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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Convergent Manufacturing of Large-Scale Components for Nuclear Applications, via Additive Manufacturing and Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy (PM)–hot isostatic pressing (PM-HIP) has long been recognized as a powerful route for producing fully dense, near net shape metallic components. By consolidating powders under high temperature and pressure, HIP provides isotropic properties, uniform microstructures, and scalability to complex geometries that are vital for sectors such as aerospace, energy, and nuclear power. Yet despite these advantages, the technology has remained constrained by costly trial and error canister fabrication, limitations of conventional forging, and incomplete knowledge about how the canister design influences final part properties. Additive manufacturing (AM), by contrast, thrives on design freedom and geometric flexibility but struggles with speed, scalability, and cost when applied to very large structures. The research presented in this report investigated how a convergent manufacturing approach, combining AM with PM-HIP, can merge the strengths of both technologies, leveraging AM’s flexibility for canister design and HIP’s consolidation capability to deliver reliable, large, and complex parts. The work progressed through three case studies that built on one another in scale and complexity. Small cylindrical canisters fabricated by conventional methods, laser powder bed fusion, and directed energy deposition were filled with stainless steel powders and subjected to HIP. The resulting parts demonstrated near-full density and mechanical properties on par with wrought stainless steel, showing for the first time that AM canisters can be a direct substitute for conventional ones without sacrificing quality. The next step involved a medium-scale, noncentrosymmetric T-valve, which is an enclosed, multibranch geometry that tested the limits of AM + PM-HIP integration. The T-valve achieved predictable shrinkage and uniform densification, confirming feasibility for enclosed designs. However, this study also revealed oxide inclusions and interfacial challenges at the AM + HIP boundary, underscoring the critical importance of controlling interface chemistry and employing robust, in situ strategies, such as melt pool monitoring and thermal monitoring, coupled with nondestructive evaluation techniques such as x-ray computed tomography. Finally, the effort culminated in fabricating a large-scale impeller weighing nearly 2000 lb and spanning 5 ft in diameter. Produced via multirobot wire arc AM and hot isostatic pressed to near-full density, the impeller validated industrial-scale feasibility. Predictive models closely matched experimental shrinkage, tensile properties were spatially uniform across the component, and the AM + PM-HIP interface proved mechanically sound despite the presence of oxide-decorated prior particle boundaries. This large-scale demonstration is a major milestone, showing that hybrid AM + PM‑HIP can reliably deliver components at reactor-relevant scales. Collectively, these studies charted a logical pathway: small-scale work built scientific confidence, medium-scale work highlighted opportunities and challenges, and large-scale work proved industrial impact. The overarching conclusion of this report is that AM + PM-HIP should not be seen as a replacement for forging but as a complementary pathway that provides the US with flexibility, resilience, and new options for manufacturing nuclear-grade components. Looking ahead, several directions emerge as critical to sustaining progress. Predictive modeling must become faster, more accessible, and more accurate, with digital twins and machine learning reducing reliance on trial and error. Powders and alloys must be optimized for HIP, with improved cleanliness, reduced oxides, and tailored chemistries that enhance creep, fatigue, and irradiation resistance. Interfaces between AM and HIP regions must be better engineered through coatings, machining strategies, and surface treatments to mitigate oxide formation and ensure reliable bonding to explore opportunities for HIP of targeted compositional parts, as well as multimaterial HIP cladding applications. Monitoring and nondestructive evaluation need to expand, incorporating multimodal sensors, x-ray computed tomography, and real-time data integration through platforms such as Pelican. At the same time, the pathway to industrial adoption requires techno-economic analysis, machinability studies, and qualification frameworks aligned with industry and regulatory standards. Finally, workforce and academic engagement must be strengthened. Programs that train technicians and engineers for US Navy and US Department of Energy manufacturing challenges should be paired with academic partnerships to support fundamental research, with open sharing of non-export-controlled data to accelerate innovation and build the next generation of experts. In conclusion, this report demonstrates that hybrid AM + PM-HIP is scientifically viable and strategically important. By combining the design agility of AM with the consolidation strength of HIP and embedding modeling, monitoring, and workforce development, this approach provided a transformative new capability for US manufacturing. The path forward is clear: hybrid AM + PM-HIP is not just a promising research direction but is also potentially an industrially relevant pathway that can reshape how nuclear-grade components are designed, qualified, and deployed.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Human Error and the International Space Station: Challenges and Triumphs in Science Operations

