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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 OSTI2024

Machine Learning for Joint Quality Control

The use of lightweight material combinations has been highly demanded in manufacturing automotive structures. However, making robust dissimilar material joints of such lightweight materials is still challenging. A significant barrier to achieving high-quality and repeatable joint performance is a deficient understanding of the relationship between the welding process, joint attributes, and joint performance. In this context, welding factors refer to material, equipment, environment, and process parameters, while joint features comprise specific microstructural attributes of the weld such as nugget size, heat affected zone (HAZ) topology, intermetallic layer thickness, and sheet thickness reduction. Joint performance is quantified in terms of strength (e.g., tensile shear, coach peel, cross-tension), weld size, and hardness, among other factors. While there have been many attempts to establish this process-structure-property relationship by developing a model derived from the associated physics and first principles, the complexity of the joining processes compounded by the complex interactions with different materials in an automotive assembly line environment, has hindered the usefulness of such attempts. The complexity is further exacerbated using different stacking materials, especially comprising dissimilar material combinations. In practice, the common approach has been the laborious process of creating welds, characterizing them, and then physically testing them through experimentation. With the emergence of artificial intelligence (AI) methods, an alternative pathway to eliciting the desired process-structure-property relationship at an accelerated pace is to use a data-driven approach by employing machine-learning (ML) techniques. This approach is benefitted by the availability of large streams of data, generated through years of research and testing by original equipment manufacturers, in the form of material, process, environmental, equipment, microstructural, and bulk-scale performance information from multimodal, multiscale sensors making measurements from laboratory-scale to production-scale processes. During Phase I efforts, which ended in fiscal year (FY) 2021, the Oak Ridge National Laboratory and Pacific Northwest National Laboratory (ORNL/PNNL) team demonstrated the effectiveness of different ML/AI frameworks in modeling complex relationships between resistance spot welding (RSW) process parameters, weld attributes, and joint properties using a subset of data from General Motors (GM). In FY 2022, the project team further refined and expanded their respective ML models to analyze additional welds with new weld stack-ups and materials to enhance the ML model predictive capability. ORNL extended its unified deep neural networks (DNN) ML training and prediction framework with new data streams of process parameters, and PNNL extended its model describing RSW process parameters’ associations with weld attributes. In FY 2023, the project team completed the development of the AI/ML architecture for analyzing aluminum/steel joints manufactured by GM via RSW and transitioned into the inline welding quality monitoring task for steel/steel RSW joints provided by GM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced Distributed Optical Fiber Sensor Systems for Pipeline Integrity Monitoring

Distributed fiber optic sensors allow the measurement of structural parameters such as static/dynamic strain, temperature, pressure, and vibrations at thousands of locations along a single fiber cable. Deep neural network (DNN) algorithms were developed for rapid data processing speed and vibration event classification.

Lalam, Nageswara↗
DOE OSTI2024

Evaluating large scale aqueous organic redox flow battery performance with a hybrid numerical and machine learning framework

Aqueous organic redox flow battery (AORFB) is a promising cost-competitive technology for large-scale energy storage. Among existing work, the dihydroxyphenazine (DHP)-based AORFB has demonstrated high energy density and low-capacity degradation in 10 cm$^2$ cells during lab tests. However, its commercial-scale performance in more complex environments remains unknown, posing a barrier to commercialization. To address this gap, this work presents a comprehensive performance evaluation of a 780 cm$^2$ DHP-based AORFB by combining a physics-based numerical model, machine learning (ML)-based surrogate models, and ML-derived sensitivity quantification. Specifically, we first select 12 key battery parameters that include 10 physicochemical and 2 operation quantities, then select 6 performance metrics that include energy efficiency (EE), discharging capacity, charging energy, and power losses due to concentration, activation, and ohmic over-potentials. With such selection, 12800 combinations of the 12 parameters are subsequently generated using the Latin Hypercube Sampling method. Such combinations, together with 38 pre-defined State of Charge, are then integrated to a validated AORFB model developed in COMSOL to compute the performance metrics. With both input parameters and performance metrics, 60 deep neural network (DNN) surrogate models are then trained to approximate the relationship between the 10 physicochemical quantities and 6 performance metrics at each flow rate and current density. Sensitivity scores are then calculated based on the DNN models. Two additional sensitivity analysis tools, i.e., MARS, and SHAP, are also used to cross-validate the sensitivity scores from the DNN. The results demonstrate that 1) the standard potential ranks first in controlling EE and charging energy, 2) the membrane conductivity is most critical for power loss and EE, and 3) specific area and reaction rate control activation power loss.

