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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2026

Automated and High-Throughput Phase Separation Control for Supramolecular Polymer Blends Enabled by Machine Learning

Supramolecular polymer blends (SPBs) offer tunable morphologies that dictate their macroscopic properties, yet their rational design is limited by the absence of predictive structure−morphology models. Here, we introduce a data-driven highthroughput workflow that integrates modular polymer synthesis, robotic formulation, automated morphology characterization, and machine learning (ML) for accelerated SPB discovery. Using a plug-and-play synthetic strategy, 33 hydrogen-bonding endfunctional homopolymers were prepared and orthogonally combined to generate 260 SPBs in 1 day. A fully automated atomic force microscopy (AFM) pipeline enabled systematic imaging, producing 2340 morphology data sets with minimal human intervention. Domain spacings were extracted through complementary imageprocessing methods and used to train ML models. A support vector regression (SVR) model accurately predicted target phase-separation sizes (50, 100, and 150 nm), which were experimentally validated. This work demonstrates the power of coupling high-throughput experimentation with ML to accelerate morphology discovery and provides one of the first large-scale experimental data sets for supramolecular polymer systems.

ML-guided polymer design↗
DOE OSTI2024

Leveraging design of experiments to build chemometric models for the quantification of uranium (VI) and HNO3 by Raman spectroscopy

Partial least squares regression (PLSR) and support vector regression (SVR) models were optimized for the quantification of U(VI) (10–320 g L −1 ) and HNO 3 (0.6–6 M) by Raman spectroscopy with optimized calibration sets chosen by optimal design of experiments. The designed approach effectively minimized the number of samples in the calibration set for PLSR and SVR by selecting sample concentrations with a quadratic process model, despite complex confounding and covarying spectral features in the spectra. The top PLS2 model resulted in percent root mean square errors of prediction for U(VI), HNO 3 , and NO 3 − of 3.7%, 3.6%, and 2.9%, respectively. PLS1 models performed similarly despite modeling an analyte with a majority linear response (i.e., uranyl symmetric stretch) and another with more covarying vibrational modes (i.e., HNO 3 ). Partial least squares (PLS) model loadings and regression coefficients were evaluated to better understand the relationship between weaker Raman bands and covarying spectral features. Support vector machine models outperformed PLS1 models, resulting in percent root mean square error of prediction values for U(VI) and HNO 3 of 1.5% and 3.1%, respectively. The optimal nonlinear SVR model was trained using a similar number of samples (11) compared with the PLSR model, even though PLS is a linear modeling approach. The generic D-optimal design presented in this work provides a robust statistical framework for selecting training set samples in disparate two-factor systems. This approach reinforces Raman spectroscopy for the quantification of species relevant to the nuclear fuel cycle and provides a robust chemometric modeling approach to bolster online monitoring in challenging process environments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Parameter uncertainties for imperfect surrogate models in the low-noise regime

Abstract Bayesian regression determines model parameters by minimizing the expected loss, an upper bound to the true generalization error. However, this loss ignores model form error, or misspecification, meaning parameter uncertainties are significantly underestimated and vanish in the large data limit. As misspecification is the main source of uncertainty for surrogate models of low-noise calculations, such as those arising in atomistic simulation, predictive uncertainties are systematically underestimated. We analyze the true generalization error of misspecified, near-deterministic surrogate models, a regime of broad relevance in science and engineering. We show that posterior parameter distributions must cover every training point to avoid a divergence in the generalization error and design a compatible ansatz which incurs minimal overhead for linear models. The approach is demonstrated on model problems before application to thousand-dimensional datasets in atomistic machine learning. Our efficient misspecification-aware scheme gives accurate prediction and bounding of test errors in terms of parameter uncertainties, allowing this important source of uncertainty to be incorporated in multi-scale computational workflows.

