Search NASA⌕ Search

SEARCH · Search NASA

Results for “process simulation modeling”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,333 records · Page 74

From Solidification Processing to Microstructure to Mechanical Properties: A Multi-scale X-ray Study of an Al-Cu Alloy Sample

We follow an Al-12 at. pct Cu alloy sample from the liquid state to mechanical failure, using in situ X-ray radiography during directional solidification and tensile testing, as well as three-dimensional computed tomography of the microstructure before and after mechanical testing. The solidification processing stage is simulated with a multi-scale dendritic needle network model, and the micromechanical behavior of the solidified microstructure is simulated using voxelized tomography data and an elasto-viscoplastic fast Fourier transform model. This study demonstrates the feasibility of direct in situ monitoring of a metal alloy microstructure from the liquid processing stage up to its mechanical failure, supported by quantitative simulations of microstructure formation and its mechanical behavior.

36 MATERIALS SCIENCE↗

Responses of estuarine circulation and salinity to the loss of intertidal flats – A modeling study

Intertidal flats in estuaries are coastal wetlands that provide critical marine habitats to support wide ranges of marine species. Over the last century many estuarine systems have experienced significant loss of intertidal flats due to anthropogenic impacts. This paper presents a modeling study conducted to investigate the responses of estuarine hydrodynamics to the loss of intertidal flats caused by anthropogenic actions in Whidbey Basin of Puget Sound on the northwest coast of North America. Changes in salinity intrusion limits in the estuaries, salinity stratification, and circulation in intertidal flats and estuaries were evaluated by comparing model results under the existing baseline condition and the no-flat condition. Model results showed that loss of intertidal flats results in an increase in salinity intrusion, stronger mixing, and a phase shift in salinity and velocity fields in the bay front areas. Model results also indicated that loss of intertidal flats enhances two-layer circulation, especially the bottom water intrusion. Loss of intertidal flats increases the mean salinity but reduces the salinity range in the subtidal flats over a tidal cycle because of increased mixing. Salinity intrusion limits extend upstream in all three major rivers discharging into Whidbey Basin when no intertidal flats are present. Changes in salinity intrusion and estuarine circulation patterns due to loss of intertidal flats affect the nearshore habitat and water quality in estuaries and potentially increase risk of coastal hazards, such as storm surge and coastal flooding. Furthermore, model results suggested the importance of including intertidal flats and the wetting-and-drying process in hydrodynamic simulations when intertidal flats are present in the model domain.

54 ENVIRONMENTAL SCIENCES↗

SALT3-NIR: Taking the Open-source Type Ia Supernova Model to Longer Wavelengths for Next-generation Cosmological Measurements

Abstract A large fraction of Type Ia supernova (SN Ia) observations over the next decade will be in the near-infrared (NIR), at wavelengths beyond the reach of the current standard light-curve model for SN Ia cosmology, SALT3 (∼2800–8700 Å central filter wavelength). To harness this new SN Ia sample and reduce future light-curve standardization systematic uncertainties, we train SALT3 at NIR wavelengths (SALT3-NIR) up to 2 μ m with the open-source model-training software SALTshaker , which can easily accommodate future observations. Using simulated data, we show that the training process constrains the NIR model to ∼2%–3% across the phase range (−20 to 50 days). We find that Hubble residual (HR) scatter is smaller using the NIR alone or optical+NIR compared to optical alone, by up to ∼30% depending on filter choice (95% confidence). There is significant correlation between NIR light-curve stretch measurements and luminosity, with stretch and color corrections often improving HR scatter by up to ∼20%. For SN Ia observations expected from the Roman Space Telescope, SALT3-NIR increases the amount of usable data in the SALT framework by ∼20% at redshift z ≲ 0.4 and by ∼50% at z ≲ 0.15. The SALT3-NIR model is part of the open-source SNCosmo and SNANA SN Ia cosmology packages.

