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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Vector-level feedforward control of LPBF melt pool area using a physics-based thermal model

Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and geometric inaccuracies, stemming in part from variations in the melt pool. Here, this paper proposes a novel vector-level feedforward control framework for regulating melt pool area in LPBF. By decoupling part-scale thermal behavior from small-scale melt pool physics, the controller provides a scale-agnostic prediction of melt pool area and efficient optimization over it. This is done by operating on two coupled lightweight models: a finite-difference thermal model that efficiently captures vector-level temperature fields and a reduced-order, analytical melt pool model. Each model is calibrated separately with minimal single-track and 2D experiments, and the framework is validated on a complex 3D geometry in both Inconel 718 and 316L stainless steel. Results showed that feedforward vector-level laser power scheduling reduced geometric inaccuracy in key dimensions by 62%, overall porosity by 16.5%, and photodiode root-mean-squared deviation by 38.5% on average. Overall, this modular, data-efficient approach demonstrates that proactively compensating for known thermal effects can significantly improve part quality while remaining computationally efficient and readily extensible to other materials and machines.

Additive manufacturing↗
DOE OSTI2025

Solid State Transformer Controls for Mitigation of E3a High-Altitude Electromagnetic Pulse Insults

This paper explores the use of a solid state transformer (SST) to mitigate the 𝐸 3𝐴 component of a high-altitude electromagnetic pulse (HEMP) insult using external energy storage optimal control techniques. In lieu of conventional passive blocking devices or feedback-controlled energy storage devices, a novel implementation of Hamiltonian error tracking is utilized to develop a feedback control law for the variable converter ratio in an SST. The findings of the simulations performed in this paper suggest that additional energy storage is not necessary to protect an individual load from a HEMP insult. The simulations performed examine the response of a single-phase SST connected to a single voltage source on a long transmission line on the one side and a single linear resistor on the other. The control law is specifically developed for the late-time, low-frequency portion of a HEMP insult, namely the 𝐸 3𝐴 components. The Hamiltonian error-based converter ratio control law is compared with nonlinear optimal feedforward controls to show that the HSSPFC is an external energy storage optimal controller.

HEMP mitigation↗
DOE OSTI2024

Adaptive Fault Current-Limiting Control of MMC for Protection of Multiterminal HVDC Systems: Preprint

For the development of multi-terminal high voltage DC (MTDC) transmission, it is critical to design the protection system that can selectively isolate the faulty area from the healthy part of the dc grid using DC circuit breakers (DCCBs) while ensuring continuous operation of converter stations in the healthy part. However, because of the lack of fault current blocking capability in half-bridge (HB) modular multilevel converters (MMCs), when a dc fault occurs, the rising fault currents can quickly reach the blocking threshold within a few milliseconds and disrupt the operation of MMCs in the healthy part. Large DC reactors are often considered in series with DCCBs to reduce the rate of rise of fault currents and prevent blocking of MMCs in the healthy part of the grid. However, large DC reactors can prohibitively increase the cost of the system, particularly when they are considered in an offshore environment, for instance in offshore wind projects. Large dc reactors can also introduce stability issues and create post-fault oscillations. This paper presents an adaptive fault current limiting control method for MMCs to avoid their blocking and enable continuous operation of MTDC systems. It contains two parts: The first part is based on circulating current feedforward control that emulates virtual reactors in each arm of an MMC, which is immediately activated when the fault current starts to increase, to reduce the rate of rise of the fault current; the second part is triggered when the fault current exceeds a preset threshold by temporarily bypassing the SMs, serving as a complement to the fault current limiting effect of the first part. Both parts do not require fault detection signal and they are activated automatically during faults. Simulation case studies of a four-terminal bipolar MMC-HVDC system are presented to demonstrate the effectiveness of the proposed control methods.

active fault current limiting↗
DOE OSTI2026

Feedforward-feedback ammonia control at a water resource recovery facility based on a digital twin with hybrid model

