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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

An experimental process parameter study on the identification of defects in additively fabricated Al6061 with laser powder bed fusion

Additively fabricated metal parts using laser powder bed fusion (L-PBF) possess sophisticated morphology due to the recurrent use of laser-induced metal powder melting and solidification. The surface and 3D morphology of these parts often include defects in the form of protrusions, depressions, pores, voids, keyholes, or cracks that are known to be influenced by laser scanning paths and layer-to-layer processing. Such inconsistent part quality hampers the extensive adoption of L-PBF. Pores and cracks are detrimental to the fatigue life of the parts and components. Quantifying and controlling part defects and optimizing processing and scanning strategy parameters adaptively in real-time through in situ monitoring systems are highly desired. This study investigates the optimization of experimental process parameters (power, scan velocity, and hatch spacing) and their effects on the cracking and porosity of Al6061 alloy using machine learning techniques. Multi-objective optimization is formulated and conducted to determine the L-PBF parameters that minimize both porosity and crack densities.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The MOST Hosts Survey: Spectroscopic Observation of the Host Galaxies of ∼40,000 Transients Using DESI

We present the Multi-Object Spectroscopy of Transient (MOST) Hosts survey. The survey is planned to run throughout the 5 yr of operation of the Dark Energy Spectroscopic Instrument (DESI) and will generate a spectroscopic catalog of the hosts of most transients observed to date, in particular all the supernovae observed by most public, untargeted, wide-field, optical surveys (Palomar Transient Factory, PTF/intermediate PTF, Sloan Digital Sky Survey II, Zwicky Transient Facility, DECAT, DESIRT). Science cases for the MOST Hosts survey include Type Ia supernova cosmology, fundamental plane and peculiar velocity measurements, and the understanding of the correlations between transients and their host-galaxy properties. Here we present the first release of the MOST Hosts survey: 21,931 hosts of 20,235 transients. These numbers represent 36% of the final MOST Hosts sample, consisting of 60,212 potential host galaxies of 38,603 transients (a transient can be assigned multiple potential hosts). Of all the transients in the MOST Hosts list, only 26.7% have existing classifications, and so the survey will provide redshifts (and luminosities) for nearly 30,000 transients. A preliminary Hubble diagram and a transient luminosity–duration diagram are shown as examples of future potential uses of the MOST Hosts survey. The survey will also provide a training sample of spectroscopically observed transients for classifiers relying only on photometry, as we enter an era when most newly observed transients will lack spectroscopic classification. The MOST Hosts DESI survey data will be released on a rolling cadence and updated to match the DESI releases.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Domain Knowledge Guided Bayesian Optimization For Autonomous Alignment Of Complex Scientific Instruments

Bayesian Optimization (BO) is a powerful tool for optimizing complex non-linear systems. However, its performance degrades in high-dimensional problems with tightly coupled parameters and highly asymmetric objective landscapes, where rewards are sparse. In such needle-in-a-haystack scenarios, even advanced methods like trust-region BO (TurBO) often lead to unsatisfactory results. We propose a domain knowledge guided Bayesian Optimization approach, which leverages physical insight to fundamentally simplify the search problem by transforming coordinates to decouple input features and align the active subspaces with the primary search axes. We demonstrate this approach's efficacy on a challenging 12-dimensional, 6-crystal Split-and-Delay optical system, where conventional approaches, including standard BO, TuRBO and multi-objective BO, consistently led to unsatisfactory results. When combined with an reverse annealing exploration strategy, this approach reliably converges to the global optimum. The coordinate transformation itself is the key to this success, significantly accelerating the search by aligning input co-ordinate axes with the problem's active subspaces. As increasingly complex scientific instruments, from large telescopes to new spectrometers at X-ray Free Electron Lasers are deployed, the demand for robust high-dimensional optimization grows. Our results demonstrate a generalizable paradigm: leveraging physical insight to transform high-dimensional, coupled optimization problems into simpler representations can enable rapid and robust automated tuning for consistent high performance while still retaining current optimization algorithms.