79 ASTRONOMY AND ASTROPHYSICS↗

Deep Learning for Subgrid‐Scale Turbulence Modeling in Large‐Eddy Simulations of the Convective Atmospheric Boundary Layer

Abstract In large‐eddy simulations, subgrid‐scale (SGS) processes are parameterized as a function of filtered grid‐scale variables. First‐order, algebraic SGS models are based on the eddy‐viscosity assumption, which does not always hold for turbulence. Here we apply supervised deep neural networks (DNNs) to learn SGS stresses from a set of neighboring coarse‐grained velocity from direct numerical simulations of the convective boundary layer at friction Reynolds numbers Re τ up to 1243 without invoking the eddy‐viscosity assumption. The DNN model was found to produce higher correlation between SGS stresses compared to the Smagorinsky model and the Smagorinsky‐Bardina mixed model in the surface and mixed layers and can be applied to different grid resolutions and various stability conditions ranging from near neutral to very unstable. The DNN model can capture key statistics of turbulence in a posteriori (online) tests when applied to large‐eddy simulations of the atmospheric boundary layer.

54 ENVIRONMENTAL SCIENCES↗

A Computer Model for Analyzing Volatile Removal Assembly

A computer model simulates reactional gas/liquid two-phase flow processes in porous media. A typical process is the oxygen/wastewater flow in the Volatile Removal Assembly (VRA) in the Closed Environment Life Support System (CELSS) installed in the International Space Station (ISS). The volatile organics in the wastewater are combusted by oxygen gas to form clean water and carbon dioxide, which is solved in the water phase. The model predicts the oxygen gas concentration profile in the reactor, which is an indicator of reactor performance. In this innovation, a mathematical model is included in the computer model for calculating the mass transfer from the gas phase to the liquid phase. The amount of mass transfer depends on several factors, including gas-phase concentration, distribution, and reaction rate. For a given reactor dimension, these factors depend on pressure and temperature in the reactor and composition and flow rate of the influent.

Guo, Boyun↗

Automated Knowledge Discovery From Simulators

A computational method, SimLearn, has been devised to facilitate efficient knowledge discovery from simulators. Simulators are complex computer programs used in science and engineering to model diverse phenomena such as fluid flow, gravitational interactions, coupled mechanical systems, and nuclear, chemical, and biological processes. SimLearn uses active-learning techniques to efficiently address the "landscape characterization problem." In particular, SimLearn tries to determine which regions in "input space" lead to a given output from the simulator, where "input space" refers to an abstraction of all the variables going into the simulator, e.g., initial conditions, parameters, and interaction equations. Landscape characterization can be viewed as an attempt to invert the forward mapping of the simulator and recover the inputs that produce a particular output. Given that a single simulation run can take days or weeks to complete even on a large computing cluster, SimLearn attempts to reduce costs by reducing the number of simulations needed to effect discoveries. Unlike conventional data-mining methods that are applied to static predefined datasets, SimLearn involves an iterative process in which a most informative dataset is constructed dynamically by using the simulator as an oracle. On each iteration, the algorithm models the knowledge it has gained through previous simulation trials and then chooses which simulation trials to run next. Running these trials through the simulator produces new data in the form of input-output pairs. The overall process is embodied in an algorithm that combines support vector machines (SVMs) with active learning. SVMs use learning from examples (the examples are the input-output pairs generated by running the simulator) and a principle called maximum margin to derive predictors that generalize well to new inputs. In SimLearn, the SVM plays the role of modeling the knowledge that has been gained through previous simulation trials. Active learning is used to determine which new input points would be most informative if their output were known. The selected input points are run through the simulator to generate new information that can be used to refine the SVM. The process is then repeated. SimLearn carefully balances exploration (semi-randomly searching around the input space) versus exploitation (using the current state of knowledge to conduct a tightly focused search). During each iteration, SimLearn uses not one, but an ensemble of SVMs. Each SVM in the ensemble is characterized by different hyper-parameters that control various aspects of the learned predictor - for example, whether the predictor is constrained to be very smooth (nearby points in input space lead to similar output predictions) or whether the predictor is allowed to be "bumpy." The various SVMs will have different preferences about which input points they would like to run through the simulator next. SimLearn includes a formal mechanism for balancing the ensemble SVM preferences so that a single choice can be made for the next set of trials.