Swinburne, Thomas D. (ORCID:0000000232554257)↗
DOE OSTI2024

Geographical Insights into Suicide Mortality Through Spatial Machine Learning

Suicide mortality is a leading cause of death in the United States, with an upward trend that emphasizes its significance as a public health issue. Previous research has employed global models like ordinary least squares (OLS) regression and local models such as geographically weighted regression (GWR). While local models are useful for analyzing spatial variations in suicide mortality, they share limitations with traditional global models, particularly about their inability to handle multi-collinearity and non-linear relationships. Machine learning approaches, like random forests (RF), can address some of these limitations but often fail to account for spatial variability. This gap highlights the need for spatial ML models specifically designed to tackle suicide mortality. This research seeks to fill this void by using a geographically weighted random forest model (GWRF) to examine the associations between county-level suicide mortality in the U.S. from 2010 to 2020 and various social and environmental determinants of health. A key aspect of our methodology is disciplined feature selection, which reduces the pool of explanatory variables by about 90%. This refinement enhances the explanatory power of both global (R2 improved from 0.59 to 0.67) and local (R2 improved from 0.64 to 0.67) RF models while reducing their run times. An analysis of the importance scores for these selected features reveals that the drivers of suicide mortality vary by context. Thus, to effectively address regional disparities and inform targeted public health interventions, a holistic approach that incorporates multiple county-level characteristics is essential.

Lebakula, Viswadeep [ORNL] (ORCID:0000000152935914↗
DOE OSTI2026

Predictive Model for Starlink Maritime Performance Using Multi-Horizon RandomForest

Low Earth orbit (LEO) satellite systems have become a crucial enabler of broadband access for maritime industries, where traditional networks are unavailable. However, the high mobility of LEO constellations and constantly changing weather conditions result in unpredictable link fluctuations, limiting the ability of maritime platforms to plan bandwidth usage proactively. To the best of our knowledge, no prior work has developed a short-term predictive model for maritime LEO connectivity using real experimental field measurements. This paper proposes a data-driven forecasting model that predicts future downlink throughput using multi-horizon RandomForest regression. The model is trained using real experimental coastal measurement data incorporating recent throughput history, network-layer indicators, and environmental variables. The proposed approach reduces mean absolute error by approximately 31% compared to a persistence baseline for 15-minute horizons. It maintains a measurable improvement at 30 minutes, despite increased stochasticity. These findings confirm that proactive bandwidth awareness is feasible on maritime platforms and can effectively support operational decisions such as adaptive streaming, routing, and resource scheduling. The performance gap between forecasting horizons also highlights the need for expanded offshore datasets to improve prediction robustness under harsher maritime environments.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Model-based economic analysis under uncertainty for PFAS treatment by granular activated carbon and ion exchange technologies

Recent drinking water regulations have imposed the need for per- and polyfluoroalkyl substances (PFAS) remediation. In response, treatment facilities may be required to retrofit existing treatment schemes to treat PFAS below maximum contaminant levels (MCLs). Adsorption technologies such as granular activated carbon (GAC) and ion exchange (IX) have been demonstrated to be effective; however, there are limited techno-economic metrics available which provide guidance on technology selection and design for diverse PFAS-containing source water conditions. Process systems engineering (PSE) tools which can traditionally perform these analyses are hindered by the data availability, model validity, and understanding of treatment phenomena for emerging contaminants. This work employs published data regressions, statistical models, process models, techno-economic analyses, and other process systems tools in a model-based uncertainty framework to consider the limitations of emerging contaminant research. Through this analysis framework, economic results are provided as probabilistic distributions based on the uncertainty of the models and diverse conditions that treatment facilities experience.

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

Machine learning for the redox potential prediction of molecules in organic redox flow battery

Here, organic redox flow batteries (ORFB) are recognized as an innovative technology for the large-scale storage of renewable energy. The redox potential of organic redox-active molecules plays a vital role in their performance. Advanced screening techniques like high-throughput experiment and machine learning (ML) have significantly enhanced organic material performance and transformed the field of ORFB. However, the scarcity of experimental data poses a considerable challenge for ML model development in this domain. In our study, we developed lightweight graph-based Gaussian process regression (GPR) models with GPU-accelerated marginalized graph kernel and hybrid kernel to predict the redox potentials of organic redox-active molecules for ORFBs, specifically focusing on small datasets. To evaluate model accuracy, we created a new experimental database of organic redox-active molecules by the data from hundreds of published papers and assembled previous computational datasets. We also considered some key parameters, such as pH conditions and solvent type, to assess their impact on redox potential prediction. Our GPR model predicted redox potentials with high accuracy across all datasets using minimal training data. The study provides powerful tools for molecule screening and design and delivers valuable guidance on designing training datasets for costly experiments.

