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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Precision Polishing of Ablator Capsules via in situ Process Monitoring and Machine Learning–Based Optimization

In inertial confinement fusion (ICF) experiments seeking output gains of unity and beyond, the quality of the ablator capsule is paramount for minimizing the hydrodynamic mix that quenches the central hot spot. Defects in the form of foreign particles or missing mass on the surface and within the wall of the capsule are primary offenders. High-density carbon capsules made for ICF experiments at the National Ignition Facility are precision polished to achieve surface smoothness on the order of a few nanometers as well as to minimize isolated defects in the form of pits. Given the critical role of this process, we are developing smart manufacturing techniques with the goal of elevating the efficiency of this process. Our approach is to use MEMS (micro-electromechanical systems)–based sensors to capture the fine vibration signals generated during the polishing process and combine them with synchronized visual feedback as needed. Beyond using these sensors for process monitoring, we use specific deep learning methods to analyze the data and extract correlations with both the process parameters and the final performance of the polishing run. Here, in this work, we describe the multiple fronts we have explored in this regard and the results we have gotten so far. This approach promises to have the potential to ultimately provide real-time feedback that can be used to ensure the progress of the run as well as a means for faster optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

LDRD FY25 Program Overview

As Lawrence Livermore National Laboratory’s (LLNL’s) Laboratory Directed Research and Development (LDRD) program enters its fifth decade of leading-edge research and development, its impact and importance have never been stronger. The program continues to advance strategic investments in pioneering science, technology, and engineering, ensuring LLNL will be ready to deliver on our mission as it evolves over the coming decades. Investing in LDRD research, and the people who perform this critical work, gives LLNL the ability to sustain our role as a leader in the Department of Energy and National Nuclear Security Administration enterprise. The LDRD program enables high-risk, high-payoff research that anticipates emerging threats and future mission needs. By nurturing the ingenuity of the Lab’s greatest asset, its people, LDRD funding advances not only our research but also grows and nurtures our workforce: engaging future innovators with student mentoring, challenging postdoctoral researchers to apply their skills to support national security, and strengthening the leadership skills of early career staff. This annual report documents how LDRD investments advance LLNL’s science, technology, and engineering across our mission space. To assess LDRD’s impact we track both short and long-term metrics such as peer-reviewed publications, number of students, or professional fellows. In addition to reviewing these metrics, I encourage you to delve deeper into the breadth of science and technology that illustrate the strategic value of this research portfolio. For instance, a recent exploratory research project used advanced manufacturing to construct miniaturized three-dimensional ion traps for a quantum computer with reduced quantum error rates to enable applications that address national security missions and support basic science. Another project has delved into studying detonation by examining deflagration to enhance the safety and security of the nuclear weapons stockpile. LDRD researchers are also deploying AI agents on two of the world’s most powerful supercomputers to automate and accelerate inertial confinement fusion experiments. Other teams are delivering more accurate optical constants to enable improved validation for aluminum to advance atomic and molecular physics models. LDRD-driven discoveries of how metals deform under extreme conditions strengthen our ability to model and design materials for demanding national security environments. National security challenges are increasingly complex and continuously evolving. LDRD focuses our most innovative science and technology on these challenges, ensuring the Laboratory is developing creative, forward-leaning solutions for our nation and the world. The following pages feature highlights of published scientific advances, patents, and honors that stem from LDRD investments. As you read this report, I hope you will understand how these investments position the Laboratory, and our partners, to meet the demands of the decades ahead.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Lincoln Advanced Science and Engineering Reinforcement (LASER) program

Lincoln University, under the Lincoln Advanced Science and Engineering Reinforcement (LASER) Program, has identified and successfully recruited over 100 students for majors in technical fields. To date, over 70 percent of these students have completed or will complete technical degrees in engineering, physics, chemistry, and computer science. Of those completing the undergraduate degree, over 40 percent have gone on to graduate and professional schools. This success is attributable to well planned approaches to student recruitment, training, personal motivation, retention, and program staff. Very closely coupled to the above factors is a focus designed to achieve excellence in program services and student performance. Future contributions by the LASER Program to the pool of technical minority graduates will have a significant impact. This is already evident from the success of the students that began the first year of the program. With program plans to refine many of the already successful techniques, follow-on activities are expected to make even greater contributions to the availability of technically trained minorities. For example, undergraduate research exposure, broadened summer, and co-op work experiences will be enhanced.