FOS: Computer and information sciences↗
DOE OSTI2024

Optimal Design of Food Packaging Considering Waste Management Technologies to Achieve Circular Economy

Plastic packaging plays a fundamental role in the food industry, avoiding food waste and facilitating food access. The increasing plastic production and the lack of appropriate plastic waste management technologies represent a threat to the environmental and human welfare. Therefore, there is an urgent need to identify sustainable packaging solutions. Circular economy (CE) promotes reducing waste and increasing recycling practices to achieve sustainability. In this work, we propose a CE framework based on multi-objective optimization, considering both economic and environmental impacts, to identify optimal packaging designs and waste management technologies. Using mixed-integer linear programming (MILP), techno-economic analysis (TEA), and life cycle assessment (LCA), this work aims to build the first steps in packaging design, informing about the best packaging alternatives and the optimal technology or technologies to process packaging waste. For the economic analysis, we consider the minimum increase in price (MIP) when adding recycling to the cost of each packaging solution, while for the environmental analysis, the greenhouse gas emissions impact was considered. A case study on ground coffee packaging is used to illustrate the proposed framework. The results demonstrate that the multilayer bag option is the most convenient when considering both the chosen economic and environmental impacts.

Life Cycle Analysis↗
DOE OSTI2024

Predicting Li-ion Battery Performance for Impurity-doped NMC Cathodes Using Deep Learning

With the electric vehicle (EV) market expansion and the energy sector's shift towards electrification, the demand for battery metals, including lithium (Li), cobalt (Co), and nickel (Ni), is set to surpass supply. A critical knowledge gap exists in the purity standards for battery precursors and the impact of impurities on battery performance. Addressing this, our study employs a Deep Machine Learning (DL) based multi-objective optimization approach to interpret the relationship between metal impurities in domestic battery resources and their effects on battery performance. We analyze experimental data from Li-ion batteries with NMC (Nickel-Manganese-Cobalt oxide) cathodes over 1000 cycles, representing approximately ~6-8 months of operation, to establish a baseline of performance without impurities. Leveraging this data, we develop a Physics-Informed Deep Learning (PIDL) framework to extend our findings to cases that include metal impurities (e.g., Fe, Cu, Al) ranging from (0.001 - 0.01) %, respectively. By incorporating physics-based features, our PIDL model can accurately estimate the performance of NMC cathodes doped with various metal impurities to provide rapid design decisions. This research paves the way for informed decisions in Li-ion battery material design and optimization, ensuring the sustainable growth of the EV market and the broader energy sector.

25 ENERGY STORAGE↗
DOE OSTI2024

Optimization of R290 variable geometry heat exchangers

Air-to-refrigerant heat exchangers (HX) are vital components in Heating, Ventilating and Air Conditioning and Refrigeration (HVAC&R) equipment. Recent literature has proposed utilizing shape-optimized, non-round tubes to reduce component size and refrigerant charge, thus enabling the adoption of low-GWP natural refrigerants like R290. However, most designs are restricted to fixed tube configurations, limiting the overall performance potential. In this work, multi-objective optimization is used in a staged approach to develop variable geometry multi-pass air-to-R290 HXs with minimal volume and airside pressure drop. Non-round tubes are used throughout the domain and each pass may have different tube arrangements to maximize HX performance. Compared to conventional fin-tube HXs, the optimized designs demonstrate more than 60% reductions in envelope volume, 30% reductions in face area, and up to 24% reduction in airside pressure drop. Additionally, the refrigerant charge reduction was up to 64%, thus enabling safe use of flammable and mildly-flammable refrigerants.