25 ENERGY STORAGE↗
DOE OSTI2024

Unveiling the transferability of PLSR models for leaf trait estimation: lessons from a comprehensive analysis with a novel global dataset

Leaf traits are essential for understanding many physiological and ecological processes. Partial least squares regression (PLSR) models with leaf spectroscopy are widely applied for trait estimation, but their transferability across space, time, and plant functional types (PFTs) remains unclear. We compiled a novel dataset of paired leaf traits and spectra, with 47 393 records for >700 species and eight PFTs at 101 globally distributed locations across multiple seasons. Using this dataset, we conducted an unprecedented comprehensive analysis to assess the transferability of PLSR models in estimating leaf traits. While PLSR models demonstrate commendable performance in predicting chlorophyll content, carotenoid, leaf water, and leaf mass per area prediction within their training data space, their efficacy diminishes when extrapolating to new contexts. Specifically, extrapolating to locations, seasons, and PFTs beyond the training data leads to reduced R 2 (0.12–0.49, 0.15–0.42, and 0.25–0.56) and increased NRMSE (3.58–18.24%, 6.27–11.55%, and 7.0–33.12%) compared with nonspatial random cross-validation. The results underscore the importance of incorporating greater spectral diversity in model training to boost its transferability. These findings highlight potential errors in estimating leaf traits across large spatial domains, diverse PFTs, and time due to biased validation schemes, and provide guidance for future field sampling strategies and remote sensing applications.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Mining Product Reviews for Important Product Features of Refurbished iPhones

Problem: Remanufacturers want to increase consumer interest in refurbished products, which motivates the need to understand which product features are important to buyers of refurbished products such as mobile phones. Research Questions: This study addresses two questions. First, which product features are most important for buyers of refurbished iPhones? Second, how do those preferences differ from the preferences of buyers of new iPhones? Methods: Online reviews of iPhones are obtained and converted into a document–term matrix. Using this text model, three subsets of features are identified using statistical analysis of frequency of mention: most frequent, average, and least frequent. A logistic regression (LR) model is then used to identify which features are most predictive of whether a review is for a new or refurbished phone. Results: Buyers of refurbished phones mention battery health, screen/display, shell condition, and brand significantly more often than other features. Directly contrasting reviews of refurbished versus new phones shows that shell condition, brand, speaker, and charger are found to be the most predictive product features indicated in reviews for refurbished phones. Of those, the shell condition is significantly more predictive than the others. Implications: The results identify product features that remanufacturers of iPhones can emphasize to increase customer demand.

Anisi, Atefeh↗
DOE OSTI2025

Remote Americium Detection Using an Optical Sensor: A D-Optimal Strategy for Efficient PLS-Based Modeling

A fiber-optic visible–near-infrared absorption spectroscopy system in a glove box was demonstrated for remote quantification of Am(III) (0–500 µM) and HNO 3 (0.1–9 M) using partial least squares regression (PLSR) models. The sensor platform, featuring a simple plug-and-play spectrophotometer, can enable noninvasive, real-time monitoring of actinide process solutions. To establish a flexible PLSR model calibration strategy, a D-optimal design developed using Nd(III) in previous studies was successfully extended to an actinide system with Am(III) to effectively minimize sample set size while maintaining robust prediction performance. The results suggest strong spectral similarities between Nd(III) and Am(III) and validate Nd(III) as an effective optical surrogate for trivalent actinide species. This work also supports the generalizability of a D-optimal training set selection approach for two-factor systems. The PLS1 models for Am(III) and HNO 3 outperformed a PLS2 model and maintained reasonable performance in the presence of interfering U(VI). The resulting sensor system and multivariate approach provides a flexible and scalable solution for process monitoring, control, and safety in diverse nuclear applications.