Burl, Michael↗

Model Evaluation of Short-Lived Climate Forcers for the Arctic Monitoring and Assessment Programme: A Multi-Species, Multi-Model Study

While carbon dioxide is the main cause for global warming, modeling short-lived climate forcers (SLCFs) such as methane, ozone, and particles in the Arctic allows us to simulate near-term climate and health impacts for a sensitive, pristine region that is warming at 3 times the global rate. Atmospheric modeling is critical for understanding the long-range transport of pollutants to the Arctic, as well as the abundance and distribution of SLCFs throughout the Arctic atmosphere. Modeling is also used as a tool to determine SLCF impacts on climate and health in the present and in future emissions scenarios. In this study, we evaluate 18 state-of-the-art atmospheric and Earth system models by assessing their representation of Arctic and Northern Hemisphere atmospheric SLCF distributions, considering a wide range of different chemical species (methane, tropospheric ozone and its precursors, black carbon, sulfate, organic aerosol, and particulate matter) and multiple observational datasets. Model simulations over 4 years (2008-2009 and 2014-2015) conducted for the 2022 Arctic Monitoring and Assessment Programme (AMAP) SLCF assessment report are thoroughly evaluated against satellite, ground, ship, and aircraft-based observations. The annual means, seasonal cycles, and 3-D distributions of SLCFs were evaluated using several metrics, such as absolute and percent model biases and correlation coefficients. The results show a large range in model performance, with no one particular model or model type performing well for all regions and all SLCF species. The multi-model mean (mmm) was able to represent the general features of SLCFs in the Arctic and had the best overall performance. For the SLCFs with the greatest radiative impact (CH4, 03, BC, and SO(sup 2-)(sub 4)), the mmm was within ±25 % of the measurements across the Northern Hemisphere. Therefore, we recommend a multi-model ensemble be used for simulating climate and health impacts of SLCFs. Of the SLCFs in our study, model biases were smallest for C"4 and greatest for OA. For most SLCFs, model biases skewed from positive to negative with increasing latitude. Our analysis suggests that vertical mixing, long-range transport, deposition, and wildfires remain highly uncertain processes. These processes need better representation within atmospheric models to improve their simulation of SLCFs in the Arctic environment. As model development proceeds in these areas, we highly recommend that the vertical and 3-D distribution of SLCFs be evaluated, as that information is critical to improving the uncertain processes in models.

Arctic Monitoring and Assessment Programme↗

Progress on the Development of a Simulation Environment for Optical Communications

Deep space laser communications require extremely accurate beam pointing to take advantage of the narrow beams achievable at optical wavelengths. This pointing accuracy must be achieved in the presence of spacecraft basebody motion which may exceed laser pointing requirements by orders of magnitude.In this paper a model of an optical band transceiver pointing control system is developed that can be used to predict performance under various operating scenarios. The transceiver model consists of an electro-mechanical model of the telescope platform and isolator. A novel photon counting detector array is used in the simulation as the focal plane detector. In the simulation we are able to inject various cases of spacecraft basebody motion based on both flight data and future mission spacecraft jitter requirements. Various models of uplink beacon flux levels and atmospheric scintillation are also available for analysis.Using these models, detector processing and control functions are implemented in the simulation. A complete acquisition sequence is demonstrated with blind acquisition and tracking of the modulated uplink beam and positioning of the downlink beam on the focal plane array. These simulations predict that pointing requirements will be met with representative disturbance models and uplink beam scintillation.

pointing control↗

Numerical simulations of the subsynoptic features associated with the AVE-SESAME I case. I - The preconvective environment

The extensive diagnostic calculations made possible by the AVE-SESAME I database are used in combination with numerical simulations from the Mesoscale Atmospheric Simulation System (MASS) model to examine the dynamics of the meso-alpha-scale features during the preconvective period from 1130 to 2030 UTC on April 10, 1979. The version of the MASS model used in this investigation is presented, and an overview of the general synoptic conditions present at the time of model initialization is presented along with the data used to initialize the model. The dynamical processes present in the numerical simulations are presented and compared with analyses of the observational data from this and other investigations of this case. The relative importance of the adiabatic and diabatic processes in creating and then initiating the release of the convective instability is discussed.