Ammonia-based aeration control (ABAC) at full-scale Water Resource Recovery Facilities (WRRFs) can be challenged by diurnal loading and transport delays. This work addressed these challenges using a hybrid feedforward–feedback controller built on Activated Sludge Model 1 (ASM1), marking the first full-scale deployment to pair a mechanistic feedforward core with data-driven corrections. The objectives were to improve ammonia setpoint tracking, assess performance of the mechanistic model when enhanced with data-driven corrections, and document full-scale operation. The hybrid model incorporates two data-driven components: (1) a Mechanistic Error Forecasting Engine (MEFE), consisting of a multivariate linear regressor and a long short-term memory (LSTM) ensemble. Defying expectations, low-parameter models outperformed more complex alternatives, reducing the mechanistic error by 71%. (2) A Residual Oscillation Forecasting Engine (ROFE), based on Fast Fourier Transform, reduced the remaining error by another 35%. Two proportional–integral (PI) feedback loops further (i) trim the feedforward output and (ii) eliminate residual controller error in the final aerobic zone. In full-scale operation, the controller reduced mean-squared error (MSE) by 94% over the baseline and produced more stable dissolved oxygen (DO) setpoints. Overall, it was proven that layering multi-timescale data-driven models on a mechanistic core can yield reliable ABAC performance at WRRFs.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1973

Application of modern control theory to the design of optimum aircraft controllers

The synthesis procedure presented is based on the solution of the output regulator problem of linear optimal control theory for time-invariant systems. By this technique, solution of the matrix Riccati equation leads to a constant linear feedback control law for an output regulator which will maintain a plant in a particular equilibrium condition in the presence of impulse disturbances. Two simple algorithms are presented that can be used in an automatic synthesis procedure for the design of maneuverable output regulators requiring only selected state variables for feedback. The first algorithm is for the construction of optimal feedforward control laws that can be superimposed upon a Kalman output regulator and that will drive the output of a plant to a desired constant value on command. The second algorithm is for the construction of optimal Luenberger observers that can be used to obtain feedback control laws for the output regulator requiring measurement of only part of the state vector. This algorithm constructs observers which have minimum response time under the constraint that the magnitude of the gains in the observer filter be less than some arbitrary limit.

Power, L. J.↗
DOE OSTI2025

Thermal Response of a Lithium Vapor Divertor to Cyclical Operation

The lithium vapor divertor concept is being developed as a method to achieve detached divertor conditions in a tokamak while minimizing impurity radiation losses from the core plasma. SOLPS-ITER modeling has previously been used to identify some of the geometric constraints and required lithium evaporation rate of a lithium vapor divertor in a medium-sized tokamak during steady-state operation. Here an updated conceptual design based on these operating requirements is introduced and the thermal response of the system is modeled during cyclical operation, consistent with operation in a short-pulse tokamak. Controllability of the temperature of the lithium capillary porous system (CPS) is achieved by adopting a design where there is no line-of-sight for radiation from the plasma to reach the heated CPS surface. Operational strategies to minimize the amount of lithium evaporated between plasma discharges while achieving steady evaporation rates during plasma discharges are discussed and modeled here. The optimal feedforward control strategy demonstrated in this work is to ramp up the temperature of the evaporator as quickly as possible immediately before a plasma discharge and then reduce the heating to match the desired steady-state net evaporation rate just before the plasma discharge begins, allowing the thermal inertia of the system to stabilize the evaporation rate during the first second of the plasma discharge.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Fuel recycling and impurity characteristics in long-pulse H-mode plasmas with full metal and dynamically coated walls on EAST

We report the basic behaviors of fuel recycling and impurity accumulation during >100 s long-pulse H-mode plasma under full metal wall conditions on EAST. Significant fuel recycling and impurity rising, particularly from heavy impurities, have been observed when operating with a bare metal wall or a deteriorate real-time coated wall, which severely limits the duration of H-mode discharges. To address this issue, a novel dynamic wall coating technique combining feedforward and feedback controls has been successfully developed. The feedforward control presets the Li powder injection rate based on prior experimental observations, whereas the feedback control dynamically modulates the Li injection rate in response to real-time Li-II line emission measurements. Using this approach, a 605 s H-mode plasma has been achieved with fuel recycling and impurity level maintained stable. This result extends the previous record of a 403 s long-pulse H-mode plasma Gong et al (2024 Nucl. Fusion 64 112013) by over 200 s. It demonstrates the effectiveness of the dynamic powder injection technique in controlling fuel recycling and impurities accumulation, while prolonging plasma duration. These findings offer valuable insights into potential applications of other low-Z powder, such as boron, in ITER.