25 ENERGY STORAGE↗
DOE OSTI2025

Machine Learning for Real-time Fusion Plasma Behavior Prediction and Manipulation (Final Report)

The goal of this project is to implement real-time analysis of 2D Beam Emission Spectroscopy (BES) data to predict and control transient and high-bandwidth events at DIII-D. In essence, we wish to bring high-bandwidth fluctuation diagnostics into the realm of real-time measurements and control. The BES ML models will necessarily be deep neural networks (DNN) with a “data flow” architecture for compatibility with high-throughput, low-latency evaluation on a field-programmable gate array (FPGA) or other emerging processor technologies. The real-time output will be fed to the plasma control system (PCS) for real-time control tasks, specifically for ELM control and avoidance and for QH-mode access and sustainment. We anticipate that the real-time analysis of fluctuation diagnostics will create new enabling technologies to predict and control transient events such as confinement mode transitions, edge-localized modes, Alfven eigenmode events, and disruptions. The proposed research is aligned with ITER research needs and DIII-D programmatic goals. For instance, the prediction and avoidance of ELM events is critical for ITER machine safety. Also, H-mode access with RMP ELM suppression in ITER is an active research area due to high separatrix density, narrow SOL width, and elevated LH transition power threshold.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

A New Perspective of Post-Weld Baking Effect on Al-Steel Resistance Spot Weld Properties through Machine Learning and Finite Element Modeling

The root cause of post-weld baking on the mechanical performance of Al-steel dissimilar resistance spot welds (RSWs) has been determined by machine learning (ML) and finite element modeling (FEM) in this study. A deep neural network (DNN) model was constructed to associate the spot weld performance with the joint attributes, stacking materials, and other conditions, using a comprehensive experimental dataset. The DNN model positively identified that the post-weld baking reduces the joint performance, and the extent of degradation depends on the thickness of stacking materials. A three-dimensional finite element (FE) model was then used to investigate the root cause and the mechanism of the baking effect. It revealed that the formation of high thermal stresses during baking, from the mismatch of thermal expansion between steel and Al alloy, causes damage and cracking of the brittle intermetallic compound (IMC) formed at the interface of the weld nugget during welding. This in turn reduces the joint performance by promoting undesirable interfacial fracture when the welds were subjected to externally applied loads. The FEM model further revealed that increase in structural stiffness, because of increase in steel sheet thickness, reduces the thermal stresses at the interface caused by the thermal expansion mismatch and consequently lessens the detrimental effect of post-weld baking on the joint performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Building a machine learning surrogate model for wildfire activities within a global Earth system model

Abstract. Wildfire is an important ecosystem process, influencing land biogeophysical and biogeochemical dynamics and atmospheric composition. Fire-driven loss of vegetation cover, for example, directly modifies the surface energy budget as a consequence of changing albedo, surface roughness, and partitioning of sensible and latent heat fluxes. Carbon dioxide and methane emitted by fires contribute to a positive atmospheric forcing, whereas emissions of carbonaceous aerosols may contribute to surface cooling. Process-based modeling of wildfires in Earth system land models is challenging due to limited understanding of human, climate, and ecosystem controls on fire counts, fire size, and burned area. Integration of mechanistic wildfire models within Earth system models requires careful parameter calibration, which is computationally expensive and subject to equifinality. To explore alternative approaches, we present a deep neural network (DNN) scheme that surrogates the process-based wildfire model with the Energy Exascale Earth System Model (E3SM) interface. The DNN wildfire model accurately simulates observed burned area with over 90 % higher accuracy with a large reduction in parameterization time compared with the current process-based wildfire model. The surrogate wildfire model successfully captured the observed monthly regional burned area during validation period 2011 to 2015 (coefficient of determination, R2=0.93). Since the DNN wildfire model has the same input and output requirements as the E3SM process-based wildfire model, our results demonstrate the applicability of machine learning for high accuracy and efficient large-scale land model development and predictions.

58 GEOSCIENCES↗
NASA NTRSDate not supplied

Artificial Neural Networks and AI in high Assurance Applications: Gaps and Techniques

In recent years, capabilties of Deep Neural Networks (DNN) and Artificial Intelligence (AI) systems have grown tremendously. They are now applied in many areas ranging from game playing, social media, science, to robotics, automotive, and aerospace applications.Based upon requirements for safety of DNN and AI in high assurance automotive and aerospace applications, I will discuss the necessity to ensure that AI technqiues for the analysis of Earth observation data and reasoning are working correctly and reliably.In this talk I will present modern techniques for the verification and validation (V&V) of DNN and other AI components as well as approaches for interpretable AI. I will discuss how these techniques can help to ensure quality of the AI results, improve confidence in their application, and facilitate human-AI interaction and collaboration.