Zack, John W.↗

Active- and transfer-learning applied to microscale-macroscale coupling to simulate viscoelastic flows

Active- and transfer-learning are applied to microscale dynamics of polymer flows for the multiscale discovery of effective constitutive approximations required in viscoelastic flow simulation. The result is macroscopic rheology directly connected to a microstructural model. Micro and macroscale simulations are adaptively coupled by means of Gaussian process regression (GPR) to run the expensive microscale computations only as necessary. This multiscale method is demonstrated with flows of a polymer solution as a model system. At the microscale level dissipative particle dynamics (DPD) is employed to model the fluid as a suspension of bead-spring micro-structures subjected to steady shear flow. The results yield the non-Newtonian viscosity and the first normal stress difference at strain rates as training data used in a GPR model. DPD parameters are calibrated with respect to experimental data for a real polymer solution. Compliance with these data requires adjustment of the DPD model's cutoff radius, which then becomes a function of the second invariant of the strain rate tensor. The FENE-P model is chosen for the macroscale description using the spectral element method (SEM) to simulate channel flow and flow past a circular cylinder. The DPD results at the lowest possible shear strain rate yield an estimate of the zero-shear rate viscosity, which allows the initiation of the macroscale flow by SEM as a Newtonian fluid. The resulting strain-rate field is surveyed to determine additional shear strain rate sampling points for the DPD system. This new information allows an initial fitting of parameters of the constitutive equation followed by new SEM simulations at the macroscale. Additionally, guided by active-learning GPR to select new sampling points, this process continues until convergence is achieved. The effectiveness of this new simulation paradigm for viscoelastic flows is tested with different macroscale operating conditions. The effective closure learned in the channel simulation is then transferred directly to the flow past a circular cylinder at low Reynolds number, where the results show that only two additional DPD simulations are required to achieve a satisfactory constitutive model. With an increase of the Reynolds number, the active-learning scheme automatically detects the inaccuracy of the learned constitutive model, and initiates additional DPD simulations for the extra data needed to once again close the microscale-macroscale coupled system. This new paradigm of active- and transfer-learning for multiscale modeling is readily applicable to other microscale-macroscale coupled simulations of complex fluids and other materials. Furthermore, the coupling between microscale and macroscale solvers can be seamlessly implemented with our open source multiscale universal interface (MUI) library.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Numerical Investigation of Plasma Flows in Magnetic Nozzles

Magnetic nozzles are used in many laboratory experiments in which plasma flows are to be confined, cooled, accelerated, or directed. At present, however, there is no generally accepted theoretical description that explains the phenomena of plasma expansion in and detachment from an externally-imposed magnetic field. The latter is an especially important problem in the field of plasma propulsion, where the ionized gas must detach from the applied, solenoidal magnetic field to realize thrust production. In this paper we simulate a plasma flowing in the presence of an applied magnetic field using a multidimensional numerical simulation tool that includes theoretical models of the various dispersive and dissipative processes present in the plasma. This is an extension of the simulation tool employed in previous work by Sankaran et al. The new tool employs the same formulation of the governing equation set, but retains the axial and radial components of magnetic field and the azimuthal component of velocity that were neglected. We aim to compare the computational results with the various proposed magnetic nozzle detachment theories to develop an understanding of the physical mechanisms that cause detachment. An applied magnetic field topology is obtained using a magnetostatic field solver, and this field is superimposed on the time-dependent magnetic field induced in the plasma to provide a self-consistent field description. The applied magnetic field and model geometry match those found in experiments by Kuriki and Okada. 4 A schematic showing the setup used in those experiments is shown. We model this geometry because there is a substantial amount of experimental data that can be compared to our computations, allowing for validation of the model. In addition, comparison of the simulation results with the experimentally obtained plasma parameters will provide insight into the mechanisms that lead to plasma detachment, revealing how they scale with different input parameters.