Williams, Willie E.↗
DOE OSTI2021

A particle-in-cell code comparison for ion acceleration: EPOCH, LSP, and WarpX

There are now more Particle-in-Cell (PIC) codes than ever before that researchers use to simulate intense laser-plasma interactions. To date, there have been relatively few direct comparisons of these codes in the literature, especially for relativistic intensity lasers interacting with thin overdense targets. To address this we perform a code comparison of three PIC codes: EPOCH, LSP, and WarpX for the problem of laser-driven ion acceleration in a 2D(3v) geometry for a 10 20 W cm -2 intensity laser. We examine the plasma density, ion energy spectra, and laser-plasma coupling of the three codes and find strong agreement. We also run the same simulation 20 times with different random seeds to explore statistical fluctuations of the outputs. We then compare the execution times and memory usage of the codes (without “tuning” to improve performance) using between 1 and 48 processors on one node. We provide input files to encourage larger and more frequent code comparisons in this field.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Monitoring and prediction of porosity in laser powder bed fusion using physics-informed meltpool signatures and machine learning

In this work we accomplished the monitoring and prediction of porosity in laser powder bed fusion (LPBF) additive manufacturing process. This objective was realized by extracting physics-informed meltpool signatures from an in-situ dual-wavelength imaging pyrometer, and subsequently, analyzing these signatures via computationally tractable machine learning approaches. Porosity in LPBF occurs despite extensive optimization of processing conditions due to stochastic causes. Hence, it is essential to continually monitor the process with in-situ sensors for detecting and mitigating incipient pore formation. In this work a tall cuboid-shaped part (10 mm × 10 mm × 137 mm, material ATI 718Plus) was built with controlled porosity by varying laser power and scanning speed. This test caused various types of porosity, such as lack-of-fusion and keyhole formation, with varying degrees of severity in the part. The meltpool was continuously monitored using a dual-wavelength imaging pyrometer installed in the machine. Physically intuitive process signatures, such as meltpool length, temperature distribution, and ejecta (spatter) characteristics, were extracted from the meltpool images. Subsequently, relatively simple machine learning models, e.g., K-Nearest Neighbors, were trained to predict both the severity and type of porosity as a function of these physics-informed meltpool signatures. These models resulted in a prediction accuracy exceeding 95% (statistical F1-score). The same analysis was carried out with a complex, black-box deep learning convolutional neural network which directly used the meltpool images instead of physics-informed features. The convolutional neural network produced a comparable F1-score in the range of 89–97%. Finally, these results demonstrate that using pragmatic, physics-informed meltpool signatures within a simple machine learning model is as effective for flaw prediction in LPBF as using a complex and computationally demanding black-box deep learning model.

36 MATERIALS SCIENCE↗
DOE OSTI2025

S&TR July-August: Beyond Ignition

On December 5, 2022, Lawrence Livermore’s National Ignition Facility achieved the first-ever successful positive-gain ignition shot. This scientific advance, heralded worldwide, required a multidecadal effort to synthesize physics theory, laser technologies, computation and diagnostic capabilities, as well as engineering, materials development, and other inputs. The question, “Can ignition be achieved?” had been answered. Since then, the Laboratory has answered the question, “Can we do it again?” with additional ignition shots at increasing yield. Now Lawrence Livermore researchers ask, “Can we improve ignition outcomes?” for the benefit of the Stockpile Stewardship Program. Interrelated articles presenting the Laboratory’s ignition science, the role of supercomputing in achieving ignition, the evolution of diagnostic instruments to measure ignition data, and the ambitious steps required to realize a fusion energy future lead to one answer: “Yes, we can.”