fuel recycling↗
DOE OSTI2026

An adaptive model-free robotic force control strategy for hydrodynamic real-time hybrid simulation of floating offshore wind turbines

Real-time hybrid simulation (RTHS) - a cyber-physical testing approach - promises to enhance the simulation fidelity of the model-scale experiments used to prototype floating offshore wind turbines (FOWTs). In hydrodynamic RTHS (hydro-RTHS), actuators emulate aerodynamic forces on model-scale FOWT specimens subjected to physical waves in a hydrodynamic laboratory. Robotic arms are promising candidates for actuation in hydro-RTHS due to their compact multi-degree-of-freedom (DOF) capabilities. Unlike classical RTHS for seismic applications, which typically relies on displacement control, hydro-RTHS requires 6-DOF force control on newly designed floating prototypes in a model-scale setting, which presents significant challenges, including modeling uncertainties, directional asymmetry, configuration drift, bandwidth limitations, and time-varying delays. To mitigate these constraints without extensive pre-test calibration, this study proposes an adaptive model-free robotic force control strategy that combines task-space explicit force control with a secondary joint-space pose-keeping task. The Adaptive Feedforward Compensator (AFC) is integrated into the force control loop to compensate for time-varying delay. Experimental testing was conducted using a Franka Emika Panda robotic arm with a 1:50 scale FOWT specimen under operational wind and wave conditions. Results demonstrate stable and consistent 6-DOF force tracking. Effective delay compensation was observed, with low-frequency delay reductions ranging from 71.4% to 91.8% and improvements in low-frequency surge force tracking of 25.0% to 52.1%. This study enhances robotic actuation performance in hydro-RTHS and introduces a force control strategy that supports reliable robotic operation in uncertain floating environments. Future work will explore disturbance-observer mechanisms to further enhance wave rejection capabilities under extreme wind and wave conditions.

17 WIND ENERGY↗
DOE OSTI2025

A Reinforcement Learning Approach to Augment Conventional PID Control in Nuclear Power Plant Transient Operation

The ability of nuclear reactors to operate their power conversion cycles more flexibly will enhance their value to energy grids with variable pricing. Current nuclear control systems are typically classical controllers that are often based on proportional-integral-derivative (PID) control. This paper presents a method of augmenting the existing PID control for difficult transient operations in nuclear power plants using a reinforcement learning–derived feedforward signal applied in real time. The agents, which are trained on a test thermal load-following problem, are designed to improve steam generator outlet temperature control for a range of fast load-following scenarios covering ramp rates from 9%/min to 15%/min. Several reinforcement learning algorithms were initially investigated for the training of the feedforward agents with deep Q-learning (DQN) and proximal policy optimization (PPO) networks, which were found to be the most promising. The DQN controllers utilize discrete actions, giving them a better disturbance rejection at steady state but inconsistent response to initial temperature deviations. In contrast, PPO-trained agents, which take continuous actions except for a dead zone around zero, were shown to have the best combination of high disturbance rejection at steady state and good tracking of the desired temperature value. The ability of the PPO agent was also examined, with the average time of decision making found to be on the order of 1 ms. The fault properties of the controller under the loss of the reinforcement learning agent feedforward signal were also examined. The controller showed strong performance in situations of “no-signal” faults. but was less good at handling “stuck-at” faults, where the feedforward signal remains at a set value. In both cases, however, the PID was able to successfully maintain stability, eventually returning the system to a steady state. It is hoped that this work will allow for the proposed control architecture to be examined for more difficult control problems such that it may eventually be used to adapt existing nuclear plants for more aggressive load-following on grids of the future.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Feedforward equilibrium trajectory optimization with GSPulse