42 ENGINEERING↗
DOE OSTI2024

Optimization and Experimental Validation of Annular Finned PCM-HX for a Domestic Hot Water Heater Application

The load profile for domestic water heating is time-dependent and can result in high energy demand during peak operating times. Shifting this peak load can have significant environmental and economic impacts. Phase change material (PCM)-based thermal energy storage (TES) is a potentially useful technology for peak load shifting in domestic hot water (DHW) applications thanks to its high latent heat and energy density. In this study, an annular finned-tube PCM-HX design concept was optimized for a load-shifting TES unit to meet the Department of Energy standard for a medium-usage DHW heater using a resistance-capacitance model (RCM) integrated with a Multi-Objective Genetic Algorithm. The optimized design comprised 70 identical annular finned-tube PCM-HX units connected in parallel and utilizing RT62HC as the PCM. A single PCM-HX unit was prototyped and tested in a vertically oriented setup with upward heat transfer fluid (HTF) flow. The hot water supply time was defined based on a cutoff temperature of 51.7°C. The as-designed mass flow rate (1.5 g/s) was tested to assess the performance of the prototyped PCM-HX unit for RCM validation. For the experimental investigation, RTD sensor bundles measured HTF temperature at the PCM-HX inlet and outlet, and a Coriolis flow meter accurately measured the HTF mass flow rate. The simulated discharging power underpredicted the experimental result by about 12%, and the simulated hot water supply time underpredicted the experimental result by approximately 13% for the as-designed mass flow rate (1.5 g/s). The average deviation of the hot water supply temperature between the experimental and RCM results during the complete PCM solidification process was 1.3 K for the as-designed mass flow rate. The overall good agreement between the experimental and RCM results provides confidence that computationally efficient models such as RCM can be utilized for design optimization of PCM-HXs.

42 ENGINEERING↗
DOE OSTI2024

Accelerated CO2 Storage Optimization Using Multi-Resolution Fourier Neural Operator at the Illinois Basin Decatur Project (IBDP)

This paper presents a deep learning-based approach for optimizing CO2 injection in carbon capture and storage (CCS) operations. We developed a multi-resolution machine learning model to significantly reduce data generation costs. Utilizing this proxy model, we implemented a multi-objective genetic algorithm to optimize well control during the CO2 injection process. The proposed approach was applied to the Illinois Basin Decatur Project (IBDP), successfully optimizing the CO2 injection schedule based on three key objectives: maximizing the amount of CO2 stored, maximizing sweep efficiency, and minimizing pressure increase. The use of the proxy model accelerated the optimization workflow by two orders of magnitude, while the cost of data generation for the proxy model was reduced by 90% by utilizing a coarse-scale model.

accelerated CO2 storage optimization↗
DOE OSTI2025

A Joint Search for the Electromagnetic Counterpart to the Gravitational-Wave Binary Black-Hole Merger Candidate S250328ae with the Dark Energy Camera and the Prime Focus Spectrograph

The first detection of an optical counterpart to a gravitational wave signal revealed that collaborative efforts between instruments with different specializations provide a unique opportunity to acquire impactful multi-messenger data. We present results of such a joint search with the Dark Energy Camera (DECam) and Prime Focus Spectrograph (PFS) for the optical counterpart of the LIGO-Virgo-KAGRA event S250328ae, a binary black hole merger candidate of high significance detected at a distance of 511$\pm$82 Mpc and localized within an area of 3 (15) square degrees at 50% (90%) confidence. We observed the 90% confidence area with DECam and identified 36 high-confidence transient candidates after image processing, candidate selection, and candidate vetting. We observed with PFS to obtain optical spectra of DECam candidates, Swift-XRT candidates, and potential host galaxies of S250328ae. In total, 3897 targets were observed by seven pointings covering ~50% of the 90% confidence area. After template fitting and visual inspection, we identified 12 SNe, 159 QSOs, 2975 galaxies, and 131 stars. With the joint observations of DECam and PFS, we found variability in 12 SNe, 139 QSOs, 37 galaxies, and 2 stars. We do not identify any confident optical counterparts, though the association is not ruled out for three variable candidates that are not observed by PFS and 6 QSO candidates without clear variability if the optical counterpart of S250328ae is faint. Despite the lack of confident optical counterparts, this paper serves as a framework for future collaborations between wide-field imagers and multi-object spectrographs to maximize multi-messenger analyses.

