main design requirements. Beam dynamics simulations indicated a need for high accuracy positioning of the lenses in the cryomodule, which triggered a study towards understanding uncertainties of the magnetic axis position relative to the geometric features of the lens. Furthermore, this report summarizes the efforts towards certification of the lenses, including results of performance tests, fringe field data, and uncertainty of the magnetic axis position.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Technical analysis of filter testing at the U.S. Department of Energy Filter Test Facility

The U.S. Department of Energy (DOE) technical standard DOE-STD-3020-2015 requires verification testing at the Filter Test Facility (FTF) of high-efficiency particulate air (HEPA) filters to be installed in nuclear facility (Hazard Category 1, 2, 3, and radiological facilities) confinement ventilation systems, or to be installed in habitability systems (e.g., filters for protection of workers required to act for the control and mitigation of emergency situations). Filters in these applications perform a safety function in accident situations, are designated as important to safety, or are necessary for habitability systems. Different FTFs have operated for decades, and results of tests are available to examine the need for and benefits of continued execution of 100 percent QA verification testing. The objective of this study and resulting report was to assess the need for 100 percent QA testing at the current FTF in Maryland, based on an examination of a database of test results from 2013 to August 2020. Filters that require independent testing per DOE-STD-3020-2015 to be installed in nuclear facilities are sent to the FTF before being shipped to the facilities. The FTF examines the documentation (e.g., certificates of compliance, results of particle penetration and airflow resistance testing by the manufacturers, labels affixed to filters and packages, and other requirements specified in purchase orders by the nuclear facility operators), implements visual inspections of the physical state of the filters, and checks the dimensions of frames. Filters that meet the documentation and visual inspection requirements are subjected to particle penetration and airflow resistance testing. In case of rejections, the filters are shipped back to the manufacturers, at the cost of the manufacturers, for replacement. Filters that pass all tests are shipped to the nuclear facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Test Report of Special Form Qualification Testing for the ORNL U ZipCan

This test report describes the special form testing activities performed on the two ZiPCans. One prototype test unit was subjected to the tests stipulated by 10 CFR 71.75 (d)(1)(i), ISO 2919:1999(E) Class 4 impact test, along with the leak rate test specified in 49 CFR 173.469(a)(4)(i). The other test unit was subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469 (b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests, as specified in ANSI N14.5-2014.The measured leak rates were converted to standard condition leak rates as specified in ASTM E 493. The determined standardized leak rates from the test and calculation for both test units met the requirements for special form certification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Data Based Shock Test Specification

It is vital that avionic packages used for testing and certifying the reliability and safety of U.S. nuclear weapons with platform aircraft survive exposure to shock environments during transportation and delivery. The objective of this research was to characterize the response to these transportation shock environments delivering accurate shock test specifications in order to set laboratory programming material and device certification rigor. Responses to shock events were analyzed in the frequency domain via the Shock Response Spectrum (SRS). Shocks were then grouped based on respective behavior of maximum response accelerations which were pseudorandomly resampled and compared to test data to form test specifications based on the MinerPalmgren hypothesis. In addition to discovering significant over testing in current shock specifications, a new systematic, data-driven approach to designing shock specifications was formulated.

42 ENGINEERING↗
DOE OSTI2018

Personnel Certifications for the Design, Installation and Maintenance of Photovoltaic Systems. Final Technical Report