One of the common tasks required for designing new plasma scenarios or evaluating capabilities of a tokamak is to design the desired equilibria using a Grad-Shafranov (GS) equilibrium solver. However, most standard equilibrium solvers are time-independent and do not include dynamic effects such as plasma current flux consumption, induced vessel currents, or voltage constraints. Another class of tools, plasma equilibrium evolution simulators, do include time-dependent effects. These are generally structured to solve the forward problem of evolving the plasma equilibrium given feedback-controlled voltages. In this work, we introduce GSPulse, a novel algorithm for equilibrium trajectory optimization, that is more akin to a pulse planner than a pulse simulator. GSPulse includes time-dependent effects and solves the inverse problem: given a user-specified set of target equilibrium shapes, as well as limits on the coil currents and voltages, the optimizer returns trajectories of the voltages, currents, and achievable equilibria. This task is useful for scoping performance of a tokamak and exploring the space of achievable pulses. The computed equilibria satisfy both Grad-Shafranov force balance and axisymmetric circuit dynamics. The optimization is performed by restructuring the free-boundary equilibrium evolution equations into a form where it is computationally efficient to optimize the entire dynamic sequence. GSPulse can solve for hundreds of equilibria simultaneously within a few minutes. GSPulse has been validated against NSTX-U and MAST-U experiments and against SPARC feedback control simulations, and is being used to perform scenario design for SPARC. The computed trajectories can be used as feedforward inputs that are connected to the feedback controller to inform and improve feedback performance. The code for GSPulse is available open-source at github.com/jwai-cfs/GSPulse_public.

equilibrium↗
DOE OSTI2025

Comprehensive assessment of deep reinforcement learning approaches for economic dispatch in nuclear-driven microgrids

As the electrical grid integrates more variable renewable energy sources such as wind and solar, the demand for distributed and flexible systems to address this increased variability becomes critical. Nuclear-driven microgrids provide a promising solution by offering stable generation to complement intermittent renewables, ensuring grid reliability and operating efficiency. This paper proposes a recurrent deep reinforcement learning framework for optimal economic dispatch in a nuclear-powered microgrid integrating renewable energy sources, small modular reactors, battery storage systems, and balance-of-plant dynamics. A three-agent control architecture is developed, where demand and renewable energy agents act as forecasters, and a reinforcement learning-based dispatch agent performs real-time energy allocation. A nonlinear programming formulation is first used to generate an optimal baseline for benchmarking. The proposed dispatch controller, based on Proximal Policy Optimization enhanced with Long Short-Term Memory networks, exploits temporal correlations in system dynamics by taking advantage of the time series used as inputs to improve policy robustness under uncertainty. Comparative analysis against established deep reinforcement learning methods, including Proximal Policy Optimization with a feedforward architecture, Soft Actor-Critic, and Twin Delayed Deep Deterministic Policy Gradient, demonstrates superior performance. Numerical results indicate that the proposed controller achieves a 0.39% cost reduction relative to the nonlinear programming benchmark and outperforms other learning-based methods by generating additional revenue of up to 0.35%. All reinforcement learning controllers compute dispatch actions in less than 0.3 s, resulting in a computational speedup of more than three orders of magnitude over the nonlinear programming baseline. The findings of this paper highlight their applicability for real-time operation and control in nuclear-integrated microgrids under volatile operating conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

NeuroCoreX: An Open-Source FPGA-Based Spiking Neural Network Emulator with On-Chip Learning

Spiking Neural Networks (SNNs) are computational models inspired by the event-driven communication and connectivity patterns of biological neural circuits. They enable high energy efficiency and natural support for diverse architectures ranging from layered networks to small-world and graphstructured topologies. In this work, we introduce NeuroCoreX, an open-source, FPGA-based spiking neural network emulator that provides real-time, on-chip learning and flexible network organization. NeuroCoreX supports both feedforward sensory inputs streamed directly from sensors or PCs via UART and recurrent on-chip connectivity, enabling simultaneous processing and learning from external stimuli and internal network dynamics-capabilities rarely available in existing FPGA SNN platforms. The system implements a Leaky Integrate-and-Fire (LIF) neuron model with current-based synapses and supports pair-based STDP learning on both feedforward and recurrent synapses. A lightweight Python interface enables interactive configuration, live monitoring, weight read-back, and experiment control. Importantly, NeuroCoreX is tightly integrated with the SuperNeuroMAT simulator, allowing SNN models to be transferred seamlessly from software to hardware for hardware-in-the-loop development. By combining real-time plasticity, flexible connectivity, and an open-source VHDL implementation, NeuroCoreX provides an extensible and accessible platform for neuromorphic research, algorithm-hardware co-design, and energy-efficient edge intelligence.

