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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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Coaxial Rotor CFD Validation and ML Surrogate Model Generation

A fixed-pitch speed-controlled coaxial rotor system was tested in the NASA Langley Transonic Dynamics Tunnel in September 2022. The rotors have a diameter of 1.35 meters and an inter-rotor spacing of 25% of the diameter. Though this test was focused on the NASA New Frontiers Dragonfly mission, the resulting dataset is relevant to a wide array of applications of multirotor vehicles, especially those using fixed-pitch variable-speed rotors. Most notably beyond Dragonfly, perhaps, is the application of coaxial rotor pair configurations for eVTOL and Urban Air Mobility (UAM) aircraft. This work provides a thorough CFD validation study quantifying coaxial rotor performance estimation with accuracy on order 5-10% using an efficient hybrid BEMT-URANS flow solver over a wide range of operating conditions. This accuracy was achieved using novel approaches for the construction of both the C81 airfoil performance lookup tables and the BEMT rotor model. These novel approaches are combined with advanced scripting to further accelerate the commercial off-the-shelf CFD solver on GPU accelerated machines. Finally, the development of machine learning surrogate models is presented to produce highly efficient and accurate rotor performance predictions for fixed-pitch variable-speed multirotor aircraft over the complete flight regime including scout, cruise, climb, descent, as well as limiting cases of vortex-ring and windmill-brake states.

Coaxial↗
DOE OSTI2025

HPC-Driven Modeling with ML-Based Surrogates for Magnon-Photon Dynamics in Hybrid Quantum System

Here, we introduce a hybrid computational framework that merges HPC-based numerical solvers with physics-informed ML surrogates for efficient modeling of magnon-photon interactions. By running short-duration, high-fidelity Maxwell-LLG simulations and feeding their results into an ML model, we substantially cut simulation time while achieving accurate predictions across larger spatiotemporal domains.

Accuracy↗
DOE OSTI2026

Enhanced accuracy through ensembling of randomly initialized auto-regressive models for dynamical systems

Computational mechanics simulations using traditional finite element methods (FEM) require prohibitively expensive computational resources for real-time engineering applications, design optimization, and digital twin implementations. While machine learning (ML) surrogate models offer significant computational speedups, autoregressive ML models for time-dependent mechanical systems suffer from error accumulation that compromises long-term prediction reliability - a critical concern for engineering applications where accuracy over extended time horizons is essential for safety and performance assessments. Here, we propose a deep ensemble framework specifically designed to address this challenge in computational mechanics applications, where multiple ML surrogate models with random weight initializations are trained in parallel and their predictions aggregated during inference. This approach leverages statistical diversity to maximize information gain from a fixed set of training data and to mitigate error propagation, while maintaining the computational efficiency that makes ML surrogates attractive for engineering practice. We validate the framework on three representative problems spanning critical areas of computational mechanics: stress field evolution in heterogeneous microstructures under complex loading (relevant to advanced materials design and composite analysis), planetary-scale shallow water dynamics (applicable to environmental and geotechnical engineering), and Gray-Scott reaction-diffusion systems (relevant to mass transport and chemical process engineering). Across all test cases, the ensemble approach demonstrates consistent error reduction of 15-33% compared to individual models. The codes for this work are available on GitHub (https://github.com/Graham-Brady-Research-Group/AutoregressiveEnsemble_SpatioTemporal_Evolution).

autoregressive prediction↗
DOE OSTI2025

Mixed-Integer Linear Programming Formulation with Embedded Machine Learning Surrogates for the Design of Chemical Process Families

In previous work, we introduced process family design. The main idea is to design a platform of common elements, and, allowing us to capture additional cost savings, simultaneously design a family of processes, and reducing both engineering and deployment timelines. We formulate this as an optimization problem, specifically a nonlinear generalized disjunctive program (GDP). We have proposed two approaches for reformulating and solving this problem: one based on full-discretization of the design space and one that uses Machine Learning (ML) surrogates to replace the nonlinear process models. Using ML surrogates to predict required system costs and performance indicators allows us to reformulate the nonlinearities in the GDP generate an efficient MILP formulation. In this work, we apply the ML surrogate approach to two case studies. One case study involves designing a family of carbon capture systems to cover a set of different flue gas flow rates and inlet CO 2 concentrations, where we consider the absorber and stripper as common unit module types. The second case study focuses on a water-desalination process, where we design a family of these processes for a variety of salt concentrations and flow rates. In both of these case studies, we demonstrate a scalable optimization approach that enables the design of multiple processes simultaneously, reducing the time-to-market and overall costs by maximizing the cost savings due to both economies of scale and economies of numbers.