Johann Schumann↗
NASA NTRS2018

Augmented Reality Data Generation for Training Deep Learning Neural Network

One of the major challenges in deep learning is retrieving sufficiently large labeled training datasets, which can become expensive and time consuming to collect. A unique approach to training segmentation is to use Deep Neural Network (DNN) models with a minimal amount of initial labeled training samples. The procedure involves creating synthetic data and using image registration to calculate affine transformations to apply to the synthetic data. The method takes a small dataset and generates a highquality augmented reality synthetic dataset with strong variance while maintaining consistency with real cases. Results illustrate segmentation improvements in various target features and increased average target confidence.

Torres, Gil↗
NASA NTRS2018

Deep Neural Network for Precision Multi-band Infrared Image Segmentation

Image segmentation is one of the fundamental steps in computer vision. Separating targets from background clutter with high precision is a challenging operation for both humans and computers. Currently, segmenting objects from IR images is done by tedious manual work. The implementation of a Deep Neural Network (DNN) to perform precision segmentation of multi-band IR video images is presented. A customized pix2pix DNN with multiple layers of generative encoder/decoder and discriminator architecture is used in the IR image segmentation process. Real and synthetic images and ground truths are employed to train the DNN. Iterative training is performed to achieve optimum accuracy of segmentation using a minimal number of training data. Special training images are created to enhance the missing features and to increase the segmentation accuracy of the objects. Retraining strategies are developed to minimize the DNN training time. Single pixel accuracy has been achieved in IR target boundary segmentation using DNNs. The segmentation accuracy between the customized pix2pix DNN and simple thresholding, GraphCut, simple neural network and ResNet models are compared.

Torres, Gil↗
NASA NTRSDate not supplied

SafeDNN: Understanding and Verifying Neural Networks

The SafeDNN project at NASA Ames explores analysis techniques and tools to ensure that systems that use Deep Neural Networks (DNN) are safe, robust and interpretable. Research directions we are pursuing include: symbolic execution for DNN analysis, label-guided clustering to automatically identify input regions that are robust, parallel and compositional approaches to improve formal SMT-based verification, property inference and automated program repair for DNNs, adversarial training and detection, probabilistic reasoning for DNNs. In this talk I will highlight some of the research advances from SafeDNN, that were already published.

Corina Pasareanu↗
NASA NTRSDate not supplied

Toward Design Assurance of Machine-Learning Airborne Systems

In recent years, Artificial Intelligence (AI) systems, enabled by Machine Learning (ML)technology, have demonstrated impressive progress and provides historic opportunities for the aviation industry. However, several key aspects of ML technology are not compatible with existing design assurance standards and make certification problematic. In this paper, we present a case study of a visual system with a Deep Neural Network (DNN) intended to detect and identify airport runway signs. Different use cases and variants of this system exhibit different levels of criticality ranging from design assurance level (DAL) D to B. We use the case study to illustrate the challenges of certification according to the current standards, such asDO-178C. We present the system design, data generation, training, and verification in detail and describe how the design assurance objectives can be met for a DAL D variant of the system. We also discuss gaps and potential approaches for the higher design assurance levels.