Any system with a human component is inherently risky. Studies in human factors and psychology have repeatedly shown that human operators will inevitably make errors, regardless of how well they are trained. Onboard the International Space Station (ISS) where crew time is arguably the most valuable resource, errors by the crew or ground operators can be costly to critical science objectives. Operations experts at the ISS Payload Operations Integration Center (POIC), located at NASA's Marshall Space Flight Center in Huntsville, Alabama, have learned that from payload concept development through execution, there are countless opportunities to introduce errors that can potentially result in costly losses of crew time and science. To effectively address this challenge, we must approach the design, testing, and operation processes with two specific goals in mind. First, a systematic approach to error and human centered design methodology should be implemented to minimize opportunities for user error. Second, we must assume that human errors will be made and enable rapid identification and recoverability when they occur. While a systematic approach and human centered development process can go a long way toward eliminating error, the complete exclusion of operator error is not a reasonable expectation. The ISS environment in particular poses challenging conditions, especially for flight controllers and astronauts. Operating a scientific laboratory 250 miles above the Earth is a complicated and dangerous task with high stakes and a steep learning curve. While human error is a reality that may never be fully eliminated, smart implementation of carefully chosen tools and techniques can go a long way toward minimizing risk and increasing the efficiency of NASA's space science operations.

Harris, Samantha S.↗
DOE OSTI2024

Benchmarking Correlation-Consistent Basis Sets for Frequency-Dependent Polarizabilities with Multiresolution Analysis

This paper presents the first converged frequency-dependent HF polarizability results for general molecules, on a set of 89 closed-shell atoms and molecules. The solver employs multiresolution analysis (MRA) in a multiwavelet basis to compute both ground and response states to a guaranteed precision, which are validated against independent numerical grid calculations on atoms and linear molecules. The MRA ground-state energies and response properties are used to evaluate results in correlation-consistent basis sets up to 5Z augmented with either single or double diffuse functions and core-polarization functions. Systematic trends are revealed through consideration of chemical composition as well as the use of machine learning to cluster convergence trends, the latter suggesting the possibility of learning and correcting basis-set error.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Hamiltonian learning using machine-learning models trained with continuous measurements

Here, we build upon recent work on the use of machine-learning models to estimate Hamiltonian parameters using continuous weak measurement of qubits as input. We consider two settings for the training of our model: (1) supervised learning, where the weak-measurement training record can be labeled with known Hamiltonian parameters, and (2) unsupervised learning, where no labels are available. The first has the advantage of not requiring an explicit representation of the quantum state, thus potentially scaling very favorably to a larger number of qubits. The second requires the implementation of a physical model to map the Hamiltonian parameters to a measurement record, which we implement using an integrator of the physical model with a recurrent neural network to provide a model-free correction at every time step to account for small effects not captured by the physical model. We test our construction on a system of two qubits and demonstrate accurate prediction of multiple physical parameters in both the supervised context and the unsupervised context. We demonstrate that the model benefits from larger training sets, establishing that it is “learning,” and we show robustness regarding errors in the assumed physical model by achieving accurate parameter estimation in the presence of unanticipated single-particle relaxation.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Adaptive Methods for Radial Basis Functions