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

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sulfur TES ML [SWR-23-02]

Sulfur TES ML contains code originally created to develop surrogate ML models to mimic the utility of CFD simulations of Sulfur TES systems. It has been adapted to provide a comprehensive package for building, training, validating, testing, and optimizing regression models with customizable features and targets.

Menear, Kevin↗
DOE OSTI2025

Similarity Metric for Data Optimization and Efficient Training of Reactive Machine Learning Force Fields for Hydrocarbon Radiolysis

Radiolysis is a common approach to sterilize polymers, chemically modify them for upcycling, and accelerate their decomposition for recycling purposes. Reactive molecular dynamics (MD) simulations provide a powerful tool to generate atomic-level trajectories of the reactive processes and quantify radiolytic chemical degradation pathways. For this, machine learning (ML) surrogate models for reactive force fields with quantum mechanical accuracy are now widely used, which require ML training data sets that can provide information on atomic environments for target chemical systems. However, radiolysis chemistry can be highly complex and diverse, which poses significant challenges for generating training data to parametrize ML models. In this regard, we developed a method for optimizing the training data set using a cosine similarity metric to help guide training set selection for radiolysis of polyethylene, a model hydrocarbon polymer, as well as to enhance the transferability of our reactive ML force field (MLFF) to a variety of molecular and polymeric systems. Our approach performs atom-by-atom comparisons between local atomic environments to pinpoint important data points associated with rare and localized events, such as radiolysis damage within structures. We apply this approach to train the Chebyshev Interaction Model for Efficient Simulation (ChIMES) MLFF model, which expresses the atomic interaction potentials in terms of linear combinations of many-body Chebyshev polynomials. We first show that our method can reduce our training set size by ∼70% while improving overall accuracy compared to more standard MD model fitting approaches. We then validate our optimum model against diverse hydrocarbon simulation data, including simple alkanes and systems with unsaturated carbon bonds, over a wide range of thermodynamic conditions. Finally, we use our ChIMES model to perform MD simulations of radiolytic damage with large-scale systems that help avoid system size effects. Overall, our approach yields an MD force field that retains most of the accuracy of the underlying quantum method while yielding many orders of improvement in computational efficiency. In conclusion, our efforts will have impact on future hydrocarbon polymer radiolysis studies, where the chemical details of the polymer–radiation interactions can have a strong effect on the resulting products observed in experiments.

Hydrocarbons↗
DOE OSTI2024

Physics-coupled data-driven design of high-temperature alloys

We present a materials design loop, which streamlines physics-coupled machine learning (ML) surrogate models to discover new alloy chemistries with improved properties. The efficacy is demonstrated by discovering a high-temperature alumina-forming austenitic (AFA) stainless steel with enhanced creep, followed by experimental validation. The ML models have been trained using a well-curated, highly consistent experimental dataset augmented with synthetic microstructural features from a computational thermodynamic approach. We have populated a large number of hypothetical AFA alloys to explore the high-dimensional composition space and have predicted their creep properties by providing the same synthetic input features obtained from the trained ML models. Uncertainties from the ML training were taken as thresholds for truncating predicted results to identify alloys with improved or deteriorated creep. Individual elemental compositions have been determined via probability density distribution analysis from the group of alloys at the top and bottom of the predicted creep values for further virtual and experimental validations. In conclusion, we anticipate that this workflow can be applied to screen desired conditions, such as chemistry and processing parameters, in high-dimensional space through physics-guided data analytics.