The North American Board of Certified Energy Practitioners (NABCEP) is the most respected, well-established, and widely recognized national certification organization for professionals in the field of renewable energy. NABCEP’s certifications were created to facilitate consumer protection, improve quality assurance, and help employers judge the skills of existing or potential employees. The certifications also allow individuals to differentiate themselves from others in their field and advance their careers while fostering increased recognition of the profession. Since NABCEP’s founding in 2002, all of its certification exams have been administered in paper-and-pencil format twice per year at 30 exam sites around the United States. The biannual test administration and relatively low number of exam sites make it challenging for many qualified renewable energy professionals to take NABCEP’s certification exams. The rigorous nature of the exam, which leads to many candidates failing the exam on their first and sometimes second attempts, combined with the low number of annual test administrations means that anyone who fails will need to wait another six months for the chance to retake the exam. These factors limited the potential growth of NABCEP’s certification programs and the resultant quality assurance within the renewable energy industry. Thanks to a generous grant by the Department of Energy’s Solar Training and Education for Professional (STEP) program, NABCEP recently began updating its Photovoltaic (PV) Installation Professional Exam and developing three new specialty certifications in PV design, PV installation, and PV commissioning & maintenance. One of the primary objectives of this STEP-funded project was to develop the exams using a computer-based testing (CBT) model to increase the number of exam administrations and available exam sites for NABCEP’s certification exams. To successfully complete this project, NABCEP partnered with Castle Worldwide, Inc. With more than 25 years of experience in test development, test administration, analysis of examinations, and has a staff of 70 experienced personnel, NABCEP was confident that Castle’s team was more than qualified to help NABCEP make the transition to CBT examinations. NABCEP and Castle Worldwide jointly developed a project management plan that included key deliverables, scope management, a work breakdown structure, roles and responsibilities, and a project schedule with milestones. The project schedule was carefully monitored to ensure that activities along the critical path were not delayed and, when deemed necessary, the project was crashed to add resources so that activities could occur in parallel. NABCEP and Castle Worldwide staff met weekly to discuss any potential schedule variances and activities which might delay the closing of the project. NABCEP also recruited 46 subject matter experts (SMEs) to work with Castle’s staff on this project. NABCEP staff, SME’s, and Castle staff worked together to develop the Job Task Analyses that form the basis for the certification exams, create new examination forms, conduct passing score studies, and complete a psychometrical analysis of potential exam items. NABCEP’s SMEs utilized Castle’s item development platform during face-to-face meetings, webinars, and remote item authoring to write, review, and approve exam items. Castle also used their software to psychometrically analyze existing exam items to confirm the reliability and validity of the NABCEP’s certification exams. On January 3rd, 2018, NABCEP’s began offering its PV Installation Professional certification exam via CBT. The exam was available at Castle’s nearly 600 exam sites in the United States. A large number of sites will help to ensure better access for solar professionals in rural and remote areas, which drives down the implicit costs of taking the certification exams. Thanks to the STEP grant and the robust partnership between NABCEP and Castle Worldwide, Inc., personnel certifications will be much more accessible and affordable for renewable energy professionals.

14 SOLAR ENERGY↗
DOE OSTI2022

2020 Awardee of Two Small Wind Turbine Certification and Listing Awards: QED

With support from the Competitiveness Improvement Project's Small Wind Turbine Certification and Listing awards, QED Wind Power LLC will expand their ability to manufacture and distribute their 20-kilowatt, small wind turbine model to larger national markets. QED Wind Power aims to achieve this by conducting and completing testing of their small wind turbine and achieve safety and performance certification and listing with support from the National Renewable Energy Laboratory. This fact sheet provides an overview of QEDWind Power's project, how the company will achieve the goals of the two awards, and how the project fits within the overall Competitiveness Improvement Project.

CIP↗
DOE OSTI2021

A Heterogeneous System for Eagle Detection, Deterrent, and Wildlife Collision Detection for Wind Turbines (Final Technical Report)

This report summarizes the design, implementation, and test of an integrated system for automated detection and deterrence of eagles, with included wind turbine blade strike detection and imaging functionality. A machine learning approach was used in conjunction with a 360° camera system for automated detection and classification of golden eagles. This was developed using footage obtained from trained golden eagles and other raptors, in collaboration with wildlife biologists and professional bird handlers. Oregon State University developed a visual deterrent system, which uses inflatable anthropomorphic sculptures with random, kinetic motion to deter eagles, and conducted limited field testing on live eagles; the deterrent can be triggered by the visual detection of eagles using the vision system. Finally, a multi-sensor module was developed that is mounted at the turbine blade root. This module measures vibration and other motions to detect blade strikes, and an integrated on-blade camera captures an image of any impacting objects. Long-term, this blade strike detection system is intended to support an automatic monitoring and certification system for the eagle detection and deterent system. Independent field testing of each system component is described. Testing of the integrated system on an operational wind turbine was conducted across three separate field tests. This includes multi-day fields tests on a General Electric 1.5MW wind turbine at the National Renewable Energy Laboratory (NREL) National Wind Technology Center (NWTC) in Boulder, CO in October 2018 and July 2019; installation procedures, test procedures, and a summary of collected data are presented. A third multi-day on-turbine field test is also presented, which was performed using a General Electric 1.5MW wind turbine at the North American Wind Research and Training Center (NAWRTC) at Mesalands Community College, Tucumcari, NM in April 2019. Across these field tests, the vision system was demonstrated using unmanned aerial vehicles (UAV), and the eagle classification algorithm was not tested; the visual deterrent system was demonstrated, including automatic, remote deployment following surrogate visual detections; and, multi-sensor on-blade data was recorded across multiple wind turbine operational conditions and through more than 100 surrogate blade strikes using soft projectiles, including the successful demonstration of automatic image capture of striking objects. This data set was also used for offline development and validation of enhanced collision detection algorithms. As summarized in this report, the development and field validation of an integrated detection, deterrent, and blade collision detection system represents a critical proof of concept for future technology development of related detection and deterrent technologies, where both deterrent as well as collision detection recording devices are needed for future siting, monitoring, and operation of wind turbine installations, both onshore and offshore.