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

An Electrical Resistance Diagnostic for Conductivity Monitoring in Laser Powder Bed Fusion

With the growing interest in metal additive manufacturing using laser powder bed fusion (LPBF), there is a need for advanced in-situ nondestructive evaluation (NDE) methods that can dynamically monitor manufacturing process-related variations, that can be used as a feedback mechanism to further improve the manufacturing process, leading to parts with improved microstructural properties and mechanical properties. Current NDE techniques either lack sensitivity beyond build layer, are costly or time-consuming, or are not compatible for in-situ integration. In this research, we develop an electrical resistance diagnostic for in-situ monitoring of powder fused regions during laser powder bed fusion printing. The technique relies on injecting current into the build plate and detecting voltage differences from conductive variations during printing using a simple, cheap four-point electrode array directly connected to the build plate. A computational model will be utilized to determine sensitivities of the approach, and preliminary experiments will be performed during the printing process to test the overall approach.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Benchmarking third-order cluster perturbation theory for electronically excited states

In this study, we investigate the reliability of cluster perturbation (CP) theory applied to the calculation of electronically excited states through a comprehensive benchmark. In CP theory, perturbative corrections are added to the properties of a parent excitation space, which converge toward the properties of a target excitation space. For the CPS(D-n) model, perturbative corrections through order n are added to the coupled cluster singles (CCS) excitation energies to target the coupled cluster singles and doubles (CCSD) excitation energies. Through a comparative analysis of excitation energy calculations across a diverse set of molecules and wavefunction methods, we present a comprehensive evaluation of the accuracy of the third-order CPS(D) model, CPS(D-3), in calculating excitation energies. Further, our findings demonstrate that CPS(D-3) is a reliable alternative to established methods, particularly CCSD, while systematically overestimating the excitation energies compared to high-level coupled cluster methods such as CC3. These results highlight the strengths and limitations of CPS(D-3), as well as the promising directions for its future development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗
DOE OSTI2022

Laser-based ultrasound interrogation of surface and sub-surface features in advanced manufacturing materials

Abstract Structures formed by advanced manufacturing methods increasingly require nondestructive characterization to enable efficient fabrication and to ensure performance targets are met. This is especially important for aerospace, military, and high precision applications. Surface acoustic waves (SAW) generated by laser-based ultrasound can detect surface and sub-surface defects relevant for a broad range of advanced manufacturing processes, including laser powder bed fusion (LPBF). In particular, an all-optical SAW generation and detection configuration can effectively interrogate laser melt lines. Here we report on scattered acoustic energy from melt lines, voids, and surface features. Sub-surface voids are also characterized using X-ray Computed Tomography (CT). High resolution CT results are presented and compared with SAW measurements. Finite difference simulations inform experimental measurements and analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Derivation of physical equations for high-speed laser welding using large language models

It is challenging to formulate complex physical phenomena that occur in a manufacturing process, particularly when the available data are limited, rendering conventional data-driven approaches ineffective. This study aims to predict humping onset in high-speed laser welding by introducing a novel framework, namely text-to-equations generative pre-trained transformer (T2EGPT). This method leverages the capabilities of large language models (LLMs), in combination with sparse experimental data and enriched literature data, to derive an interpretable and generalizable equation for predicting humping initiation. By capturing key correlations among physical parameters, T2EGPT generates a compact and dimensionless expression that accurately predicts hump formation. The equation reveals that humping arises from the interplay between inertia-driven backward melt flow and capillary-driven surface stabilization, where inertial forces drive molten metal backward and capillary forces resist surface deformation. Furthermore, compared to traditional data-driven models, T2EGPT demonstrates enhanced predictive accuracy and cross-material transferability. More broadly, this study highlights the potential of LLMs to integrate textual information with data-driven discovery, enabling the extraction of physical laws in data-scarce scientific domains.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Performance Analysis of PIConGPU: Particle-in-Cell on GPUs using NVIDIA’s NSight Systems and NSight Compute