Gautam, Ashish [ORNL]↗
DOE OSTI2025

Extended Galerkin Neural Network Approximation of Singular Variational Problems with Error Control

We present extended Galerkin neural networks, a variational framework for approximating general boundary value problems (BVPs) with error control. The main contributions of this work are (1) a rigorous theory guiding the construction of new weighted least squares variational formulations suitable for use in neural network approximation of general BVPs, and (2) an “extended” feedforward network architecture which incorporates and is even capable of learning singular solution structures, thus greatly improving approximability of singular solutions. Furthermore, numerical results are presented for several problems, including steady Stokes flow around reentrant corners and in convex corners with Moffatt eddies in order to demonstrate efficacy of the method.

a posteriori error estimate↗
DOE OSTI2025

Benchmarking a Tunable Quantum Neural Network on Trapped-Ion and Superconducting Hardware

We implement a quantum generalization of a neural network on trapped-ion and IBM superconducting quantum computers to classify MNIST images, a common benchmark in computer vision. The network feedforward involves qubit rotations whose angles depend on the results of measurements in the previous layer. The network is trained via simulation, but inference is performed experimentally on quantum hardware. The classical-to-quantum correspondence is controlled by an interpolation parameter, $a$, which is zero in the classical limit. Increasing $a$ introduces quantum uncertainty into the measurements, which is shown to improve network performance at moderate values of the interpolation parameter. We then focus on particular images that fail to be classified by a classical neural network but are detected correctly in the quantum network. For such borderline cases, we observe strong deviations from the simulated behavior. We attribute this to physical noise, which causes the output to fluctuate between nearby minima of the classification energy landscape. Such strong sensitivity to physical noise is absent for clear images. We further benchmark physical noise by inserting additional single-qubit and two-qubit gate pairs into the neural network circuits. Our work provides a springboard toward more complex quantum neural networks on current devices: while the approach is rooted in standard classical machine learning, scaling up such networks may prove classically non-simulable and could offer a route to near-term quantum advantage.

FOS: Physical sciences↗
DOE OSTI2025

Reinforcement Learning for In-Spill Optimization of the Mu2e Resonant Extraction: Compensating Non-Stationarity

We present design considerations and challenges for the fast machine learning component of a third-order resonant beam extraction regulation system being commissioned to deliver steady beam rates to the mu2e experiment at Fermilab. Dedicated quadrupoles drive the tune toward the 29/3 resonance each spill, extracting beam at kV multiwire septa. The overall Spill Regulation System consists of (1) a “slow” process using ~100-spill averages to adjust the base quad ramp infrequently, (2) a feedforward harmonic content compensator, and (3) the “fast” ML agent reacting during each ongoing spill with on-the-fly additive corrections to the sum of (1) and (2). We have demonstrated improved beam-rate steadying for a fast ML agent compared to a PID controller using a quasi-physical spill simulation, and demonstrated distillation of that simulation into a predictive surrogate model. Current work includes a data-and-training pipeline to generate data-aware surrogates with real-world dynamics, even as the dynamics shift unpredictably. The surrogates are to act as RL environments against which to train our fast ML control agents before deploying them on FPGA in the live system. Further current efforts focus on modeling and controlling beam loss around the storage ring, understanding additional available hardware inputs to the model, and the interplay of these with beam-steadying performance.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

Quantum-Enhanced Dark-Matter Sensing with Large Photon Number Fock States in a High-Q SRF Cavity

Wave-like dark matter candidates such as axions or dark photons in the microwave frequency range can be probed using resonant superconducting cavities. We demonstrate a quantum-enhanced sensing approach based on a multimode, high-Q superconducting RF (SRF) cavity, where a large Fock state is prepared in the storage mode via sideband transitions mediated by a transmon ancilla and a measurement-based feedforward protocol, achieving high-fidelity Fock states [1]. The prepared |n⟩ state induces stimulated emission from the dark-matter field, providing an (n + 1) enhancement in transition probability and proportional boost in signal rate [2]. A secondary cavity mode functions as an in-situ reference to calibrate noise. We present the control sequence, noise-referencing strategy, and projected sensitivity improvements for axion and dark-photon detection. This multimode architecture combines large Fock state preparation with noise calibration, offering a practical path to increased scan rate in cavity-based dark-matter searches.

Kim, Taeyoon↗