Avionics↗
NASA NTRSDate not supplied

Variance Decomposition of MEDLI2 Reconstructed Heating Using Neural Networks

The Mars Entry, Descent, and Landing Instrumentation (MEDLI2) sensor suite collected data during entry of the Mars 2020 Perseverance rover into Mars’ atmosphere. This suite included a network of MEDLI2 Instrumented Sensor Plugs (MISPs). Each MISP was comprised of a cylinder made of Thermal Protection System (TPS) material with 1-3 embedded thermocouples (TCs), and it was flush mounted into the heatshield or backshell. Data from these in-depth TCs were used to reconstruct the aeroheating environment of the vehicle throughout entry. Surface heating was posed as an inverse problem, with the goal of estimating the surface heating by minimizing an objective function of the difference between MISP temperature measurements during flight and the temperature predictions derived from the Fully Implicit Ablation and Thermal response (FIAT) program. Given an aerothermal environment, FIAT calculates the material response and provides in-depth temperatures throughout the TPS material. To achieve the reverse, an internal tool called FIAT_Opt runs through multiple different environments until the output temperature at the TC depth closely matches the flight data. 95% confidence intervals on the reconstructed surface heating were obtained using Monte Carlo analysis, in which uncertainties in the thermocouple depth and the TPS material properties (e.g., density, thermal conductivity, heat capacity, emissivity) based on flight-lot material testing were included. A variance decomposition method using Sobol indices was employed to assess the sensitivity of the reconstructed peak heating to the TC placement and material property uncertainties. Variance decomposition was found to require tens of thousands of FIAT_Opt runs in order for the Sobol indices to converge. With a single FIAT_Opt run taking on the order of 40 minutes, the required number of computations would take months to complete, even if using multiple CPUs. To mitigate this problem, three machine learning models (ridge regression with cross-validation, random forest regression, and a deep neural network) were trained and tested using the 2000 Monte Carlo runs that were already completed. A subset of 1600 runs were used to train the model (i.e., training set), while the remaining 400 runs were used as the test set. The predictions from the deep neural network (DNN) on the test set showed nearly perfect agreement to the actual values computed with FIAT_Opt (R2 > 0.99). Using the DNN as a surrogate model, the variance decomposition using 50,000 runs was completed within minutes. The resulting Sobol indices showed that the reconstructed peak surface heating was most sensitive to the uncertainties in the thermal conductivity (ST = 0.37) and heat capacity (ST = 0.26). This method can be leveraged to provide requirements for material property measurements needed to improve the accuracy of surface heating prediction and ultimately lead to the reduction of design margins in the future. This presentation will include background on the MEDLI2 suite; the method used for inverse heating estimation; the way that material property uncertainties were accounted for using Monte Carlo analysis; a brief background on variance decomposition; the motivation for using machine learning in this context; how a neural network was trained on the data to enable variance decomposition in a fraction of the time; and the variance decomposition results for one of the MISPs.

Hannah Alpert↗
NASA NTRSDate not supplied

Machine-Learning for Safety Critical Airborne Applications Part II: Case Study

The exceptional progress in the field of Artificial Intelligence (AI) systems, enabled by Machine Learning (ML) technology in recent years provides historic opportunities for the aviation industry. Current certification standards for avionics were developed prior to the ML renaissance and have several fundamental incompatibilities with the ML technology. WG-114 is working hard to release a new standard as soon as possible but for now there is no recognized means of compliance for ML based systems even of low criticality. In this talk, we present the custom ML workflow that can be used comply with all objectives of the current certification standards for a low-criticality (DAL D and C) ML-based system. To illustrate the practical application of the custom ML workflow we present a case study of a system based on a Deep Neural Network (DNN) intended to detect and identify airport runway signs. We present the system design, data generation, training, and verification in detail and describe how the design assurance objectives can be met for a DAL D and DAL C systems.

Johann Schumann↗
NASA NTRS2023

Predicting Two-Dimensional Airfoil Performance Using Graph Neural Networks

Computer simulations require the use of meshes to simulate geometries. These meshes capture important geometric features of the design and can be used in machine learning modeling. This report explores the use of graph neural networks (GNNs) to learn features from two-dimensional (2D) airfoil designs represented as a set of nodes connected using edges. This type of network is common in aerospace applications: most geometries are represented as a mesh in order to perform analysis. The objective of this work is to use GNNs to predict the performance of 2D airfoils generated using the program XFOIL. The predicted performance parameters include bulk quantities such as coefficients of lift (C L ), drag (C d , C dp ), moment (C m ), and node-specific quantities such as coefficient of pressure (C p ). In this report, a spline convolutional graph-based neural network is compared with deep learning neural networks to predict both bulk and node-specific quantities. The findings indicate the GNNs are able to predict bulk quantities quite well; however, when the number of outputs is increased, the deep neural network (DNN) proves to be better in its prediction capability. Two different normalization strategies were compared in the training of both GNNs and DNNs: minmax and standard deviation. In both types of networks, standard deviation scaling proved to be the best.

machine learning↗
NASA NTRS2023

Detail Enhancement of AIRS/AMSU Temperature and Moisture Profiles Using a 3D Deep Neural Network

In recent decades, spaceborne microwave and hyperspectral infrared sounding instruments have significantly benefited weather forecasting and climate science. However, existing retrievals of lower troposphere temperature and humidity profiles have limitations in vertical resolution, and often cannot accurately represent key features such as the mixed layer thermodynamic structure and the inversion at the planetary boundary layer (PBL) top. Because of the existing limitations in PBL remote sensing from space, there is a compelling need to improve routine, global observations of the PBL and enable advances in scientific understanding and weather and climate prediction. To address this, we have developed a new 3D deep neural network (DNN) which enhances detail and reduces noise in Level 2 granules of temperature and humidity profiles from the Atmospheric Infrared Sounder (AIRS)/Advanced Microwave Sounding Unit (AMSU) sounder instruments aboard NASA’s Aqua spacecraft. We show that the enhancement improves accuracy and detail including key features such as capping inversions at the top of the PBL over land, resulting in improved accuracy in estimations of PBL height.