Radial basis functions (RBFs) are a powerful tool for constructing high-order accurate reduced representations of scattered data in arbitrary dimension and on manifolds. We present a method of constructing data approximations in which we utilize a functional tail to capture a global background profile and a RBF neural network (NN) to capture the smaller-scale features. In the RBF NN the RBF centers, matrix shape parameters were selected adaptively for each RBF. We also utilized a geodesic notion of distance on the manifold on which the data lies, e.g., the spherical geodesic for data on the sphere. Although each of these ideas have been been investigated separately in previous works, their combination into a single algorithm is novel. We defined a machine learning problem in which these properties are learned to minimize the data reduction error. We demonstrate the algorithm for applications of scattered data reduction in the plane and on the sphere.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1992

Discrete time learning control in nonlinear systems

In this paper digital learning control methods are developed primarily for use in single-input, single-output nonlinear dynamic systems. Conditions for convergence of the basic form of learning control based on integral control concepts are given, and shown to be satisfied by a large class of nonlinear problems. It is shown that it is not the gross nonlinearities of the differential equations that matter in the convergence, but rather the much smaller nonlinearities that can manifest themselves during the short time interval of one sample time. New algorithms are developed that eliminate restrictions on the size of the learning gain, and on knowledge of the appropriate sign of the learning gain, for convergence to zero error in tracking a feasible desired output trajectory. It is shown that one of the new algorithms can give guaranteed convergence in the presence of actuator saturation constraints, and indicate when the requested trajectory is beyond the actuator capabilities.

Longman, Richard W.↗
NASA NTRS1991

Search-based model identification of smart-structure damage

This paper describes the use of a combined model and parameter identification approach, based on modal analysis and artificial intelligence (AI) techniques, for identifying damage or flaws in a rotating truss structure incorporating embedded piezoceramic sensors. This smart structure example is representative of a class of structures commonly found in aerospace systems and next generation space structures. Artificial intelligence techniques of classification, heuristic search, and an object-oriented knowledge base are used in an AI-based model identification approach. A finite model space is classified into a search tree, over which a variant of best-first search is used to identify the model whose stored response most closely matches that of the input. Newly-encountered models can be incorporated into the model space. This adaptativeness demonstrates the potential for learning control. Following this output-error model identification, numerical parameter identification is used to further refine the identified model. Given the rotating truss example in this paper, noisy data corresponding to various damage configurations are input to both this approach and a conventional parameter identification method. The combination of the AI-based model identification with parameter identification is shown to lead to smaller parameter corrections than required by the use of parameter identification alone.

Glass, B. J.↗
NASA NTRS1987

Learning control for robotic manipulators with sparse data

Learning control algorithms have been proposed for error compensation in repetitive robotic manipulator tasks. It is shown that the performance of such control algorithms can be seriously degraded when the feedback data they use is relatively sparse in time, such as might be provided by vision systems. It is also shown that learning control algorithms can be modified to compensate for the effects of sparse data and thereby yield performance which approaches that of systems without limitations on the sensory information available for control.

Morita, Atsushi↗
DOE OSTI2024

SPIDARman: System-Level Physics-Informed Detection of Anomalies in Reactor Collected Data Considering Human Errors

In nuclear power plants (NPPs), anomalies arising from sensors or human errors (HEs) can undermine the performance and reliability of plant operations. Anomaly detection models can be employed to detect sensor errors and HEs. Additionally, physics-informed machine learning models can utilize the known physics of the system, as described by mathematical equations, to ensure that sensor values are consistent with physical laws. Hence, we propose SPIDARman: System-level Physics-Informed Detection of Anomalies in Reactor Collected Data Considering Human Errors, a holistic physics-informed anomaly detection approach based on generative adversarial networks (GANs) to detect anomalies in both automatically collected sensor data and manually collected surveillance data. Here we test our approach on data collected from a flow loop testbed, showcasing its potential to detect anomalies. Results demonstrate that the proposed model performs better than the baseline GAN-based models in detecting sensor and surveillance anomalies, suggesting the potential of physics-informed anomaly detection GAN models in NPPs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Stable Simulation of the Community Atmosphere Model Using Machine‐Learning Physical Parameterization Trained With Experience Replay