Zhang, Haibin [Natl. Astron. Observ. of Japan] (OR↗
DOE OSTI2025

Surrogate Neural Architecture Codesign Package (SNAC-Pack)

Neural Architecture Search is a powerful approach for automating model design, but existing methods struggle to accurately optimize for real hardware performance, often relying on proxy metrics such as bit operations. We present Surrogate Neural Architecture Codesign Package (SNAC-Pack), an integrated framework that automates the discovery and optimization of neural networks focusing on FPGA deployment. SNAC-Pack combines Neural Architecture Codesign's multi-stage search capabilities with the Resource Utilization and Latency Estimator, enabling multi-objective optimization across accuracy, FPGA resource utilization, and latency without requiring time-intensive synthesis for each candidate model. We demonstrate SNAC-Pack on a high energy physics jet classification task, achieving 63.84% accuracy with resource estimation. When synthesized on a Xilinx Virtex UltraScale+ VU13P FPGA, the SNAC-Pack model matches baseline accuracy while maintaining comparable resource utilization to models optimized using traditional BOPs metrics. This work demonstrates the potential of hardware-aware neural architecture search for resource-constrained deployments and provides an open-source framework for automating the design of efficient FPGA-accelerated models.

Weitz, Jason [UC, San Diego] (ORCID:00090004631535↗
DOE OSTI2025

Machine Learning-Driven Optimization of Building Enclosures for Moisture Durability and Thermal Performance

The design of moisture-durable building enclosures with low embodied carbon often involves an iterative process of selecting the materials for the specific exposure conditions to meet the performance requirements. While hygrothermal simulations are commonly used to evaluate moisture durability, they often require advanced expertise for proper implementation. Machine learning (ML) provides a promising alternative by streamlining the design process and minimizing the reliance on complex simulations. This study presents a machine learning-based approach for predicting moisture durability in residential wall assemblies. The ML model was trained to estimate the mold index and maximum moisture content of various layers under typical exposure conditions. The model achieved a high predictive accuracy, with a coefficient of determination (R²) exceeding 0.90 when compared to traditional hygrothermal simulations on materials that were not part of training the ML model. Building on these results, the ML model was developed into a practical tool for optimizing wall assembly designs. This tool allows users to automatically optimize material selections based on energy, moisture, and carbon performance criteria. By incorporating multi-objective optimization, the tool identifies configurations that minimize embodied carbon while maintaining moisture safety and code-compliant thermal performance. Additionally, it provides insights into how material choices influence assembly durability, energy efficiency, and carbon reduction. The tool will be implemented in the Building Science Advisor (BSA) to enhance its performance and provide more granularity on the results. This research highlights the potential for ML-driven tools to simplify the design of high-performance building enclosures, offering architects and engineers a faster, more efficient way to balance critical performance factors.

Salonvaara, Mikael [ORNL] (ORCID:0000000318991554)↗
DOE OSTI2026

Use of Digital Real-Time Simulation and Optimization to Identify Maximum Real Power Injection on the Banshee Distribution Network: Preprint

This study investigates the hosting capacity of the Banshee Distribution Network by optimizing the real power injection at carefully selected Distributed Energy Resource (DER) locations. The analysis is conducted within the framework of power system operational constraints, including bus voltage ranges, thermal line ratings, and transformer loading limits. A Python-based Genetic Algorithm (GA), implemented using the PyGAD library, is employed to iteratively identify the optimal power injection configuration that maximizes network utilization while preserving system reliability. The methodology integrates a real-time simulation environment using the Real-Time Digital Simulator (RTDS), allowing high-fidelity evaluation of power flow and voltage behavior under each proposed injection scenario. By coupling the optimization algorithm with real-time simulation feedback, this approach ensures that both static and dynamic constraints are enforced during the evaluation process. The GA leverages evolutionary operators such as selection, crossover, and mutation to navigate the nonlinear search space efficiently. The results of the study delineate the feasible hosting capacity at three targeted buses, reflecting maximum real power levels that can be injected without causing voltage violations, transformer overloading, or line congestion. These findings provide a decision- support tool for distribution planners and utilities aiming to integrate higher penetrations of DERs in existing infrastructure. Additionally, the work lays the foundation for extending such optimization techniques to multi-objective formulations, including economic dispatch and reactive power coordination, in future studies.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