Sankaran, Kamesh↗

Numerical Investigation of Plasma Flows in Magnetic Nozzles

Magnetic nozzles are used in many laboratory experiments in which plasma flows are to be confined, cooled. accelerated, or directed. At present, however, there is no generally accepted theoretical description that explains the phenomena of plasma detachment from an externally-imposed magnetic field. This is an important problem in the field of plasma propulsion, where the ionized gas must detach from the applied, solenoidal magnetic field to realize thrust production. In this paper we simulate a plasma flowing in the presence of an applied magnetic field using a multidimensional numerical simulation tool that includes theoretical models of the various dispersive and dissipative processes present in the plasma. This is an extension of the simulation tool employed in previous work by Sankaran et al. The new tool employs the same formulation of the governing equation set. but retains the axial and radial components of magnetic field and the azimuthal component of velocity that were neglected in other works. We aim to compare the computational results with the various proposed magnetic nozzle detachment theories to develop an understanding of the physical mechanisms that cause detachment. An applied magnetic field topology is obtained using a magnetostatic field solver and this field is superimposed on the time-dependent magnetic field induced in the plasma to provide a self-consistent field description. The applied magnetic field and model geometry match those found in experiments by Kurtki and Okada. We model this geometry because there ts a substantial amount of experimental data that can be compared to our computations, allowing for validation of the model. In addition, comparison of the simulation results with the experimentally obtained plasma parameters will provide insight into the mechanisms that lead to plasma detachment, revealing how the 3 scale with different input parameters.

Polzin, K. A.↗

Black Start of Unbalanced Microgrids Harmonizing Single- and Three-Phase Grid-Forming Inverters

As power systems are transforming with increasing penetrations of inverter-based resources (IBRs), system restoration using IBRs has drawn attention. Using distributed grid-forming (GFM) assets located near critical loads, either three-phase or single-phase, to establish microgrid voltages in the absence of a bulk grid, a distribution system could obtain high system survivability. For swift and secure recovery of a critical load in a single-phase lateral, local single-phase GFM inverters can form a microgrid, and then it can be combined with a neighbouring grid with the inverters remaining in GFM mode for voltage and frequency regulation until the bulk grid comes online. It leads to dynamic interoperation of single-phase GFM inverters with three-phase ones in the black start process. This paper studies the novel approach with electromagnetic transient (EMT) simulations. To evaluate the potential and the technical challenges of the heterogeneous IBR-driven black start, three-phase and single-phase GFM inverter models are developed, including negative-sequence control for voltage balance and a phase-by-phase current limiter (three-phase) and current magnitude limiter (single-phase). To examine dynamic aspects of the black-start process, the EMT simulation also models transformer and motor dynamics emulating their inrush and startup behavior as well as network dynamics. Involvement of grid-following assets to facilitate the black-start process is also modeled. By allowing multiple GFM inverters to collectively black start without leader-follower coordination, regardless of phases, a system can achieve extreme resilience. An inverter-driven black start of a heavily unbalanced 2-MVA distribution feeder using 1 three-phase and 3 single-phase GFM inverters is demonstrated. The simulation shows the heterogeneous system can maintain stability with the single-phase GFM dynamics coupled with the three-phase one.

grid-forming inverter↗

Black Start of Unbalanced Microgrids Harmonizing Single- and Three-Phase Grid-Forming Inverters: Preprint

As power systems are transforming with increasing penetrations of inverter-based resources (IBRs), system restoration using IBRs has drawn attention. Using distributed grid-forming (GFM) assets located near critical loads, either three-phase or single-phase, to establish microgrid voltages in the absence of a bulk grid, a distribution system could obtain high system survivability. For swift and secure recovery of a critical load in a single-phase lateral, local single-phase GFM inverters can form a microgrid, and then it can be combined with a neighbouring grid with the inverters remaining in GFM mode for voltage and frequency regulation until the bulk grid comes online. It leads to dynamic interoperation of single-phase GFM inverters with three-phase ones in the black start process. This paper studies the novel approach with electromagnetic transient (EMT) simulations. To evaluate the potential and the technical challenges of the heterogeneous IBR-driven black start, three-phase and single-phase GFM inverter models are developed, including negative-sequence control for voltage balance and a phase-by-phase current limiter (three-phase) and current magnitude limiter (single-phase). To examine dynamic aspects of the black-start process, the EMT simulation also models transformer and motor dynamics emulating their inrush and startup behavior as well as network dynamics. Involvement of grid-following assets to facilitate the black-start process is also modeled. By allowing multiple GFM inverters to collectively black start without leader-follower coordination, regardless of phases, a system can achieve extreme resilience. An inverter-driven black start of a heavily unbalanced 2-MVA distribution feeder using 1 three-phase and 3 single-phase GFM inverters is demonstrated. The simulation shows the heterogeneous system can maintain stability with the single-phase GFM dynamics coupled with the three-phase one.