Alloy design↗
DOE OSTI2026

An overview of 3D field optimization for control of transport and edge instabilities on KSTAR

An international team from several laboratories and universities has made key advances over the last few years in the control of plasma transport and edge instabilities with applied 3D fields in the KSTAR tokamak to optimize long pulse operation scenarios. This overview begins with the optimization of both core and edge resonant magnetic perturbations (RMP) to improve fast ion confinement to avoid excessive limiter heat loads due to fast ion losses and successful modeling of the experimental results. Integrated and advanced plasma control techniques with machine learning (ML) and adaptive control were then used to optimize the 3D field spectrum in real-time to control edge localized modes (ELMs) while avoiding core locked modes that could disrupt the plasma. Accelerating the offline model of 3D fields with a surrogate ML model can optimize ELM suppression in the edge while limiting the impact of the applied RMP fields deeper in the plasma core in real-time. In addition, the impact of the 3D fields on the divertor heat load has been modeled and compared with experimental measurements. An analysis of a multi-machine database including KSTAR has been performed to better understand the metrics for the observed RMP thresholds for ELM suppression and the resulting plasma performance. Predictive modeling of the operational space for ELM suppression and density pumpout due to RMP has shown the importance of magnetic islands in the plasma edge and their impact on plasma turbulence. This research has culminated in the development of successful long pulse operational scenarios on KSTAR while attempting to overcome challenges of the new tungsten divertor.

3D fields↗
DOE OSTI2025

Open-source generation of sigma profiles: impact of quantum chemistry and solvation treatment on machine learning performance

The combination of machine learning (ML) models with chemistry-related tasks requires the description of molecular structures in a machine-readable way. The nature of these so-called molecular descriptors has a direct and major impact on the performance of ML models and remains an open problem in the field. Structural descriptors like SMILES strings or molecular graphs lack size-independence and can be memory intensive. Machine-learned descriptors can be of low dimensionality and constant size but lack physical significance and human interpretability. Sigma profiles, which are unnormalized histograms of the surface charge distributions of solvated molecules, combine physical significance with low dimensionality and size-independence, making them a suitable candidate for a universal molecular descriptor. However, their widespread adoption in ML applications requires open access to sigma profile generation, which is currently not available. This work details the development of OpenSPGen – an open-source tool for generating sigma profiles. Also presented are studies on the effect of different settings on the efficacy of the generated sigma profiles at predicting thermophysical material properties when used as inputs to a Gaussian process as a simple surrogate ML model. We find that a higher level of theory does not translate to more accurate results. We also provide further recommendations for sigma profile calculation and use in ML models.

Salih, Fathya Y. M. [University of Notre Dame, IN ↗
DOE OSTI2025

Forecasting Multi-Step-Ahead Street-Scale Nuisance Flooding using a seq2seq LSTM Surrogate Model for Real-Time Application in a Coastal-Urban City