Adam B Milstein↗
NASA NTRS2022

TruePAL – An AI Assistant for First Responder Safety

This paper presents the development of an AI assistant, Trusted and Explainable Artificial Intelligence for Saving Lives (TruePAL), to provide real-time warning of risks of potential crashes to the first responders. The TruePAL system employs an AI and deep learning technology for saving first responders and roadside crews lives in and around active traffic. A deep neural network (DNN) and a Non-Axiomatic Reasoning System (NARS) are implemented as an AI system. A mobile app with AI interface is developed to perform verbal communication with the first responders. The TruePAL team has developed an explainable AI approach by opening up the DNN blackbox to extract the activation filters of various features and parts of the targeted objects. The combination of DNN and NARS makes the TruePAL system explainable to the users. TruePAL ingests on-board cameras, radar, and other sensor signals, analyzes the environment and traffic patterns to generate timely warning to drivers and roadside crews to avoid crashes. The TruePAL team, in collaboration with the Miami/Dade Police Dept., has designed five use cases and multiple sub-scenarios in a CARLA driving simulator to test the capability of TruePAL in timely warning to the first responder drivers in potential crash scenarios. We have successfully demonstrated its capability of timely warning in over a dozen scenarios based on the use cases. The preliminary test simulation results show that TruePAL could provide the drivers and crew members advanced warning before a crash occurs.

Chow, Edward↗
NASA NTRSDate not supplied

Estimating Bidirectional Reflectance and Monitoring Stability of SNPP-VIIRS Reflective Solar Bands Using A Deep Neural Network

The NASA Clouds and the Earth's Radiant Energy System project provides the scientific community with observed top-of-atmosphere shortwave and longwave fluxes for climate monitoring and climate model validation. To provide consistent VIIRS cloud retrievals, the CERES Imager and Geostationary Calibration Group (IGCG) must understand and quantify the stability of the VIIRS instruments. To achieve this, the IGCG utilizes tropical deep convective clouds (DCCs) as invariant targets. Proper seasonal characterization of the DCC bidirectional reflectance distribution function (BRDF) is key to the success of DCC-based calibration methods, particularly for shortwave infrared (SWIR) bands. This article proposes the use of a deep neural network (DNN) to characterize VIIRS solar reflective band BRDF reflectance, with which individual channel trends are isolated by manipulating the DNN time input. Initial results show that the DNN method can extract statistically significant SNPP-VIIRS band trends, using only SNPP-VIIRS inputs, that are correlative to and match the magnitude of significant trends determined using methods that rely on an external angular distribution model. It may be possible to apply this approach to actively monitor the stability of new instruments without the need for predetermined seasonal BRDF corrections.

Benjamin Scarino↗
NASA NTRSDate not supplied

Deep Neural Network Based Convergence Classification for Computational Fluid Dynamics

A supervised deep learning approach is coupled with heuristic convergence criteria to construct a classification model for detecting the completion (convergence) of computational fluid dynamics (CFD) simulations. Heuristic convergence criteria alone are not always sufficient and more complex decisions are often left to a human analyst. The proposed approach leverages heuristic convergence criteria as well as two deep neural network (DNN) models, one binary and one multi-class, to improve the efficiency and consistency of convergence classification across a wide range of flight regimes. The DNN models presented are each trained on a subset of ascent aerodynamic CFD simulations for NASA’s Space Launch System and were produced using NASA’s unstructured Navier-Stokes solver FUN3D. Individual solutions are analyzed intermittently and are classified as sufficiently converged, further iterations required, or switch from steady Reynolds Averaged Navier-Stokes (RANS) to unsteady RANS CFD based on the iterative histories of four aerodynamic coefficients. The implemented classification model is shown to produce solutions that closely correlate to solutions produced by a human analyst. This work lays groundwork for expanding the capabilities of DNNs for automating and improving more of the CFD process.

SLS↗