In recent years, machine learning (ML) models have been used to improve physical parameterizations of general circulation models (GCMs). A significant challenge of integrating ML models into GCMs is the online instability when they are coupled for long‐term simulation. We present a new strategy that demonstrates robust online stability when the physical parameterization package of an atmospheric GCM is replaced by a deep ML model. The method uses experience replay with a multistep training scheme of the ML model in which the model's own output at the previous time step is used in the training. Predicted physics tendencies in the replay buffer with the most recent errors in the training iterations are reused, making the ML model learn from its own errors. The training method reduces the gap between the offline and online environments of the ML model. The method is used to train the ML model as the physical parameterization of the Community Atmosphere Model (CAM5) with training data from the Multi‐scale Modeling Framework high resolution simulations. Three 6‐year online simulations of the CAM5 are carried out by using the ML physics package. The simulated spatial distributions of precipitation, surface temperature and zonally averaged atmospheric fields demonstrate overall better accuracy than that of the standard CAM5 and benchmark model even without the use of additional physical constraints or tuning. This work is the first to demonstrate a solution to address the online instability problem in climate modeling with ML physics by using experience replay.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Deep Learning Advances Arctic River Water Temperature Predictions

The accelerated warming in the Arctic poses serious risks to freshwater ecosystems by altering streamflow and river thermal regimes. However, limited research on Arctic River water temperatures exists due to data scarcity and the absence of robust methodologies, which often focus on large, major river basins. To address this, we leveraged the newly released, extensive AKTEMP data set and advanced machine learning techniques to develop a Long Short-Term Memory (LSTM) model. By incorporating ERA5-Land reanalysis data and integrating physical understanding into data-driven processes, our model advanced river water temperature predictions in ungauged, snow- and permafrost-affected basins in Alaska. Our model outperformed existing approaches in high-latitude regions, achieving a median Nash-Sutcliffe Efficiency of 0.95 and root mean squared error of 1.0°C. The LSTM model learned air temperature, soil temperature, solar radiation, and thermal radiation—factors associated with energy balance—were the most important drivers of river temperature dynamics. Soil moisture and snow water equivalent were highlighted as critical factors representing key processes such as thawing, melting, and groundwater contributions. Glaciers and permafrost were also identified as important covariates, particularly in seasonal river water temperature predictions. Our LSTM model successfully captured the complex relationships between hydrometeorological factors and river water temperatures across varying timescales and hydrological conditions. This scalable and transferable approach can be potentially applied across the Arctic, offering valuable insights for future conservation and management efforts.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1998

Preliminary Work for Examining the Scalability of Reinforcement Learning

Researchers began studying automated agents that learn to perform multiple-step tasks early in the history of artificial intelligence (Samuel, 1963; Samuel, 1967; Waterman, 1970; Fikes, Hart & Nilsonn, 1972). Multiple-step tasks are tasks that can only be solved via a sequence of decisions, such as control problems, robotics problems, classic problem-solving, and game-playing. The objective of agents attempting to learn such tasks is to use the resources they have available in order to become more proficient at the tasks. In particular, each agent attempts to develop a good policy, a mapping from states to actions, that allows it to select actions that optimize a measure of its performance on the task; for example, reducing the number of steps necessary to complete the task successfully. Our study focuses on reinforcement learning, a set of learning techniques where the learner performs trial-and-error experiments in the task and adapts its policy based on the outcome of those experiments. Much of the work in reinforcement learning has focused on a particular, simple representation, where every problem state is represented explicitly in a table, and associated with each state are the actions that can be chosen in that state. A major advantage of this table lookup representation is that one can prove that certain reinforcement learning techniques will develop an optimal policy for the current task. The drawback is that the representation limits the application of reinforcement learning to multiple-step tasks with relatively small state-spaces. There has been a little theoretical work that proves that convergence to optimal solutions can be obtained when using generalization structures, but the structures are quite simple. The theory says little about complex structures, such as multi-layer, feedforward artificial neural networks (Rumelhart & McClelland, 1986), but empirical results indicate that the use of reinforcement learning with such structures is promising. These empirical results make no theoretical claims, nor compare the policies produced to optimal policies. A goal of our work is to be able to make the comparison between an optimal policy and one stored in an artificial neural network. A difficulty of performing such a study is finding a multiple-step task that is small enough that one can find an optimal policy using table lookup, yet large enough that, for practical purposes, an artificial neural network is really required. We have identified a limited form of the game OTHELLO as satisfying these requirements. The work we report here is in the very preliminary stages of research, but this paper provides background for the problem being studied and a description of our initial approach to examining the problem. In the remainder of this paper, we first describe reinforcement learning in more detail. Next, we present the game OTHELLO. Finally we argue that a restricted form of the game meets the requirements of our study, and describe our preliminary approach to finding an optimal solution to the problem.