17 WIND ENERGY↗
DOE OSTI2019

The Critical Role of International Standards and Certification for the Marine Energy Industry

In 2007 the International Electrotechnical Commission (IEC) initiated Technical Committee (TC) IEC/TC 114 to develop standards for marine energy converters including wave, tidal and other water current converters. Following the inaugural plenary meeting in 2008, the first IEC/TC 114 Technical Specification (TS), Terminology, was published in 2011 and significant work on the development of other TSs is ongoing. Initial conformity assessment activities began in 2011 and the Marine Energy Operational Management Committee (ME-OMC) of the IEC Renewable Energy (IECRE) System was established in 2014. An update on the status of international, consensus-based, marine energy standards and certification deliverables will be provided, including the development of Renewable Energy Test Reports (RETRs) under the IECRE. Currently, IEC/TC 114 has fourteen participating member (P-Member) countries and thirteen observer member (O-Member) countries. Nine Project Teams (PTs), two Ad-hoc Groups (AHGs), and seven Maintenance Teams (MTs) are engaged in writing new TSs, assessing information on TS applications and preparing the published TSs for release of 2nd Editions. To date, IEC/TC 114 has published ten TSs covering subjects including wave and tidal energy converter performance assessment and wave and tidal resource assessment. Additional TSs are expected to be published in 2019 covering river and ocean thermal energy converters and resources, among others. TSs developed by IEC/TC 114 and applied by the industry are essential to reduce risk and increase confidence in marine energy systems. These TSs serve as the fundamental underpinnings of international, 3rd party conformity assessment systems, such as the IECRE. The IECRE is currently comprised of fifteen Member Bodies and operates three Sectors: Marine Energy (ME), Solar Photovoltaic (PV) and Wind Energy (WE). The IECRE ME sector has reached a critical milestone in the development of 3rd party conformity assessment deliverables for the marine energy industry. With the approval of IECRE 03 Ed. 2 and OD 300-200 Ed. 1, the ME Sector established a mechanism for the acceptance of Renewable Energy Test Laboratories (RETLs) with a scope in the IEC TS 62600-200 (Power Performance Assessment of Electricity Producing Tidal Energy Converters). A three-year transition period for test laboratory self- assessment based on ISO/IEC 17025 accreditation has been implemented to encourage RETL participation in the ME Sector. A detailed review of IEC/TC 114 and ME-OMC activities is provided and the critical connection between the development and implementation of international standards, and the associated conformity assessment rules and procedures, and the continued growth and commercial success of the marine energy industry is highlighted and examined. Emphasis is given to the role standards and certification play in risk reduction, improved quality and reliability, and increased confidence for the entire range of industry stakeholders.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Software Quality Assurance Plan ANSYS LSDYNA Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic and electromagnetic simulation capabilities. ANSYS LS-DYNA is the most used explicit simulation program capable of simulating the response of materials to short periods of severe loading. Its many elements, contact formulations, material models, and other controls can be used to simulate complex models with control over all the details of the problem. ANSYS LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Engineers can tackle simulations involving material failure and look at how the failure progresses through a part or through a system. Models with large amounts of parts or surfaces interacting with each other are also easily handled, and the interactions and load passing between complex behaviors are modeled accurately. Using computers with higher numbers of CPU cores can drastically reduce solution times. In addition, many consulting firms and hundreds of universities use ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. ANSYS has successfully passed over 100 customer quality system audits against American Society of Mechanical Engineers (ASME) NQA-1 and 10 CFR Part 50, Appendix B, since the company was founded, over 60 of which have been since 1997. ANSYS has successfully passed over 100 International Organization for Standardization (ISO) 9001 assessments. ANSYS design analysis software is the first created within a quality system with ISO 9001 certification, which is the internationally accepted quality standard. Product development, testing, maintenance, and support processes also meet the US Nuclear Regulatory Commission’s (NRC’s) quality requirements, as they have for nearly four decades. ANSYS staff perform more than 60,000 software verification tests before releasing each new product. ASME NQA-1-2012 (Subpart 2.7 is specific to software) is the industry- and NRC-accepted approach (consensus standard) for meeting 10 CFR Part 50, Appendix B, requirements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Experimental Procedure and Results for Contact Thermal Conductance Measurements performed during FY 2021