grid-forming inverter↗

iMatTOUGH: An open-source Matlab-based graphical user interface for pre- and post-processing of TOUGH2 and iTOUGH2 models

TOUGH2 and iTOUGH2 are powerful models that simulate the heat and fluid flows in porous and fracture media, and perform parameter estimation, sensitivity analysis and uncertainty propagation analysis. However, setting up the input files is not only tedious, but error prone, and processing output files is time consuming. Here, we present an open source Matlab-based tool (iMatTOUGH) that supports the generation of all necessary inputs for both TOUGH2 and iTOUGH2 and visualize their outputs. The tool links the inputs of TOUGH2 and iTOUGH2, making sure the two input files are consistent. It supports the generation of rectangular computational mesh, i.e., it automatically generates the elements and connections as well as their properties as required by TOUGH2. The tool also allows the specification of initial and time-dependent boundary conditions for better subsurface heat and water flow simulations. The effectiveness of the tool is illustrated by an example that uses TOUGH2 and iTOUGH2 to estimate soil hydrological and thermal properties from soil temperature data and simulate the heat and water flows at the Rifle site in Colorado.

58 GEOSCIENCES↗

Reduced-order modeling of near-field THMC coupled processes for nuclear waste repositories in shale

Performance assessment (PA) of geologic radioactive waste repositories requires three-dimensional simulation of highly nonlinear, thermo-hydro-mechanical-chemical (THMC), multiphase flow and transport processes across many kilometers and over tens to hundreds of thousands of years. Integrating the effects of a near-field geomechanical process (i.e. buffer swelling) into coupled THC simulations through reduced-order modeling, rather than through fully coupled geomechanics, can reduce the dimensionality of the problem and improve computational efficiency. In this study, PFLOTRAN simulations model a single waste package in a shale host rock repository, where re-saturation of a bentonite buffer causes the buffer to swell and exert stress on a highly fractured disturbed rock zone (DRZ). Three types of stress-dependent permeability functions (exponential, modified cubic, and Two-part Hooke’s law models) are implemented to describe mechanical characteristics of the system. Overall, our modeling study suggests that compressing fractures reduces DRZ permeability, which could influence the rate of radionuclide transport and exchange with corrosive species in host rock groundwater that could accelerate waste package degradation. Less permeable shale host rock delays buffer swelling, consequently retarding DRZ permeability reduction as well as chemical transport within the barrier system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A Novel Approach to Modeling Biomass Pyrolysis in a Fluidized Bed Reactor

A novel approach to simulating biomass pyrolysis in a fluidized bed of mostly inert material is presented. The bed is assumed to be externally heated, although simulation of autothermal operation with partial oxidation of the products is a future objective. Combining pyrolysis reaction kinetics developed by the CRECK Modeling Group and a previously published component properties model, material and energy balances are closed by tracking the residence time of biomass particles without regard for their exact spatial distribution. The model is used to simulate a pilot-scale fluidized bed pyrolysis process being developed at Iowa State University, and model predictions are compared with experimental results for red oak and corn stover feedstocks. The results are in general agreement, with the model typically predicting more noncondensable gas and less low-boiling liquid products. The differences are ascribed to the limitations of the kinetics model. This model provides a rigorous energy balance for fluidized bed pyrolysis processes that can be incorporated into commercial flowsheet models with the capacity for future addition of partial oxidation reactions and implementation of improved kinetics models.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

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↗