DEVELOPMENT AND APPLICATION OF RISK ANALYSIS TOOLKIT FOR PLANT RESOURCE OPTIMIZATION

This paper presents the development of methods and tools that are being designed to optimize plant operations (e.g., maintenance/replacement schedules and optimal maintenance postures for plant components) in a manner that is more cost effective than current approaches and makes better use of available component health and cost data. These methods include both data- and model-based optimization methods. Model-based optimization methods directly include reliability and cost models to determine an optimal plant operational strategy. We consider gradient-based and evolutionary (based on genetic algorithms) optimization methods. The second class of methods target more specific use cases (e.g., project schedule optimization) and are not based on reliability models directly, but they require specific component reliability and cost data. This class of methods is based on variants of the knapsack problem with an aim to determine an optimal project schedule that maximizes the overall NPV. This paper also presents multi-objective methods designed to identify an optimal maintenance posture based on a Pareto frontier analysis. Rather than dictating the “right” tradeoff (i.e., identify the absolute best posture), we show how it is possible to perform a trade space exploration approach (i.e., identify value and costs of several postures and let the analysis account for desired value and cost metrics). This is performed by identifying maintenance postures that maximize value (e.g., system availability) and minimize operational costs, i.e., the Pareto frontier in a value-cost trade space. For all these methods we present detailed applicative examples that show their validity from a decision-making perspective.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Implementation of fuel management multi-cycle optimization capabilities in RAVEN optimization framework

Optimization in nuclear fuel-management assists the core reload engineer with finding optimal out-of-core and in-core strategies. RAVEN is INL’s open source software that is equipped with fuel-management optimization capabilities including single-cycle, single- and multi-objective optimization of pressurized water reactors (PWRs) loading patterns (LP) of a fresh core using genetic algorithm (GA) and non-dominated sorting genetic algorithm (NSGA-II). In practice, however, medium and long term planning of fuel-management needs a multi-cycle approach, where the history and availability of fuel assemblies is considered in the optimization process. In this paper, we present a description of an initial expansion of RAVEN fuel-management optimization capabilities for a multi-cycle optimization framework. N-th cycle optimization capabilities that account for the unique history of recycled fuel assembly in the core were added. The multi-cycle optimization approach taken is formulated as a cycle-wise optimization problem where out-of-core decisions are used to onset each cycle optimization. Out-of-core decisions are managed externally to the in-core optimization by a fuel inventory management module. A proof-of-concept optimization problem is also presented.

42 - ENGINEERING↗
DOE OSTI2024

Proof-of-Concept for Sensor Modeling in MOOSE for the Design of Autonomous Nuclear Reactor Control

Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. For this reason, recent studies have investigated autonomous control by using adaptive model predictive control and multi-objective optimization for heat pipe–cooled microreactors under normal and heat pipe failure conditions. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this poster, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

LC-Opt: Benchmarking Reinforcement Learning and Agentic AI for End-to-End Liquid Cooling Optimization in Data Centers