PIConGPU, Particle In Cell on GPUs, is an open source simulations framework for plasma and laser-plasma physics used to develop advanced particle accelerators for radiation therapy of cancer, high energy physics and photon science. While PIConGPU has been optimized for at least 5 years to run well on NVIDIA GPU-based clusters, there has been limited exploration by the development team of potential scalability bottlenecks using recently updated and new tools including NVIDIA’s NVProf tool and the brand-new NVIDIA NSight Suite (Systems and Compute) tools. PIConGPU is a highly optimized application that runs production jobs at scale on a system Oak Ridge Leadership Facility’s (OLCF) Summit supercomputer (using the full machine at 4600 nodes; at 98% of GPU utilization on all ~28000 NVIDIA Volta GPUs). PIConGPU has been selected as one of the the eight applications for OLCF’s coveted Center for Accelerated Application Readiness (CAAR) program aimed at the facility’s Frontier supercomputer (OLCF’s first exascale system to launch in 2021), to partner with our vendors (primary vendors: AMD and Cray/HPE) ensuring that Frontier will be able to perform large-scale science when it opens to users in 2022. To this effect, performance engineers on the PIConGPU team wanted to dive deep into the application to understand at the finest granularity, which portions of the code could be further optimized to exploit the hardware on Summit at it’s maximum potential and also to elucidate which key kernels should be tracked and optimized for the CAAR effort to port this code to Frontier. Any bottlenecks that are observed via performance profiling on Summit are likely to also impact scalability on the Frontier-dev system and the Frontier Early Access (EA) system. Additionally, the engineers wanted to take a closer look at the newest NVIDIA profiling tools which allows us to identify the most useful features on these tools and will provide an opportunity to compare it to new AMD and Cray’s performance analysis tool releases and provide feedback to our vendor partners on what features are most important and mission critical for CAAR efforts. The primary goal of this report is to focus on the evaluation of PIConGPU’s most time-intensive kernels using NVProf and NSight Suite. Three kernels, Current Deposition (also known as Compute Current), Particle Push (Move and Mark), and Shift Particles are known to be some of the most time-consuming kernels in PIConGPU. The Current xi Deposition kernel and Particle Push kernel both set up the particle attributes for running any physics simulation with PIConGPU, so it is crucial to improve the performance of these two kernels. In this report, we measure single GPU metrics for the three kernels, offer high level takeaways from the conducted analysis, and compare the profiling data from NSight Compute to that of NVProf. This analysis was performed using a grid size of 240 x 272 x 224, and 10 time steps with the Mid-November Figure of Merit (FOM) run setup. The Traveling Wave Electron Acceleration (TWEAC) science case used in this run is a representative science case for PIConGPU. This execution can also be used for baseline analysis on AMD MI50/ MI60 systems. As of the time of writing, the PIConGPU application has limited use for features of NSight Systems, so this report will mainly focus on insights garnered from NSight Compute. For this analysis, we run the “full” metric set available in NSight Compute version 2020.1.2 and use NSight Systems version 2020.3.1 to generate the application timeline.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1999

Solid Surface Combustion Experiment Yields Significant Observations

The spread of a flame over solid fuel is not only a fundamental textbook combustion phenomenon, but also the central element of destructive fires that cause tragic loss of life and property each year. Throughout history, practical measures to prevent and fight fires have been developed, but these have often been based on lessons learned in a costly fire. Since the 1960 s, scientists and engineers have employed powerful tools of scientific research to understand the details of flame spread and how a material can be rendered nonflammable. High-speed computers have enabled complex flame simulations, whereasand lasers have provided measurements of the chemical composition, temperature, and air velocities inside flames. The microgravity environment has emerged as the third great tool for these studies. Spreading flames are complex combinations of chemical reactions and several physical processes including the transport of oxygen and fuel vapor to the flame and the transfer of heat from the flame to fresh fuel and to the surroundings. Depending on its speed, air motion in the vicinity of the flame can affect the flame in substantially different ways. For example, consider the difference between blowing on a campfire and blowing out a match. On Earth, gravity induces air motion because of buoyancy (the familiar rising hot gases); this process cannot be controlled experimentally. For theoreticians, buoyant air motion complicates the problem modeling of flame spread beyond the capacity of modern computers to simulate. The microgravity environment provides experimental control of air motion near spreading flames, with results that can be compared with detailed theory. The Solid Surface Combustion Experiment (SSCE) was designed to obtain benchmark flame spreading data in quiescent test atmospheres--the limiting case of flames spreading. Professor Robert Altenkirch, Vice President for Research at Mississippi State University, proposed the experiment concept, and the NASA Lewis Research Center designed, built, and tested the SSCE hardware. It was the first microgravity science experiment built by Lewis for the space shuttle and the first combustion science experiment flown in space.

Sacksteder, Kurt R.↗