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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 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

A 3D Model to Predict Explicit Morphologies and Volume Fraction of Lack-of-Fusion Pores Generated in Selective Laser Melting Processes

The performance of an additively manufactured (AM) component is dependent on the distribution of process-induced defects in addition to the complex microstructure of the material, surface roughness of the component and the process-induced residual stresses. For instance, it has been well demonstrated that lack-of-fusion (LoF) pores produced in the selective laser melting (SLM) AM process can significantly limit the fatigue performance of the material. Although two-dimensional (2D) models exist to predict the 2D profiles of LoF pores, the 2D pore profiles cannot be directly inserted into a three-dimensional (3D) microstructure domain that is output from several prevailing process simulation packages. A few commercial packages that simulate the SLM process can predict LoF pores in a 3D domain, but the morphologies of LoF pores are voxelated and hence do not capture sharp corners of the pores, thereby obviating their use in fatigue crack initiation studies. In order to address the aforementioned gaps, a high-fidelity model that predicts not only the volume fraction, but also the explicit 3D morphologies and spatial distributions of LoF pores has been developed using a computer aided design-based environment. The model has been partially validated for Ti-6Al-4V alloy by comparing the predictions of the volume fraction of LoF pores predicted by the model with experimental data obtained from the literature. Absolute error in predicted volume fraction of LoF pores varied between 5.16% and 1.87% for energy density values between 13 J/mm3 and 45 J/mm3 where a significant amount (over 3% volume fraction) of LoF porosity was measured. The absolute error was within 1.87% for energy density values greater than 45 J/mm3.

Saikumar R. Yeratapally↗
NASA NTRS2013

The Mars Science Laboratory (MSL) MMRTG In-Flight: A Power Update

The MSL Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) was fueled on October 28, 2008 by the Department Of Energy (DOE) in preparation for a late 2009 launch. Shortly after, the MSL launch was delayed approximately 2 years until 2011. The fueled MMRTG was placed in storage to await the new date for liftoff. Occasional measurements of the MMRTG's power output were taken and compared with power predictions that pre-dated fueling. An error in the predictive models was quickly recognized and remedied. The resultant predictions, while improved, carried significant uncertainty. This uncertainty did not deter the launch of MSL, but did alter the planned mission on the surface of Mars. Once launched, the MSL spacecraft provided a hi-fidelity telemetry stream measuring the generator's electrical and thermal performance. These data were used to update the predictive models and a new prediction of the performance of the MMRTG on the surface of Mars was run just before Entry, Descent, and Landing (EDL) at Mars. The MSL MMRTG is working extremely well, providing power above predictions and operating within its flight allowable temperature limits. The generator was producing approximately 114 W at the beginning of the surface mission. This paper will elaborate on power modeling for the MSL MMRTG along with a review of some of the data recorded from the MSL cruise to Mars, EDL, and the early days of the surface mission.

thermoelectric↗
DOE OSTI2020

The Impact of Nuclear Physics Uncertainties on Galactic Chemical Evolution Predictions

Modeling the evolution of the elements in the Milky Way is a multidisciplinary and challenging task. In addition to simulating the ~13 billion years evolution of our Galaxy, chemical evolution simulations must keep track of the elements synthesized and ejected from every astrophysical site of interest (e.g., supernova, compact binary merger). The elemental abundances of such ejecta, which are a fundamental input for chemical evolution codes, are usually taken from theoretical nucleosynthesis calculations performed by the nuclear astrophysics community. Therefore, almost all chemical evolution predictions rely on the nuclear physics behind those calculations. In this proceedings article, we highlight the impact of nuclear physics uncertainties on galactic chemical evolution predictions. We demonstrate that nuclear physics and galactic evolution uncertainties both have a significant impact on interpreting the origin of neutron-capture elements in our Solar System. Those results serve as a motivation to create and maintain collaborations between the fields of nuclear astrophysics and galaxy evolution.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1990

A study of turbulence models for prediction of transitional boundary layers

Calculations of two-dimensional transitional boundary layer flows in zero and favorable pressure gradients are presented. The major focus is on the evaluation of current turbulence models to predict quantities such as skin-friction and heat transfer coefficients. Three turbulence models using the mixing length concept along with a one-equation model are considered. These models are tested by comparison with the experiments of Blair and Werle, who investigated flows over a heated flat plate for various levels of free-stream turbulence.