In coastal-urban cities facing an elevated risk of nuisance flooding (by rain and tide) due to increased heavy rainfall, sea level rise, urbanization, and aging drainage systems, real-time flood forecasting at the street-scale can provide useful information to transportation decision-makers. Physics-Based Models (PBMs) that offer high accuracy come with high computational runtimes and costs that limit their application for real-time flood forecasting. To address this challenge, Machine Learning (ML) surrogate models trained from PBMs have been proposed to provide street-scale flood forecasts. Previous related studies have focused on using Long Short-Term Memory (LSTM) architectures to model hourly flood depth on streets. While LSTM models can capture input sequences effectively, they fall short in accurately preserving output sequences, limiting their suitability for multi-step-ahead forecasts. The seq2seq LSTM architecture offers a key advantage here by capturing the full sequence of input–output, making it potentially more suitable for multi-step-ahead flood forecasts compared to traditional LSTM models. However, seq2seq LSTM has not been tested for street-scale flood forecasting, particularly for rapidly fluctuating nuisance flooding events which require special attention to its temporal sequences. Hence, in this study, we applied the seq2seq LSTM model to explore multi-step-ahead street-scale nuisance flooding and compared its results to the traditional LSTM model as a benchmark model. LSTM and seq2seq LSTM surrogate models were applied to 22 flood-prone streets in Norfolk, Virginia, as a case study with a 4-hr (short-term) and 8-hr (long-term) lead time. The models were trained with environmental (rainfall and tide) and topographic (elevation, Topographic Wetness Index, and Depth-To-Water) features along with PBM-derived water depths for different storm events. The results demonstrated satisfactory performance of both LSTM and seq2seq LSTM surrogate models throughout the forecast period compared to the PBM. However, the seq2seq LSTM showed lower Mean Absolute Error (MAE)/ Root Mean Square Error (RMSE) and higher Nash–Sutcliffe Efficiency (NSE)/ correlation than the LSTM across most lead times, particularly for long-term forecasting due to its supremacy in handling both input–output sequences together, which is missing in the traditional LSTM. For example, in the long-term, the average RMSE ranges were 0.0268–0.0373 m for LSTM and 0.0226–0.0319 m for seq2seq LSTM, while in the short-term, they were 0.0263–0.0293 m and 0.0261–0.0283 m, respectively. Additionally, while both models exhibited similar performance in distinguishing flooded and non-flooded streets for flood depth ≥ 0.1 m, the seq2seq LSTM model demonstrated superior performance for higher flood depths (such as ≥ 0.2 m and ≥ 0.3 m). Once trained, inference took only 0.09 to 0.11 s (short-term) and 0.30 to 0.35 s (long-term) per storm event for the 22 streets, making the application highly suitable for real-time decision-making during nuisance flood events.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Enhanced descriptor identification and mechanism understanding for catalytic activity using a data-driven framework: revealing the importance of interactions between elementary steps

We report accurate identification of descriptors for catalytic activities has long been essential to the in-depth understanding of catalysis and recently to set the basis for catalyst screening. However, commonly used methods suffer from low accuracy in predictability. This study reports an enhanced approach to accurately identify the descriptors from a kinetic dataset using a machine learning (ML) surrogate model. CO hydrogenation to methanol over Cu-based catalysts was taken as a case study. Our model captures not only the contribution from individual elementary steps but also the interaction between relevant steps within a reaction network, which was found to be essential for high accuracy. As a result, six effective descriptors are identified, which are accurate enough to ensure the trained gradient boosted regression (GBR) model for good prediction of the methanol turnover frequency (TOF) over metal (M)-doped Cu(111) model surfaces (M = Au, Cu, Pd, Pt, Ni). More importantly, going beyond the purely mathematical ML model, the catalytic role of each identified descriptor can be revealed by using model-agnostic interpretation tools, which enhances the insight into the promoting effect of alloying. The trained GBR model outperforms the conventional derivative-based methods in terms of both the predictability and the mechanism understanding. It opens alternative possibilities toward accurate descriptor-based rational catalyst optimization.

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

Tutorial: Machine-Learning-Based CREASE-2D Analysis of 2D SAXS Profiles to Characterize Anisotropic Nanostructures in Soft Materials

We present a tutorial to guide users on how to extend the Computational Reverse Engineering Analysis of Scattering Experiments-2D (CREASE-2D) framework to interpret their experimental two-dimensional small-angle scattering (SAS) data from soft materials (e.g., polymers, peptide amphiphiles, biomolecular fibrils). Unlike most traditional SAS analysis approaches, which typically rely on azimuthally averaged onedimensional (1D) profiles, CREASE-2D utilizes the complete 2D scattering profile to reveal information about anisotropy in the structure. In past applications, CREASE has provided insights into complex structural features, including the cross-sectional shapes of assembled nanostructures and dispersity in these features, which are difficult to discern with existing analytical models. While (1D- ) CREASE has been applied to SANS and SAXS data, this tutorial shares the steps for implementing CREASE-2D using an example of a dipeptide solution system, for which we have SAXS data. We present details for these steps involved in using CREASE-2D to interpret SAXS profiles: how to preprocess SAXS data, define relevant structural features, generate three-dimensional real-space structures for specific values of these features, train a machine learning (ML) surrogate model to predict scattering profiles for given structural features, and optimize these features using genetic algorithms (GA). Then, we use these steps to interpret complex 2DSAXS data collected from dipeptide solutions that, in microscopy images, exhibit nanoscale structures that could be elliptical tubes/ flat tapes/cylinders or a combination of these cross sections. Open-source codes, computational hardware, and software requirements, as well as the strengths and limitations of this protocol, are also presented. We expect researchers working with (soft) biomaterials, peptide amphiphiles, amphiphilic polymer solutions, polymer nanocomposites, and blends of particles/polymers will find this CREASE-2D method and this tutorial of use.