Clouse, Jeff↗
DOE OSTI2025

Accelerating Discovery of Atomistic Defects via Machine Learning

The quantification of defects such as vacancies in crystalline structures is a cornerstone of materials science research. Traditional efforts often rely on manual detection, a process that is time-intensive, prone to human error, and challenging to scale. Here we leverage machine learning (ML) methods to identify and quantify vacancies within a crystalline lattice, aiming to expedite detection while improving accuracy. Additionally, we explore the transferability of these ML techniques, identifying characteristics of atomistic imaging data that complicate this task. We show how the integration of ML can drive innovation, providing a powerful tool that will play an increasingly crucial role in the future of materials science.

2D materials↗
NASA NTRSDate not supplied

Avoiding Selection Bias in Generating Examples of Plans in the Presence of Heuristic Error

It is generally understood that heuristic error hurts the performance of search algorithms, measured in terms of search effort. Hence there is an interest in understanding how to reduce heuristic error. One way to do this is to learn a heuristic from a set of examples of plans generated offline, e.g. bootstrapping methods. In this paper, we consider how some methods for generating examples of plans may skew the training set in the presence of heuristic errors. Initial theoretical results show that duplicate detection is one source of selection bias in the canonical A* algorithm. We introduce a duplicate selection scheme for A* that avoids selection bias in generating cost-optimal examples, without compromising memory efficiency, and develop ideas in the satisficing setting. We evaluate our approach on n x m grids with multiple cost-optimal solutions and synthetic heuristic error. Finally, we attempt to extend these ideas to the problem of generating extreme examples of plans.

Alison S Paredes↗
DOE OSTI2026

A Hybrid Biophysical‐Machine Learning Framework for Diurnal Surface Energy Flux Estimation Using Proximal Sensing

Thermal infrared-based remote sensing of surface energy fluxes has traditionally relied on high spatial resolution satellite data with revisit frequencies on the order of weeks. In this study, we evaluate a biophysics-based analytical surface energy balance model for predicting latent energy ( LE ) and sensible heat ( H ) fluxes using proximal sensing observations. The Surface Temperature Initiated Closure (STIC1.2) model has been extensively validated across a wide range of spatial and temporal scales using various satellite-derived thermal infrared data sets. Here we extend this validation by applying STIC at sub-hourly temporal resolution over multiple growing seasons for four distinct agricultural systems. We further develop and evaluate novel STIC variants that incorporate machine learning (ML) techniques to eliminate the need for surface energy balance observations, specifically net radiation and soil heat flux, thereby enhancing model applicability in data-sparse settings. The integration of a ML component to estimate surface available energy is shown to have strong predictive performance for both LE (R 2 = 0.81–0.94) and H (R 2 = 0.46–0.72) across all agricultural systems examined here, demonstrating the potential of hybrid biophysical-machine learning approaches for surface energy balance modeling with minimal data requirements. This study concludes with a novel application of explainable machine learning (exML) to diagnose sources of model error. This exML framework attributes residual prediction errors to both model input variables and environmental drivers not explicitly included in the simulation experiments. This approach provides a new pathway for improving model design and integrating previously overlooked yet influential variables into future model iterations.

evapotranspiration↗