Abid, Ridha↗
DOE OSTI2020

Combining mechanistic and machine learning models for predictive engineering and optimization of tryptophan metabolism

Abstract Through advanced mechanistic modeling and the generation of large high-quality datasets, machine learning is becoming an integral part of understanding and engineering living systems. Here we show that mechanistic and machine learning models can be combined to enable accurate genotype-to-phenotype predictions. We use a genome-scale model to pinpoint engineering targets, efficient library construction of metabolic pathway designs, and high-throughput biosensor-enabled screening for training diverse machine learning algorithms. From a single data-generation cycle, this enables successful forward engineering of complex aromatic amino acid metabolism in yeast, with the best machine learning-guided design recommendations improving tryptophan titer and productivity by up to 74 and 43%, respectively, compared to the best designs used for algorithm training. Thus, this study highlights the power of combining mechanistic and machine learning models to effectively direct metabolic engineering efforts.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Data-driven prediction of geometry- and toolpath sequence-dependent intra-layer process conditions variations in laser powder bed fusion

Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.

42 ENGINEERING↗
DOE OSTI2017

Data-Driven Nonlinear Subspace Modeling for Prediction and Control of Molten Iron Quality Indices in Blast Furnace Ironmaking

Blast furnace (BF) in ironmaking is a nonlinear dynamic process with complicated physical-chemical reactions, where multi-phase and multi-field coupling and large time delay occur during its operation. In BF operation, the molten iron temperature (MIT) as well as Si, P and S contents of molten iron are the most essential molten iron quality (MIQ) indices, whose measurement, modeling and control have always been important issues in metallurgic engineering and automation field. This paper develops a novel data-driven nonlinear state space modeling for the prediction and control of multivariate MIQ indices by integrating hybrid modeling and control techniques. First, to improve modeling efficiency, a data-driven hybrid method combining canonical correlation analysis and correlation analysis is proposed to identify the most influential controllable variables as the modeling inputs from multitudinous factors would affect the MIQ indices. Then, a Hammerstein model for the prediction of MIQ indices is established using the LS-SVM based nonlinear subspace identification method. Such a model is further simplified by using piecewise cubic Hermite interpolating polynomial method to fit the complex nonlinear kernel function. Compared to the original Hammerstein model, this simplified model can not only significantly reduce the computational complexity, but also has almost the same reliability and accuracy for a stable prediction of MIQ indices. Last, in order to verify the practicability of the developed model, it is applied in designing a genetic algorithm based nonlinear predictive controller for multivariate MIQ indices by directly taking the established model as a predictor. Industrial experiments show the advantages and effectiveness of the proposed approach.

Blast furnace (BF)↗
NASA NTRS1992

AMTEC system performance studies using the detailed electrode kinetic and transport model

A detailed electrochemical model of the alkali metal thermoelectric converter (AMTEC) electrode and current collector grid has been developed recently. Comparative evaluations of the resulting differences in model predictions reveal that the new detailed model predicts up to 50 percent higher electrode power densities at condenser operating temperatures above 600 K. The new model, with experimentally determined parameters, was used to recalculate the projected system performance of previously reported 1- and 100-kWe AMTEC space power systems that had incorporated earlier electrolyte/electrode models. It was found that when the detailed model was used to determine the electrode power densities, enhanced specific power and efficiencies are predicted.

Sievers, Robert K.↗
DOE OSTI2017

Regression-based reduced-order models to predict transient thermal output for enhanced geothermal systems

Reduced-order modeling is a promising approach, as many phenomena can be described by a few parameters/mechanisms. An advantage and attractive aspect of a reduced-order model is that it is computational inexpensive to evaluate when compared to running a high-fidelity numerical simulation. A reduced-order model takes couple of seconds to run on a laptop while a high-fidelity simulation may take couple of hours to run on a high-performance computing cluster. The goal of this paper is to assess the utility of regression-based reduced-order models (ROMs) developed from high-fidelity numerical simulations for predicting transient thermal power output for an enhanced geothermal reservoir while explicitly accounting for uncertainties in the subsurface system and site-specific details. Numerical simulations are performed based on equally spaced values in the specified range of model parameters. Key sensitive parameters are then identified from these simulations, which are fracture zone permeability, well/skin factor, bottom hole pressure, and injection flow rate. We found the fracture zone permeability to be the most sensitive parameter. The fracture zone permeability along with time, are used to build regression-based ROMs for the thermal power output. The ROMs are trained and validated using detailed physics-based numerical simulations. Finally, predictions from the ROMs are then compared with field data. We propose three different ROMs with different levels of model parsimony, each describing key and essential features of the power production curves. The coefficients in the proposed regression-based ROMs are developed by minimizing a non-linear least-squares misfit function using the Levenberg–Marquardt algorithm. The misfit function is based on the difference between numerical simulation data and reduced-order model. ROM-1 is constructed based on polynomials up to fourth order. ROM-1 is able to accurately reproduce the power output of numerical simulations for low values of permeabilities and certain features of the field-scale data. ROM-2 is a model with more analytical functions consisting of polynomials up to order eight, exponential functions and smooth approximations of Heaviside functions, and accurately describes the field-data. At higher permeabilities, ROM-2 reproduces numerical results better than ROM-1, however, there is a considerable deviation from numerical results at low fracture zone permeabilities. ROM-3 consists of polynomials up to order ten, and is developed by taking the best aspects of ROM-1 and ROM-2. ROM-1 is relatively parsimonious than ROM-2 and ROM-3, while ROM-2 overfits the data. ROM-3 on the other hand, provides a middle ground for model parsimony. Based on R 2 -values for training, validation, and prediction data sets we found that ROM-3 is better model than ROM-2 and ROM-1. For predicting thermal drawdown in EGS applications, where high fracture zone permeabilities (typically greater than 10 –15 m 2 ) are desired, ROM-2 and ROM-3 outperform ROM-1. As per computational time, all the ROMs are 10 4 times faster when compared to running a high-fidelity numerical simulation. In conclusion, this makes the proposed regression-based ROMs attractive for real-time EGS applications because they are fast and provide reasonably good predictions for thermal power output.