CREASE↗
DOE OSTI2024

Bridging Hydrological Ensemble Simulation and Learning Using Deep Neural Operators

Ensemble-based simulation and learning (ESnL) has long been used in hydrology for parameter inference, but computational demands of process-based ESnL can be quite high. To address this issue, we propose a deep neural operator learning approach. Neural operators are generic machine learning algorithms that can learn functional mappings between infinite-dimensional spaces, providing a highly flexible tool for scientific machine learning. Our approach is built upon DeepONet, a specific deep neural operator, and is designed to address several common problems in hydrology, namely, model parameter estimation, prediction at ungaged locations, and uncertainty quantification. Here we demonstrate the effectiveness of our DeepONet-based workflow using an existing large model ensemble created for an eastern U.S. watershed that is instrumented with 10 streamflow gages. Results suggest DeepONet achieves high efficiency in learning an ML surrogate model from the model ensemble, with the modified Kling-Gupta Efficiency exceeding 0.9 on holdout test sets. Parameter inference, carried out using the trained DeepONet surrogate model and genetic algorithm, also yields robust results. Additionally, we formulate and train a separate DeepONet model for physics-informed, seq-to-seq streamflow forecasting, which further reduces biases in the pre-trained DeepONet surrogate model. While this study focuses primarily on a single watershed, our approach is general and may be extended to enable learning from model ensembles across multiple basins or models. Thus, this research represents a significant contribution to the application of hybrid machine learning in hydrology.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Improving Trustworthiness of Data-Driven Power Grid Contingency Analysis With Bayesian Residual Graph Neural Networks

The evolving energy landscape requires novel tools to efficiently perform contingency analysis and reliability assessment of power grids, potentially in real-time. The high computational cost of traditional power flow solvers limits their applicability in practice. Machine learning (ML) surrogates such as deep neural networks (NNs) accelerate power flow solvers computations, enabling high-order contingency analysis and real-time decision-making by learning highly nonlinear functions and integrating grid topology via graph architectures. However, (graph) NNs lack predictive power away from training data and do not provide predictive confidence estimates. Here, we present a Bayesian residual graph NN that integrates knowledge from low-fidelity data via residual training and embeds granular quantification of uncertainties, improving trustworthiness critical for high-consequence decision-making. Applying Bayesian concepts to NNs is challenging due to the high-dimensionality of both the parameter space, complicating derivation of a meaningful prior, and the output space in large grid systems, requiring enhanced techniques to assess the predicted high-dimensional uncertainties. Our contributions include: (1) Deriving a prior for fully connected and graph NNs that leverages low-fidelity data to guide mean predictions and appropriately control prior predictive uncertainty. (2) Integrating this prior within an ensembling with anchoring scheme for efficient approximate posterior inference. (3) Deriving enhanced metrics to assess accuracy of both the mean and uncertainty predictions in high dimensions, appropriately accounting for correlations propagated through graph layers. The resulting Bayesian residual graph NN is tested on a contingency analysis task for 14-bus and 118-bus grids.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Autonomous MultiScale Library

AMSLib provides infrastructure to tightly couple multi-scale physics simulation code with ML surrogate model inference. It provides a wholistic runtime execution paradigm to supports uncertainty quantification, surrogate model inference, persistent data storing throughout the execution of a simulation.

Bhatia, Harsh↗