actinide↗
DOE OSTI2024

Short-Term Probabilistic Solar Forecasting via Reinforcement Learning over ECMWF

In this paper, we present an innovative reinforcement learning approach for short-term solar forecasting, leveraging data from the European Centre for Medium-Range Weather Forecasts (ECMWF). The methodology begins with the application of the System Advisor Model (SAM) to transform various ECMWF numerical weather prediction members into predictive photovoltaic power generation. To enhance the precision of deterministic forecasting, we introduce a dynamic model selection algorithm based on Q-learning. This algorithm dynamically identifies and utilizes the most accurate ensemble member for forecasting purposes. Furthermore, we employ a support vector regression surrogate model with a Gaussian distribution to generate probabilistic forecasts, providing a holistic view of solar energy generation uncertainty. To expedite the training process and make it more practical for real-world applications, we integrate a rolling update workflow. This innovative workflow reduces the training period from months to a mere 19 days, making our method highly efficient. Numerical results of the case study show that in comparison to benchmark models, the proposed method improves the deterministic and probabilistic solar forecasting accuracy by up to 40.84% and 48.42%, respectively.

ensemble forecasting↗
DOE OSTI2024

Rapid and high-throughput determination of sorghum ( Sorghum bicolor ) biomass composition using near infrared spectroscopy and chemometrics

Compositional characterization of biomass is vital for the biofuel industry. Traditional wet chemistry-based methods for analyzing biomass composition are laborious, time-consuming, and require extensive use of chemical reagents as well as highly skilled personnel. In this study, near-infrared (NIR) spectroscopy was used to quickly assess the composition of above-ground vegetative biomass from 113 diverse, photoperiod-sensitive, biomass-type sorghum (Sorghum bicolor) accessions cultivated under field conditions in Central Illinois. Biomass samples were analyzed using NIR spectra collected in the spectral range of 867–2536 nm, with their chemical compositions determined following the National Renewable Energy Laboratory (NREL) protocol. Advanced spectral pre-treatment and band selection techniques were utilized to develop calibration models using partial least squares regression (PLSR). The models’ effectiveness was assessed through cross-validation and independent data tests. The predictions for moisture, ash, extractives, glucan, xylan, acid-soluble lignin (ASL), acid-insoluble lignin (AIL), and total lignin were accurate and reliable, demonstrating the capability of NIR spectroscopy to provide rapid and precise characterization of sorghum biomass. The results demonstrated that NIR spectroscopy is an efficient tool for rapidly characterizing sorghum biomass, making it a sustainable option for screening desirable feedstock for biofuel or bioproduct production.

09 BIOMASS FUELS↗
DOE OSTI2024

Data for Rapid and High-Throughput Determination of Sorghum ( Sorghum bicolor ) Biomass Composition using Near Infrared Spectroscopy and Chemometrics

Compositional characterization of biomass is vital for the biofuel industry. Traditional wet chemistry-based methods for analyzing biomass composition are laborious, time-consuming, and require extensive use of chemical reagents as well as highly skilled personnel. In this study, near-infrared (NIR) spectroscopy was used to quickly assess the composition of above-ground vegetative biomass from 113 diverse, photoperiod-sensitive, biomass-type sorghum ( Sorghum bicolor ) accessions cultivated under field conditions in Central Illinois. Biomass samples were analyzed using NIR spectra collected in the spectral range of 867–2536 nm, with their chemical compositions determined following the National Renewable Energy Laboratory (NREL) protocol. Advanced spectral pre-treatment and band selection techniques were utilized to develop calibration models using partial least squares regression (PLSR). The models’ effectiveness was assessed through cross-validation and independent data tests. The predictions for moisture, ash, extractives, glucan, xylan, acid-soluble lignin (ASL), acid-insoluble lignin (AIL), and total lignin were accurate and reliable, demonstrating the capability of NIR spectroscopy to provide rapid and precise characterization of sorghum biomass. The results demonstrated that NIR spectroscopy is an efficient tool for rapidly characterizing sorghum biomass, making it a sustainable option for screening desirable feedstock for biofuel or bioproduct production.