58 GEOSCIENCES↗
DOE OSTI2024

Dynamic data-driven multiscale modeling for predicting the degradation of a 316L stainless steel nuclear cladding material

Here, we have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE↗
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↗
NASA NTRS1981

Multi-parameter yield zone model for predicting spectrum crack growth

A phenomenological load interaction model referred to as the Multi-Parameter Yield Zone model is presented which accounts for crack growth retardation caused by previous overloads, acceleration due to current overloads, and underload effects. In the present model, load interaction effects are calculated utilizing a residual stress intensity concept. Crack growth retardation and acceleration are accounted for by decreasing or increasing, respectively, the effective stress ratio used in a modified Forman's (1967) crack growth equation. Results of spectrum crack growth predictions for 2219-T851 aluminum are presented.

Johnson, W. S.↗
NASA NTRS2015

Estimation of Aerosol Optical Depth at Different Wavelengths by Multiple Regression Method

This study aims to investigate and establish a suitable model that can help to estimate aerosol optical depth (AOD) in order to monitor aerosol variations especially during non-retrieval time. The relationship between actual ground measurements (such as air pollution index, visibility, relative humidity, temperature, and pressure) and AOD obtained with a CIMEL sun photometer was determined through a series of statistical procedures to produce an AOD prediction model with reasonable accuracy. The AOD prediction model calibrated for each wavelength has a set of coefficients. The model was validated using a set of statistical tests. The validated model was then employed to calculate AOD at different wavelengths. The results show that the proposed model successfully predicted AOD at each studied wavelength ranging from 340 nm to 1020 nm. To illustrate the application of the model, the aerosol size determined using measure AOD data for Penang was compared with that determined using the model. This was done by examining the curvature in the ln [AOD]-ln [wavelength] plot. Consistency was obtained when it was concluded that Penang was dominated by fine mode aerosol in 2012 and 2013 using both measured and predicted AOD data. These results indicate that the proposed AOD prediction model using routine measurements as input is a promising tool for the regular monitoring of aerosol variation during non-retrieval time.

Tan, Fuyi↗
NASA NTRS2008

Wake Vortex Inverse Model User's Guide

NorthWest Research Associates (NWRA) has developed an inverse model for inverting landing aircraft vortex data. The data used for the inversion are the time evolution of the lateral transport position and vertical position of both the port and starboard vortices. The inverse model performs iterative forward model runs using various estimates of vortex parameters, vertical crosswind profiles, and vortex circulation as a function of wake age. Forward model predictions of lateral transport and altitude are then compared with the observed data. Differences between the data and model predictions guide the choice of vortex parameter values, crosswind profile and circulation evolution in the next iteration. Iterations are performed until a user-defined criterion is satisfied. Currently, the inverse model is set to stop when the improvement in the rms deviation between the data and model predictions is less than 1 percent for two consecutive iterations. The forward model used in this inverse model is a modified version of the Shear-APA model. A detailed description of this forward model, the inverse model, and its validation are presented in a different report (Lai, Mellman, Robins, and Delisi, 2007). This document is a User's Guide for the Wake Vortex Inverse Model. Section 2 presents an overview of the inverse model program. Execution of the inverse model is described in Section 3. When executing the inverse model, a user is requested to provide the name of an input file which contains the inverse model parameters, the various datasets, and directories needed for the inversion. A detailed description of the list of parameters in the inversion input file is presented in Section 4. A user has an option to save the inversion results of each lidar track in a mat-file (a condensed data file in Matlab format). These saved mat-files can be used for post-inversion analysis. A description of the contents of the saved files is given in Section 5. An example of an inversion input file, with preferred parameters values, is given in Appendix A. An example of the plot generated at a normal completion of the inversion is shown in Appendix B.