Liquid cooling is critical for thermal management in high-density data centers with the rising AI workloads. However, machine learning-based controllers are essential to unlock greater energy efficiency and reliability, promoting sustainability. We present LC-Opt, a Sustainable Liquid Cooling (LC) benchmark environment, for reinforcement learning (RL) control strategies in energy-efficient liquid cooling of high-performance computing (HPC) systems. Built on the baseline of a high-fidelity digital twin of Oak Ridge National Lab's Frontier Supercomputer cooling system, LC-Opt provides detailed Modelica-based end-to-end models spanning site-level cooling towers to data center cabinets and server blade groups. RL agents optimize critical thermal controls like liquid supply temperature, flow rate, and granular valve actuation at the IT cabinet level, as well as cooling tower (CT) setpoints through a Gymnasium interface, with dynamic changes in workloads. This environment creates a multi-objective real-time optimization challenge balancing local thermal regulation and global energy efficiency, and also supports additional components like a heat recovery unit (HRU). We benchmark centralized and decentralized multi-agent RL approaches, demonstrate policy distillation into decision and regression trees for interpretable control, and explore LLM-based methods that explain control actions in natural language through an agentic mesh architecture designed to foster user trust and simplify system management. LC-Opt democratizes access to detailed, customizable liquid cooling models, enabling the ML community, operators, and vendors to develop sustainable data center liquid cooling control solutions.

Naug, Avisek [Hewlett Packard Enterprise]↗
DOE OSTI2026

Surrogate Neural Architecture Codesign Package (SNAC-Pack)

Neural architecture search (NAS) is a powerful approach for automating model design, but existing methods often optimize for accuracy alone or rely on proxy metrics such as bit operations (BOPs) that correlate poorly with hardware cost. This gap is particularly large for FPGA deployment, where cost is dominated by a multi-dimensional budget of lookup tables, DSPs, flip-flops, BRAM, and latency. We present the Surrogate Neural Architecture Codesign Package (SNAC-Pack), an open-source AutoML framework for hardware-aware neural architecture codesign and end-to-end FPGA deployment. SNAC-Pack runs a multi-objective global search with Optuna and NSGA-II, loading trials to a shared SQLite store that enables parallel workers across compute nodes. A hardware surrogate model outputs per-trial resource and latency estimates, avoiding the synthesis cost that would otherwise dominate the search loop. A local search stage then applies quantization-aware training (QAT) together with iterative magnitude pruning in a combined compression loop, after which the final model is synthesized to FPGA firmware via the hls4ml Python library. A YAML configuration and an optional agentic frontend let users run the pipeline on new datasets without modifying the framework. We demonstrate SNAC-Pack on jet classification at the Large Hadron Collider and superconducting qubit readout, discovering compact architectures that match or exceed strong baselines on the task metric while reducing FPGA resource utilization and, in the qubit readout case, reducing the design space exploration process from months of manual fine-tuning to hours of automated search.

Weitz, Jason [UC, San Diego]↗
DOE OSTI2026

Sparse Phase Ansatzes for Resource-Efficient Qudit State Preparation via the SNAP-Displacement Protocol

Efficient preparation of nonclassical bosonic states is a central requirement for quantum computing, simulation, and precision metrology. We study resource-efficient quantum state preparation in bosonic qudit systems using the SNAP-displacement (SD) protocol. Existing SD-based approaches typically require a large number of gates and SNAP phases, resulting in complex control pulses with longer ansatz durations and amplified impact of photon-loss and control errors. In this work, we focus on the near- to medium-term regime, in which noisy quantum devices impose trade-offs on the fidelity that can be achieved, which must be taken into account. Specifically, we propose to optimize only a subset of the SNAP phases and introduce three progressively more general sparse ansatzes. To provide fine-grained control and identify the most suitable ansatz for a given target fidelity, we further employ a scalarized multi-objective optimization that trades off fidelity against either the number of phases or the duration of the ansatz. Numerical results for several target states and qudit dimensions up to $d=64$, evaluated through the hypervolume of the Pareto frontiers, show that these sparse ansatzes achieve favorable trade-offs over the fully parameterized SD protocol in both ideal and noisy settings. The advantage is strongest and most consistent when minimizing the number of phases, while improvements in ansatz duration are smaller and more dependent on the target-state family and noise level, suggesting a practical route to more efficient near- and medium-term bosonic state preparation.

Ferrari Dacrema, Maurizio [Milan Polytechnic] (ORC↗