Biomass Analytics↗
DOE OSTI2024

On the predictability of turbulent fluxes from land: PLUMBER2 MIP experimental description and preliminary results

Accurate representation of the turbulent exchange of carbon, water, and heat between the land surface and the atmosphere is critical for modelling global energy, water, and carbon cycles in both future climate projections and weather forecasts. Evaluation of models' ability to do this is performed in a wide range of simulation environments, often without explicit consideration of the degree of observational constraint or uncertainty and typically without quantification of benchmark performance expectations. We describe a Model Intercomparison Project (MIP) that attempts to resolve these shortcomings, comparing the surface turbulent heat flux predictions of around 20 different land models provided with in situ meteorological forcing evaluated with measured surface fluxes using quality-controlled data from 170 eddy-covariance-based flux tower sites. Predictions from seven out-of-sample empirical models are used to quantify the information available to land models in their forcing data and so the potential for land model performance improvement. Sites with unusual behaviour, complicated processes, poor data quality, or uncommon flux magnitude are more difficult to predict for both mechanistic and empirical models, providing a means of fairer assessment of land model performance. When examining observational uncertainty, model performance does not appear to improve in low-turbulence periods or with energy-balance-corrected flux tower data, and indeed some results raise questions about whether the energy balance correction process itself is appropriate. In all cases the results are broadly consistent, with simple out-of-sample empirical models, including linear regression, comfortably outperforming mechanistic land models. In all but two cases, latent heat flux and net ecosystem exchange of CO 2 are better predicted by land models than sensible heat flux, despite it seeming to have fewer physical controlling processes. Land models that are implemented in Earth system models also appear to perform notably better than stand-alone ecosystem (including demographic) models, at least in terms of the fluxes examined here. The approach we outline enables isolation of the locations and conditions under which model developers can know that a land model can improve, allowing information pathways and discrete parameterisations in models to be identified and targeted for future model development.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Deconvoluting thermomechanical effects in X-ray diffraction data using machine learning

X-ray diffraction is ideal for probing the sub-surface state during complex or rapid thermomechanical loading of crystalline materials. However, challenges arise as the size of diffraction volumes increases due to spatial broadening and because of the inability to deconvolute the effects of different lattice deformation mechanisms. Here, we present a novel approach that uses combinations of physics-based modeling and machine learning to deconvolve thermal and mechanical elastic strains for diffraction data analysis. The method builds on a previous effort to extract thermal strain distribution information from diffraction data. The new approach is applied to extract the evolution of the thermomechanical state during laser melting of an Inconel 625 wall specimen which produces significant residual stress upon cooling. A combination of heat transfer and fluid flow, elasto-plasticity and X-ray diffraction simulations is used to generate training data for machine-learning (Gaussian process regression, GPR) models that map diffracted intensity distributions to underlying thermomechanical strain fields. First-principles density functional theory is used to determine accurate temperature-dependent thermal expansion and elastic stiffness used for elasto-plasticity modeling. The trained GPR models are found to be capable of deconvoluting the effects of thermal and mechanical strains, in addition to providing information about underlying strain distributions, even from complex diffraction patterns with irregularly shaped peaks.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Ventenata dubia projected to expand in the western United States despite future novel conditions

Abstract Distributions of both native and invasive species are expected to shift under future climate. Species distribution models (SDMs) are often used to explore future habitats, but sources of uncertainty including novel climate conditions may reduce the reliability of future projections. We explore the potential spread of the invasive annual grass ventenata ( Ventenata dubia ) in the western United States under both current and future climate scenarios using boosted regression tree models and 30 global climate models (GCMs). We quantify novel climate conditions, prediction variability arising from both the SDMs and GCMs, and the agreement among GCMs. Results demonstrate that currently suitable habitat is concentrated inside the invaded range of the northwest, but substantial habitat exists outside the invaded range in the Southern Rockies and southwestern US mountains. Future suitability projections vary greatly among GCMs, but GCMs commonly projected decreased suitability in the invaded range and increased suitability along higher elevations of interior mountainous areas. Climate novelty did not appear to undermine the prediction reliability in many cases where the climate–species relationship was fully represented by the occurrence data. GCM‐derived variability resulting from variation in future cool season precipitation and temperature seasonality was greatest in the Rocky Mountains. SDM‐derived variability was higher in currently suitable habitat, and few GCMs projections agreed that these areas would contain future suitable habitat. However, while prediction variability was high, many GCM projections agreed that parts of the Rocky, Wasatch, and Uinta Mountains would contain highly suitable habitat in the future. As disturbances in the interior mountains occur in coming decades, reducing some natural barriers to invasion, land managers, and conservationists will need to monitor for ventenata in post‐disturbance environments. Changes to invasion potential may not play out for several decades, but results related to current potential may have applications for early detection and rapid response planning.

Environmental Sciences & Ecology↗