Lai, David↗
DOE OSTI2016

Uncertainty Quantification and Comparison of Weld Residual Stress Measurements and Predictions.

In pressurized water reactors, the prevention, detection, and repair of cracks within dissimilar metal welds is essential to ensure proper plant functionality and safety. Weld residual stresses, which are difficult to model and cannot be directly measured, contribute to the formation and growth of cracks due to primary water stress corrosion cracking. Additionally, the uncertainty in weld residual stress measurements and modeling predictions is not well understood, further complicating the prediction of crack evolution. The purpose of this document is to develop methodology to quantify the uncertainty associated with weld residual stress that can be applied to modeling predictions and experimental measurements. Ultimately, the results can be used to assess the current state of uncertainty and to build confidence in both modeling and experimental procedures. The methodology consists of statistically modeling the variation in the weld residual stress profiles using functional data analysis techniques. Uncertainty is quantified using statistical bounds (e.g. confidence and tolerance bounds) constructed with a semi-parametric bootstrap procedure. Such bounds describe the range in which quantities of interest, such as means, are expected to lie as evidenced by the data. The methodology is extended to provide direct comparisons between experimental measurements and modeling predictions by constructing statistical confidence bounds for the average difference between the two quantities. The statistical bounds on the average difference can be used to assess the level of agreement between measurements and predictions. The methodology is applied to experimental measurements of residual stress obtained using two strain relief measurement methods and predictions from seven finite element models developed by different organizations during a round robin study.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Milestone 1.2.10: Steady-state H 2 “roll over” point data for aluminum alloys 1100 and 6061

Extended (> 50 years) dry storage is being evaluated by the U.S. Department of Energy (DOE) for the disposition of ~ 18 metric tons of aluminum-clad spent nuclear fuel (ASNF). Transition of the current ASNF inventory into dry storage—using the standard DOE canister—necessitates a rigorous, predictive understanding of the long-term physical and chemical factors that may influence the integrity of the proposed storage canister, including radiolytic molecular hydrogen (H 2 ) generation. Current model predictions employ initial radiolytic yields of H 2 , the values of which change as the cladding’s H 2 -precursor inventory is depleted and H 2 itself becomes progressively more involved in radiolytic and surface dissociation processes. Consequently, the absorbed radiation dose that this steady-state H 2 yield corresponds to is essential for the evaluation and improvement of model predictions. Here, we report our findings on the long-term generation of H 2 from the gamma irradiation (≤ 36 MGy) of corroded AA1100 and AA6061 coupons in helium environments at ambient temperature and ~ 50% RH. Our findings show that AA1100 systems reached steady-state by ~ 36 MGy, while higher doses were necessary for AA6061 systems. This discrepancy was attributed to the AA6061 coupons developing a thicker corrosion layer that led to the trapping of H 2 and its precursors, and potentially additional chemistries, ultimately delaying the depletion of H 2 precursors and the system’s “roll over” point. Further, current model predictions—based on previous AA1100 data—do not show steady-state attainment until above 120 MGy, which is not the case for the AA1100 data collected here. Consequently, the new alloy dependent data presented here are important for the continued improvement of predictive computer models for evaluating the feasibility of extended storage of ASNF in helium backfilled canisters.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
NASA NTRS1994

The application of Newman crack-closure model to predicting fatigue crack growth

Newman crack-closure model and the relevant crack growth program were applied to the analysis of crack growth under constant amplitude and aircraft spectrum loading on a number of aluminum alloy materials. The analysis was performed for available test data of 2219-T851, 2024-T3, 2024-T351, 7075-T651, 2324-T39, and 7150-T651 aluminum materials. The results showed that the constraint factor is a significant factor in the method. The determination of the constraint factor is discussed. For constant amplitude loading, satisfactory crack growth lives could be predicted. For the above aluminum specimens, the ratio of predicted to experimental lives, Np/Nt, ranged from 0.74 to 1.36. The mean value of Np/Nt was 0.97. For a specified complex spectrum loading, predicted crack growth lives are not in very good agreement with the test data. Further effort is needed to correctly simulate the transition between plane strain and plane stress conditions, existing near the crack tip.

Si, Erjian↗