Weapons Test Engineering groups at LANL are responsible for testing and simulating weapon assemblies and subassemblies in support of qualification and certification of nuclear weapon systems. The complex nature of the assemblies themselves coupled with the loading environments, gives rise to low confidence and high uncertainties in the interpretation of both experimental and simulated results. In an effort to reduce these uncertainties, a project was started at LANL to perform focused and systematic experiments combined with simulations to increase confidence in both arenas. A key goal of the work performed under the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests TRUST program, focuses on identifying and minimizing sources of uncertainty associated with experimental and computational techniques. Specifically, with the above as motivation, a measurement procedure was developed by MST-8 to perform thermal conductivity measurements on cylinders of both similar and dissimilar metallic systems as a function of loading conditions and varying material interface morphologies between these components.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability eXpansion (DCX) Strategy

This document details the strategy proposed to meet the National Nuclear Security Administration (NNSA) requirement for the Dual-Axis Radiographic Hydrodynamic Test (DARHT) Facility Sustainment and Modernization projects identified in multiple NNSA Stockpile Stewardship and Management Plan (SSMP) reports to Congress [NNSA, 2020; 2021; 2022; 2023; 2024]. DARHT has become indispensable for the certification of the primaries of U.S. nuclear weapons since the current U.S. moratorium halted underground nuclear testing more than 30 years ago. However, aging facilities, evolving technology, and other issues are limiting or threatening the capability of DARHT to meet NNSA’s expanding mission needs now and into the future. This DARHT Capability eXpansion (DCX) strategy was developed to address NNSA needs by extending DARHT’s reliability and resilience, increasing the quality and quantity of DARHT data, and enabling hydrodynamic measurements in complex environments. The strategy can be implemented through integration of line-item projects, acquisition of major items of equipment, and other actions coordinated with the execution of the SSMP. This strategy document is intended for U.S. Government officials, particularly authorizers, appropriators, and program leaders. It may also be furnished to DARHT users, customers, collaborators, stakeholders, and visitors as needed

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

Towards in-situ certification of additively manufactured parts: the vital roles of physics-based and data-driven models

Certifying additively manufactured (AM) parts in-situ at the completion of a build is an enticing prospect, as it can help reduce the high costs associated with post-build testing and evaluation. However, achieving this goal presents significant challenges that may keep it aspirational for the foreseeable future. Nonetheless, incremental progress can pave the way forward. A critical aspect of in-situ certification involves continuous quality checking due to the random nature of the AM process and the difficulties in detecting defects or anomalies once layers are built over. While real-time in-situ monitoring strategies assisted by machine learning (ML) play a pivotal role in auditing part quality, they must ideally be supported by real-time (or near real-time) adaptive process control enabled by ML-assisted decision-making. By analyzing in-situ monitoring data in real-time (or near real- time) to dynamically adjust manufacturing parameters, such intervention can ensure AM parts are built to meet stringent certification standards. This can be achieved virtually by using high-fidelity performance models for the physical testing and evaluation tasks. In this short editorial, we discuss the key contributions made by data-driven and physics-based models in providing intelligence to the monitoring and process control tasks underpinning in-situ certification and in the simulation of the build’s performance under test and service conditions. While our focus lies in metal AM, the concepts discussed here are also relevant to other AM processes.

: In-situ monitoring↗